低能耗汽车的前端模块设计 Design of front end module for ...The 3rd International Auto Polymer Technology Annual Conference 2015 低能耗汽车的前端模块设计 Design

The 3rd International Auto Polymer Technology Annual Conference 2015

低能耗汽车的前端模块设计

Design of front end module for cars with low fuel consumption

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2HBPO / 2015 / R&D

Agenda

Introduction of HBPO睿联（HBPO）简介Function and structure of front end module前端模块的功能和构成Design of front end module for low fuel consumption面向低能耗的前端模块设计Lightweight design of front end carrier前端模块支架的轻量化设计Active grille shutter主动式进气格栅Summary总结


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Agenda



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HBPO as business partner

Full service from HBPO, the specialist

Automakers constantly faced with increasing vehicle complexity are trying to manage limited design and research engineering resources. To solve this dilemma, many automakers are turning to module specialists like HBPO.

In the area of front-end modules, HBPO is the world’s only supplier who can offer the entire process chain – from design and development, through the logistics operations. At the same time, HBPO is setting new design benchmarks and market solutions which are as technically advanced as they are financially attractive.

Headlamps

Carrier

Cooling module

ActiveGrill Shutter

Crash ManagementSystem


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Milestones

1997

First outsourced front-end assembly

VW Golf A3 delivered by Hella Meerane / Germany

Hella-Behr Fahrzeugsysteme GmbH forms Hella Behr Vehicle

Systems in the USA

HBPO GmbH is formed

Joint Venture HHBPO (HBPO; DRB Hicom) Malaysia

HHBPO as key player of thefront-end market in ASEAN

First outsourced front-end module with development responsibility and supplier management SKODA Fabia

Joint Venture SHB (Hella-Behr & Samlip, in Korea) is formed

SHB was the first front-end module supplier in the Korean

market

HBPO manufactures more than3 million front-end modules

in one year

1992 1999 2004 20122002 2008


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Customer portfolio


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Stages of responsibilities in FEM segment

CompleteSystem

Integration

DevelopmentProject

AssemblyProject

PurchasingAssembly Logistics Program Management

Supplier manage-ment and decisionmaking

OEM HBPO

Close interactionsbetween OEM andHBPO, with maximumresponsibilityto HBPO

Design & Development

Program Mgmt.

PurchasingAssembly & Logistics

INC

RE

AS

ING

RE

SP

ON

SIB

ILIT

Y Dodge Journey

Audi Q3

Volkswagen Polo

Design and Develop-Ment outsourced to HBPO and close interactions with OEM

Assembly Logistics Program Management

DesignDevelopmentPurchasing


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Core competencies

Program Management

�Program team

�Quality management

�Supplier management

�Engineering change

management

Development

�Advanced engineering

�Design engineering

�Simulation & FEA

�Prototypes & validation

Production

� Injection molding

�Tool tracking

�Change management

Assembly

�Factory planning &

construction

� Industrial engineering

�Module assembly

Logistics

� Inbound logistics

�JIS logistics

�Containers

� Information logistics


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Facts & Figures

Sales (in million Euro)

Units (in million FEM) incl. 100% JV

Europe54%

Americas21%

Asia25%

2014: 5,2 m. FEM

931

1.056

1.283

1.415 1.434

2010 2011 2012 2013 2014

4,04,4

4,8 4,85,2


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Global network

Mexico

Puebla, Toluca,San José Chiapa

USA

Troy

Canada

Windsor

Brazil

São Paulo

Spain

Martorell, Pamplona

England

Banbury

Germany

Lippstadt, Meerane,Rastatt, Ingolstadt,

RegensburgCzech Republic

Mnichovo Hradište

Slovakia

Lozorno

Hungary

Kecskemét, Győr

Japan

Tokyo

Malaysia

Shah Alam,Pekan, Kulim,

Tanjung Malim

China

Shanghai,Beijing

South Korea

Seoul, Busan, Pyeongtaek, Ulsan, Jillyang, Seosan, Hwasung

14 Countries24 JIS Assembly Plants

9 Corporate & Sales and Development Centers

14 Countries24 JIS Assembly Plants

9 Corporate & Sales and Development Centers


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Agenda



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Typical content of a front end module

Fan(s)

Shroud

Radiator

FEM-Carrier

Fascia/Bumper Cover

Headlamp

Bumper beam

Latch bridge

Other additional components

� Air guide

� Active Grill Shutter

� Sensors: Adaptive Cruise Control

� Cameras

� Wascher tanks

� Pedestrian Protection

� …

Latch


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Example ofmodules

Ford Fusion

VW Beetle

Porsche Panamera

AudiQ7

DaimlerA-Class

BMWMini

Porsche Cayenne

Carrier ● ● ● ● ● ● ●

Cooling system ● ● ● ● ● ●

Air guides ● ● ● ● ●

CMS ● ● ● ● ● ●

Head lamps ● ● ●

Bumper Cover ● ●

Active grill shutter ●

Integration level of front end module


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Example of front end module

Chrysler Town & Country

Porsche Panamera


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Example of front end module – BMW Mini


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Example of front end module - Porsche Macan

Air guide systemwith AGS

CMS

Foam

Lower stiffener

Assy CarrierGuide profile headlamp

Latch system withlatch support

Hose systemV6 BT HP cooling module

Macan FEM V6 BT HP

ACC-sensor

Fanfare


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Agenda



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� cost reduction

� Production

� Usage

Requirements on front vehicle structure

� Pedestrian Protection

� Occupant protection: 96/79/EG, Euro NCAP, Narrow Offset

� Insurance Crash: RCAR / IIHS

� Durability

� Safety

� Comfort

� Entertainment

� Styling / Design

� Emission reduction

� Aerodynamics


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CO2 Reduction – Regulations

CO2 limits for cars in major auto markets in g CO2 / km in the European test cycle

Source: ICCT


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CO2 Reduction – EU regulation and effect of car weight

The heavier a car, the more defficult to meet the target of EU.

Therefore, to reduce the weight is one of key factor to reduce CO2 emission

130

9578

2015 2021 2025

Average CO2 emission of

all new registered cars


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CO2 Reduction – EU regulation for monetary penalty

� To minimize penalty is very important for a car maker to make its product profitable.

� As far as cost of a solution to reduce CO2 emission is more lower than the penalty, the solution has good change to be applied.

From 2018 on

limit exeedance of g CO2/km is x

=> Penalty is 95x


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Contribution of front end module

� by using

� active grill shutter

� air guides

� by lightweight design

Countermeasures to reduce CO 2 emission

Countermeasures to reduce oil consumption

� improvement of engine efficiency

� rolling risistance of the tires

� reduction of drag coefficient Cd

� reduction of car weight

� using electricity

� …


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Agenda



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Requirements on front end carrier

Quality

� Dimensional stability� Form stability� High temperature stability� Adequate corrosion stability� Adequate surface quality

Production

� Manufacturing� Assembling

Safety

� High stiffness� High rigidity� High durability� Good crash performance

Cost

� Material� Fabrication� Assembly� Invest� Logistics

Environment protection

� Low weight� Good recyclability� Low emission� Minimized logistics� Package compactness

Technology� Freedom of design� Package� Changeability


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Examples of carrier designed by HBPO

Project Technology Material

Porsche Cayenne E2 In Mold Hybrid Steel / PP LGF30

Ford Fusion Post Mold Hybrid Steel / PP LGF40

Porsche Panamera Magnesium AM50

KIA Cerato In Mold Hybrid Steel / PA6 GF30

BMW Mini Post Mold Hybrid Steel/ PA6 GF30

Daimler Vito / Viano In Mold Hybrid Steel/ PP LGF30

Daimler MFA In Mold Hybrid Alu/PA6 GF60

Audi Q7 In Mold Hybrid Steel / PP LGF30

Audi Q7 W12 In Mold Hybrid Steel/ PA6 GF30

Audi Q3 In/Post Mold Hybrid Steel/PA6 GF30

Audi A3 In Mold Hybrid Steel/PA6 GF30

Chrysler Town&Country Post Mold Hybrid Steel / PP SGF30

Dodge Journey In Mold Hybrid Steel / PP LGF20

Renault Koleos In Mold Hybrid Steel / PA6 GF30


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Light weight design

DesignMaterial

Structural optimization

Tailored & Patch

Function- & part-integration

Magnesium (Mg)

Compositeplastics

Aluminum (Al)

Steel (St)

Hybrid & Multi-Material-Construction

Light weight design of carrier


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Light weight materials

Properties Steel Aluminum MagnesiumComposite (GF)

Composite (CF)

Plastic GF

Rigidity (Tensile load)

E / ρ 1 1 1 <0.73 ～1.4 <0.27

Buckling stability E1/2 / ρ 1 1.7 2.1 <1.8 ～2.7 <1.2

Bending rigidity (same space)

E ~0.9 / ρ 1 1.1 1.2 <0.85 ～1.6 <0.35

Durability σ/ ρ 1 0.75 0.8 <1.25 ～2,5 <0.6

The bigger the ratio, the higher the light weight potential


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Hybrid structure vs. welded steel structure: Daimler V ito/Viano

Welded steel structure6.9 kg

Hybrid structureSteel / PP LGF304.3 kg

high function integration

- ca. 2.8 kg ( - 40%)


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Hybrid structure: carrier of Audi A3

� In-mold hybrid structure� One piece� Steel / PA6 GF30� only to use steel if necessary


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Hybrid structure: carrier of Audi A3 with different variants

Cooling position front

Cooling position front Cabrio

Cooling position rear

Cooling position rear Cabrio


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Hybrid / multimaterial design: carrier of Audi Q3

� Head lamp arm� PP GF30: 0.5 kg / part

� multi pieces design� In mold hybrid structure� seperated latch bridge L&R to enable tolerance compensation� production in a familiy tool

Gewicht: 5,0 kg


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Hybrid / multimaterial design: carrier of Porsche Ma can

Porsche Macan Carrier Basic Porsche Macan Carrier Top

Steel / PP-LGF30:～2.2 kg

Aluminium / PP-LGF30:～1.7 kgFascia carrier TopFascia carrier Basic

Carrier leftCarrier right

Assy weight: ～6.1 kg

Sheet metal weight: ～2.8 kg


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Bulkhead: PP LGF40 Latch support: SteelUpper cooling fixation: clip

Multimaterial design: carrier of Ford CD 338

post-mold hybrid structure


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Magnesium carrier vs. hybrid carrier: Porsche Param era

5,2kg � 3,5kg

� 33 %

ca. 1.7 kg (-33%)

Hybrid structure for prototype5.2 kg

Low cost

Magnesium casting structurefor series production3.5 kg

High cost


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HBPO Light weight design – Cayenne E2

� Steel hybrid� PP LGF30� Open profile� 2.45 kg

� Full-plastic carrier (PA6 GF30)� CF-sheet for closing profile� Tape fixed with vibration welding� 2.1 kg

Latch

Plastic

GF/CF-Tape

series part

� Composite hybrid� PP LGF30� Open profile� 1.75 kg

Composite sheet as inlay Composite sheet as closing sheet


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HBPO Light weight design – Cayenne E2

GF or CF Tape t=1,5mm PA6 Matrix

Carrier inPA6 GF30%

Friction Welding Area

Vibration welding as joining technology to represen t a closed profile structure


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Comparison between lightweight designs

Analysis carrier concepts Porsche Cayenne E2

Optical Modal Analysis

Part Weight G kg

1. naturalfrequency fHz

f/Gratio

Steel hybrid 2.45 31.6 13

Composite hybrid 1.75 27.7 16

Full plastic withclose CF-sheet

2.1 46.9 22


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Injection molded with composite inlay, PA Matrix, 50% GF, Bi directional 80/20

Worldwide first composite carrier with inmold formed multiple composite inlays

Carrier weight: 4.7 kg � 1.5 kg weight reduction in comparison to steel hybrid

6,2kg � 4,7kg

Composite sheet vs. Steel sheet

� 25 %


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Structural optimisation

5,2kg � 3,5kg

� 33 %

Stiffness based structural optimization• Frequency response analysis• Eigenvalue analysis• Linear statics

Methods• Topological optimization• Topographical optimization• Gauge optimization

Optimization of plastic rips

Optimization of sheet metal

Optimization of thicknessof metal sheets

Optimization of beads


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Structural optimization – topological optimisation

5,2kg � 3,5kg

Target: to fulfil the stiffness requirement with mi nimal weight

Optimization of plastic rips

� Close sheet to increase stiffness

� Weight based optimization

� 2 mm steel sheet with cut-outs

� Cost based optimization

� 1.8 mm steel sheet without cut outs

Optimization of sheet metal

� define package� define ejection direction


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Target

� to maximize the first eigenvalue of the BIW

� to understand the influence of the BIW on the structure of carrier

Result

� BIW has a huge influence of the Ribbing strategy

� By taking the BIW into the topological optimization, the BIW performance can increase by 0.1 % without mass and cost increase

Structural optimization – carrier as part of BIW

5,2kg � 3,5kg

Blue model: without BIWGray model: with BIW.


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Agenda



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Active Grille Shutters help reduce Drag


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HBPO Active Grill Shutter projects

Connection bracket

Actuator

Flaps (6 Flaps)

Actuator bracket

Frame

Screw actuator bracket

Active Grill Shutter Macan

� Assembly-weight: 1,3kg

� Actuator installed centrally

� Poka-Yoke solution at the flap pivot bearings


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By reducing drag: ～- 1.0 gCO2/km

By incraesing weight (2,0 kg): ～+ 0.17 gCO2/km

---------------------------------------------------------------------

～- 0.83 gCO2/km

Comparable with weight reduction: ～- 0.83 / 0.085 = 10 kg

Penalty in EU (after +3 gCO2/km): ～0.83 x 95 = 79 €

System cost of the shown AGS: ～ 25 € << 79 €

Effect of active grill shutter on CO 2 emission


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Active Grill Shutter

Customer Advantages and Technical Items:

Drag coefficient reduction

CO2 emission reduction / fuel consumption reduction

Noise reduction, especially at cold start

Improvement of heat up condition powertrain

Protect cooling system


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HBPO Active Flex Shutter

Active Flex Shutter: Shutter located to the bumper cover

Main components

1. Rear Frame

2. Flexible Closing Plate

3. Drive shaft

4. Actuator

5. Front Frame

1

2

3

45


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Agenda



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Summary

Front end module has a significant impact on the fuel consumption

Light weight design helps to reduce fuel assumption or CO2 emission

AGS helps to reduce fuel assumption or CO2 emission

HBPO can support you to realize light weight structure and AGS efficiently

Gaoming Zhao

HBPO GmbHResearch & DevelopmentRixbecker Straße 11159552 Lippstadt, Germany

Phone: +49 2941 2838-411Mobile: +49 172 2585 024E-Mail: [email protected] www.hbpogroup.com

Thanks for you attention!

Documents

低能耗汽车的前端模块设计 Design of front end module for ...The 3rd International Auto Polymer Technology Annual Conference 2015 低能耗汽车的前端模块设计 Design