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Sustainable Production Technologies of Emission Reduced Light weight Car concepts SuperLIGHT-Car www.superlightcar.com

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Title: Sustainable Production Technologies of Emission Reduced Light weight Car concepts SuperLIGHT-Car www.superlightcar.com


1
Sustainable Production Technologies of Emission
Reduced Light weight Car concepts
SuperLIGHT-Carwww.superlightcar.com
  • Public Presentation
  • September 2005

2
Table of contents
  • Project key figures
  • The SLC consortium
  • Research context
  • Motivation and objective
  • Potential reduction of CO2 emission
  • Project scope
  • Workflow and major milestones
  • The SuperLIGHT-Car roadmap
  • Contact details

3
Project Key Figures
  • Project full title Sustainable Production
    Technologies of Emission Reduced Light weight
    Car concepts (SLC)
  • Project coordinator Volkswagen AG
  • Project partners 7 OEMs CRF, DC, Porsche,
    Renault, Volvo, Opel, VW
  • 10 RD Companies
  • 10 Suppliers
  • 8 Universities
  • 3 SME
  • Start Date of contract 01/02/2005
  • Duration 48 months
  • Total Budget 19,2 MEUR
  • Funding 10,5 MEUR

4
The SLC consortium
5
Research contextRequirements for new vehicles
development
6
Research contextMaterial trends in vehicle
production
Materials used m
80
70
60
50
40
30
20
Steel
Rubber/Others
10
Plastics
Non iron - metals
0
1975
Aluminium
1980
1995
2005
7
Research contextMain challenge multi-material
concepts
Design
Multi Material Concept
Materials
Processes
Advanced LM-Spaceframe
Steel Spaceframe
Advanced Steel body
Affordability of weight reduction
Stainless Steel Spaceframe
Coil-coated shell
Advanced Composites (FRP)
Steel thin wall casting
High strength Steels
Steel Unibody
Composites
gt 2012
Approach
8
Motivation and Objectives
  • Motivation
  • The Mission of SuperLIGHT-CAR is the
    realization of advanced multi-material vehicle
    structures using break-through technologies for
    economic, lightweight design. It is the aim to
    apply advanced light weight materials, design and
    manufacturing techniques into series production.
  • Objective
  • The main objective of SLC is the development of
    innovative multi-material light weight design for
    vehicle structures achieving
  • 30 weight reduced vehicle structure (BIW)
  • Cost reduced multi-material manufacturability
  • High volume capability
  • Benchmark performance (C-class segment)
  • Recyclability / Sustainablity

9
Potential reduction of CO2 emissions
  • Case study - Compact Class
  • Vehicle total weight 1160 kg
  • Weight Car body (BIW) 296 kg
  • 30 Lightening (BIW) 89 kg
  • Corresponding fuel consumption reduction 0,3
    l/100km
  • Life time road performance 100.000 km
  • Life time fuel consumption minimization 265 l (
    665 kg CO2)

- 89 kg
? 0,3 l / 100km fuel saving, ? 265 l fuel
saving in car life time
Lisboa
Brussels
10
ScopeIntegrated lightweight design development
  • Material
  • Steels
  • Light metals
  • Polymers

Light Weight Design
  • Manufacturing
  • Forming
  • Joining
  • Surface Treatment
  • .
  • Design
  • unibody
  • spaceframe
  • Monocoque

11
Key technologies / scientific domains
SP4 Proto
Physical prototypes
SP1 Concepts
MM part/module concepts
Virtual prototypes
SP2 Tech
Hybrid vehicle concepts
Low cost high volume manufacturability
MM design guidelines
Uniform class A surfaces
Multi-attribute vehicle optimisation
Multi-Material Lightweight Car
SP3 Tools
Joining and (Dis)Assembly
Design for environment
Technology monitoring
Failure prediction
Cost simulation
Crash/Fatigue simulation
12
Design scopeImprovement of lightweight design
quality
Development of light weight quality
Rp0,2 lt 140 MPa Rp0,2 180-220 MPa Rp0,2
260-420 MPa Rp0,2 gt 1000 Mpa
Distribution of steel grades
MB Mass BIW CT Torsional Stiffness A
Footprint
Objective SuperLight Car LSLC lt 2
13
Materials manufacturingAffordable
multi-material design
high
Research approach
Cut Lightweight costs (Vision)
/kg
high
low
Steel Body (today)
Production Costs
Advanced Light Metals
- 20
Lightweight costs (today)
- 40
/kg
- 60
Vehicle Weight kg
low
14
Workflow and major milestones
SP1 - Design
FR Composites (RTM / LFT)
Advanced Steels
Light metals
2/2006 Preliminary SLC concept
6/2007 Detailed CA design
SP2 - Forming, Joining and surface technologies
SP4 SLC front structure demonstrator
Preliminary technology assessment
Parts / materials / technologies coupled
Final technological assessment
LCA / Cost assessment tool
SP3 Enabling Tool Development
Validation of SLC concept / prototype
2/2005
1/2006
6/2007
1/2009
6/2008
15
Roadmap of SuperLIGHT-CarIntegrated Project
within the EU 6th RTD FP
SLC Multi-Material Concept
Testing
and Validation
Design Simulation Construction guidelines VR
Engineering Crash-Simulation Repair
strategies Recyclability End of Life Assessment

Production
of Parts
Breakthrough low weight Vehicle Concepts
Modelling
Simulation
Forming and shaping Multi-material
joining Process optimization Processing
simulation Prototyping Manufacturability Assembly
concept
Affordable Manufacturability
Material concepts Semi finished
products Materials combination Surface
quality Durability Material simulation Material
properties
Fibre
Light
metals
Advanced
reinforced
Aluminum
Applied Material Technologies
Steels
Composites
Magnesium
Multi-Material-
Technologies
2015
2006 2007 2008 2009
16
SLC Contact details
  • VOLKSWAGEN AG
  • Dr.-Ing. Martin Goede
  • Group Research
  • Vehicle Research / Vehicle Lightweight
    Construction
  • Letter box 1777
  • D - 38436 Wolfsburg
  • Email contact_at_superlightcar.com
  • Website www.superlightcar.com
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