Full Aluminum Body for PEV
Fei Xiong (Ph.D) GEELY Auto About Geely Auto Contents
Why aluminum – Lightweight Technology
Geely PEV Project
PEV Lightweight Target
PEV Lightweight Technology Analysis
Challenges Contents
Why aluminum – Lightweight Technology
Geely PEV Project
PEV Lightweight Target
PEV Lightweight Technology Analysis
Challenges Why Aluminium - Lightweight? Why Aluminium - Lightweight? Why Aluminium - Lightweight?
~35 kg ~ 13 kg Why Aluminium - Lightweight? --- Automotive Lightweight Technology Background
Policies
Fuel Customers GB19578、CAFE、ACEA Fuel Economy
Vehicle Dynamics
OEM Competitiveness Cost
1kg reduction in weight results in $10 saving.
Emission Competitiveness
July 1, 2014 – National IV emission standard Lightweight technology – company core competitiveness
Toyota: Target – weight reduction of 10~30% by 2016 in its all small to medium vehicles .. Almost every OEM has its own lightweight target 、、、 Why Aluminium - Lightweight? --- Automotive Lightweight Technology Background
Lightweight Index Trend
L=2.56~4.91 L=2.22~3.62 L=1.26~3.42 Average 3.29 Average 2.8 Average 2.48 4.91 opel_zafira 5 ford_focus 4.5 4.16 hyundai_i40_new nissan_leaf 4 3.62 3.59 bmw_1series 3.42 3.41 3.26 range_rover_evoque 3.5 3.17 3.09 3.08 2.96 3.06 Mercedes-Benz_B-Class 2.79 2.79 2.79 3 2.56 2.66 mazda_cx-5 2.41 2.34 2.47 2.42 2.5 2.22 Audi_A6 FORD Fusion/Mondeo 1.73 2 1.55 SKODA RAPID 1.26 HONDA CIVIC 1.5 BMW 3 Series 1 AUDI A3 Cadillac ATS 0.5 Jajur Rang Rover L405 0 Lexus IS Honda FIT ALFA ROMEO 4c COUPE Renault Capture Range Rover Sport Infiniti Q50 Mercedes-Benz S-Class Lamborghini Aventador BMW i3 2011 2012 2013 Why Aluminium - Lightweight? ------AutomotiveAutomotive LightweightLightweight Technology Technology Background Background
L=1.2~4.99 Average 2.95
6 5 3.91 3.2 2.23 4 4.99 3.35 2.87 2.7 3 3.02 1.98 3.02 1.2 2 1 0
2014
10 Why Aluminium - Lightweight? --- Automotive Lightweight Technology Background
Lightweight Technology
Materials Structure Process
11 Why Aluminium - Lightweight? --- Automotive Lightweight Technology Background
One of the best candidate materials for lightweight
6016T6, B180, 1.0mm 0.7mm LBK – Material Lightweight Index Al - better lightweight material in comparison with steel. （Higher load capacity per unit weight） Why Aluminium - Lightweight? ------AutomotiveAutomotive LightweightLightweight Technology Technology Background Background
Densi ty
Automotive Lightweight demand is pushing wider application of Al alloys. s n so o n To o /Tn Contents
Why aluminum – Lightweight Technology
Geely PEV Project
PEV Lightweight Target
PEV Lightweight Technology Analysis
Challenges Full Alluminium in Geely PEV
AMA platform
XXX model – 5 yrs 200K
Max Length Width Height W/Base Distance Model* Speed mm mm mm mm km km/h
A 2742 1566 1566 1868 250 120 Contents
Why aluminum – Lightweight Technology
Geely PEV Project
PEV Lightweight Target
PEV Lightweight Technology Analysis
Challenges PEV Lightweight Target (PALS Model)
- Products Attribute Leadership Strategy
Based on the benchmark and competitors 'data ( no less than 5 data) , calculating the average to define C’s average. L－~10%；A－~20%；C－~40%；U－~30%；
第 17 页 PEV Lightweight Target (PALS Model) - Products Attribute Leadership Strategy
Benchmark - Smart Smart curb mass: 943kg，PALS model shows it’s in the uncompetitive rage.
Leadership
Among of Leaders
Competitive
Uncompetitive
A lightweight target of 750kg is set with 5 different body structure designs. PEV Lightweight Target (PALS Model)
- Products Attribute Leadership Strategy
f(ρ)= 푀 푘∗ 퐿−푤ℎ +푤ℎ ∗푊∗퐻 Contents
Why aluminum – Lightweight Technology
Geely PEV Project
PEV Lightweight Target
PEV Lightweight Technology Analysis
Challenges PEV Lightweight Technology PEV Body Design Analysis
Steel CFRP+Polymer Steel Struct.+Al Full Al Body ASF+Al or Struct.+Polyme Cover Cover （Range Polymer Cover） r Cover （Lamborghini （Audi A6） Rover） （Audi A8） （Smart ） ）
PEV Body Design Analysis PEV Body Design Analysis PEV Body Design Analysis PEV Body Design Analysis PEV Body Design Analysis • Design 1：Steel Structure+Polymer Cover • Design 2：Steel Structure + Al Cover • Design 3：Al Unibody • Design 4：ASF + Al / Polymer Cover • Design 4：CFRP Structure+Polymer Cover 参考RangeRover 铝合金车身相对钢 参考兰博基尼慕 参考audi A8铝 制车身减重39%. 拉贡设计，按等 制车身相对钢制 187*（1-39%） 效体积、密度近 ＝ － ﹢ 车身减重40%. • CFRP+Polymer Closures =114kg 似计算，车身骨 187*（1-40%） 架重量80kg。 ＝ － ﹢ =112kg Plastic Smart电动版整备重量 － W电池 ﹢ W电池 （80km或150km续 ﹢ 航） ＝ － ﹢ ＝ － ﹢ ﹢ ＝ － ﹢ ﹢ Plasti Steel Curb Mass － ﹢ aluminum c Al Closure Struct+Compo BIW （Steel Polymer Closure Curb Mass Struct+Composit sit Closure Actual W整备重量 W车身 ﹢ W冲压铝合金骨架﹢ W铝合金覆盖件 (Predic)kg Closures） － （Smart ） （kg） （钢结构+塑料覆盖件） （钢结构+塑料覆盖件） W整备重量 － W白车身 ﹢ W-碳纤维骨架 ﹢ W塑料覆盖件 Steel 整备重量 － W白车身 ﹢ W铝合金骨架 ﹢ W铝合金或塑料覆盖件 （钢结构+塑料覆盖件） （钢结构+塑料覆盖件） Struct+Al/Poly ASF+Al or （钢结构+塑料覆盖件） （钢结构+塑料覆盖件） W全铝车身 231 863 mer Closure BIW Curb Mass Polymer （参考Range Design 3 BIW Curb Mass CurbMass （kg） (pred) kg Closure Design 4 Design 2 BIW（kg） Rover） （kg） (Pred)kg CFRP+Polymer （Audi A6） (Pred)kg （Benchmark BIW Curb Mass Al Unibody 150 770 Closures Design 5 Steel Struct+Al Audi A8） ASF +Al Closure 148 768 （kg） (Pred) kg W电池重量：参考左图仿真结果，在整备质量（不含电池）一 223 855 Cover ASF + Polymer Closure 156 774 CFRP+Polymer 定的条件下，电池容量与续航里程成正比，推导电池重量与续 124 756 Closure 航里程也成正比。依此关系，基于Smart（145km续航、电池 178kg），分别计算Smart 80km、150km续航里程的电池重 量为98kg、184kg。 PEV Lightweight Technology SEV Body Design Analysis
• Lightweight Design – Mass Analysis
BIW & Curb Mass Evaluation
Predic. BIW Pred. Curb No. Body Design Method (kg） Mass（kg） 1 Steel Struct.+Polymer Cover 231 863 2 Steel Struct.+Al Cover 223 855 3 Full Al Body 150 770
ASF+Al Cover 148 768 4 ASF +Polymer Cover 156 774 5 CFRP+Polymer Cover 124 741 PEV Lightweight Technology
PAS Analysis
领先区间 670kg
领先间区间 757kg
竞争性区间 916kg
无竞争性区间
Based on the PALS analysis: ① Design 1 and 2 shown uncompetitivenss (Range U) ② Design 3, 4 and 5 shown the curb mass is among A or C. ③ Design 5 shown the curb mass is minimum, among leaders. PEV Lightweight Technology Lightweight Recommendation
Annual Production > Annual Production 10000 <5000台 CFRP Design
CFRP+Polymer Full Al Body ASF+Al/Polymer （Lamborghini ）
Full Alluminium Body Cost Assessment Al Lightweight Body Cost Assessment ASF + Al / Polymer Cover Cost Evaluation CFRP Body Cost Assessment Materials Body BIW Weight Percent Cost Evaluation – Full Al Unibody Materials Weight BIW Cost Design （kg） （Audi A8） （kg） Al sheet 35% 39.2 AL casting 35% 39.2 • BIW Cost Evaluation Percent Materials Design 4.1 BIW Weight 112 Al extrusion 22% 24.64 Proposal Materials （Range Weight BIW Cost （kg） RMB$5989 Rover） （kg） ASF + AHSS 4% 4.48 Materials (~USD$1000) BIW Weight Percent Aluminum UHSS 4% 4.48 Design No. Materials Weight BIW Cost Al sheet 74% 84.36 （kg） （Murciélago） cover 36 （kg） AL casting 15% 17.1 （Aluminum Al sheet / 36 cover） 80 CFRP 100% 80 114 Al extrusion 6% 6.84 7765RMB Al sheet 35% 39.2 Steel / #3 AHSS 4% 4.56 22.17 RMB$15027 (~USD1500) AL casting 35% 39.2 Design 5 44 (USD$2500) UHSS 1% 1.14 112 Al extrusion 22% 24.64 PP+EPDM-TD20 / Design 4.2 （Plastic cover） 12.79 AHSS 4% 4.48 36 RMB$4847 （ / ASF + PP-LGF40 / Aluminum Al sheet 36 UHSS 4% 4.48 (~USD$800) 9.35 cover） Plastic Steel / 22.17 cover 44 PP+EPDM- / 12.79 （Plastic cover） TD20 PP-LGF40 / 9.35 Contents
Why aluminum – Lightweight Technology
Geely PEV Project
PEV Lightweight Target
PEV Lightweight Technology Analysis
Challenges Challenge
Lightweight Design and Manufacturing Process
• Example 1: Aluminium Engine Hood
A l Engine Hood Cost E veluation
C ost Com parison between Al and Steel Engine Hoods
A l Engine Hood O neTime Steel Engine Hood O neTime PerU nit PerU nit Cost Investment Investment C ost M at.Cost Int.Panel ¥ 190.00 IntPanel ¥ 87.00 E xt.Panel ¥ 210.00 E xtPanel ¥ 96.00
Stam p Cost Tooling（RM B$10K ） ¥ 350.00 ¥ 17.50 Tooling（RM B$10K ） ¥ 350.00 ¥ 17.50 Stem ping(RM B$) ¥ 0.80 Stem ping(RM B$) ¥ 0.80
Joining A dhesive (RM B$) ¥ 5.00 A dhesive (RM B$) ¥ 5.00 SPR (RM B$) ¥ 20.00 ¥ 1.00 SpotW elding (RM B$) ¥ 3.00
SPR Cost (RM B$) ¥ 15.00
C oating Filter Equip. ¥ 2.00 ¥ 0.10 NoC hange F. ¥ 1.00
Total (RMB) ¥440.40 Total (RMB) ¥209.30 Challenge Lightweight Design and Manufacturing Process
• Example 2: Aluminium Front Bumper
Front Bumper Impact Result Comparison
Front Impact Results Longitudinal Beam LB Energy L/R B Pillar Lower End L/R Door Frame Collapse (mm) Absorption（%） Accelleration(g) Deformation (mm) Orig.(Steel) 425.8 36.60 34.20/34.70 0.817/2.732 Proposal 1 558.1 30.56 37.61/40.58 1.450/3.333 Proposal 2 455.5 36.89 36.93/40.28 1.255/3.126 Proposal 3 471.2 37.19 35.07/42.28 0.811/2.981
40% Offset Impact Results
Longitudinal Beam LB Energy L/R B Pillar Lower End L/R Door Frame Collapse (mm) Absorption（%） Accelleration(g) Deformation (mm) Orig.(Steel) 619.5 15.20 35.16/40.49 35.620/10.310 Proposal 1 641.1 12.84 41.35/43.58 56.484/12.337 Proposal 2 634.0 15.45 46.3/40.54 41.597/13.844 Proposal 3 658.6 16.02 42.05/41.94 40.410/6.900 Challenge
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