LightCab Technology concept International Panel, SAE Congress 2013, 8 th October Jörg Ohlsen, CEO EDAG

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Owen Peters
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1 LightCab Technology concept International Panel, SAE Congress 2013, 8 th October 2013 Jörg Ohlsen, CEO EDAG

2 LightCab Technology concept 1 Drivers LightCab Challenges and conceptual formulation 2 Product concept Variants, Structural concept, Modularity, Materials 3 Network Engineering Product & Process Process chain, Development Plan 4 LightCAB Engineering Highlights: Lightweight, Performance, Production 5 Production concept Tools, Dies & Production systems digital 6 Conclusion Status of concept

Process Process chain, Development Plan 4 LightCAB Engineering Highlights: Lightweight,

3 Lightcar Family

4 LightCab ight nnovative eometric scalable igh performance echnology ost optimised pprovable ase for further investigations

5 Drivers LightCab Goals (Performance / Requirements) Weight Reduction of min. 20% (including requirement of reaching higher targets) (Base: Actual European Heavy truck High roof Cab BIW`s) Package Package protection of Euro 6 requirements Modular Concept LightCab Family Durability, Life cycle, Repair concepts High durability (lifetime > 1,5 Mio km) Corrosion resistance Requirements for 2. and 3. markets to be considered Passive Safety / Crash ECE R29-3 (new regulations 2011) and Trailer Back load case Reduced intrusion (absolute / relative to occupant) Safety concept Cab

Euro 6 requirements Modular Concept LightCab Family Durability, Life cycle, Repair concepts High durability (lifetime > 1,5 Mio km) Corrosion

6 Drivers LightCab Goals (Performance / Requirements) Comfort Minimisation of structural package Optimised dynamic stiffness Dimensional Quality Improvement Fit & Finish Reduction of Tolerances Cabin & Vehicle Process stability Quantities thousand Units / Year High Process Flexibility Costs Reduction of development costs Reduction of invest costs Reduction of product costs

Tolerances Cabin & Vehicle Process stability Quantities 40-100 thousand Units / Year High

7 LightCab Technology concept 1 Drivers EDAG LightCab Challenges and conceptual formulation 2 Product concept Variants, Structural concept, Modularity, Materials 3 Network Engineering Product & Process Process chain, Development Plan 4 LightCAB Engineering Highlights: Lightweight, Performance, Production 5 Production concept Tools, Dies & Production systems digital 6 Conclusion Status of concept

8 The LightCAB - Family Family Range: 16t-40t Scalable by variable Profiles (high potential reduction invests) Modular concept (Product and Production) Complexity management Scalable Fixed

9 Product Concept Materials Ultra high strength steel (UHSS) High strength steel (HSS) Thin wall steel casting Mild Steel Thermo Plastic Composite

10 EDAG LightCab Technology concept 1 Drivers EDAG LightCab Challenges and conceptual formulation 2 Product concept Variants, Structural concept, Modularity, Materials 3 Network Engineering Product & Process Process chain, Development Plan 4 LightCAB Engineering Highlights: Lightweight, Performance, Production 5 Production concept Tools, Dies & Production systems digital 6 Conclusion Status of concept

Process Process chain, Development Plan 4 LightCAB Engineering Highlights: Lightweight, Performance,

Network Engineering Product & Process Cabin BIW Process chain Etc Quality Production Production - Parts, Subassy Manufacturing equipment CUSTOMER

11 Network Engineering Product & Process Cabin BIW Process chain Etc Quality Production Production - Parts, Subassy Manufacturing equipment CUSTOMER Productiondevelopment Project Management Toolmaker Concepts Styling Product development CAE, DIM M., DMU Quality Prototypes Test / Validation Die / Tool Development

Productiondevelopment Project Management Toolmaker Concepts Styling Product

12 Network Engineering Product & Process Synchronised Timing plan Product Development Production Development Tool Development

13 EDAG LightCab Technology concept 1 Drivers EDAG LightCab Challenges and conceptual formulation 2 Product concept Variants, Structural concept, Modularity, Materials 3 Network Engineering Product & Process Process chain, Development Plan 4 LightCAB Engineering Highlights: Lightweight, Performance, Production 5 Production concept Tools, Dies & Production systems digital 6 Conclusion Status of concept

Total Cabin BIW: 102 kg 104 kg 36 kg 7 kg 60 kg 10 kg 319 kg Reference Weights EU BIW Total Cabin

14 LightCab Highlights Weight status Weight status Cabin BIW Floor incl. Bulkhead Side panels LH/RH Back panel Roof Frame upper Roof Additional Brackets ca. Total Cabin BIW: 102 kg 104 kg 36 kg 7 kg 60 kg 10 kg 319 kg Reference Weights EU BIW Total Cabin BIW: kg Weight reduction BIW Potential kg Possible savings up to 24 % Requirements Weight (Base current BIW High roof Sleeper Cabin)

15 Highlights Technologies i.e. 3D rolled profiles (laser welded) High strength Boron-Steels (22MnB5) Strength: Base material: Hardened: 500 N/mm² 1600 N/mm² Inline partial hardened (automated) Design to Requirements for safety areas Designed to specification: ECE R29-3 Test B (A-Pillar impactor) Best Welding conditions to casting parts View angle conditions Package optimised

Highlights Technologies i.e. Low Pressure Thin-Wall Steel Castings Substitution shell construction Ceramic moulds with lost cores Strength up to 760 N/mm² E-module =14%; corrosion resistant Min.

16 Highlights Technologies i.e. Low Pressure Thin-Wall Steel Castings Substitution shell construction Ceramic moulds with lost cores Strength up to 760 N/mm² E-module =14%; corrosion resistant Min. thickness = 1,7mm Max. functional integration Reference: EDAG LightCar 2010 Functional Integration: Door Hinges / breaks Corner piece hinges / Stop Dashboard fixings Interfaces Electric

17 LightCab Highlights i.e. Tolerance concept Front View Functional defined Locator & Fixing concept Optimised F&F (Cab & Vehicle) Floor ASM Side panel ASM Module assurance Stable Process

18 LightCab Highlights i.e. Changed law ECE R29 ECE R29-3 Test A Modified Test B New (29,4 KJ) Test C New (Phase 1 > 7,5t) Test A Test B Test C

19 LightCab Highlights i.e. Structural concept - CAE Investigation ECE R29-03 Test A Test B Test C Status: Max intr. 157 mm No cracks BIW Survival space Status: Max intr. 165 mm No cracks BIW Survival space Status: Max intr. Side 62 mm Top 65 mm No cracks BIW Survival space

23 EDAG LightCab Technology concept 1 Drivers EDAG LightCab Challenges and conceptual formulation 2 Product concept Variants, Structural concept, Modularity, Materials 3 Network Engineering Product & Process Process chain, Development Plan 4 LightCAB Engineering Highlights: Lightweight, Performance, Production 5 Production concept Tools, Dies & Production systems digital 6 Conclusion Status of concept

24 Production concept Tooling concept / Method plan Engineering Method & Simulation Realisation Simultaneous up to SOP Engineering Concept

25 Production concept Tooling concept / Invest & Product costs Engineering Cost & Weight optimization Cost optimised Alternative Product & concepts Process Targets

26 Production concept Virtual Production Engineering Layout Simultanous Engineering Concept Virtual SOP Realisation up to SOP

27 Production concept Layout Geostation Cycle time 291s 2 Shifts/Day Cabins/Year

28 Production concept Modular Geostation One data set with direct link to product data management system (TCE) used by both engineering tools: Process Simulate & Process Designer

29 EDAG LightCab Technology concept 1 Drivers EDAG LightCab Challenges and conceptual formulation 2 Product concept Variants, Structural concept, Modularity, Materials 3 Network Engineering Product & Process Process chain, Development Plan 4 LightCAB Engineering Highlights: Lightweight, Performance, Production 5 Production concept Tools, Dies & Production systems digital 6 Conclusion Status of concept

30 Conclusion Status of EDAG LightCab 2.0 Weight reduction Package Durability, Life cycle, Repair concepts Passive Safety / Crash Structural requirements Dimensional Quality Process stability Process flexibility Costs (Material, Tooling & Piece cost)

31 Thank you for your attention EDAG light cab: We can carry something more

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