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The New Opel Meriva EuroCarBody.pdf

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THE NEW OPEL MERIVA EUROCARBODY
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The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 The New Opel The New Opel Meriva Meriva EuroCarBody 2010 October 19/20/21 Bad Nauheim Gunther Heim Advanced Engineering Body GM Europe Jose-Luis Perez-Freije Simulation Integration Manager, Small Cars GM Europe Thomas Jahn Manufacturing Engineering Body Lowers GM EuropeThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 2 Table of Content 1. Introduction 2. Engineering 3. ManufacturingThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 3 Table of Content 1. Introduction  Heritage and FlexDoors ?  Further Highlights  Dimensions 2. Engineering 3. ManufacturingThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 2003 2010 Heritage Opel Meriva Concept Opel Concept M 2008 2002 4The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Rear-hinged doors were used in carriages, centuries before the car was developed They became standard for most cars, trucks and busses in the early 20 th century Heritage 5The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 In the late 30s all the cars in Opel’s range featured rear-hinged doors From Compact Cars like the Kadett… …via the Kapit?n… …to Luxury Cars like the Admiral Nevertheless rear-hinged doors were abolished in in Germany in 1963 due to safety reasons. Until 2003, when Rolls-Royce relaunched them. A good time for Opel to start with innovation too! Heritage 6The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 FlexDoors ? The New Opel Meriva 7The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 8 FlexDoors ?  Better control on kids  Better accessThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 9 Table of Content 1. Introduction  Heritage and FlexDoors ?  Further Highlights  Dimensions 2. Engineering 3. ManufacturingThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 FlexFix ? rear carrier system  Unique to Opel  Always available  Excellent ergonomics 10The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Panoramic Glass Roof Panoramic Glass Roof The New Opel Meriva 11 Improved visibility: Improved visibility: Slim and narrow Slim and narrow realigned A realigned A- -Pillars Pillars Improved visibility: Improved visibility: Slim and narrow Slim and narrow realigned A realigned A- -Pillars PillarsThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010  Stretching over both rows of seats  Electrically operated sunshade  Makes the whole car feel light and airy Panoramic Glass Roof 12The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 AGR – Aktion Gesunder Rücken* Seal of approval FlexFix ? FlexFix ? FlexSpace ? FlexSpace ? FlexDoors ? FlexDoors ? Ergonomic Seat AGR Ergonomic Seat AGR FlexRail ? FlexRail ? *Campaign for a healthy back The New Opel Meriva 13The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Latest Press-Releases auto motor sport: “Innovativstes Sitzkonzept in dieser Klasse“ Auto Zeitung: “Nicht nur praktisch, auch chic“ Auto Bild: “Ergonomisch überlegen“ Auto Stra?enverkehr: “Hier steigt man gerne ein“ auto motor sport: “Mehr Freude am Mitfahren“ Auto Bild: “Kompakter Raumkünstler“ Focus online: “Der Rolls-Royce-Effekt“ Focus online: “Mütter werden Meriva m?gen“ Auto Express: “What a difference a door makes!” car: “It's pretty spacious for such a small car“ Auto Express: “great real-world practicality” 14The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Awards of the specialized Press Auto BILD Design Award Plus X Award AGR Seal of approval 15 in the category SUVs, vans and 4-wheel cars in the category minivan for innovation, design, functionality and ergonomics for the overall concept as an ergonomics systemThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 16 Table of Content 1. Introduction  Heritage and FlexDoors ?  Highlights  Dimensions 2. Engineering 3. ManufacturingThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Dimensions – Meriva A vs. Meriva B 17 Frontal area (A) 2,35 m2 Coefficient of drag (c D ) 0,32 Drag area (c D x A) 0,75 m2 Luggage volume 360 l – 1410 l Tank capacity 53 lThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Dimensions – Meriva A vs. Meriva B 4288 2644 1615 1488 1812 1994 1509 (+14) (+236) (-9) (+39) (+118) (+45) (+46) Frontal area (A) 2,42 m2 (+0,07 m 2 ) Coefficient of drag (c D ) 0,33 (+0,01) Drag area (c D x A) 0,80 m2 (+0,05 m 2 ) Luggage volume 400 l – 1500 l (360 l – 1410 l) Tank capacity 54 l (+ 1l) 18The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 19 Table of Content 1. Introduction 2. Engineering  Concept (BOM), Materials and Weights  Body Structure – Stiffness and Strength  Passive Safety 3. ManufacturingThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Concept / Bill of Material (BOM) 20 Underbody Front: Concept Zafira B Underbody Rear: Concept Meriva A Front Seat structure: Global Front Seat Rear Seat structure: Improved FlexSpace ? seat folding system Chassis: C/o Zafira BThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Manufacturing Technologies appr. 6 kg New Meriva 325 kg Lightweight design achieved through: Dimensions Meriva A Styling New Features FlexDoors ? New Requirements Safety/RCAR Topology Optimization appr. 9 kg Material Substitution appr. 15 kg Weight of Body in White (BIW) 21 375 kg 275 kg Euro NCAP Zafira BThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Weight of Body in White (BIW) Further weight reduction loops after design release Weight Reduction Team & Cost Management Team Performance Manufacturing Engineering Vehicle Simulation Vehicle System Engineers …… Vehicle refinement and optimization 22The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Materials and Weights - Overview Meriva A Meriva B 0 400 800 1.200 1.600 2.000 0 200 400 600 800 1.000 1.200 1.400 Tensile Strength /MPa Yield Strength /MPa HSLA BH Low Strength Steel High Strength Steel Ultra High Strength Steel Advanced High Strength Steel CP MS PHS Press Hardened Steel Mild TRIP DP HSIF AL 1,4% Mild Steels 49,3% BH & HSS 49,3% Mild Steels 35,6 % BH & HSS 43,3 % DP 13,1 % PHS 5 % AL 3 % 23The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Materials and Weights - Overview Mild Steels BH & HSS DP PHS AL 24 5 % 3 % 35,6 % 13,1 % 43,3 %The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 25 Table of Content 1. Introduction 2. Engineering  Concept (BOM), Materials and Weights  Body Structure – Stiffness and Strength  Passive Safety 3. ManufacturingThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Body Structure Efficiency (BSE) BSE = m : Mass BiW K T : Torsion stiffness A : Area of tread x wheelbase K T = F · L m K T . A deg . s 2 m 4 . 10 3 N · m deg Meriva A MerivaB Meriva A 4,82 Meriva B 3,82 -21 % better BSE 26The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Global Static Stiffness 27 F F Rear End Bending Front End Bending Global Bending Global Torsion Improvement vs. predecessor Values shown for Meriva BThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Global Dynamic Stiffness Torsion Box Closed reinforcement rings well connected to longitudinal body structure Front Upper Floor Cross Member connected with C-Pillar reinforcement, using reinforcements for FlexDoor ? Simulated values 28 Meriva A Meriva B Meriva A Meriva BThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Rear Door Development REAR DOOR (DOOR AND PILLAR-STIFFNESS): Frame stiffness (B-, C-Pillar) Aerodynamic Wind load (< 3mm) Door Sag (Door + Hinge) (< 4 elastic and < 1mm plastic Deformation) Door Overpull Beltline lateral Stiffness Dynamic Behavior Buckling & Oil Canning Door Slam F=785 N Sag F=196 N / F=491N Overpull Target fulfilled : 60.000 door slams 30.000 windows closed 20.000 glass in middle position 10.000 window open No contact between screw and door up to 50 kg load Slam v=1 m/s (sealing already in contact) Reinforcement of inner body panelThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Cross Car Beam Structural Solutions:  Design and gage optimization to fulfill safety and stiffness criteria  Usage of a tube in tube design and bolted through hinge pillar Meriva A Meriva B IP-Beam 8,5 kg 30 Improvement 1 st Natural Frequency Steering Column: Meriva B vs. Meriva A Column in BIW Column only (Frequency with extended steering column)The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Structural Loadpaths - Overview 31 Lower Load Path Main Load Path Upper Load Path Airbag SystemsThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 32 Table of Content 1. Introduction 2. Engineering  Concept (BOM), Materials and Weights  Body Structure – Stiffness and Strength  Passive Safety 3. ManufacturingThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Front Impact – Euro NCAP ODB 64kph 33The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Structural Loadpaths – Front Impact & Challenges 34 Slim A-Pillar (1,45 mm PHS) Small Hinge Pillar (HSS) Front Rail Assembly carry over from Zafira (HSS) Roll Forming Tunnel (1,3mm DP800) Center Floor “Tailored Welded Blank” 1.8mm DP800 / 0,75 HSS Roll Forming Rocker reinforcement (1,8mm DP800) Closed sections Front Floor “Tailored Welded Blank” 1,75mm / 1mm (HSS)The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Structural Loadpaths – Front Impact Optimization of FlexDoor ? for Front Impact Reduction of Loads through beltline Rear Door Front Door Doors in Tailored Welded Blank 35 Door Pads to prevent unfavorable ContactThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Front Impact – Euro NCAP ODB 64kph  Optimized progressive energy absorption  Maximum structural integrity and robustness of passenger compartment  Negligible displacements of A-pillar and IP beam  Minimal dash intrusions X-displacement Meriva A Meriva B 1.4 Gasoline Turbo 65 kph 36The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Side Impact – Euro NCAP 50 kph & Pole 29 kph 37The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Structural Loadpaths – Side  PHS B-pillar reinforcement  PHS seat cross member  PHS door beams  Dual phase steel roof frame middle  Dual phase steel rocker PHS seat crossmember PHS B-Pillar designed for robust impact behavior and trigger to avoid cracks 38The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Side Impact – Euro NCAP 50kph  Increased survival space and robustness  Optimized load transfer paths  Significantly reduced intrusions and intrusion velocities - 45 % 1.4 Gasoline Turbo 50 kph - 31 % 39The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Side Impact – Euro NCAP 50kph Meriva A Meriva B y-displacement 40The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Side Impact – Pole 29 kph  Maximum survival space  Stable seat cross member load path with limited deformations  Structural integrity is given, no seam openings 41 1.4 Turbo 29 kph PHS seat cross memberThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 42 Structural Loadpaths – Rear Impact Structural integrity also given with FlexFix ? Bike Carrier 1.7 Diesel Max. vehicle weight, 2 Dummies, fully equipped Additional reinforcement to carry high loads Kinematics FlexFix ? Bike Carrier Moving Rigid Barrier (1800 kg), full overlap, 54 kph The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Pedestrian Protection – Head Impact RCAR driven front edge Headlamps with collapsible brackets 43 Optimized package ensures sufficient deformation space Thin sheet strategy: hood outer panel 0,6 mm hood inner panel 0,5 mmThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Pedestrian Protection – Head Impact ?Swan neck“ hinge concept Fenders mounted on deformable brackets Collapsible wiper system pivots Lowered brace wheel- house and front upper 44The New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Backward movement for RCAR leads to stiff structure of bonnet front edge close to head impact test area. Special cut outs were added. Parting line fascia - hood was moved backwards for RCAR. 45 Pedestrian Protection – Head ImpactThe New Opel Meriva GME Engineering Gunther Heim, Jose-Luis Perez-Freije, Thomas Jahn Thursday, October 21, 2010 Weight optimized fiber- reinforced plastic lower bumper stiffener with full elastic behavior in lower leg. Low density foam structure in front of the bumper beam Backward positioned
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