918 Spyder Lightweight design and innovative materials. Schlatt, Switzerland, 9 th October 2014

Transcription

1 918 Spyder Lightweight design and innovative materials Schlatt, Switzerland, 9 th October 2014

2

3 The 918 Spyder project

4 Porsche supersportscars have a long tradition GT Carrera GT Spyder Street GT RS Spyder Hybrid Race

5 918 Spyder fusion of contradictions Design Easy drivability M1 M2 M2 M1 E-drive High performance Boost: 286 hp E-Range: 31 km CO 2 Emission: 70 g/km Nordschleife km/h: 2.6 s km/h: 7.2 s Nordschleife: 6:57 min

6 System extra weight owed to different components Electric system Two permanent magnetized synchronous motors Performance oriented high voltage battery with lithium ion cells (water-cooled by an inside cooling plate) Two power electronics modules High voltage wiring Pressure tank lockable pressure tank to prevent fuel vapor from escaping to environment

7 System extra weight owed to different components Cooling system cooling circuit water: High temperature (combustion engine): 2 front radiators, 1 rear radiator Expansion tank aluminum, external ventilation valve (opening pressure: 1.6 bar) Fluid capacity: 23.9 l Middle temperature / Low temperature (electric machine, power electronics, battery): 1 rear radiator Expansion tank aluminum Electric feed pump Fluid capacity: 9.4 l cooling circuit oil: 1 oil-to-air radiator Fluid capacity: 10.7 l High temperature - cooling circuit Middle / Low temperature - cooling circuit Oil - cooling circuit

8 Compensation of hybrid system extra weight [Kg] +43 Interior quality and vehicle safety Gear box (7 gear PDK) Sound system +317 Battery system Electric drive train High voltage wiring Cooling 1,883 1,634 1,475 Curb weight in accordance with DIN

9 How to manage lightweight design? Lightweight-design in sports car development Lightweight management Material lightweight design Conceptional lightweight design Intergration of functions

10 Material lightweight design

11 Choice of technology depends on the production volume Number of pieces 10 parts/year 600 parts/year 5,000 parts/year Prepreg-Autoclave CFRP moulds RTM Out of Autoclave Prepreg press Pultrusion Steel (aluminum) moulds Investment / unit costs / peak production volume / quality Capacity of the market

12 Rolling Chassis

13 All-carbon fiber structure: a unique feature of Porsche supersports cars Monocoque Crash integrity Vehicle stiffness Visible carbon fiber Integration of fuel tank and HV-battery Back Carrier Integration of rear wing drive, rear lights, control unit Support Frame Front Axis Integration of front axle and front electric motor Resin Transfer Moulding Engine Frame Required to resist temperatures of 150 C Integration of rear axle and rear drive train Prepreg - Autoclave

14 Resin Transfer Moulding: process chain Preforming & Assembly Resin injection Integral part Use of economical fabrics and preforming methods Optimized single preforms Integral RTM-process by Mubea Carbo Tech 6-piece steel mould, 44 tons (2,500 mm x 2,000 mm x 1,200 mm) Low injection pressure Epoxy resin system Integral hollow structure Large visible carbon fibre areas Moderate industrialisation possible Motorsport performance

15 First use of carbon inserts in a street legal production car 27 cast aluminum inserts 10 C-SMC inserts

16 Different ways of corrosion protection Duplex-coating Adhesive film FGRP Duplex coated steel bolt for structural connections Surface S628 (zinc-nickel alloy with restricted layer thickness) organic coating (KTL) Inserts are covered in adhesive film before used in the tool Milled sacrificial layer made out of glass fibre, in contact area with metalic components.

17 Static of the carbon fiber structure Carrera GT Static tortional stiffness: 28,500 Nm/ 918 Spyder Static tortional stiffness: > 40,000 Nm/ Static bending stiffness: 9,000 N/mm Static bending stiffness: > 16,000 N/mm

18 Comparison of 918 Spyder and Carrera GT carbon fiber structure Formula Lightweight rating: L = (Lower values are better) Carrera GT Weight: = 190 kg Static rotational stiffness: = 28,500 Nm/ Lightweight rating: 918 Spyder Weight: = 215 kg Static rotational stiffness: > 40,000 Nm/ Lightweight rating: average passenger cars > 2.5

19 CFRP overview car body panels Outside mirror Bonnet Roof Roof Roll bar cover Side panel front Wing Wing Door outside Door inside Fender Door Sill Resin Transfer Moulding Prepreg - Autoclave Prepreg - Out of Autoclave

20 Front cover low weight thanks to CFRP Carrera GT 918 Spyder CFRP front cover with V-gap Prepreg with honeycomb Bolt-on points realized through aluminum inserts surface approx. 1.1 m² Total weight 5.5 kg Affecting CFRP front cover Prepreg monolithic with bonded reinforcement Bolt-on points realized through steel inserts surface approx. 2.3 m² Total weight 11 kg kg

21 Comparison of different Porsche front covers weight [kg] weight per unit area [kg/m²] Macan Panamera Carrera GT 918 Spyder 0 Macan Panamera Carrera GT 918 Spyder

22 Innovative door system Carrera GT 918 Spyder Door glass Steel side intrusion bar Door panel out of CFRP Prepreg 3 kg 4.75 kg 5.76 kg Door glass Steel side intrusion bar Door panel out of CFRP RTM (inside) and Prepreg (outside) 3.32 kg 3.1 kg 3.65 kg kg

23 CFK stabilizer Steel construction CFRP construction Weight optimised tubular steel stabiliser with thin wall technology Coupling rod welded out of steel components Stabilizer clamps out of aluminum Total weight 2.6 kg Total costs 100 % Braided CFPR-torsion tube with bonded aluminum lever Coupling rod aluminium with rolled Unibal-bearing Stabilizer clamps out of aluminum Total weight 1.1 kg Total costs 3,461 % kg

24 CFRP oil tank 911 GT3 918 Spyder Oil defoaming through cyclone separator Steel-wall thickness mm Fuel tank weight 3.8 kg Minimal oil capacity 4.2 l Purchase price 100 % Oil defoaming through innovative oil guidance CFRP-wall thickness 1.6 mm Fuel tank weight 1.95 kg Minimal oil capacity 5.5 l Purchase price 590 % kg

25 918 Spyder Weissach package: Titanium vs. steel 12 titanium screws (front axle) + 10 titanium screws (rear axle) Titanium has 57 % lower density than steel Saved weight 0.7 kg

26 Comparison of different exhaust systems 911 Carrera S 991 GT3 981 Boxster S Carrera GT 918 Spyder 42.6 kg 39.6 kg 34.4 kg 30.5 kg 28.1 kg Stainless steal exhaust system Stainless steal exhaust system Stainless steal exhaust system Stainless steal exhaust system Top pipes and thinwalled Inconel

27 Exhaust System: Stainless Steel vs. Inconel Exhaust system 911 GT3 Exhaust system 918 Spyder Stainless steel exhaust system Top pipes and thin-walled Inconel Total weight 39.6 kg Total weight 28.1 kg kg

28 Integration of functions

29 Integration of Air intake box into the engine frame Air intake box CFRP engine frame Air filter Air to combustion engine Rear e-motor cooling air Carbon fiber clean air box

30 Vaccum container integrated in heat-protection shields Heat-protection panel Vacuum container Heat-protection panel for engine electrics High temperature CFRP Specific air rooting Total weight 6.8 kg Additional use as heat protection element High temperature CFRP

31 Shear panel integrated in HV battery Floor panel Battery Housing Mechanical integration of the high voltage battery Contributes 3% to global torsion stability disproportionate Floor panel builds the aerodynamic undershield of the car Total weight 5 kg

32 Conceptuel lightweight design

33 Wheel hub design Porsche standard 918 Spyder Weight front axle 22.3 kg Wheel carrier/hub/bearing/drive train Weight rear axle 22.9 kg Saved weight front axle 2 x 1.7 kg Saved weight rear axle 2 x 2.3 kg kg

34 Combustion Engine Carrera GT 918 Spyder V10 5.7l 40 V DOHC naturally aspirated V8 4.6l 32 V DOHC naturally aspirated P max 612 hp (447 8,000 rpm P max 608 hp (447 8,700 rpm P specific hp/l (78 8,000 rpm P specific 132 hp/l (97 8,700 rpm M max 590 5,750 rpm M max 540 6,700 rpm Total weight 205 kg Total weight 137 kg kg

35 Lightweight technology for the engine V8 crankshaft Cayenne (naturally aspirated engine) 918 Spyder Steel crankshaft Total weight 20.7 kg Steel crankshaft, Axial oil supply Total weight 12.7 kg kg

36 Not always CFRP CFPR construction PA6GF30 construction Total weight 2.24 kg Total weight 3.48 kg Part costs 1,680 Part costs 110 Investment 158,000 Investment 170,000 TTO 1.75 Mio TTO 0.27 Mio 1.48 Mio. 1, kg kg x vehicle Limit of costs per kg = 1,000 choice of PA6GF30 construction

37 The result of uncompromising lightweight construction

38 Fastest road vehicel: 6:57 minutes on the Nordschleife 08:16 Time in minutes 08:02 07:48 07:33 07:19 07:04 Electric vehicle Electric vehicle Target 918 Spyder 918 Spyder Hybrid Petrol engine Petrol engine 997 GT2 RS Petrol engine Hybrid Carrera GT Petrol engine Petrol engine 06: CO2 Emissions in g/km

39 l/100 km fuel consumption (NEDC)

40 Overwhelming press feedback The 918 an astounding technical achievement. An absolutely all-new car, using bleedin'-edge techniques wherever you look Denn Vollgas entfesselt nichts anderes als eine Urgewalt, die über beide Achsen herfällt Bestechend präzise, irrwitzig schnell und beinahe spielerisch zu beherrschen press echo The Porsche 918 Spyder is a Work of Scientific Madness: Welcome to the 21st century supercar. It s like a sprinter falling out of bed and going straight into a world record Alles in allem bietet der 918 Spyder einen überwältigenden Eindruck von Geschwindigkeit bei gleichzeitig völlig unkritischem Benehmen Schon rein elektrisch ein Renner, wird der Porsche mit der vereinten Kraft der drei Motoren zu einer Rakete. Allerdings braucht man nicht den Mut eines Evel Knievel, um diese Rakete zu reiten.

41 Summary Plug-In Technology is suited to beat conventional vehicle technology Lightweight design is the key factor for success of Plug-In Hybrid For successful lightweight design lightweight materials, lightweight concept and functional integration has to be used Supersportscars can be ice breakers for new technologies e.g. CFRP, electric 4 WD

42 Thank you