Presentation8 Audi
Presentation8 Audi
1
Agenda
Project tasks
2
Project tasks
The new Audi A8
3
Project tasks
The new Audi A8
4
Project tasks
5
Project tasks Ultimate
Differentiators Audi brand
ambassador
Generous Dynamic
sense of space exterior design
STYLING
6
Project tasks
Styling
7
Project tasks
Comfort: interior dimension and space concept
1467 W3-2
H196
690
H100-B
1644 W101-1
1635 W101-2
8
Project tasks
Comfort: exterior dimension and space concept
A8
A8 L
9
Project tasks
Driving dynamics and efficiency: modular longitudinal platform
10
Project tasks
Conflict of interests
11
Project tasks
12
Agenda
History ASF®
13
History ASF®
A8 (D2) Body concept
1994
14
History ASF®
A8 (D2) Production concept
15
History ASF®
A8 (D3) Body concept
2003
16
History ASF®
A8 (D3) Production concept
17
Agenda
18
Development and production targets
Body concept: technical development targets
Weight
Styling
Stiffness Safety
Efficiency
modular longitudinal
platform–architecture
19
Development and production targets
Production concept: targets
Tolerance management
20
Agenda
21
Evolution and integration
Structure concept
22
Evolution and integration
Material concept
23
Evolution and integration
Production concept
ET Kotflügel li.
Seite innen li.
Frontklappe
Türen links
Säule B li.
SAD
ZP 5.1 ZP 5.3
B0
2009 2010
SGR Hinterwagen
ET Kotflügel re.
Seite innen re.
QT Hutablage
Türen rechts
Heckklappe
Säule B re.
A8 (D3)
A8 (D4)
A8 L (D3)
new building integration A8 L (D4)
19 months
24
Evolution and integration
Virtual planning
25
Evolution and integration
Integration into vehicle–body assembly line
A8 (D3)
Step 1
A8 L (D4)
Step 2
A8 L (D4)
Status after implementing A8 (D4)
26
Evolution and integration
Production concept: assembly sequence
27
Evolution and integration
Methodology of design suitable for production
Audi–Product Process LF
P r o d u c t d e f i n i t i o n P r o d u c t d e v e l o p m e n t
Component development Series development/ series preparation
Concept phase
Design phase
Validation phase
28
Evolution and integration
Impact on products
Modified areas
29
Agenda
Innovations in detail
30
Innovations in detail
Omega cross member
31
Innovations in detail
Gapless roof joint (Dachnullfuge)
Z–Balance
Design solution – gapless roof joint for A8 and roof module for A8 L
32
Innovations in detail
Flow Drill Screws (FDS)
33
Innovations in detail
B–pillar made of partially form hardened steel
Spot–welded joints
HC 340
34
Innovations in detail
Integrated suspension unit
Predecessor A8
35
Innovations in detail
Novelis Fusion AS250
AC170
AC170
36
Innovations in detail
Rear longitudinal beam – new design principle
A8 (D3) A8 (D4)
37
Innovations in detail
Rear longitudinal beam – virtual engineering
38
Innovations in detail
Rear longitudinal beam – material development
V crash
M crash
39
Innovations in detail
Rear longitudinal beam – summary
40
Innovations in detail
Side panel – manufacturability
Feasible design
41
Innovations in detail
Side panel – virtual validation
Feasibility study
► Forming simulation of the complete process
► Prototype production was a close–to–production process
► Stamping simulation including transfer operations
► Forming analysis to verify the stamping
42
Innovations in detail
Side panel – elastic and plastic forming behaviour
Logistics/component handling
43
Innovations in detail
Side panel – elastic and plastic forming behaviour
44
Agenda
45
Engineered hang on parts
46
Engineered hang on parts
Spare wheel well in fibre reinforced plastic
47
Engineered hang on parts
Spare wheel well in fibre reinforced plastic
48
Engineered hang on parts
Hybrid front end
49
Engineered hang on parts
Hybrid front end
Short fibres
molding
Impact–
extruding Endless fibres organo sheet
PA6 GF30
Organo
50
Agenda
Results
51
Results
Crash
► Optimum crash and safety performance due to the high energy absorption
capacity of aluminium and the ASF®–Structure
► Safety aspects for passenger and partner protection in focus
► Repair friendly concept – german insurance classification VK 29
In best class
52
Results
Complies with all crash load cases
Front crash Side crash Others
Euro NCAP
FMVSS 214 NPRM
40%, 64 km/h FMVSS 225 (Isofix)
75°–Pole (ES–2), 20 mph
V8 FSI QUATTRO
IIHS
Damage Type
Barrier (2x SID–IIs), 50 km/h
In best class
53
Results
Interaction of passive and active safety systems
► Eight airbags
► Impact contour for partner protection
► Electro mechanical seat belt pre load system
► Braking guard system, anti–lock braking system
► Cornering light, night vision
pre sense basic pre sense rear braking guard side assist adaptive cruise control lane assist night vision
54
Results
BIW stiffness
Bending 30,8
30,4
Torsion 30
29,6
29
+25 %
Frequency [Hz]
27
55
Results
BIW stiffness
56
Results
Weight change during the development process
247, 0 kg
Weight [kg]
Body–in–white: 231,0 kg
Body–in–white incl. hang on parts: 300,7 kg
236, 8 kg
235, 4 kg 235, 5 kg Project target: 233, 0 kg
57
Results
Lightweight Quality Index
1,2
mRK
Lightweight quality L =
CT x A
mRK = Body mass
1,6
CT = Torsional stiffness
1994 2003 2010 A = Area (track x wheelbase)
A8 (D2) 2,2 A8 (D3) A8 (D4) Lightweight quality with hang on parts: 1,6
58
Results
BIW concept
59
Results
Number of parts – BIW
Number of parts
A8 (D2) A8 (D3) A8 (D4)
334 267 243
Aluminium castings
Aluminium extrusions
25
30 Number of parts reduced
60
Results
Overview joining technologies in A8
NEW
NEW
Automated welded mass bolts
NEW
61
Results
Joining equivalents
A8 (D3) Joining technologies : Harbour Value A8 (D4) Joining technologies:
- 27,7%
1962 Self piercing rivets 1847 Self piercing rivets
64 m MIG welding 25 m MIG welding
20 m Laser welding ZP–5 without doors and hatches 6m Laser welding
5m Laser–MIG welding 632 Flow Drill Screws
17 m Structural bonding 202 Spot welds
44 m Structural bonding
62
Results
Production time
- 27%
Production time
A8 (D3) A8 (D4)
63
Results
Investments
- 80%
Infrastructure
-Production
40%
Investments
equipment
A8 (D3) A8 (D4)
64
Results
Logistics
A520 F000
6 days prior ready–to–operate
A520
65
Results
Integration result
66
Results
Contribution to sustainability – aerodynamics
► Development of main shape and detail optimization using numerical fluid dynamic
simulation CFD (Computational Fluid Dynamics)
► Optimized airflow and acoustic efficient underbody trim piece design
► Efficient engine compartment flow Vehicle A8 (D3) A8 (D4)
► Optimized wheels and tyres CD 0,27 0,26
A 2,33 2,41
CD value 0,63 0,63
CD x A
0,45
0,43
A0 Range
0,40
A Range
0,38
C Range
0,35
D Range
0,33
0,30
0,28
A8
0,25
B Range
0,23
0,20
1,9 2,1 2,3 2,5 2,7 2,9
Frontal area [ m² ] CD value = 0,26 → best in class
67
Results
Contribution to sustainability – recycling and environment
► Closing the material life cycle: assorted return of production discarded metal
(and scrap) of body parts
► Reduction of CO₂ emissions within production of 4000t per year
► The ASF® consists of more than 50% secondary aluminium
► Average fuel consumption and emission 18% reduced
► The 3,0 TDI front–wheel drive produces only 159g/km CO₂ equates to 6,0l/100km
68
Agenda
69
Product highlights for the customer
Differentiator styling
70
Product highlights for the customer
Differentiator comfort
COMFORT
71
Product highlights for the customer
Differentiator driving dynamic and efficiency
DRIVING DYNAMIC
AND EFFICIENCY
72
Product highlights for the customer
Press resonances
Nicht nur im Alphabet der Erste … Unter den drei deutschen Top–Limousinen
ist der neue Audi A8 jetzt der Längste und bietet als einziger eine Aluminium–
Karosserie und Allradantrieb serienmäßig an.
The A8, with class leading looks, comes with fine diesel
engines, an elegant cabin and a superb driving environment.
If you care about aesthetics, it is the limo of choice.
Einen besseren Platz als hinten rechts im neuen Audi A8 L gibt es kaum.
…offering dynamic excellence for those twirling the steering wheel and five–star
appointments for those occupying the rear seats. The 2011 Audi A8L W–12 is one
such vehicle.
… sehr sicher, hoher Komfort, viel neue Technik, ausgezeichnete Feinabstimmung,
sehr gute Fahrleistungen…
73
EuroCarBody Award 2010
74