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Porsche Engineering Magazine

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Porsche Engineering Magazine Edition 01/2003 Porsche Engineering Magazine A sound foundation: State-of-the-art materials and technologies are used for the Cayenne bodyshell. Cruiser powered by Porsche: Porsche Engineering colla- borated with Harley-Davidson in developing their water- cooled V-Rod engine. Porsche styling: Virtual reality has become an indispensable tool for design studios. Contents The Porsche Engineering Group Porsche is the only car manufacturer GmbH (PEG), a subsidiary of to make its extensive engineering Dr. Ing. h.c. F. Porsche AG, is knowledge available to international responsible for the sports car con- customers from various sectors. structor’s global contract develop- In conjunction with its domestic and ment activities. Editorial Page 4 Body Complete Vehicle Electrical & Electronics Chassis Systems Industrial Design Acoustics are our forte Page 13 A sound foundation: the bodyshell of the Porsche Cayenne Page 5 foreign subsidiaries, the Porsche In so doing Porsche Engineering Engineering Group provides expert- has access to the resources of ise on a global scale in the fields of more than 3,000 engineers from automotive engineering and trans- construction, prototype, production port under the Porsche Engineering planning, procurement, logistics banner. and production divisions. Insights High-performance sports car with techno- logy of the future Page 23 Even more power, driving pleasure and safety Page 24 Virtual reality and collaborative engineering Page 25 Powertrain & Driveline Testing Facilities Styling Engineering Support Porsche Styling – a virtual look into the future Page 20 Special Done with the wind Page 26 Cruiser developed with Porsche Engineering Page 16 Editorial Dear Readers Surely one of the most noteworthy In developing the Cayenne, we have events was the successful comple- perfected many new technologies tion of our collaboration project and ideas that we can now offer to with Harley-Davidson to develop the Porsche Engineering clients as well. The start of a new year is always a good time to We have added a number of highly reflect on the accomplishments of the past year. qualified employees to our team in the Electrical/Electronics division. Porsche Engineering was privileged to work on many Our “Porsche Speech Technology” challenging projects in 2002, and we would like to is just one of the exceptional solu- take this opportunity to thank our clients for the trust tions we are offering in this promis- ing sector. they placed in us. We wish you a successful year 2003 Power Cruiser V-Rod. The engine/ and enjoyable reading. transmission unit, one of the Cruiser's highlights, was developed Your Editorial Team jointly with Porsche Engineering. We will face new challenges in 2003, but the Porsche Engineering Group is ready to meet them head on. 4 Bodyshell construction Body A sound foundation: the bodyshell of the Porsche Cayenne Bodyshell of the Cayenne Turbo under the vehicle skin The bodyshell of a high-quality Sports Utility Vehicle must meet high demands and greatly outperform the structure of a pure sports or off-road vehicle. Thanks to the use of modern materials and technologies, the Cayenne demonstrates exem- plary driving characteristics both on and off the road and simultaneously meets the very strict Porsche safety requirements. The Cayenne thus underscores Porsche's competence in the field of lightweight steel construction. Body concept der frame. The innovative alterna- tive is a unitized body. The advan- In the initial design phase of the tages of the two concepts were Cayenne, Porsche first examined determined by simulation so that the two types of bodyshell con- they could be combined when struction that are conventionally designing the Cayenne's structure: used for Sports Utility Vehicles. a unitized body with integral frame. With the classic solution, the body- Engineers firmly integrated the shell is mounted on a separate lad- frame into the floor assembly and 5 Body Bodyshell construction definition of the assembly sequence and direction. The necessary sepa- ration levels between individual modules and the new mounting con- cept, positively influences the dimensional stability of the body- shell and thus also the functional reliability of adjacent components. Material concept Platform and frame forestructure The Cayenne bodyshell is a shell- type structure consisting of double- designed structural members that The sidewall section, comprising sided galvanized sheetmetal panels run along the entire length of the the inner and outer A, B, C and D- of various thicknesses. When they vehicle, passing underneath the pillars, plus the side portion of the defined the material concept, the floor panel in the area of the pas- roof frame and the outer wheel Porsche engineers consistently senger cell. This arrangement with housing, is affixed to the floor applied the knowledge they gained straight structural members is par- panel, roof cross-members and end from earlier projects and studies ticularly advantageous when it panels and then welded in place. concerning mechanical parameters comes to absorbing crash loads. This modular design principle, and deformability. A large portion of All axle and equipment mounting which was selected early on in the the vehicle's load-bearing structure points are located in the continuous development process includes the consists of DP and TRIP steels, side members. With this concept, the side members shield the func- DP 600 tional parts and equipment and CPW 800 thereby protect them from damage ZStE 340 during demanding off-road use. Trip 700 The remainder of the bodyshell structure on the floor assembly is modular. The frame forestructure with structural members, shock towers, web plates and brackets completes the platform, to which the preassembled sidewall assem- Load-bearing structure of high-strength and super-high-strength sheet-steel materials with yield points higher than 340 MPa blies are attached in the first step. 6 Bodyshell construction Body rigid body that meets the strictest Material distribution safety standards and is simultane- CPW800 DP600/H340X ously lightweight (392 kilograms Soft grades 2% 20% (DX...., DC...) without doors and lids). 36% BTR155 Innovative joining methods 3% Trip 700/ RA-K40/70 4% The joining methods appropriate for each specific material and load are Microalloyed and BH grades (ZStE 180 used for the Cayenne's bodyshell. BH...ZStE340) 28% These methods include MIG braz- Taillored Blank (ZStE/H340X) Others ing, MAG welding, resistance spot- 6% 1% welding and laser welding. The Materials used in the bodyshell number, position and length of join- which have very good work-harden- ing properties. Their high energy- absorption capacity and strength 50 DC04- 06 make them the ideal materials for [%] 40 H180- 300BD the deformation areas of the body 80 DX53- 54D and for the rigid passenger cell. By H300/340XD 30 RA-K contrast, panels such as the floor Aluminium panel, roof and sidewall are manu- 20 H260- 420LAD factured from softer steel grades 10 Magnesium with good deep-drawing properties. Elongation at break A 0 0100200 300 400 500 600 Porsche decided to use the most Proof stress Rp0.2 [MPa] suitable type of steel for each part of the body, taking the load, the Strength and elongation values of materials used in the bodyshell manufacturing, and joining methods into account. Therefore 64 percent This makes the Cayenne the world's ing elements were optimized in an of the body consists of high- first series-production vehicle in its iterative process with the aid of strength and super-high-strength class to incorporate such a large numerical simulation methods. The steel materials. amount of multi-phase steels in its use of multi-phase steels alone structure (DP: dual-phase steels, required extensive studies to deter- TRIP steels, CPW: complex-phase mine the best joining method. The steels). With these innovative mate- evaluation of metallographic and rials, it was possible to develop a quasi-static tests showed that multi- 7 Body Bodyshell construction phase steels can be joined with Passive safety lisions, absorbing the lion's share high process reliability using MIG of the kinetic energy. Another tech- brazing, MAG welding, resistance Taken together, the structural, nological highlight protects occu- spotwelding and laser welding, pro- material and joining concepts have pants in side impacts: the sill is vided that the electrode forces are produced a bodyshell with a rigid strengthened by a super-high- adequate during spotwelding. passenger cell offering a high level strength reinforcement tube made Cyclical tests on standardized spec- of protection against intrusion. of BTR 155 seamless drawn tubing, imens verified that multi phase Deformation zones at the front and which has a tensile strength of steels can achieve similar endurance rear protect the passenger cell. 1,400 to 1,800 MPa. It runs along properties under shear loads to The straight side members and the the entire side of the vehicle those of soft deep-drawing steels. high-strength material in particular between the front and rear wheels make a substantial contribution to and is supported on the side mem- the passive safety. They deform in bers and tunnel. Forces occurring a specific manner without local in a side impact are absorbed by buckling in frontal and rear-end col- seat cross-members of CPW 800 Bodywork and roof The technological “pièce de résis- tance” among the joining methods used for the Cayenne is the laser- brazing process for the roof seam. It was possible to exploit all of the advantages offered by laser braz- ing, i.e. a nearly rework-free and tight connection that can be pro- duced at a high process speed and with good repeat accuracy. The high static torsional rigidity of 36,900 Nm/° gives occupants a feeling of safety and solidity, even when one wheel is hanging in the air. 8 Bodyshell construction Body steel, which are welded transverse- 110 ly into the structure and connect Cayenne the reinforcement tube to the tun- pilot series nel.
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