Presenting Lightweight Construction In Modern Vehicles · PDF filePresenting Lightweight Construction In Modern Vehicles To Evaluate And ... luxury SUV with a total vehicle weight

Presenting Lightweight Construction In Modern Vehicles To Evaluate And Address Its Challenges From A Lifecycle Perspective

GALM 2016, Birmingham Dr. Christoph Haberling, Audi AG

2

Mission – Light weighting Comfort and efficiency: weight and requirements

Titel oder Name, Abteilung, Datum

luxury SUV with a total vehicle weight less than 2000 kg

Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16 source: F. Venier, Audi

3

Lightweight design Approach in different steps

Titel oder Name, Abteilung, Datum Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16 source: F. Venier, Audi

4

Production concept Joining technologies cell and hang on parts


5

Goals of body in white development and production Material logic in the Audi Spaceframe Multi Material Mix


6

Lightweight design Material mix and structure concept


Structure: 41 % Aluminium 59 % Steel

Complete Body: 50 % Aluminium 50 % Steel

Aluminium sheet Aluminium extrusion

Steel conventional

Aluminium casting

Steel hot formed


7

Results Weight comparison to predecessor


Wholistic lightweight approach = ultra®–lightweight design


8

Optimizing transmissions

Optimizing combustion engines

Lightweight design, aerodynamics, rolling resistance

CO2-reduction potentials: ICE options

Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16

9

Global trends and general constraints

Challenges for the automotive industry

Climate change Urbanization

Political framework

Scarcity of resources Markets in upheaval

New technologies Shifting values Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16

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Global trends: Influencing and interacting factors

1 – Technology ►  Characteristic properties

of different drivetrain technologies.

►  effects of renewable fuels (e-fuels, „green“ power)

4 – Market and Customer ►  Technological requirements

of the customers ►  acceptance of additional

costs ►  competition

2 – Infrastructure ►  Kind of production

(CNG, power, hydrogen) ►  Economic feasibility ►  Government aid

3 – Legislation ►  CO2-legislation ►  Limitation of

emissions (NOx…) ►  Energy-Legislation ►  Incentives for alternative drives ►  Resource efficiency


11

Risk of oversimplification … Su

stai

nabi

lity

issu

es

Climate change

loss of species

overfishing

shortage of ressources

regional scarity of potable water

desertification

destruction of rain forest

erosion of top soil

Clim

ate

chan

ge CO2-footprint

NOXe

methane

particulate matter

…

CO

2-

foot

prin

t

tank-to-wheel (tailpipe)

cradle-to-cradle

tailp

ipe

well-to-wheel

source: „Grüne Lügen“, Friedrich Schmidt-Bleek

acidification


12

Systematic Holistic

Networked

Life cycle

Thinking in cycles Orientation to nature

To implement sustainable development, you need a wider perspective

LCA – A Method for Sustainable Product Development


13

LCA – Decision-making Tool for Sustainable Development The Life Cycle Assessment

20

Production

Use

Cycle concept

Recycling


14

Inventory analysis

Extraction of raw materials

Manufacture

Production

Use/ traffic

Recovery/ recycling

Effect indicators

CO2

CH4

SO2

NOX

HC

R11

Estimated effect

Global warming

Eutrophication

Summer smog

Acidification

Ozone breakdown

Life Cycle Assessment - tracking Effects on the environment

Relevant industrial standards: ISO 14040 et seq.


15

cradle-to-grave

~20% ~1%

tank-to-wheel (use)

cradle-to-gate (materials and car production)

well-to-tank (fuel

production)

well-to-wheel (fuel production + use)

Production Use Recycling

Input energy

materials

Output emissions

waste

Cradle to grave CO2 emissions Cars with internal combustion engine


16

Recycling

0 km 200,000 km

Gre

enho

use

gase

s [t

CO

2 equ

ival

ent]

In Life Cycle Assessment, all effects on the environment during the lifetime of the vehicle are taken into account

Net reduction in greenhouse gases

Break-even

Depreciation distance

Additional manufacturing burden

by lightweight design

Conventional construction Environmentally acceptable

lightweight construction

Use Manufacture and production

The Audi Life Cycle Assessment – procedure



17

Manufacturing Recycling Use

- 16%

0

10,000

20,000

30,000

40,000

50,000

60,000

0 20,000 40,000 60,000 80,000 100,000 120,000 140,000 160,000 180,000 200,000

GW

P (g

loba

l-war

min

g po

tent

ial)

[kg

CO

2 equ

ival

ent]

Operating life [km]

Audi Q7 3.0TDI quattro 180kW tiptronic (MJ2015)

Audi Q7 3.0TDI quattro 200kW tiptronic (MJ2016)

Break-even point ~ 34,000 km

Additional Manufacturing burden

Improvements in greenhouse gas emissions of 16% compared to the previous model over the life cycle

LCA – Decision-making Tool for Sustainable Development LCA for the AUDI Q7 - result for greenhouse gas emissions

16 Uwe Heil, I/EG-X1, 2015-03-19

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Alternative drives

Optimizing transmissions

Optimizing combustion engines

Lightweight design, aerodynamics, rolling resistance

CO2-reduction potentials: further options – alternative drives


19

The new Audi Q7 e-tron

►  Drivetrain of the Audi Q7 e-tron quattro Material mix:

3.0 TDI engine

8 speed Automatic transmission High-voltage-battery

Charging point

Power electronics Electric motor

Electric motor


20

Greenhouse gas emission value of the Audi Q7 e-tron quattro in compared with the Audi Q7 3.0 TDI over the entire life cycle


The additional costs associated with the hybrid drive system on the Audi Q7 e-tron quattro are offset after approximately 128,000 km when running the vehicle on the EU power mix and after just approximately 38,000 km when running the vehicle on electricity generated from hydroelectric power.

21

Distribution of CO2 equivalents to the LCA for different vehicles

~ 80% ~20% Petrol engine

Assumptions: Compact-class car Mileage: 200,000 km Petrol engine: 5.5 l / 100 km PHEV: 1.5 l/100 km BEV: 15 kWh / 100 km CO2 equivalent: 11 g/kWh

~ 5% ~ 95 % BEV*

~ 50% ~ 50 % PHEV*

Use (well-to-wheel) Manufacturing

Using traction batteries makes the production phase increasingly more significant in terms of the environment

LCA – Decision-making Tool for Sustainable Development

Comparison of different vehicle concepts

* electricity from renewable sources


22

Effects of light - weighting (efficiency - CO2 reduction) ICE vs. BEV

Significantly lower compared to an ICE vehicle

Significantly lower compared to an ICE vehicle

BEV ICE

100 kg

Weight reduction: CO2 savings: Additional range:

100 kg

The efficiency improvement of weight reduction measures is most important for ICE

Weight reduction:


23

BEV: The need for Light weighting for weight compensation will increase compared to ICE

reference vehicle

CO2 impact of

Light weighting

CO2 impact caused

by additional features /

performance needed

CO

2 pro

duct

ion


reference vehicle

Light weighting

additional features /

performance needed

Vehi

cle

wei

ght

24

Recycling

0 km 200,000 km

Gre

enho

use

gase

s [t

CO

2 equ

ival

ent]

In the future there will be a stronger need also to optimize the manufacturing burden

Net reduction in greenhouse gases

Break-even ? Additional manufacturing burden

by lightweight design

Conventional construction lightweight construction

Use Manufacture and production

Life Cycle Assessment – procedure



25

The Audi Life Cycle Assessment Use of sustainable materials – on component basis

* Carbon-fibre-reinforced polymer

•  Greenhouse gas emissions from various materials due to the manufacturing process

The scatter values (red bars) for the various materials are due to the different manufacturing and recycling methods that can be used.

[kg CO2 equivalent / kg component ] [kg CO2 equivalent / functionally equivalent component ]

0 5 10 15 20 25 30 35 40 45

CFRP *

Magnesium

Aluminum

Steel - 40%

lightweight construction potential

- 55% lightweight construction potential

- 55% lightweight construction potential

Dr.-Ing. Christoph Haberling, AUDI AG, London 25/04/13 Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16

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The Audi Life Cycle Assessment - CO2 balance share of the material groups for the manufacturing process

A6 A8

proportional weight CO2eq. proportional weight CO2eq.

other materials

polymers

other metals

light metals

steel / iron


27

Solutions for castings

Diecasting offers possibilities for local opimization

Outer structure

Free room for material

Optimized part

source: Mr Haverkamp, Audi Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16

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multiple castings tools

Use of multiple or combinded set of castings

Win-win: advantage in economics and CO2 emissions

0%

20%

40%

60%

80%

100%

Component cost Processing time per part

1 part per shot 6 parts per shot

Combinded set of castings

source: DGS

source: ALCOA

source: Mr Haverkamp, Audi Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16

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The aluminium cycle Audi is looking at all steps of the process chain

alloying smelting

secondary castings

Semi finished goods Primary production Products

Audi is participant Aluminium Stewardship Initiative

sorting etc.

Optimized in house recycling

Secondary Aluminium is mainly used for drive train components and can be recycled again and again

Tracking possibilities of advanced EOL

technologies

Shredder and sorting

Aluminium fraction

dismantling


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LCA – A Method for Sustainable Product Development

Renewable fuels – Audi e-fuels

The principle behind Audi e-fuels: CO2 is used as the raw material to manufacture e-fuels and is used in the cycle

Customer fills up with renewably produced fuel

CO2 used as raw material

In fuel production:

Binding CO2

Fuel production

vehicle

CO2 collector

Petrol station


31

Vehicle production*

Fuel production* Total*

Compact-class car

Vehicle use*

Conventional vehicle (petrol) 113 30 25

BEV (Renewable energy mix)

0

43

3

95 Construction of

e-gas plant

33 Audi A3 g-tron (with Audi e-gas)

-75

Construction of e-gas plant

∑ 168

∑ 46

∑ 53

-75 95

Construction of e-gas plant

*g CO2 equivalent per km over 200Tkm

A vehicle running on Audi e-gas overall emits a similar volume of CO2 as an e-vehicle running on renewable energy.

LCA – A Method for Sustainable Product Development Comparison of CO2 emissions over the life cycle


32

Conclusion:

►  Choose an appropriate balance sheet calculation to evaluate a system

►  Light weighting will be more a weight compensatory measure than today

►  Environmental impact by production will come more and more into the focus

►  The Recycling of process and end-of-life scrap has to be optimized for all new lightweight materials on a high material quality level

►  The use of more “green” energy and recycled material for production of new materials can decrease the environmental impact of light weight materials dramatically

Titel oder Name, Abteilung, Datum Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16

Thank you.

www.audi.de/umweltbilanz

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Presenting Lightweight Construction In Modern Vehicles · PDF filePresenting Lightweight Construction In Modern Vehicles To Evaluate And ... luxury SUV with a total vehicle weight