PRIMA GIORNATA DELL INNOVAZIONE

Transcription

1 PRIMA GIORNATA DELL INNOVAZIONE LIVORNO - 5 Dicembre 2008 MAGNA CLOSURES Franco GOttino, Executive Director Engineering Magna Closures Europe CONFINDUSTRIA LIVORNO

2 A Global Presence for Global OEMs* Magna Facilities 220 Production 56 Engineering, R&D Magna Employees 82,000 Canada , ,300 Asia Pacific USA , ,000 Europe Mexico 12 9,900 South America *As at June 2005

3 Magna Product Capabilities BODY CLOSURES MIRRORS STRUCTURES INTERIORS EXTERIORS POWERTRAIN SEATING COMPLETE VEHICLES

4 Magna Closures Europe - Locations Head Office: Sailauf, Germany 9 Production sites 4 Sales & Engineering ca 2,300 Employees São Paulo/ Brazil Redditch / GB Headquarters Sailauf / D Hambach / F Paris / F Munich / D Bremen / D Myslowice / PL Praha / CZ Turin / I Guasticce / I East London / S Africa As at August 2006

5 Complete Doors Modular Door Product Portfolio Electronics & Obstacle Detection Systems PLG, PSD, Roof & WS Control Units Contact & Non-Contact Obstacle Detection Systems Hardware & Software Door Modules Sealed Hardware Trim Integrated Trim Structural Plastic Driver Controls Adjustable Pedals Fixed Pedals Park Brakes Liftgate, Tailgate, Mid-Door Modules Structural Frame Window System Latches Electronics Module Power Closures Power Liftgate Power Sliding Door Integrated Electronics Obstacle Detection Window Systems Single Rail Dual Rail Arm and Sector Quarter Systems Rear Systems Latching Systems Side Door Latches Electronic Latches Non-Contact Entry Systems Liftgate Latches Decklid Latches Handle Assemblies Inside Handles Outside Handles

6 Closures Engineering Capabilities Advanced Technology Group Advanced material & product research & development Prototype and vehicle integration CAE/Virtual Validation Group Centre of Excellence Application Engineering Design Standards Product performance Warranty Product Assurance Campaign Prevention Testing Kinematic Simulation Finite Element Analysis Engineering evaluation Design verification Production validation Platform specific packaging Validation & launch Customer support Resident Engineering Liaison with Customers

7 L INNOVAZIONE La Magna Closures Europe investe ogni anno circa 1 mil per l innovazione a fronte di un budget di ingegneria di 6 mil

8 MAIN ADVANCED ACTIVITIES ES POWER SYSTEM E-Latch Full electronic latch EMS2 POWER LIFT GATE Next Generation Latch DOOR MODULES Integrated Alluminium Inner Panel Module POWER SLIDING DOOR WINDOW REGULATORS Smart gear & Brushless motor

9 DRIVEN BY WIRE E-Latch

10 Design goals Complexity, Cost, Development time, diversity, weight, packaging Latch market trend Optimization DOUBLE DOUBLE LOCK LOCK & & PCL PCL// PR PR DOUBLE DOUBLE LOCK LOCK & & PCL PCL DOUBLE DOUBLE LOCK LOCK CDL CDL MECHANICAL MECHANICAL Pure mechanical latch Mechanical function Central door lock function Mechanical function Central door lock function Double lock function Mechanical function Central door lock function Double lock function Power child lock Mechanical function Central door lock function Double lock function Power child lock Power release ELECTRONIC ELECTRONIC Selective door lock function Double lock function Power child lock Power release Passive entry Functions, User benefits, Reliability IMPRESE X INNOVAZIONE = I3

11 Design goals CONFORT & FEELING IMPROVE STYLE OPPORTUNITIES COST REDUCTION SAFETY GUARANTEED

12 System perimeter Conventional vs Fully E-latch system Conventional Electrical link Mechanical link E-latch Electrical link Mechanical link MAIN BATTERY MAIN BATTERY BODY COMPUTER BODY COMPUTER InSide handle OutSide handle Key cylinder InSide handle OutSide handle Key cylinder DOOR ECU Conventional DOOR ECU E- Remote control Nr4 actuators: Central door lock Dead lock Child lock Power release Remote control BACK-UP ENERGY Nr1 actuator: Power release

13 Risk assessment product definition Main functions at door level 30 Functions analysis: process flow Document extract Sub-functions at door level 80 Sub-functions failures 716 System component responsible 15 Concept actions 716

14 Risk Analysis Project MAGNA & VSI (Vehicle Safety Institute) Goals and Obectives: Risk Assessment for drive by wire latch Comparison with traditional architecture Recommended Actions to reduce the risks Inputs / database: Fatality Analysis Reporting System (FARS) Zentral Datenbank Tödlicher Unfälle (ZEDATU) National Automotive Sampling System General Estimates System (NASS-GES) Traffic Safety Facts of the NHTSA report linkage activation; 290% component failure; 340% unknown + inertial loading; 6190% fork bolt bypass; 450% n = 656 structural failure; 2730% Analyzed Risks: Safe exit from the car Ejection Water Fire

15 Risk Analysis Project MAGNA & VSI (Vehicle Safety Institute) Risk Analysis Process Flow Main Risks Accident Scenarios Latch Failure Modes User Effects Impact Points 1 - Frontal - Side - Rear - Roll Over Actuation 1 (by I/S handle, by O/S Handle, linkages, switches) Water 2 - Complete Submerging - Partial submerging (latch in the water) - Partial submerging (latch not in the water) Mechanical 2 (damage of striker / latch, door deformation, rod buckling, striker / latch failure) - Restricted Exit - Burning - Drowning - Ejection - Others - Fire 3 - Frontal Occurance - Side Occurrance - Latch Wiring broken / Arcing Electronical / ECU (damage of wiring, shorts or broken wiring, wiring or connector disconnection) 3

16 Product description Latch description Feature Details Nr1 actuator for power release and memory function Actuator Absorption similar to Door lock motor Schematic 1 S2 S1 M S3 6 Power release with 5kN seal load guaranteed Main pawl pivotted on eccentric cam Ratchet Double notch on auxiliary pawl Main pawl Resistance: double FMVSS std206 Aux Ratchet Latching system Hall sensor used Sensor Packaging Aux pawl S1 Door open signal: ratchet status S2 Door Ajar signal: both ratchtes status S3 Pawl signal: both pawls status (optional) Package (mm): 150 x 75 x 35 Weigth (gr): 500 Same latch for front, rear and sliding door with moveble window IMPRESE X INNOVAZIONE = I3 Actuator side view 7

17 Product description Latch description: concept Feature Details evolution One-rotation concept Release stop sensor Latch resizing and optimization Packaging Integration of E-latch ECU Reset stop sensor Same functions of the previous description Actuator One rotation sense Sensor Two more sensor for actuator control ECU integration Actuator noise: no bumper need Advantages Absorption & Reliability: motor never in stall condition Costs reduction (ECU components) ECU Risk analyses: 1 Release stop sensor failure: ECU drive the motor till Reset stop sensor Loss of memory function (feeling failure) ECU send a warning signal to BCM 2 Reset stop sensor failure: ECU drive the motor till Release stop sensor Impossible to close the door - no risk for the user ECU send a warning signal to BCM IMPRESE X INNOVAZIONE = I3

18 Product description CAE analysis and Evaluation test Power release function with 5kN seal load supplied by SuperCAP verification Adams simulation SperCAP ECU for testing Release Reset Latch on 500N seal load fixture Comparison data V=12V T=23 C Release time at stall point Reset time at stall point SL N na na CAE TEST ms ms Latch on 5kN seal load fixture