SAE Gov/Ind Meeting: Vehicle Lightweighting Technology
January 30, 2013
Washington DC
Volkswagen Group of America
Engineering and Environmental Office (EEO)
- CONFIDENTIAL MATERIAL For Internal Group Distribution Only
Importance of Lightweight Design
NEDC Cycle
NEDC Cycle
*Courtesy of Audi AG, Dr. Sindel
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Volkswagen Group of America EEO
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Volkswagen Group
Automotive Division
Passenger Cars
Commercial Vehicles,
Power Engineering
• Targeting 8 million units per year light duty
• Hundreds of manufacturing facilities worldwide
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Volkswagen Group of America EEO
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Volkswagen Group’s Move Towards Modularization
Fahrzeugpreis
A000
A00
A0
A
B
C
D
E
NSF
New Small Family
MQB Modularer Querbaukasten
MLB
Modularer Längsbaukasten
MSB
MSB Modularer Standardantriebsbaukasten
MLB
MQB
NSF
Fahrzeugklassen
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Volkswagen Group of America EEO
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MQB Example: Volkswagen Golf Mark VII
Mainstream value focusing on advanced steels
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Volkswagen Group of America EEO
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Volkswagen Golf: Evolving Design, Consistent Value
1974 Golf I
2003 Golf V
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1983 Golf II
1991 Golf III
2008 Golf VI
Volkswagen Group of America EEO
1997 Golf IV
2012 Golf VII
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“My how you have grown”
1974 Mark I
2013 Mark VII
Length
150
168
Width
63
71
Height
55.5
57
Cargo Volume
13 cu-ft
14 cu-ft
Weight
1708 lbs
2656 lbs
Power
50 hp
84-138 hp Gasoline
103-148 hp Diesel
Torque
58 lb-ft
118-184 lb-ft Gasoline
184-236 lb-ft Diesel
Accel
15.8 sec
8.4-11.9 sec Gasoline
8.4-11.9 sec Diesel
Top Speed
87 mph
110-131 mph
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Volkswagen Group of America EEO
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Driving Mainstream Value for Mass Market Cars
It was therefore important to us to build the most fuel-efficient Golf
ever, which at the same time had to remain affordable. And we’ve
succeeded in doing that. The Golf Mk7 is extremely fuel efficient,
equipped as standard with the Stop/Start system and brake energy
recovery mode and yet—to take Germany as an example—at a base
price of €16,975 not a cent more than its predecessor’s entry level
model.
—Prof. Dr. Martin Winterkorn, Group Chairman, Volkswagen AG
Cost Savings Achieved
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Structural Unit Cost
-20%
Engineering Resources
-30%
Production Time
-30%
Volkswagen Group of America EEO
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Foundation of the MQB
Modular-Transverse-Construction Kit
•
•
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Spanning multiple models, sizes, and price ranges
2 million units per year by 2014, raising to 4 million by 2016
Volkswagen Group of America EEO
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MQB‘s flexible design able to accommodate alternative drives
Conventional drive
Alternative/Regenerative
TSI Gasoline
EA211
EcoFuel
CNG
Electric drive
TDI Diesel
EA288
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Plug-in
Volkswagen Group of America EEO
EDrive
FlexFuel
Ethanol
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MQB Helping to Improve Product and Margins
Material costs 100 %
Distribution of savings
Additional serial and
optional content,
previously reserved to
premium class
Hat
ca. 40%
Potential savings
MQB
platform
ca. 60%
Lower cost per unit
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Savings to be partly
absorbed to fulfill
regulatory and legal
requirements:
Less EHpV1)
Less one-off expenditures
Savings
Margin
improvement
Profit
Expenditures
Invest
1)
EURO 6
Pedestrian protection
Engineered Hours per Vehicle
Volkswagen Group of America EEO
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The New Golf: Up to 100kg Weight Reduction
-37kg
Superstructure*
-26kg
Running gear*
-22kg
Engine*
Use high-strength & advanced high-strength steel
grades (HSS) and reduce sheet thickness
VI
VII
-12kg
Special equipment*
Steel
-3kg
Adv. HS steel
Ultra-high-strength steel, hot formed
Electrical*
* Model-dependent
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Volkswagen Group of America EEO
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Lightweight Achievements
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Future Potential for Additional Mass Reduction (MQB)
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Volkswagen Group of America EEO
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Example Cost-Effectiveness Curves for Weight Reduction
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Volkswagen Group of America EEO
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MLB Example: Audi A6
Expanding the use of mixed-material concepts
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Volkswagen Group of America EEO
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Lightweight Structure Pathways
*Courtesy of Audi AG, Dr. Sindel
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Volkswagen Group of America EEO
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Bending the Arc of Weight
40-80kg reduction from previous model
Intensive use of aluminum sheet
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Volkswagen Group of America EEO
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Audi A6 Lightweight Design Elements
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Volkswagen Group of America EEO
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Volume Drives Available Processes and Designs
20% aluminum construction
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Volkswagen Group of America EEO
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3L TDI Weight Reduction
24kg weight savings in Audi 3L TDI engine
Reduced wall thickness
• high-strength vermicular graphite
cast iron.
Plastic multi-section intake
• replaces aluminum
Redesigned cylinder heads
Reduced number of timing chains
Integrated high-pressure pump
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Volkswagen Group of America EEO
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Lightweight Challenges
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We know where this is going…
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Volkswagen Group of America EEO
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Not LOL-ing
“Yes, hello. I had a slight fender bender.”
“Can your shop weld aluminum?”
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Volkswagen Group of America EEO
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Audi Certified Aluminum Repair Facilities
33 shops in the US are certified to repair Audi aluminum
vehicles
•
•
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TÜV certification required, must be renewed every 2 years.
$x00,000 investment in tooling, welders, training
Volkswagen Group of America EEO
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Thermal Expansion of Exterior Body
Panel gaps have become an important measure of perceived body quality and
impacts exterior styling
•
•
•
Vehicles are subjected to high temps due to solar load when parked
Body panels will expand and shrink depending on material and temp
Advanced engineering techniques required to predict deformations and assure quality fit and finish
Measured and simulated body
expansion due to thermal load
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Volkswagen Group of America EEO
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Advanced Materials Misbehaving Themselves
Example of hemming operation resulting in “roping” due to
surface plastic deformation
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Volkswagen Group of America EEO
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Multi-Material Joining Techniques Become More Complex
•
•
•
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Mixed material joining must
account for dissimilar materials
and their interactions
Significant investment in tooling
Process time can be impacted
Volkswagen Group of America EEO
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Summary
Volkswagen Group is bending the arc on weight with modular
construction kits
Standardization of platforms frees capital to be expended on more
advanced designs and premium content
For mainstream vehicles, lightweighting requires solutions that
remain affordable
Challenges remain with the implementation of mixed-material
vehicle concepts
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Volkswagen Group of America EEO
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