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The New OPEL Corsa Body- EuroCarBody 车身工程.pdf

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THE NEW OPEL CORSA BODY EUROCARBODY 车身 工程
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GME Engineering 1 The New OPEL Corsa Body EuroCarBody 2006 K.P. Manns S. ZielkeGME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 2 The New OPEL Corsa Corsa Positioning For spirited ; Ped Ped Pro Pro ? ? NVH and NVH and Fatique Fatique ? ? Manufacturing Manufacturing Strategies Strategies Main Main mass mass reduction reduction activities activities: : ? ? PHS PHS B B- -Pillar Pillar Reinf Reinf. . - -4,5kg 4,5kg ? ? PHS PHS A A- -Pillar Pillar Reinf Reinf. . - -3,0kg 3,0kg ? ? Hybrid Front Hybrid Front - -1,5kg 1,5kg ? ? Usage Usage of of Thin Thin Metal Metal - -5,2 kg 5,2 kg ? ? Usage Usage of HSS Steel of HSS Steel - -8,9kg 8,9kgGME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 10 The New OPEL Corsa Simulation Areas PTC PTC UTM UTM Aerodynamics Aerodynamics Statics Statics Dynamics Dynamics Closures Closures Crash Crash Veh Veh. Fatigue . Fatigue Chassis Chassis Structure Structure Vehicle Vehicle Dynamics Dynamics Ride/Steering Ride/Steering Overall Overall Struct Struct. Borne . Borne N & V N & V High Freq. High Freq. Acoustics Acoustics Airborne Airborne N & V N & V Class Leading Driving Dynamics Set new standards in respect to handling, agility and response. To reach this ambitious targets, the new Corsa has a completely newly designed chassis with improvements and innovative design solutions in all areas. Improvement of mobilities for all chassis attachment points Crash Excellent Overall Crash performance, very good 5- Star EuroNCAP rating and improved Insurance classification HVAC HVACGME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 11 The New OPEL Corsa Body Targets - Weight Efficiency The Weight Efficiency of the new OPEL Corsa has been increased by 33% compared with predecessor. Higher structural efficiency (effective utilization of material) m [kg]: BIW mass included bolted elements, glued windscreen and front sub frame K t [kNm/deg]: Torsional stiffness of BIW included bolted elements and glued windscreen A [m 2 ]: Wheel Base x Tread ? ? ? ? o ? = 3 4 2 10 deg m s A K m iency ture effic Body struc T ? ? ? ? o ? = = deg Nm L F M K T T a a 0,0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 Weight Efficiency [(kg/(kNm/grd*m2))] Old Corsa 3-DR MJ 2000 New Corsa 3-DR MJ 2007 - -33% 33%GME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 12 0 5 10 15 20 25 30 Torsion [kNm/deg] Bending [kN/mm] Front End Bending [kN/mm] Rear End Bending [kN/mm] Old Corsa 3-DR MJ 2000 New Corsa 3-DR MJ 2007 The New OPEL Corsa Body Targets - Torsion-/Bending Stiffness Vehicle feels stiffer, better driving dynamics Less relative movement between parts, better quality, lower gaps between body and hang-on parts can be realized (Values are measured values, Bending and Torsion stiffness with cradle, with glass) +122% +122% +67% +67% +97% +97% +72% +72%GME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 13 0 5 10 15 20 25 30 35 40 45 50 1st torsional mode [Hz] 1st bending mode [Hz] Old Corsa 3-DR MJ 2000 New Corsa 3-DR MJ 2007 The New OPEL Corsa Body Targets - Global Dynamic BIW-Modes Increased dynamic global modes with reduced magnitude compared to old Corsa. The first global torsional mode could be improved by 12 % compared with old Corsa. The first global bending mode could be improved by 9,5 % compared with old Corsa. Direct driving feeling / better handling Improved comfort level Better tuning of driving dynamic possible Reduced interior noise levels +12% +12% +9,5% +9,5%GME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 14 29 30 31 32 33 34 35 1st natural frequency, BIW vertical [Hz] Old Corsa 3-DR MJ 2000 New Corsa 3-DR MJ 2007 The New OPEL Corsa Body Targets - Dynamic Steering Column 1st natural frequency improved by 11% versus old Corsa. Improved vibration levels at man/machine interface (very low steering wheel vibrations, in particular with diesel motors at idle) Improved steering feel, sensitivity and feedback +11% +11%GME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 15 The New OPEL Corsa Body Targets - Noise & Vibrations Optimized short sub frame with additional crossbar Optimized Hybrid front with integrated radiator system Reduced Road Noise Reduced Road Noise Damper Ratio ~1 Lower A-Bushing stiffness possible (The A-bushing area is a dominant road noise path from the rear suspension) Optimized Front Rail Reinf. (e.g. for idle boom noise the RH engine mount is important Optimized Rear Floor Dash Panel ReinforcementsGME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 16 The New OPEL Corsa Body Targets - Noise & Vibrations Tools Major NVH development tools: Major NVH development tools: - Mobility Analysis for Coupling points of Chassis to Body was performed to reduce the force transmission from engine mounting and road to body - Frequency Based Substructuring Method Since the acoustic performance is still not predictable in detail hybrid models were integrated in the early phase of the architecture definition - Binaurale Transfer Path Analysis (BTPA) is used mostly as a standard and strong tool to identify and to analyze single transfer paths and noise sources (e.g. noise transfer from Axle coupling points to passenger cavity). A noise potential could be defined before hardware is available. - Analysis Tool for Road Noise Performance for definition of a property that describes the sensitivity of a car structure under different road excitation (method called spindle sensitivity) - Statistic Energy Analysis (SEA): Acoustic air borne sound ( > 400Hz), development of insulation package BTPA components of an airborne and a structure-borne transfer path [Christian Sch?nherr, GME] Engine speed (RPM) Sound pressure level (dB(A)) Predecessor Corsa New Opel Corsa 10 dB 1000 rpm Interior Noise Level 2nd Order Corsa 1,3l Diesel Engine [Christian Sch?nherr, GME]GME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 17 The New OPEL Corsa Virtual Road Load Data Acquisition - Procedure I. Build dynamic full-vehicle model: virtual prototype + virtual driver III. Calculate virtual load time histories Fi(t) for chassis- and body-parts IV. Compare relative damage caused by virtual loads F i (t) virtual loads II. Ride on digital durability-tracks (Dudenhofen) 0,00 0,50 1,00 1,50 2,00 2,50 Fx_rack_lh Fx_rack_rh Fx_tierod_lh Fx_tierod_rh Fy_rack_lh Fy_rack_rh Fy_tierod_lh Fy_tierod_rh Fz_rack_lh Fz_rack_rh Fz_tierod_lh Fz_tierod_rh Relative Damage (--) A B C D H I J parameter set-ups Pothole 1-3 Hill Section Washboard Hump Track L-Turns Belgian Block Wave Section ..... etc. objective: run complete durability programs (SD1, SDG0, E0, G0, SDS)GME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 18 The New OPEL Corsa Body Targets - Fatigue Radiator Door hinge Hood slam Tailgate slam Door slam Spot weld durability REC Trimmed Body Fatigue simulation Durability development was driven by: Durability development was driven by: Durability Program Dudenhofen Tire program, 17 and Sport Chassis Chassis tuning typical for OPEL carsGME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 19 Joining Joining Technique Technique New Corsa New Corsa Spot welds 3756 MIG welds (mm) 520 Clinch spots 50 Structural Bonding 1275 Weld studs 178 Parts 291 Sealing Sealing Seams Seams (mm) (mm) Paint Shop 88445 Body Shop 3600 The New OPEL Corsa Manufacturing -JoiningGME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 20 Ellesmere Ellesmere Port Port Azambuja Azambuja Zaragoza Zaragoza Antwerpen Antwerpen Kaiserslautern Kaiserslautern Bochum Bochum R Rü üsselsheim sselsheim Eisenach Eisenach Gleiwitz Gleiwitz Trollh Trollh? ?ttan ttan § § Corsa HB3/HB5 Corsa HB3/HB5 § § Corsa Corsa DelVan DelVan § § Meriva Meriva § § Corsa HB3 Corsa HB3 Zaragoza Zaragoza Eisenach Eisenach The New OPEL Corsa Manufacturing Footprint – Bodystyle AllocationGME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 21 Plant Total Zaragoza Eisenach [jph] [Units/year] Shifts Corsa HB5 Corsa HB3 Corsa DelVan Total Corsa Meriva Flex [jph] 92,4 ~ 450.000 3 25 50 3 55 46 36 ~ 180.000 3 - 36 - 36 - The New OPEL Corsa Manufacturing Footprint – CapacityGME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 22 § 100% Utilization of new GM/Fiat architecture (common for 3/5 dr) § Maximum reuse of existing equipment § Modular Build § Bolted Door Hinges § Single line concept in both plants § Validation Car build in plant starting 35 weeks before SORP § Run out of 2nd manufacturing line in Zaragoza Bodyshop in May 05 § No building extension The New OPEL Corsa Strategy & Assumptions – Manufacturing DirectionsGME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 23 Underbody Underbody Marriage Marriage Roof Roof Framing Framing / / Respot Respot Body In White Body In White FRONT FLOOR UNDERBODY REAR ROCKER PANEL BACK PANEL LOWER ROOF STRUCTURE ROOF ASM FENDER RH TAIGATE ASM DOORS RH FENDER LH HOOD ASM DOORS LH BRAZE WHEELHOUSE SIDE PANEL LH SIDE PANEL RH PANEL REAR END Engine Engine Cmpt Cmpt The New OPEL Corsa Mainline – Assembly SequenceGME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 24 The New OPEL Corsa Bodyshop Migration – Process Overview Zaragoza Line 1: 55JPH Line 1: 55JPH HOPs HOPs Respot Respot Roof Roof Roof Roof Respot Respot Body Body Framing Framing Respot Respot Roof Roof Subassies Subassies UB UB- - Marriage Marriage Subassies Subassies UB UB- - Marriage Marriage Bodyside Bodyside Compl Compl. . Framing Framing Inner Inner Bodyside Bodyside Inner Inner Framing Framing Outer Outer Bodyside Bodyside Outer Outer Roof Roof Roof Roof Respot Respot BIW BIW HOPs HOPs HOPs HOPs HOPs HOPs Corsa `00 Corsa `00 Meriva Meriva BIW BIW Bodyside Bodyside Compl Compl. . UB UB- - Marriage Marriage Subassies Subassies Subassies Subassies UB UB- - Marriage Marriage Bodyside Bodyside Compl Compl. . Body Body Framing Framing BIW BIW Line 1: 47JPH Line 1: 47JPH Line 2: 47JPH Line 2: 47JPH Line 3: 46JPH Line 3: 46JPH Basic Process 2004 2004 2005 2005 2006 2006 Apr Apr′ ′05 05 Body Body Framing Framing Respot Respot Respot Respot Respot Respot Respot Respot Respot Respot Tabbing Tabbing Tabbing TabbingGME Engineering EuroCarBody 2006 The New OPEL Corsa Body Program Notebook Monday, 25 September 2006 / 25 The New OPEL Corsa Bodyshop Migration – Process Overview Zaragoza Line 1: 55JPH Line 1: 55JPH HOPs HOPs Respot Respot Roof Roof Respot Respot Body Body Framing Framing Respot Respot Roof Roof Subassies Subassies UB UB- - Marriage Marriage Framing Framing Inner Inner Bodyside Bodyside Inner Inner Framing Framing Outer Outer Bodyside Bodyside Outer Outer Roof Roof BIW BIW HOPs HOPs HOPs HOPs Meriva Meriva BIW BIW Bodyside Bodyside Compl Compl. . UB UB- - Marriage Marriage Subassies Subassies Line 3: 46JPH Line 3: 46JPH 2004 2004 2005 2005 2006 2006 SORP Jul SORP Jul ′ ′06 06 Respot Respot Respot Respot Tabbing Tabbing Corsa `06 Corsa `06 Final Process
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