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

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

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

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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

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 40-100 thousand Units / Year High Process Flexibility Costs Reduction of development costs Reduction of invest costs Reduction of product costs

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

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

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

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

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

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

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

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: 380 420 kg Weight reduction BIW Potential 61 101 kg Possible savings up to 24 % Requirements Weight (Base current BIW High roof Sleeper Cabin)

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. thickness = 1,7mm Max. functional integration Reference: EDAG LightCar 2010 Functional Integration: Door Hinges / breaks Corner piece hinges / Stop Dashboard fixings Interfaces Electric

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

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

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

LightCab 2.0 / R 29-03 A Folie 20 von # Copyright 2010 EDAG GmbH & Co. KGaA. All rights reserved. Peter Roos

LightCab 2.0 / R 29-03 B Folie 21 von # Copyright 2010 EDAG GmbH & Co. KGaA. All rights reserved. Peter Roos

LightCab 2.0 / R 29-03 C Folie 22 von # Copyright 2010 EDAG GmbH & Co. KGaA. All rights reserved. Peter Roos

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

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

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

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

Production concept Layout Geostation Cycle time 291s 2 Shifts/Day 75.000 Cabins/Year

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

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

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)

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