A Winner: Car Body Design Development of the Hyundai ?· A Winner: Car Body Design Development ... BiW…

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  • w w w . a u t o s t e e l . o r g

    A Winner: Car Body Design Development of the Hyundai Sonata

    Carsten Hfer Hyundai Motor Europe Technical Center

  • Background History Customer proposition Styling Practicality Performance Efficiency

    Development process Platform strategy Weight optimization Stiffness Material Safety

    Overview of Ulsan Plant Manufacturing strategy Flexible production system Productivity Quality

    Hyundai Sonata at GDIS Conference 2013

    Product Concept BIW Concept /

    Product Concept

    Background History Customer proposition Styling Practicality Efficiency

    Development process Weight optimization Stiffness Material Safety

    BiW Concept

  • i40 intro.m4v

  • Product Concept Hyundai Sonata at GDIS Conference 2013

    Product Concept BIW Concept /

  • Product Concept Hyundai Sonata at GDIS Conference 2013

    Product Concept BIW Concept /

  • 7

    2010 Sedan 2011 Sedan & Wagon

    2004

    1998

    Product Concept Hyundai Sonata at GDIS Conference 2013

    Product Concept BIW Concept /

  • Product Concept BIW Concept /

    Product Concept

    Best in class roominess Class leading practicality

    Sporty and emotional Modern interior

    Target best in TCO Competitive pricing

    3 USPs: rear seat reclining, auto defog, heated steering wheel

    Best in class with 113g CO2/km

    Hyundai Sonata at GDIS Conference 2013

  • Product Concept BIW Concept /

    Product Concept Hyundai Sonata at GDIS Conference 2013

  • Product Concept BIW Concept /

    Product Concept Hyundai Sonata at GDIS Conference 2013

  • Product Concept BIW Concept

    Product Concept

    Cargo capacity 19. 5 cu. ft. (553 liters) with the rear seats occupied Up to 60.7 cu. ft. (1718 liters) with the rear seats folded down

    Hyundai Sonata at GDIS Conference 2013

    /

  • Product Concept

    0.32

    0.29 0.30

    0.29

    Predecessor i40 Competition

    Cd

    8,013

    8,878 8,840

    Predecessor i40 Competition

    10,082 22%

    132

    155 148

    Predecessor i40 Competition

    CO2 (g/km)

    214

    Hyundai Sonata at GDIS Conference 2013

    Product Concept BIW Concept /

  • Product Concept BIW Concept /

    BIW Concept Hyundai Sonata at GDIS Conference 2013

  • Product Concept BIW Concept /

    BIW Concept

    SOP

    SOP

    -6 -4 -2

    Full schedule predecessor 24M

    Full schedule i40 18M

    Model Fix

    Design

    Design Model Fix

    Test

    Test

    Hyundai Sonata at GDIS Conference 2013

  • Product Concept BIW Concept /

    BIW Concept

    Achieved a 7.6% reduction in BIW weight compared to predecessor.

    438kg

    Design concept Final drawings

    456.3kg

    Competition

    438kg

    EVI process

    Design optimization -27.3kg

    Hyundai Sonata at GDIS Conference 2013

  • BIW Concept

    Rearranging the part assembly allowed for a reduction of the material thickness From single part with uniform thickness to three parts with different, optimized thickness

    Hyundai Sonata at GDIS Conference 2013

    Product Concept BIW Concept /

  • BIW Concept

    Change of the form from linear interior to radial interior lead to a material thickness reduction Divergence angle to improve airflow and NVH performance

    Hyundai Sonata at GDIS Conference 2013

    Product Concept BIW Concept /

    Spare Member (0.8 ) Spare Member (1.0 )

  • BIW Concept

    Increased the torsional stiffness by 141% and the bending stiffness by 19%. Achieved 11% more torsional and 23% more bending stiffness compared to competition

    0.32

    24

    14.6 0.29

    Predecessor i40

    28.6 35.3

    Hyundai Sonata at GDIS Conference 2013

    Product Concept BIW Concept /

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