Reduction of CO2-Emissions CO2-Reduction Attractiveness
Fuel Consumption Reduction [%]
SuperLIGHT-CAR
SuperLIGHT-CAR
Fuel Saving Potential through Vehicle mass reduction Case study - Compact Class • Vehicle total weight: 1160 kg • Weight Car body (BIW) : 330 kg • 30% Lightening (BIW): 100 kg • Corresponding reducted fuel consumption: 0,3 l/100km • Life time road performance: 100.000 km
- 100 kg ≅ 0,3 liter / 100km fuel saving, ≅ 300l fuel saving in car life time 35.000 l
Brussels
35.000 l
35.000 l
Total Passenger Car Production in Europe: 17 Mio. / year (VDA Data, 2001) Fuel Saving: 5,1 Mio m³ (~ 145.000 Petrol lorries) Reduction of CO2-Emissions: 12,75 Mio t 35.000 l
35.000 l
Close lorry convoy of 2100 km
VOLVO
35.000 l
Athens
Dr. M. Goede / SLC / December 2003
• Life time fuel consumption minimization: 300 l (= 750 kg CO2)
Aluminum space frame Extrusion and cast node Composites Integrated panels Riveting + Adhesive bonding
Dr. M. Goede / SLC / December 2003
Weight save 20% Overcost 20-40%
VOLVO
SuperLIGHT-CAR
Dr. M. Goede / SLC / December 2003
PNGV Hyper Light Body : CFRC panels & Al rails : weight save 180 / 280kg
VOLVO
SuperLIGHT-CAR
Scope
Example – Potential of Fibre Reinforced Polymer Components Steel 18,2 kg 28 parts
Cost
Steel floor panel
CRF floor panel
CRF 9,7 kg 1 part
- Functional integration - Reduced number of parts - Lower invest and tooling cost
Volume
VOLVO
Dr. M. Goede / SLC / December 2003
Aluminium floor panel
SuperLIGHT-CAR
OBJECTIVES
Roadmap of SuperLIGHT-CAR
INNOVATIONS: Advanced material technologies New Modular Architecture Advanced functional integration Affordability & Costeffectiveness Multi-Material-Joining Multi-Material Simulation Multi-Material Recycling
th a LC Analysis / EL Assessment P t Testing and Validation en m Manufacturability / Cost analysis op l e v Production of Parts De
Multi-Material Design 30 % weight reduced body (BIW) High Volume Capability Qualified Passive Safety Reduced environmental impact Reduced CO2-Emission
Modelling & Simulation Applied Material Technologies Design Concepts
Fibre reinforced Composites
Advanced Steels
Light metals Aluminum Magnesium
Multi-Material-Technologies
Material concepts Semi finished products Materials combination Surface quality Durability Material simulation Material properties
Forming and shaping Multi-material joining Process optimization Processing simulation Prototyping Manufacturability Assembly concept
Design Simulation Construction guidelines VR Engineering Crash-Simulation Repair strategies Recyclability End of Life Assessment
Breakthrough low weight Vehicle Concept
Affordable Manufacturability
Advanced Material Technologies 2005
2006
2007
2008
VOLVO
Time
Dr. M. Goede / SLC / December 2003
Material Processing Technologies
Dr. M. Goede / SLC / December 2003
SuperLIGHT-CAR
VOLVO
SuperLIGHT-CAR
SLC philosophy
• Product-driven: towards scientific results exploitation in industrial environments • Top-down approach: from vehicle needs to materials and technologies opportunities • Multi disciplinary approaches and teams
• Part of a bigger framework: coordinated under EUCAR umbrella (especially materials’ working group - EGM) • Integrate finished and running project results
VOLVO
Dr. M. Goede / SLC / December 2003
• Collaboration with strongly committed best-in-class partners
SP4: Demonstration Virtual and physical Prototype (VR BIW / Front structure)
SP5: Management, Dissemination,
VOLVO
Car Body Concepts
Enabling Tools
Virtual Prototyping Dr. M. Goede / SLC / December 2003
SP2: Manufacturability
Major Milestones and Expected Outcome
SP1 - Design
FR Composites (RTM / LFT)
Advanced Steels
Light metals
9/2005 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 1/2005
1/2006
Validation of SLC concept / prototype 6/2007
VOLVO
6/2008
12/2008
Dr. M. Goede / SLC / December 2003
SuperLIGHT-CAR
Dr. M. Goede / SLC / December 2003
SuperLIGHT-CAR
VOLVO
SuperLIGHT-CAR
Expected key results
• Virtually designed multi-material car body concepts • Simulation Tools for Vehicle multi-parameter optimisation • Physical prototype of C Class car front structure • Scenarios for other car classes & production volumes
• Mass production feasible multi-material joining processes • Qualified crashworthiness / passive safety • ‘Green design tool’ plus verified sustainability of concepts VOLVO
Dr. M. Goede / SLC / December 2003
• Qualified Process Technologies for high volume manufacturability
Budget magnitude and project duration
Project Budget:
=
20 Mio €
EC >50% Funding:
=
10,5 Mio €
German participation: France = Italie
49% 12,5%
Consortium :
40 partners
EUCAR label :
results access to affiliated Cies
Project Duration:
48 months (2/2005 – 1/2009)
Submission:
Call 2B on Surface Transportation (april 2004) Priority 6: Surface Transport / Light structures Fzg-Leichtbau
