Carbon Fibre - SMMT · Develop affordable carbon fibre body architecture, delivering significant...
Transcript of Carbon Fibre - SMMT · Develop affordable carbon fibre body architecture, delivering significant...
© Penso Consulting Ltd 2014Technology : DrivenPage 1
Carbon Fibre:
Enabling Mass Production Technologies for vehicle
lightweighting
© Penso Consulting Ltd 2014Technology : DrivenPage 2
Engineering, Prototyping & High Volume Production
Composites
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Key Drivers – CO2 Emmissions:
• All OEM’s must make cars that comply with EU & Global Legislation
• From 2012 - 2020 mass based CO2 limits will be applied to new cars
• OEM’s must address the Sustainability challenge in a cost effective
manner, whilst maintaining vehicle attributes & making vehicles that
appeal to their customers
Hybrid Elec Vehicles
Flywheel [Kinetic]
Plug in Hybrids
Electric Vehicles
Combustion
Transmission
Driveline
Powertrain Efficiency
Weight Efficiency
Vehicle Architecture
BIW & Closures
Chassis parts
Material application
Joining technology
LCA
Weight v attributes
Aerodynamics
Rolling resistance
PT & Thermal
Energy management
- Chassis systems
- Electrical
Climate systems
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Weight Reduction
Global convergence of CO2 emissions targets
CO
2E
qu
iva
len
t/km
Co
nve
rted
to
NE
DC
Te
st C
ycle
10
1g
/km
19
g/k
m
CO2 Equivalent/km converted to NEDC Test Cycle
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Weight effect on CO2C
O2
g/
km
PetrolDiesel
Hybrid
Modus
Citroen C2
Focus
Jaguar S 2.7
Jaguar XF 2.7
Insight
Prius
Civic
Lexus GS450h
Lexus RX400h
Lexus LS600h
Citroen C1
50
100
150
200
250
300
500 1000 1500 2000 2500
LWV Vehicle
weight saves
combined with
PT & Parasitic
loss reduction
CAN get us to
CO2 targets
Kerb weight (kg)
Engineering activity to reduce CO2 emmission
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Body Design & Analysis:
Simulation Test
Average Acceleration (g) 24.9 25.0
Residual Length (mm) 135 134
• Body Engineering & Optimisation:
• Compliant with FIA Regulations
Composite Enabling Technologies:
Engineering Design: Design for Performance
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Brief Description:
Develop affordable carbon fibre body
architecture, delivering significant weight
saving and high volume production
feasibility
Project Overview:
Funded by Technology Strategy Board
High Volume CFRP Production
36-months
Project value £16.8 mil
Project Partners:
VarCity Programme:
Vehicle ARchitectures for CITY cars
Composites Enabling Technologies
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Composite Business Development:
WP1
Vehicle (Body) Architecture
Design Concepts &
Vehicle Integration
(JLR) WP2
CFRP Material
Selection & Development
(CYTEC)
WP3
CFRP Component
Manufacturing Process
Development
(PENSO)
WP5
Adhesive Material
Development
(SIKA)
WP8
Demonstrator Body
Build
(PENSO)
WP9
Virtual testing (CAE)
Physical testing
LCA & Cost Analysis
(JLR)
WP7
Demonstrator Part
Manufacture
(PENSO)
WP10
Dissemination
&
Exploitation
(JLR)
WP6
Joining & Fixing Strategy
& Fastener
Development
(AVDEL)
WP4
Body Assembly
Automation & Tooling
(EXPERT)
Te
ch
no
log
y D
eve
lop
me
nt
De
mo
ns
trato
r D
eve
lop
me
nt
VarCity Workstreams and Partners:
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Composite Enabling Technologies:
VarCity & Partner Workstream Outputs:
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Composite Enabling Technologies:
Manufacturing Processes:
Preform & Lay-up Automation
Semi-Automatic &
Fully Automatic Bonding
Materials:
Large tow CF, NCFs & Textiles
Materials:
Snap Cure Resin Systems
Legacy Materials
Design for Performance
Hot Compression Moulding
High Pressure Resin Transfer Moulding.
2014
Autoclave Processes
2015 2016 2017 2018 2019 20202013
High Volume Vehicle or Systems e.g. closuresVolume >50,000BIW weight <150kgInvestment <£40mPiece Costs <£2,000
High Performance Super Cars:Volume <3,000BIB weight <160kgInvestment <£5mBIB unit Costs <£10,000
Design for Performance,
Manufacturing & Cost
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Composite Enabling Technologies:
Simultaneous Tooling Development:
Substantial Research and Development into manufacturing processes for high volume CFRP production, simultaneously aligned with tooling development to suit product performance and cost requirements.
Prototype tooling in aluminium
Low volume production using aluminium tools
High volume production using steel tooling
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Composite Enabling Technologies:
Hot Compression Moulding & High Pressure Resin Transfer Moulding:
High tonnage press facilities with large platen formats, allowing the production of large integrated components.
High pressure RTM equipment automatically linked to specific presses.
Ultrasound NDT Equipment for panel inspection. (Lamination characteristics, bonding characteristics etc.)
Inspection Booth
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Composite Enabling Technologies:
Research Industrialisation:
• Composites press facility expansion with semi-automated and fully automated press lines.
• Fully automated BIB assembly facility
• Tool Room expansion for increased capacity requirements
• Full “turnkey” composites facility from product engineering through to volume production supply.
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Penso - January 2015
Thank you for your attention