Great Wall - Haval Coupe - Workshop Manual - 2015 - 2015

HAVAL COUPE Body Lightweight Design and Attribute Integration Dr. Lei Shi Technical Director R&D of Great Wall Motor April 15, 2015 Detroit, MI USA Agenda Background Design Approach Lightweight Design Attributes - NVH - Safety - etc. Summary 2 Overview What we are? - We are China’s largest SUV and pickup manufacturer, with over 30 holding subsidiaries, more than 60,000 employees, four vehicle production bases and a production capacity of 800,000 units. - We own Haval and Great Wall brands, covering products range of SUV, passenger car and pickup. - Our assets had amounted to 61.345 billion RBM by Dec. 31, 2014. - We persist in focused development, uphold the brand concept of "focus, dedication and specialization" Our products: SUV, Pickup and Sedan SUV 35 2014 SUV Top-ten Sales Ranking in China 31.59 20 15 HAVAL 25 Unit: 10, 000 Top one: HAVAL 30 23.74 16.82 14.53 13.60 12.47 11.45 10.70 10.06 10 9.87 5 - First produce economic type of SUV in domestic. - Hover H6 got “China annual SUV prize” in 2012, which sales so popular and even hard to meet the purchase requirement. HAVAL H8 HAVAL H6 HAVAL Coupe-c 0 HAVAL Coupe HAVAL H9 HAVAL H6 Update HAVAL H2 3 Overview What we are? Pickup - Domestic sales for GW pickup gains No.1 in 14 continually years. Together with Toyota, Ford pickup named as “World three pickup”. Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas. Saloon car - C50 C30 C2OR C50 Update First made the saloon car in 2007, got No 2 in terms of sales quantity in 2011. First pass EWVTA as Chinese self-owned saloon brand manufacture. 4 Overview What we are? Pickup - Domestic sales for GW pickup gains No.1 in 14 continually years. Together with Toyota, Ford pickup named as “World three pickup”. Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas. Saloon car - C50 C30 C2OR C50 Update First made the saloon car in 2007, got No 2 in terms of sales quantity in 2011. First pass EWVTA as Chinese self-owned saloon brand manufacture. 5 Overview What we are? 长城汽车新技术中心 Europe GWM New R&D Center ChinaJapan North America 长城汽车欧洲技术分中心 长城汽车日本技术分中心 长城汽车北美技术分中心 GWM European R&D Center GWM Japan R&D Center GWM North America R&D Center (On-going) 6 Goal of R&D The goal of R&D activities: Style Freeze Data Freeze •T/Section •Ext/Int •S.E. •Feasibility Report •M/Section •CAE & Physical Test •S.E.. •Neighbor Parts Status Background | Design Approach | Lightweight Design | Attributes Overdesign Optimumdesign Data Freeze Through CAE verification Reduce Style Change & Data Change Underdesign How to freeze data? 7 Goal of R&D Background | Design Approach | Lightweight Design | Attributes The goal of R&D activities: Design Change Cut--off Cut Reach Performance Target within given cost and weight Weight + Cost = Performance 8 Roadmap of WR Cost Background | Design Approach | Lightweight Design | Attributes Advanced Steel & Process & More Light Material Conventional Material & Process Maximum use of HSS & Process Trad. Line D A Ideal Line B Cost Target C Opt. Body Performance Lightweight Design Cost & Weight saving Design CAE iteration Optimum Design Process with multiple iteration of CAE Weight Target Weight 9 Roadmap of WR Background | Design Approach | Lightweight Design | Attributes -A Kg -B Kg -C Kg -D Kg -E Kg Total WR Weight reduction (Kg) Strategy: Sequential effect/benefit for lightweight design By weight reduction By thermal losses reduction By aerodynamics resistance reduction By secondary weight reduction Total FEI Fuel efficiency improvement Starting points Efficiency benefit sequence: Mass reduction of passenger cabin and ripple effect will lead to greater fuel efficiency and secondary mass reduction 10 Roadmap of WR Background | Design Approach | Lightweight Design | Attributes -A Kg -B Kg -C Kg -D Kg -E Kg Total WR Weight reduction (Kg) Strategy: Sequential effect/benefit for lightweight design By weight reduction By thermal losses reduction By aerodynamics resistance reduction By secondary weight reduction Total FEI Fuel efficiency improvement Starting points 11 Strategy of WR for Body Structure Background | Design Approach | Lightweight Design | Attributes Predecessor architecture BIW mass Right size For a given set of conditions & loads, find the lightest & efficient structure that is able to meet design targets. Right topology Right material Right Design details New vehicle BIW mass 12 Strategy of WR for Body Structure Background | Design Approach | Lightweight Design | Attributes A MDO platform integrating all the vehicle attributes is developed to achieve the weight target under CAE environments What is MDO? Multidisciplinary Design Optimization (MDO) is a methodology for improving design of engineering systems, e.g., automobile, aircraft, or spacecraft, in which everything influences everything else. NVH: Torsion, Bending, Dynamic stiffness Offset impact: 偏置碰 64kph Frontal 正碰： 35mph Madymo: FC1-USNCAP FC2-EuroNCAP 13 Door-ring Structure Background | Design Approach | Lightweight Design | Attributes Hot stamping process 1. Blanking 2. Blank heat up (over 900 degrees) 3. Forming & quenching 4. Post form operations Remove Weld Line Predecessor HAVAL Coupe 14 Roof Cross-member Design Background | Design Approach | Lightweight Design | Attributes Weld Line Predecessor HAVAL Coupe 15 MDO- based Lightweight Design Background | Design Approach | Lightweight Design | Attributes MDO Integration BIW Trimmed-body Safety BIW NM Trimmed-body VTF/NTF/IPI Full Frontal Bending Stiff Trimmed-body Acoustic Mode 40% Offset Torsion Stiff Trimmed-body Bending Mode Side Impact BIW IPI Trimmed-body Torsion Mode Roof Crush 16 Front Seat Background | Design Approach | Lightweight Design | Attributes To achieve 3.0 Kg weight saving per vehicle 17 Closure-Liftgate Background | Design Approach | Lightweight Design | Attributes To achieve 1.71 Kg weight saving per vehicle while meeting design target requirements 18 Lightweight Index Weight Background | Design Approach | Lightweight Design | Attributes 0 LWI 3.96 3.74 3.67 0 Kg HAVAL Coupe Predecessor 0 Competitor Predecessor HAVAL Coupe -21.3 Kg Weight reduction Lightweight index 19 Attributes Improvement Background | Design Approach | Lightweight Design | Attributes Attributes Available Space (AAS):  VehicleAttributes − T arg etAttributes  AAS = mean  ∑  T arg etAttributes   Predecessor HAVAL Coupe 0 Predecessor HAVAL Coupe 0 +8% AAS +7% -22% -18% -26% -29% Safety attributes NVH attributes 20 Weight Reduction Background | Design Approach | Lightweight Design | Attributes Weight reduction summary: Weight 0 Seat IP -1 0 Kg HAVAL Coupe Predecessor Weight 0 Closures -5.09 -6.11 -21.3 BIW WR Total: 12.2 Kg To achieve 33.5 Kg weight reduction w/o using light alloys 21 Summary • Successfully developed a platform to integrate all vehicle attributes to achieve weight targets while meeting design requirements • Weight reduction: Totally achieve 33.5 Kg weight reduction w/o using light alloys Lightweight index has been improved 7.3% (through optimization of the body structure) as well as outperformed the competitor • Vehicle attributes: Body rigidity-top class body rigidity performance through improvement of joint efficiency in all areas of the cabin Also, safety and NVH attributes are improved (w/ 7-8% enhancement) • Almost 40 RBM cost saving per vehicle with structural adhesive usage optimization 22 Thanks! Questions/Comments? 23 23