EuroCarBody 2010 12th International Car Body Benchmark ConferenceCar body benchmarking data summary Volvo S601. WeightsTotal weight body-in-white: 415.2 kgDefined as the total weight of the car body including doors and closures, as well as all parts that are fitted in the body shop (e.g. integrated bumper beams), excluding paint. Corresponding view: (The colour scheme of the parts shown makes use of the RGB colour code for the material classification, see section 2.)EuroCarBody 2010, Benchmarking Data Summary Extra parts: Part description Corresponding viewVolvo S 60WeightBody structure:321.5 kgDoor structure:63 kgHood and fenders:15.2 kgBootlid:15.5 kgBody-in-white weights of doors, closures and fenders Front doors (both): Rear doors (both): Hood: Bootlid: Front fenders (both): Total weight body-in-white without doors, closures and fenders:34.2 kg 28.8 kg 10.2 kg 15.5 kg 5.0 kg 321.5 kgEuroCarBody 2010, Benchmarking Data SummaryVolvo S 602. Material mix in the body-in-white including doors and closuresBased on metallurgical/chemical material classesMaterials: corresponding metallurgical classes Low Strength Steels: Mild steels High Strength Steels (HSS): High Strength Interstitial-free Steels (HSIF), Bake Hardening Steels (BH), High Strength Low Alloy Steels (HSLA) Steels Advanced High Strength Steels (AHSS): Dual Phase Steels (DP), Transformation Induced Plasticity Steels (TRIP) Stainless steels: Austenitic stainless steels Ultra High Strength Steels (UHSS): Complex Phase Steels (CP), Martensitic Steels (MS) Press Hardened Steels (PHS) Aluminium sheets: 7xxx series Aluminium Aluminium sheets: 6xxx series Aluminium sheets: 5xxx series Aluminium extrusion profiles Cast aluminium Magnesium Plastics Fibre reinforced plastics Duroplastics, including Sheet Molding Compound (SMC) Thermoplastics RGB colour codeR 153, G 204, B 255 R 051, G 102, B 255% 38 29.5 14.5 0.2 14.2 0.8 1.1 0.9 0.8 -R 255, G 153, B 204 R 051, G 051, B 153 R 204, G 153, B 255 R 128, G 000, B 128 R 051, G 204, B 153 R 000, G 255, B 000 R 204, G 255, B 204 R 153, G 204, B 000 R 051, G 153, B 102 R 255, G 255, B 000 R 255, G 000, B 000 R 255, G 153, B 000 R 153, G 051, B 000 R 192, G 192, B 192Other materials, namely:_________________________________________________The following graph may serve as a guide to locate the properties of the metallurgical steel classes:2.000 Press Hardened Steel 1.600Tensile Strength /MPaPHS1.200Advanced High Strength SteelCP TRIP DP HSLA BHMS800Ultra High Strength Steel400MildHSIFHigh Strength SteelLow Strength Steel 0 0 200 400 600 800 1.000 1.200 1.400 Yield Strength /MPaEuroCarBody 2010, Benchmarking Data SummaryVolvo S 603. Stiffness dataMeasured / Calculated 1st Torsional Eigenfrequency body*: 1st Lateral Eigenfrequency body*: 1st Vertical Eigenfrequency body*: 44 Hz 41.8 Hz 59.4 Hz*Parts included in the measurement/calculation of the body frequencies: Body, GOR, front wind screen and rear window Static torsional stiffness Static bend stiffness 23,300 Nm/° n. sp.4. Contact area= track (1.588 m) x wheelbase (2.776 m) = 4.408 m25. Joining processesused in the body shop, including all bought-in parts and sub-assemblies Joining technique Number of joints or length of seams 3966 3.69 m 4.88 m 2.47 m 35.9 m Weldspot equivalents (WSE) 3966 185 325 82 718CalculationSpot welds Arc welding Laser welding Conventional brazing Laser brazing Adhesive joining Rivets Clinch-spots Screws (incl. flow drills)1:1 20 mm = 1 WSE 15 mm = 1 WSE 20 mm = 1 WSE 30 mm = 1 WSE 50 mm = 1 WSE 1 joint = 1 WSE 1 joint = 1 WSE 1 joint = 1 WSETotal WSE:5276EuroCarBody 2010, Benchmarking Data SummaryVolvo S 606. Production conceptProcess stability/availability: = total up-time in the body shop 85 %Re-tooling or re-use factor: = [1 – Project investment excluding operational costs / “all new“] x 100with „all new“ = Value of the total installed investment80 %Degree of mechanisation: = Automated Work Content* / Total Work Content*98.5 %* Work Content refers to the sum of Standardized Work Contents in the Body Shop, calculated according to the Harbour Report system, excluding lay-in operations, handling of parts, logistic operationsBodyshop-Index BSIn. sp.=project investment, architecture [€] + additional investment for the specific model [€] net production of the model [car units/hour] × Total WSE of the model ** as calculated in section 5No. of production sites: namely in: Intended production volume:1 Gent, Belgium 90,000 units/yearCar body production lead time: n. sp. = the time spent by the unit in the body shop, from the start of the first underbody parts to the handing over of the body-in-white to the paint shop, including car body interim storage**** More accurate definition (Harbour): • Start counting when work begins at the first station of the underbody (motor compartment or rear floor, whichever station begins first). • The end of the measurement is the beginning of the delivery from body in white to the paint shop. If the vehicle changes skids or pallets, the process ends as soon as the vehicle leaves the original pallet. If the vehicle is going on a lift to transfer to the paint shop, the process ends as soon as the body in white is in final position to begin transfer.Cycle time (mainline bodyshop): Degree of material utilisation/scrap rate: Total number of parts in the BIW: Number of parts, including external parts, in weight classes < 100 g: 100 g - 1 kg: 1 kg - 5 kg: > 5 kg: (all assemblies broken down into their component parts)74 seconds 54 % 366 54 191 93 28EuroCarBody 2010, Benchmarking Data SummaryVolvo S 607. Targeted market regions and origin of build…….of the vehicle presented at the EuroCarBody: Targeted market region(s): Origin of build: USA, China, Russia, Sweden, UK Gent, Belgium8. Development strategies / initial propositionsSpecific aims of the development: Sportiest, most dynamic and emotional sedan/estate offer in the Volvo portfolio. Safest in segment. Specific improvements reached compared to the predecessor: Improved safety performance in field and in rating. Improved pedestrian performance (active and passive). More efficient packaging resulting in more leg room. Improved visibility A-pillar. Specific comparisons to direct competition in the market: n. sp.9. Damage and repair strategyQualitative description of the repair strategy: n. sp. Engine variant D5 –153 kW RCAR basket of parts*: Front: Bumper cover, Bumper absorber, Bumper beam Insurance classification 23 VKRear: Bumper cover, Bumper beam* Parts to be repaired after a standardised RCAR low speed (15 km/h) offset insurance crash (front and rear, respectively). See /Papers/Procedures/rcar_test_protocol_angled_barrier.pdf10. Additional information:Crash performance data: Euro NCAP not yet available Development time: = time from design freeze to SOP/job one Life cycle analysis data: n. sp.n. sp.。