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    CCA28 Rom-Caroseria

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    Csabesz Benczo
    This document discusses various aspects of vehicle frames and bodies, including materials, design, manufacturing techniques, passive safety features, comfort features, and special vehicles. It focuses on how new materials, composite materials, and manufacturing techniques like spot welding, bonding, and hydroforming allow automakers to reduce weight while increasing body stiffness, crash safety, and features. It also examines harness complexity, airbag construction, and passive safety systems. Comfort elements like HVAC systems, noise vibration harshness isolation, ergonomics, and convertible tops are evaluated. Finally, it looks at strength structures for off-road and police special use vehicles.

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    CCA28 Rom-Caroseria

    Uploaded by

    Csabesz Benczo
    12 views7 pages
    This document discusses various aspects of vehicle frames and bodies, including materials, design, manufacturing techniques, passive safety features, comfort features, and special vehicles. It focuses on how new materials, composite materials, and manufacturing techniques like spot welding, bonding, and hydroforming allow automakers to reduce weight while increasing body stiffness, crash safety, and features. It also examines harness complexity, airbag construction, and passive safety systems. Comfort elements like HVAC systems, noise vibration harshness isolation, ergonomics, and convertible tops are evaluated. Finally, it looks at strength structures for off-road and police special use vehicles.

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    CCA28_rom-Caroseria

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    This document discusses various aspects of vehicle frames and bodies, including materials, design, manufacturing techniques, passive safety features, comfort features, and special vehicles. It focuses on how new materials, composite materials, and manufacturing techniques like spot welding, bonding, and hydroforming allow automakers to reduce weight while increasing body stiffness, crash safety, and features. It also examines harness complexity, airbag construction, and passive safety systems. Comfort elements like HVAC systems, noise vibration harshness isolation, ergonomics, and convertible tops are evaluated. Finally, it looks at strength structures for off-road and police special use vehicles.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    12 views7 pages

    CCA28 Rom-Caroseria

    Uploaded by

    Csabesz Benczo
    This document discusses various aspects of vehicle frames and bodies, including materials, design, manufacturing techniques, passive safety features, comfort features, and special vehicles. It focuses on how new materials, composite materials, and manufacturing techniques like spot welding, bonding, and hydroforming allow automakers to reduce weight while increasing body stiffness, crash safety, and features. It also examines harness complexity, airbag construction, and passive safety systems. Comfort elements like HVAC systems, noise vibration harshness isolation, ergonomics, and convertible tops are evaluated. Finally, it looks at strength structures for off-road and police special use vehicles.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 7

    18.

    FRAME AND BODY

    Fig. 18.1 Body structure – VW Lupo

    Fig. 18.2 Body structure – Citroen C4

    18.1. STRENGTH ASSURANCE


    Materials
    Composite Materials
    vezi si AE_SAE2004_03 p.48-49 – materiale compozite

    - 194 -
    Technology

    Fig. 18.3 Structural element for car body realised of rolled steel
    Design

    Fig. 18.4 The use of new materials, design and manufacturing techniques permits weight reduction
    simultaneously with increased body stiffness, crash safety and interior storing features and
    optimised acoustics, vibration level and travel comfort (VW)
    Maserati: torsion stiffness: 32000 Nm/°, bending stiffness 13000 N/mm.
    Ferrari 360 Spider: torsion stiffness: 8500 Nm/° ???, bending stiffness 4200 N/mm ???.
    Volkswagen Passat's static torsion stiffness is 32.400 Nm/°, 57 per cent more than that of its
    predecessor. The bodywork structural weight is 298 kg (total mass unloaded is 1348 kilograms).

    - 195 -
    High-tensile steel was used in 74 per cent of the bodywork structure.
    The modern cars must be as light as possible while offering improvements in terms of crash
    safety and body stiffness.
    The increased body stiffness is achieved by new design (shape-hardening), techniques
    (optimised tensile joining technology – "warm-worked" and structural bonded components) and
    materials.
    Spot and laser welding techniques
    Componential (for one part) and structural (between parts) bonding
    In terms of new manufacturing processes, Dana is counting on magnetic pulse welding and
    hydroforming – among others – to enable further innovation in structural product development. An
    electronic, no-heat process, magnetic pulse welding is used to join ferrous and non-ferrous metals
    for a bond that is stronger than possible with conventional welding. Hydroforming involves fluid
    being injected into dies under high pressure to shape tubes. Dana is using a new hydroforming
    process, called Robo-Clamp, to make engine cradles for the Ford Windstar.

    18.2. HARNESS

    Fig. 18.5 Complexity of a modern car harness (electrical wires and connectors)

    - 196 -
    18.3. PASSIVE SAFETY

    Fig. 18.6 Control elements of effort repartition

    Fig. 18.7 Airbag construction

    - 197 -
    Fig. 18.8 Passive safety system for pedestrian protection – Siemens-VDO

    18.4. COMFORT
    HVAC

    Fig. 18.9 Ventilation air flows in a compact car (Smart)

    NVH isolation
    Unlike its predecessor, the new Passat is equipped with transversely integrated engines. VW
    has made the most of this conversion to continue to perfect comfort levels via the engine and
    - 198 -
    gearbox suspension. In addition to vibration comfort levels, which once again play a significant role
    at this stage, the developers focussed their attention on the engine coupling and optimum no-load
    features. The Passat is therefore equipped with a three-point pendular distribution, resulting in the
    near-perfect isolation of engine and bodywork. Uncoupling the multi-rod rear axle with the aid of
    subframes proves equally as innovative.
    The decisive feature that makes the new Passat so comfortable is the auxiliary frame that
    uncouples the rear axle from the body. The frame itself is very light due to the use of high-tensile
    steels. The insulation from the bodywork is achieved with four voluminous rubber-metal bearings.
    As a result, the insulation of the auxiliary frame provides superior acoustics and driving comfort
    and a car that is generally very quiet when it comes to wheel noise while having a road-holding
    behaviour that makes it fun to drive on country roads or motorways.

    Ergonomics

    Fig. 18.10 Assurance of the correct viewing field for the instruments cluster for very small (5
    percentile female – top side) and very large (95 percentile male – bottom side) drivers by the seat
    position change

    - 199 -
    Convertible

    Fig. 18.11
    18.5. SPECIAL VEHICLES

    Fig. 18.12 Strength structure of sport vehicle participating in off-road raids – VW Touareg

    Fig. 18.13 Unimog U 500 for police activities

    - 200 -

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