FLAVA Flexible Lightweight Architecture for Volume Applications. James Williams, Program Manager

Transcription

1 FLAVA Flexible Lightweight Architecture for Volume Applications James Williams, Program Manager 1

2 Company Overview Strategic Business Units Consulting Composite Technologies Special Operations Accreditation TS16949 ISO9001 Strategic Alliances (Oct 2015) Clients ENGINEERING CENTRE Coventry, UK ENGINEERING OFFICE Brentwood, UK SALES AGENTS Italy Germany 2

3 Penso Complete Turnkey Solution Provider Capabilities Body Programme Experience Concept Definition Virtual Series Proto Validation Launch Steel Aluminium CFRP 3

4 FLAVA (Q Q1 2019) Description Develop the composite design, material and manufacturing technologies required to implement a modular, multimaterial composite structure suited for large production volume Benefits Weight savings Reduced CO 2 emissions Manufacture of composite intensive vehicle prototypes Development of UK supply chain 25 month programme Co-funded by Advanced Propulsion Centre Grow export sales 4

5 FLAVA: Detailed Engineering & Manufacturing Work Scope Flexible vehicle architecture Multiple Powertrains Mixed Material lightweighting Solution development for ecoat A-Surface Painting Quality. On-line inspection & Repair CFRP Repair Strategy for both on-line and inservice development of MMA adhesive to ease disassembly Materials Development Change from batch production & storage to in-line, continuous production Auto Kitting Development Development for high-rate continuous in-line preforming and automated handling of preforms Composite tooling Blow-moulding to give even lighter, higher performance parts Composite Press Forming Co-curing different thicknesses of Core in the same part at the required production rate. Composite Body Assembly Assembly of hybrid components and structures e.g. bare and e- coated metallics Use of MMA adhesive allowing tuneable cure times 5

6 Why FLAVA? The Market: Legislative driven CO 2 Trends Powertrain Electrification Step Change in CO 2 Required to Meet Challenges Powertrain Electrification delivers additional improvements to meet targets but Hybrid Elec Vehicles Plug in Hybrids Electric Vehicles Transmission Driveline Powertrain Efficiency Modular Platform Architecture Ultra Lightweight CFRP for battery mass offset Must be combined with weight reduction strategy to offset battery mass (>500kg) to deliver Range Performance Business model Flexible Platform Architecture is Required to enable powertrain options 6

7 Industry Drivers for Innovation EU CO 2 Emission Reduction Targets 95 per gram penalty payment for excess emission 7

8 Industry Drivers for Innovation EU CO 2 Emission Reduction Targets Industry Drivers?? 95 per gram penalty payment for excess emission? 8

9 Industry Drivers for Innovation EU CO 2 Emission Reduction Targets Industry Drivers Lightweight Technology? 95 per gram penalty payment for excess emission? 9

10 Benefits from Composites to BIW Structures Composites 45% weight save Steel 60% Part reduction Aluminium 65% weight save Aluminium Composites BOM Reduction Steel Source: NCC Tool Cost Reduction 10

11 Benefits from Composites to BIW Structures Composites 45% weight save Steel 60% Part reduction Aluminium 65% weight save Aluminium Composites BOM Reduction Steel Source: NCC Tool Cost Reduction 11

12 Benefits from Composites to BIW Structures Structure Design Part Manufacture Manufacturing Footprint Steel Body: 250 Panels Autoclave: 3 Hours+ Footprint required CFRP Body: 50 Panels Press Form: <10 Minutes 1/3 footprint required 12

13 Benefits from Composites to BIW Structures Structure Design Part Manufacture Manufacturing Footprint Steel Body: 250 Panels Autoclave: 3 Hours+ Footprint required CFRP Body: 50 Panels Press Form: <10 Minutes 1/3 footprint required 13

14 Benefits from Composites to BIW Structures Structure Design Part Manufacture Manufacturing Footprint Steel Body: 250 Panels Autoclave: 3 Hours+ Footprint required CFRP Body: 50 Panels Press Form: <10 Minutes Reduced footprint required 14

15 High Volume Press Form Process Hot Compression Moulding Cycle times 1-10 minutes Double A surface part HP-RTM Cycle times 4-15 minutes Good part integration Cored Press Forming Cycle times 4-10 minutes Complex varying core section Hollow Press Forming Cycle times 15 minutes Complex hollow form & shapes Parts made in minutes, not hours 15

16 Composite Manufacturing History Various Aerospace Programmes: Engineering < 2010 Zytek LMP1: Body Design & Analysis 2011 Engineering Autoclave material & Processes VARCITY: Affordable CF body structure Press formed & HP-RTM moulded panels to cost & cycle time 5-10 minutes Prototype plate build of 10 bodies HP-RTM Tools Press Forming Tools Engineering for Volume Prod n Bimini Roof: Design & manufacture of a complete hood system C-X75: Engineering Megacity: Composite Body Project Donnington: High Volume Structures Engineering and CFRP Body Legacy materials 2x Prototypes series production 3500 components Tooling lifetime Prototype 2012 build Test & Validate Crash, Durability Plate Body Build 1 per week Press Rate HP-RTM Tools Press Tools Engineering Lightweight Rail Composite Door Leaf: Press Cored Production 2017 HERA: Affordable CFRP Body engineering for GT Press formed, Press Cored & Press Blow moulding technology Proto Body in Black assembly December off Prototype vehicles Q1,Q Crash & Durability testing Q2,Q F-Type SVR Wing: Press Blow Moulded Variable wall thickness FLAVA: High volume composite assembly facility Modular, multi-material composite structure Manufacture of composite intensive vehicle prototypes Rate & Quality Test & Validate Crash, Durability Press form Rate Engineering for Volume Prod n

17 Industry Drivers for Innovation EU CO 2 Emission Reduction Targets Industry Drivers Lightweight Technology Modular Platforms 95 per gram penalty payment for excess emission? 17

18 Flexible Platform Concept BEV Battery Electric ICE Internal Combustion PHEV Plug in Hybrid Electric Fully flexible concept solution possible with ground up design 18

19 Flexible Platform Concept - Powertrain Management BEV Battery Electric BEV Floor Common Cell ICE Internal Combustion PHEV Plug in Hybrid Electric ICE/PHEV Floor 19

20 Modular Floor Construction 20

21 Industry Drivers for Innovation EU CO 2 Emission Reduction Targets Industry Drivers Lightweight Technology Modular Platforms 95 per gram penalty payment for excess emission Volume Production 21

22 Composite Manufacturing Site Coventry, UK P1 P2 P3 Composite component production 3200 SQ MTRS CNC tool machine shop Composite press hall Low volume paint / lacquer Bonding and finishing cells Prototype studios Engineering and Business hub > 4400 SQ MTRS Composite body assembly Body-in-black assembly hall Flexible auto assembly space capable of producing up to 30,000 per annum In construction phase Due for completion Q Vehicle trim and final assembly > 4400 SQ MTRS Electronics, Trim and final assembly Vehicle conversion for DAG / MBUK 22

23 Composite Manufacturing Site Coventry, UK November 2017 March 2018 March 2018 August

24 Composite Manufacturing Site - Assembly Process 7th axis robots work across both stations simultaneously Underfloor geometry assembly Maximise utilisation during adhesive curing dead time Auto part load stillage's 24

25 Composite Manufacturing Site - Assembly Process Bodyside sub assembly automation Robotic integration with operator load and geometry windows Robot mounted to 7 th axis slide Bodyside Inner to Outer marriage bond fixture Bodyside Inner geometry fix station Stand mounted adhesive gun Bodyside Inner geometry fix station Dynamic plan view of cell layout 25

26 Composite Manufacturing Site Coventry, UK 26

27 Thank you for your attention! James Williams, Program Manager