Automotive interior trends and their impact on component weight

Transcription

Automotive interior trends and their impact
on component weight reduction
Manuel Poyant
Manager SWS/DAB Core Engineering
TRW Automotive Systems GmbH
Hefner-Alteneck Str. 11
63743 Aschaffenburg
© TRW Automotive 2012
Automotive Interiors Expo 2013 M. Poyant
1
Agenda
§  Automotive trends
§  Legislation requirements
§  Steering wheel & driver airbag weight distribution
§  Weight reduction – Concept design
•  Cushion folding
•  Inflator technology
§  Weight reduction – Alternative materials
•  Foam systems
•  Bio-polymers
§  Conclusion
2
Automotive trends
§  „Info Mobility“ (Human Machine Interface)
–  Ease of use HMI solutions (touch screen, voice recognition...)
–  Target : high value appearance & minimum of driver distraction
Source : Seat
§  „Eco Mobility“ (Sustainability)
–  High customer sensitivity towards „Green Image“ (efficiency, Co2
reduction…)
–  Environment protection & resource management (product & process)
–  European norm ISO 26000 „Guidance for social responsibility”
§  „Safe Mobility“ (Occupant safety)
–  Rising traffic density à Target = “Null” accident
–  Changes in Safety regulations (LCC) & customer requirements
3
Automotive trends
§  Demographic change
–  “Mega City” à growth of „small“ & „small premium“ segment
–  „Silver age“ More active older population à growth of „premium“ segment
§  Standardisation & Individualization
•  Realization of OEM‘s brand specific user experience
•  Focus on unique interior solutions è colors & trim
•  Request for simplicity è intuitive operation of functionalities
•  Emotional & functional attributes è increasing interior perception
§  Weight reduction
–  CO2 reduction (legislation 2015 120g/km – 2020 95g/km)
–  Fuel consumption reduction (new market in US „40+mpg“)
(Chevrolet Spark, Sonic, Honda Fit, „clean diesel“)
4
Agenda
•  Foam systems
•  Bio-polymers
§  Conclusion
5
CO2 Legislation requirements
Equivalent to
145 g/km
5.6l/100km for Petrol
4.9l/100km for Diesel
130 g/km
120 g/km
Phase in period
Equivalent to
4.1l/100km for Petrol
3.6l/100km for Diesel
2012 65% of total fleet
95 g/km
Emission limits are set according to the mass of vehicle, using a limit value curve. The curve is set in such a way
that a fleet average of 130 grams of CO2 per kilometer is achieved by 2015.
6
Vehicle weight evolution
+ 32%
Expected target
2020 à -14% equivalent to 13g CO2 or 0.46l/100km
2025 à -20% equivalent to 18.5g CO2 or 0.66l/100km
(100kg à - 0.25l/km à - 7g CO2/km)
Cars have been becoming heavier for decades.
CO2 legislation and requirements for lower fuel consumptions impose changes
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Weight reduction potential
§  The two basic approaches to reducing weight are
•  Concept design
•  Alternative materials selection
§  Regarding materials, there has been a trend towards the use of light metals and
their alloys (most commonly used are aluminum & magnesium). The new trend is to
use composite materials
§  Challenges
•  Component integrity cannot be impaired
•  Production process (e.g small wall thickness by plastic component)
•  Cost represents a particular challenge for fundamentally more expensive
materials (e.g. carbon)
8
Agenda
•  Foam systems
•  Bio-polymers
§  Conclusion
9
Steering wheel weight distribution
Steering wheel
Armature
560 g.
Foam
450 g.
Bezel
110 g.
Mufu
100 g.
Paddles
60 g.
Others (leather, screw..)
60 g.
Total
1.340 g.
10
Driver airbag weight distribution
Driver airbag
Emblem
25 g.
Cover
160 g.
Cushion
220 g.
Bag retainer
145 g.
Inflator
350 g.
Reaction plate
165 g.
Others
65 g.
Total
1.130 g.
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Weight reduction - Design evolution
http://www.km77.com/00/renault/proto/captur/renault-captur-prototipo.asp
http://www.grueneautos.com/wp-content/uploads/2009/09/vw-l1-ein-liter-auto-7.jpg
Light weight design
http://www.autobild.de/bilder/bilder-porsche-918-spyder-preis-1589354.html
http://www.spiegel.de/fotostrecke/fotostrecke-68376-6.html
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Weight reduction – Driver airbag evolution
2004
2008
2012
2016
Weight
1550g
1350g
1100g
900g
13
Agenda
•  Foam systems
•  Bio-polymers
§  Conclusion
14
Concept design – Cushion folding
Benefit 16 to 25%
space reduction
§  „Compact Module“ Technology allows a significant reduction of
the design space needed to fold the airbag cushion
§  Surrounding components dimensions, (e.g. Airbag cover, bag
retainer…) can then be reduced, leading to a weight reduction
- 80 g. based on standard design
15
40 mm
30 mm
40 mm
Concept design - Inflator Technolgogy
63mm
Inflator
53mm
63mm
DI10G46
DI10G36
DI10G45
Production year
2009
2013
2014
Design volume
125 cm3
93 cm3
88 cm3
350 g.
270 g.
260 g.
n.A
- 23%
-26%
Weight
Weight reduction
16
Agenda
•  Foam systems
•  Bio-polymers
§  Conclusion
17
Alternative materials – Foam systems
Foamed wheel weight reduction
500
480
(gr.)
460
440
420
400
2002
2006
2010
2014
Foam system
FFS3
FFS7
FFS6
Production year
2004
2008
2014
Density
400 kg/m3
370 kg/m3
355 kg/m3
Weight
487 g.
450 g.
425 g.
n.A
- 7.6 %
- 12.7 %
Weight reduction
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Alternative materials – Bio-polymer
§  Why Bio-polymer ?
–  Social & environmental responsibility
–  Emissions reduction
–  Elimination/reduction of hazardous substances
–  Compliance with national and international laws
Fig. 1 – Driver airbag container
(z.B. 1907/2006 REACH)
§  Test results
–  Reduced emission level
–  Good dimensional stability
–  Similar of better material performance
–  Excellent negative temperature performance
–  7.5% weight reduction achieved
Fig. 2 – Failure probability
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Agenda
•  Foam systems
•  Bio-polymers
§  Conclusion
20
Summary - Weight reduction „Potential“
Weight saving potential
Solution
Weight
saving
Driver airbag cover
Concept
design
40 g.
Inflator
Concept
design
90 g.
Airbag cushion
Concept
design
20 g.
Alternative
material
20 g.
Concept
design
15 g.
Alternative
material
12 g.
Alternative
material
25 g.
Reaction plate
Foamed wheel
Total achievable weight reduction
222 g.
(weight reduction achievable on standard SW & DAB design)
21
Thank you for your attention
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Automotive interior trends and their impact on component weight

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