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HAVAL COUPE Body Lightweight Design and Attribute
Integration
Dr. Lei Shi
Technical Director
R&D of Great Wall Motor
April 15, 2015
Detroit, MI USA
� Background
� Design Approach
� Lightweight Design
Agenda
� Attributes- NVH
- Safety
- etc.
� Summary
2
Overview
- We are China’s largest SUV and pickup manufacturer, with over 30 holding subsidiaries, more than 60,000
employees, four vehicle production bases and a production capacity of 800,000 units.
- We own Haval and Great Wall brands, covering products range of SUV, passenger car and pickup.
- Our assets had amounted to 61.345 billion RBM by Dec. 31, 2014.
- We persist in focused development, uphold the brand concept of "focus, dedication and specialization"
SUV
Our products: SUV, Pickup and Sedan
What we are?
31.59
23.74 25
30
35Unit: 10, 000
2014 SUV Top-ten Sales Ranking in China
HA
VA
L
Top one: HAVAL
- First produce economic type of SUV in domestic.
- Hover H6 got “China annual SUV prize” in 2012,
which sales so popular and even hard to meet the
purchase requirement.
HAVAL H8 HAVAL H6 HAVAL Coupe-c HAVAL Coupe HAVAL H9 HAVAL H6 Update HAVAL H2
3
16.82 14.53 13.60 12.47 11.45 10.70 10.06 9.87
0
5
10
15
20
HA
VA
L
Overview
What we are?
- Domestic sales for GW pickup gains No.1 in 14 continually years.
- Together with Toyota, Ford pickup named as “World three pickup”.
- Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas.
Pickup
- First made the saloon car in 2007, got No 2 in terms of sales quantity in 2011.
- First pass EWVTA as Chinese self-owned saloon brand manufacture.
- Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas.
Saloon car C50 C30 C2OR C50 Update
4
Overview
What we are?
- Domestic sales for GW pickup gains No.1 in 14 continually years.
- Together with Toyota, Ford pickup named as “World three pickup”.
- Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas.
Pickup
- First made the saloon car in 2007, got No 2 in terms of sales quantity in 2011.
- First pass EWVTA as Chinese self-owned saloon brand manufacture.
- Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas.
Saloon car C50 C30 C2OR C50 Update
5
Europe
North AmericaJapanChina
长城汽车新技术中心GWM New R&D Center
Overview
What we are?
长城汽车北美技术分中心长城汽车欧洲技术分中心 长城汽车日本技术分中心GWM European R&D Center GWM Japan R&D Center GWM North America R&D Center (On-going)
6
Goal of R&DBackground | Design Approach | Lightweight Design | Attributes
The goal of R&D activities:
Style Freeze •T/Section
•Ext/Int
•S.E.
•Feasibility
Report
Data Freeze•M/Section
•CAE & Physical
Test
•S.E..
•Neighbor Parts
Status Through
CAECAEOptimum-Optimum-
Over-
design
Over-
design
Data
ReduceStyle Change &
Data Change
CAECAEverification
Optimum-
design
Optimum-
design
Under-
design
Under-
design
Data
Freeze
How to freeze data?
7
Goal of R&DBackground | Design Approach | Lightweight Design | Attributes
The goal of R&D activities:
Design ChangeDesign ChangeDesign ChangeDesign ChangeCutCut--offoff
Reach Performance Target
within given cost and weight
Weight Cost Performance+ =
8
Roadmap of WRBackground | Design Approach | Lightweight Design | Attributes
Co
st
AD
Conventional Material & ProcessAdvanced Steel & Process& More Light Material
Ideal Line
Maximum use of HSS & Process
Trad. Line
WeightWeight
Target
Co
st
Targ
et Opt. Body Performance
B
C
Ideal Line
Optimum Design Process withmultiple iteration of CAE
Lightweight Design Cost & Weight saving Design
9
CAE iteration
Roadmap of WRBackground | Design Approach | Lightweight Design | Attributes
Strategy: Sequential effect/benefit for lightweight design
We
igh
t
red
uct
ion
(K
g)
-A Kg -B Kg -C Kg -D Kg -E Kg
Tota
l W
R
Fu
el
eff
icie
ncy
imp
rov
em
en
t
By weight
reduction
Tota
l F
EI
By thermal
losses reduction
By aerodynamics
resistance reduction
By secondary
weight reduction
Starting
points
10
Efficiency benefit sequence: Mass reduction of passenger cabin and ripple effect
will lead to greater fuel efficiency and secondary mass reduction
Roadmap of WRBackground | Design Approach | Lightweight Design | Attributes
Strategy: Sequential effect/benefit for lightweight design
We
igh
t
red
uct
ion
(K
g)
-A Kg -B Kg -C Kg -D Kg -E Kg
Tota
l W
R
Fu
el
eff
icie
ncy
imp
rov
em
en
t
By weight
reduction
Tota
l F
EI
By thermal
losses reduction
By aerodynamics
resistance reduction
By secondary
weight reduction
Starting
points
11
Strategy of WR for Body Structure
For a given set of conditions & For a given set of conditions &
loads, find the lightest & efficient loads, find the lightest & efficient
structure that is able to meet structure that is able to meet
design targets.design targets.
Right
topology
Right
size
Predecessor
architecture
BIW mass
Background | Design Approach | Lightweight Design | Attributes
design targets.design targets.
Right
Design
details
Right
material
New vehicle
BIW mass
12
Strategy of WR for Body StructureBackground | Design Approach | Lightweight Design | Attributes
What is MDO? Multidisciplinary Design Optimization (MDO) is a methodology for improving design of engineering
systems, e.g., automobile, aircraft, or spacecraft, in which everything influences everything else.
NVH: Torsion, Bending,
Dynamic stiffness
A MDO platform integrating all the vehicle attributes is developed to achieve the
weight target under CAE environments
13
偏置碰:
64kph
正碰:
35mph
Madymo:
FC1-USNCAP
FC2-EuroNCAP
Offset
impact
Frontal
Door-ring StructureBackground | Design Approach | Lightweight Design | Attributes
Hot stamping process
1. Blanking 2. Blank heat up (over 900 degrees) 3. Forming &
quenching 4. Post form
operations
Remove
Weld Line
Predecessor HAVAL Coupe
14
Weld Line
Roof Cross-member DesignBackground | Design Approach | Lightweight Design | Attributes
Weld Line
Predecessor HAVAL Coupe
15
MDO- based Lightweight Design
BIW Trimmed-body Safety
Trimmed-body
VTF/NTF/IPI
BIW NM
Full Frontal
MDOIntegration
Background | Design Approach | Lightweight Design | Attributes
16
Trimmed-body
Acoustic Mode
Trimmed-body
Bending Mode
Trimmed-body
Torsion Mode
Bending Stiff
Torsion Stiff
BIW IPI
40% Offset
Side Impact
Roof Crush
To achieve 3.0 Kg weight saving per
vehicle
Front SeatBackground | Design Approach | Lightweight Design | Attributes
17
Closure-LiftgateBackground | Design Approach | Lightweight Design | Attributes
To achieve 1.71 Kg weight saving per
vehicle while meeting design target
requirements
18
We
igh
t
Lightweight Index
3.96
Background | Design Approach | Lightweight Design | Attributes
19
0 Kg
We
igh
t
0
Weight reduction Lightweight index
-21.3 Kg
3.96
LWI
0
3.673.74
Competitor
Predecessor
HAVAL Coupe
HAVAL Coupe
Predecessor
Attributes Available Space (AAS):
−= ∑
esetAttributT
esetAttributTributesVehicleAttmeanAAS
arg
arg
0 0
Attributes Improvement
HAVAL CoupePredecessor HAVAL CoupePredecessor
Background | Design Approach | Lightweight Design | Attributes
20
-22%
-29%
-18%
-26%AA
S
Safety attributes NVH attributes
+8%+7%
Weight reduction summary:
Weight ReductionBackground | Design Approach | Lightweight Design | Attributes
-5.09
-1
0 Kg
We
igh
t
0Predecessor
HAVAL Coupe
We
igh
t
0Closures Seat IP
21
To achieve 33.5 Kg weight reductionw/o using light alloys
-6.11
-5.09
Total: 12.2 KgBIW WR
-21.3
Summary
• Successfully developed a platform to integrate all vehicle attributes to achieve weight targets while meeting design requirements
• Weight reduction:
Totally achieve 33.5 Kg weight reduction w/o using light alloys
Lightweight index has been improved 7.3% (through optimization of the body structure) as well as outperformed the competitor
• Vehicle attributes:
22
• Vehicle attributes:
Body rigidity-top class body rigidity performance through improvement of joint efficiency in all areas of the cabin
Also, safety and NVH attributes are improved (w/ 7-8% enhancement)
• Almost 40 RBM cost saving per vehicle with structural adhesive usage optimization
Thanks!
Questions/Comments?
2323