2004 FORD F-150 STEEL BUMPER TECHNOLOGY

Transcription

1 2004 FORD F-150 STEEL BUMPER TECHNOLOGY Rob Fontichiaro Meridian Automotive Systems

2 AGENDA Overview of Meridian Automotive Systems F-150 Front Bumper Design and Performance F-150 Rear Bumper Integrated Hitch Design and Performance Q/A

3 Meridian Automotive Systems Company Overview

4 Exterior Composites Exterior Lighting Interiors Meridian Automotive Systems Company Profile

5 Front End and Rear End Modules Stamped High Strength Steel Bumpers Painted Plastic Fascias Trailer Hitch Systems Rollfromed Bumper Beams & Foam Energy Absorbers

6 Meridian Automotive Systems Manufacturing Facilities OHIO Jackson TEXAS Arlington CANADA Brantford, Ontario MEXICO Celaya INDIANA Angola Grabill Huntington Rushville Shelbyville KANSAS Kansas City LOUISIANA Shreveport MICHIGAN Canton Dearborn Detroit Grand Rapids (3) Ionia (2) NEW YORK Canandaigua NORTH CAROLINA Lenoir Newton Salisbury

7 Ionia, Michigan Manufacturing and Test Facility

8 Ionia, Michigan Manufacturing

9 2004 FORD F-150 FRONT BUMPER

10 2004 Ford F-150 Front Bumper System Molded and painted A- gloss TPO plastic upper fascia with plastic eggcrate structure Front Bumper: Deep drawn SAE J gage Chrome, A-gloss, or G-gloss Paint Chrome blanks are flat polished prior to stamping Removable tooling inserts for forming with and without foglamp holes Added internal bracket structure to improve low speed impact performance

11 2004 F-150 Front Bumper Structure High Strength Steel 950 frame mounting bracket and corner hit brackets

12 5mph Corner Barrier FEA Allowable stroke: 93mm Actual stroke: 90mm

13 2004 FORD F-150 REAR BUMPER INTEGRATED HITCH

14 2004 Ford F-150 Rear Bumpers Styleside Flareside

15 Typical Non-Integrated Step Bumper and Receiver Hitch Two redundant towing systems: 5,000lb. Step Bumper: 65 lbs. 9,900lb. Receiver Hitch: 50 lbs. Total Weight: 115 lbs.

16 Meridian Integrated Hitch Development History Development work began in late 1997 for the Ford F-150, Expedition, Navigator, and Super Duty applications.

17 U.S. Patent Number 6,139,044 Filed June 5, 1998 Awarded October 31, 2000

18 Meridian Integrated Hitch on 2004 Ford F-150 Bumper Bars: High Strength SAE J Brackets: High strength 950 steel. Tubes: ASTM A500 -Grade B, 42,000psi yield strength Hitch brackets ship end item to final assembly plant. 9,900lb. Tow Rating Integrated Hitch Bumper: 105 lbs. 50% take rate 10 lb. save on affected vehicles

19 2004 F-150 Rear Design Hurdles Leaf Spring Clearance Spare Tire Clearance Shackle Bracket Clearance Frame Horn Interface Additional Issues: Assembly operations at 3 customer assembly plants Shipping rack requirements for 5k and 9900lb bumpers Common hitch structure on flareside and styleside Corner hit performance Up/Down and cross-car bumper adjustment (+/- 6mm) Winch access clearance D-pillar and Sheet Metal Clearance

20 F-150 Styleside and Flareside Integrated Hitch Bumpers Styleside Flareside

21 Modular Hitch Design Unique end brackets for flareside vs. styleside Flange modified for flareside Styleside Flareside

22 First Welder Modular Hitch Section out of 1 st Welder

23 Second Welder Finished Hitch out of 2 nd Welder

24 Final Bumper Assembly

25 1.5mph Corner Hit FEA

26 2.5mm Center Barrier FEA

27 2.5mph Center Pendulum FEA

28 Low Speed Impact Physical Testing

29 Bench Durability Fatigue FEA

30 Fatigue Testing in Ionia Test Lab

31 Reduced piece cost Reduced weight Summary of Integrated Hitch Advantages Reduced assembly plant indirect labor costs (inventory, logistics, material handling) Bumper complexity at assembly plants can be eliminated by implementing In Line Vehicle Sequencing Reduced assembly plant direct labor costs Eliminated hitch rack fleet and transit costs to assembly plants

32 Q/A and Follow-up Rob Fontichiaro Engineering Program Management (313) David Holmes Director of Sales (313)