Dr. Axel Friedrich
Notwendigkeit und Möglichkeiten
des Leichtbaus von Pkw
Klima
http://data.giss.nasa.gov/gistemp/graphs/Fig.A.lr g.gif
5
Warum ist Leichtbau so wichtig?
• Niedrige Masse ist die Voraussetzung niedrige CO2 Emissionen
• ca 6-8% Minderung der CO” Emissionen durch 10%
Verringerung der Fahrzeugmasse.
– Massenaddtionseffekt:
• Verringerte Masse verringert auch die Motorleistungsanforderungen
• Reduzierte Powertrain Anforderung verringerte PT Masse
• Reduzierte Pt Masse reduzierter Rahmen, Federn, Bremsen...
• Re-iterativer Prozess
• Massenreduktion kann verwendet werden, um die erhöhte Masse von alternativen Antrieben zu
kompensieren (Hybrid-Fz, Elektro-Fz)
International Council on Clean Transportation
The goal of the ICCT is to dramatically reduce
conventional pollutant and greenhouse gas emissions from personal, public and goods transportation in order to improve air quality and human health, and mitigate climate change.
http://www.theicct.org/
Slide 6
Aktivitäten des
International Council for
Clean Transport (ICCT)
Slide 9
Vergleich der Pkw GHG Standards
US EU Mexico
• GHG/CAFE standards for
2017-2025 • CO2 standards for 2020 • FE standards for 2016/2020
• Conventional pollutant standards
• EPA/NHTSA/CARB: Proposed rules Sept. 1st
• CARB final rules planned in Oct.; EPA/NHTSA final rule mid-late 2012
• EU impact assessment: Late 2011 to early 2012
• Formal proposal: Issued in mid-
• New long-term target: 20132012
• Negotiations with industry ongoing – resolution expected later this year
• Ricardo Simulation Work
• DRI Safety Study
• FEV Crash Simulation
• Potential additional FEV cost teardown work
• Attribute parameter paper
• FEV: Technology costs
• Adapting US Ricardo simulation work for EU
• Potential additional simulation work for EU
• Respond to industry comments/questions
• Used vehicle analysis
• Phase-in of FE standards
• Review of emission standards proposal
• John German
• Ed Pike
• Anup Bandivadekar
• Peter Mock
• John German
• Anup Bandivadekar
• Kate Blumberg
• Nic Lutsey (?)
• Juan Pablo (?)
ICCT Engagement Weltweit
China India Rest of World
• Phase III and IV Fuel Consumption Standard
• Vehicle Emission and Fuel Quality Standards
• FE standards for 2015/2020
• Auto Fuel Policy 2011-2020 • Monitoring and advising development of CO2
standards, and complementary policies
• Phase III LD FC std.:
Implemented starting in 2012
• Emissions: China IV in July 2011; Beijing China V 2012
• Fuel quality: 150-ppm sulfur gasoline; 50-ppm in Beijing, Shanghai, Guangzhou
• PV FE standards on the cards
• In the pipeline standards for 2-3 wheelers, N1 vehicles
• No proposed air pollution
regulatory action (currently Euro 3 with Euro 4 for major cities)
• Chile: Support feebate design
• Australia: LDV CO2 standards for 2015 & 2020
• South Korea: 2015 FE/GHG standard; tyre efficiency std
• Brazil: Revision of labeling
• Workshop on fiscal measures
• Ongoing support on labeling, test cycle, regulatory design
• Technology path to Euro6
• Best practices in emission standards enforcement
• Iyer study on 2-3 wheelers
• TERI sulfur workshop
• Possible Shakti/ICCT project with Prof. Pundir
• Ongoing India model development work
• Outreach of fiscal measures work (feebates/ fiscal policies reports)
• Major update of PV standards report
• Labeling white paper
• Hui He
• Freda Fung
• Vance Wagner
• Anup Bandivadekar
• Francisco Posada
• Alan Lloyd
• Hui He
• Anup Bandivadekar
• John German
ICCT Engagement Weltweit
Leichtbau Material entwicklung
12
Lotus mass‐reduction crash simulation work
– CARB/EPA/NHTSA collaboration
– Computer‐Aided Engineering (CAE)
– Simulate vehicle in front, side, offset crashes
– Validate crashworthiness of 30%+ mass‐reduced vehicle – Completion in winter/spring 2011
Lotus Projekt
14
Introduction
• The Energy Foundation contracted with Lotus Engineering to generate a technical paper which would identify potential mass reduction
opportunities for a selected baseline vehicle representing the crossover utility segment.
• A 2009 Toyota Venza was selected as the baseline vehicle for evaluation. A 4 door, I4 FWD Venza was torn down and each component weighed and measured for evaluation.
• All volume, and dimensional attributes of the Venza were retained.
• The low mass vehicle target was to meet or exceed all safety requirements, including crash and roof crush.
• The mass reduction portion of the study by Lotus Engineering
encompassed all vehicle systems, sub-systems and components, less powertrain. The hybrid powertrain was developed by EPA based on mass reduction targets.
15
Overall Methodology
Overall goal - Maintain the vehicle functional attributes for all systems and capabilities while decreasing vehicle mass with acceptable cost.
1. Low Development vehicle will maintain same footprint
2. High Development vehicle is allowed to increase wheelbase and track within vehicle segment for additional mass reduction (WB=+6.1”, T=0.6”)
The methodology consists of:
1. Selecting a baseline vehicle: Toyota Venza and benchmarking it
2. Defining safety, function and performance objectives:
comparable to 2009 Venza
3. Defining current and new vehicle architecture
4. Investigating new technologies, including materials, processes, new designs, etc
5. Selecting suppliers for key systems to provide mass and cost input
6. Creating a mass/cost assessment matrix for the technologies 7. Creating Low Development and High Development BOM’s
16
Venza Specifications
• Powertrain
– 2.7-liter double overhead cam (DOHC) 16-valve dual independent VVT-i 4-cylinder; 182 hp @ 5800 rpm, 182 lb.-ft. @ 4200 rpm.
– Ultra Low Emission Vehicle II (ULEV-II)
– 6-speed electronically controlled automatic overdrive transmission
• The estimated 0 - 60 MPH time for a Toyota Venza I4 (3760 lbs, 182 bhp) is 9.5 seconds.
Based on a weight/power ratio of 21.6 lbs/HP (curb weight + 175 lbs. for the driver).
• Electric Power Steering - rack-and-pinion with power-assist
• Body construction - Reinforced unitized body
• Classified as an LDT2 – Curb-weight: 3760
GVWR: 4960
17
• A Toyota Venza was completely disassembled to develop a comprehensive list of all components and their respective mass.
• A Bill of Materials (BOM) was developed around nine major vehicle sub-systems. The top four by mass (Bold text) were selected for extensive mass reduction opportunities:
– Body in White (BIW) – Chassis/Suspension – Closures/Fenders – Interior
– Front and rear bumpers – Front and rear lighting – Thermal (HVAC)
– Glazing – Electrical
Selected Systems for Reduction
18
Mass Reduction Design Approaches
• Smart design
– Optimize load paths within structures to reduce stresses on components
• Use of computer-aided engineering (CAE) design tools – Parts integration/reduction of fasteners
– Optimize structure sections Material substitution
– High-strength steels – Aluminum
– Magnesium
– Plastics and composites
• Mass Reduction Concepts broadly applicable to all vehicle subsystems – Engine and transmission
– Chassis and suspension
– Body, closure panels, glazing
– Seats and other interior components
– Powertrain thermal management and HVAC systems
• Ancillary system weight reduction possible after initial mass reduction efforts – Brakes, suspension, tires, powertrain…..
• Low mass concepts are equally applicable to light-duty and heavy-duty vehicles
19
Summary of Results
The Low Development mass was 21.5% less than the baseline Venza with a projected cost factor of 98%.
The High Development mass was 39.1% less than the baseline Venza with a projected cost factor of 103%.
These mass reductions were achieved through a synergistic “Total Vehicle” approach where every vehicle system contributed.
Increased costs were offset through cost reductions created in other systems.
Base LD LD HD HD
Mass Cost Factor Mass Cost Factor
Body 382.50 324.78 0.98 221.06 1.35
Closures/Fenders 143.02 107.61 1.02 83.98 0.76
Bumpers 17.95 15.95 1.03 17.95 1.03
Thermal 9.25 9.25 1.00 9.25 1.00
Electrical 23.60 16.68 0.95 15.01 0.96
Interior 250.60 182.00 0.97 153.00 0.96
Lighting 9.90 9.90 1.00 9.90 1.00
Suspension/Chassis 378.90 275.50 0.96 209.00 0.96
Glazing 43.71 43.71 1.00 43.71 1.00
Misc. 30.10 22.90 0.99 22.90 0.99
Totals: 1289.53 1012.28 785.76
Base Venza Powertrain Mass 410.16 Mass LD Cost Mass HD Cost
Base Venza Total Mass 1699.69 78.5% 97.9% 60.9% 103.0%
20
Material Changes – Complete Vehicle
21
High Development Model
39% lower mass, highly integrated, efficient load paths, low parts count, low mass materials, low energy assembly
22
Body Structure Comparison
Materials
•Aluminum
•Magnesium
•Steel
•Composite
•Mass: 221 kg. (42% reduction)
•Cost factor: 135% (vs. baseline)
Materials
•Steel
•Mass: 382 kg
•Cost: 100%.
High Development Baseline Toyota Venza
