2006-OPEL-CORSA
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LHD
3dr RHD LHD
5dr
DVan
LHD RHD
§ Bodyshop control system: build in sequence starting from M/Cmpt (leading assembly) § Proliferation of R/Cmpt for Base model, DelVan and Rear End Carrier § 3/5 dr differenciation from A-Pillar, dedicated Hang-on parts (styling requirement)
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 5
The New OPEL Corsa
Common Platform & Derivates
Delivery Van
5-DR
3-DR
Base Architecture • Platform developed together with FIAT with some adaptations to meet Opel in-house requirements with flat floor for OPC and Flex Fix
Tailored Blanks
Al 2%
Percentage of BIW mass
> 1000 MPa 4%
Al 1%
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 8
The NeBiblioteka Baidu OPEL Corsa
Weight Reduction - Material Mix
Old CORSA:
New CORSA:
> 200 MPa 18%
> 200 MPa 23% > 300 MPa 18%
Mild Steel 57%
> 300 MPa 34% Mild Steel 32% > 500 MPa 11%
• The first of its kind in the world: the revolutionary Flex Fix ® • The flexible carrier system is fully integrated in the vehicle
GME Engineering
EuroCarBody 2006
RHD
Base REC Base REC Base REC Base REC
Base Base Base Base Base Base Base Base TLS TLS TLS TLS TLS TLS TLS TLS
18 Body Variants
§ Proliferation for option Top 84 Body Variants loaded sun roof only at end of Framing 2 process Old Corsa § No engine or country specific Body variants
Full flex. in Bodyshop for all options and variants because of combined tools
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 7
Monday, 25 September 2006 / 3
The New OPEL Corsa
Styling - Dimensions
1488 (+42)
869 (+122)
2511 (+20) 3999 (+183)
619(+41)
1485 (+68)
1478 (+70)
Further Interior dimensions: Trunk volume Width at beltline (Rear) Width betw. Armrest rear Knee clearance front (Rear) Head clearance rear
Re-Use Content
Cost of Ownership
Weight Reduction Quality Styling Less Variants
Innovations
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Old Corsa 285 l 1352(1330) 1300 1068 (35) 940
New Corsa 310 l 1361(1300) 1365 1074 (42) 932
Difference + 25 l + 9 ( -30) +65 +6 (+7) -8
GME Engineering
EuroCarBody 2006
Chassis Structure
Airborne N&V
Struct. Struct. Borne N&V
Vehicle Dynamics
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 10
The Weight Efficiency of the new OPEL Corsa has been increased by 33% compared with predecessor. Ø Higher structural efficiency (effective utilization of material)
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 6
The New OPEL Corsa
Less Variants in Zaragoza
Corsa
Bodystyle LHD/ RHD R/End Carr. Sunroof
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 2
The New OPEL Corsa
Key Drivers For Body
Development Timing Passive Safety Body Targets Manufacturing
The New OPEL Corsa
Body Targets - Weight Efficiency
Old Corsa 3-DR MJ 2000 New Corsa 3-DR MJ 2007
-33%
0,0 1,0 2,0 3,0 4,0 5,0 6,0 7,0
Weight Efficiency [(kg/(kNm/grd*m2))]
Body structure efficiency =
m KT ⋅ A
deg ⋅ s 2 3 m 4 ⋅ 10
KT =
M T F ⋅ L Nm = α α deg
m [kg]: Kt [kNm/deg]: A [m2]:
BIW mass included bolted elements, glued windscreen and front sub frame Torsional stiffness of BIW included bolted elements and glued windscreen Wheel Base x Tread
Old Corsa Body 232 kg
New Corsa 279,6 kg
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 9
The New OPEL Corsa
The New OPEL Corsa Body
EuroCarBody 2006 K.P. Manns S. Zielke
GME Engineering
1
The New OPEL Corsa
Corsa Positioning For spirited & fun loving individuals, the seductive Corsa with its athletic dynamic styling, puts the fun into driving
The New OPEL Corsa
Weight Reduction - Figures
Weight increase mainly driven by: by: • Dimensions • Safety Requirements; Requirements; Ped Pro • NVH and Fatique Doors Hood Tailgate Total 37,6 kg 13,7 kg 8,1 kg 291,5 kg 43,7 kg 10,7 kg 8,6 kg 342,6 kg • Manufacturing Strategies Main mass reduction activities: activities: • PHS B-Pillar Reinf. Reinf. • PHS A-Pillar Reinf. Reinf. • Hybrid Front • Usage of Thin Metal • Usage of HSS Steel -4,5kg -3,0kg -1,5kg -5,2 kg -8,9kg
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 4
The New OPEL Corsa
Innovations
Panorama Sunroof FlexFlex-Fix®
• Underlines the progressive exterior design • 25 % more opening vs. previous Corsa
Simulation Areas
UTM PTC HVAC Closures Aerodynamics Crash Statics Dynamics
High Freq. Acoustics
Veh. Veh. Fatigue Ride/Steering Overall
Class Leading Driving Dynamics Set new standards in respect to handling, agility and response. To reach this ambitious targets, the new Corsa has a completely newly designed chassis with improvements and innovative design solutions in all areas. Improvement of mobilities for all chassis attachment points Crash Excellent Overall Crash performance, very good 5- Star EuroNCAP rating and improved Insurance classification
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 11
The New OPEL Corsa
3dr RHD LHD
5dr
DVan
LHD RHD
§ Bodyshop control system: build in sequence starting from M/Cmpt (leading assembly) § Proliferation of R/Cmpt for Base model, DelVan and Rear End Carrier § 3/5 dr differenciation from A-Pillar, dedicated Hang-on parts (styling requirement)
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 5
The New OPEL Corsa
Common Platform & Derivates
Delivery Van
5-DR
3-DR
Base Architecture • Platform developed together with FIAT with some adaptations to meet Opel in-house requirements with flat floor for OPC and Flex Fix
Tailored Blanks
Al 2%
Percentage of BIW mass
> 1000 MPa 4%
Al 1%
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 8
The NeBiblioteka Baidu OPEL Corsa
Weight Reduction - Material Mix
Old CORSA:
New CORSA:
> 200 MPa 18%
> 200 MPa 23% > 300 MPa 18%
Mild Steel 57%
> 300 MPa 34% Mild Steel 32% > 500 MPa 11%
• The first of its kind in the world: the revolutionary Flex Fix ® • The flexible carrier system is fully integrated in the vehicle
GME Engineering
EuroCarBody 2006
RHD
Base REC Base REC Base REC Base REC
Base Base Base Base Base Base Base Base TLS TLS TLS TLS TLS TLS TLS TLS
18 Body Variants
§ Proliferation for option Top 84 Body Variants loaded sun roof only at end of Framing 2 process Old Corsa § No engine or country specific Body variants
Full flex. in Bodyshop for all options and variants because of combined tools
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 7
Monday, 25 September 2006 / 3
The New OPEL Corsa
Styling - Dimensions
1488 (+42)
869 (+122)
2511 (+20) 3999 (+183)
619(+41)
1485 (+68)
1478 (+70)
Further Interior dimensions: Trunk volume Width at beltline (Rear) Width betw. Armrest rear Knee clearance front (Rear) Head clearance rear
Re-Use Content
Cost of Ownership
Weight Reduction Quality Styling Less Variants
Innovations
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Old Corsa 285 l 1352(1330) 1300 1068 (35) 940
New Corsa 310 l 1361(1300) 1365 1074 (42) 932
Difference + 25 l + 9 ( -30) +65 +6 (+7) -8
GME Engineering
EuroCarBody 2006
Chassis Structure
Airborne N&V
Struct. Struct. Borne N&V
Vehicle Dynamics
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 10
The Weight Efficiency of the new OPEL Corsa has been increased by 33% compared with predecessor. Ø Higher structural efficiency (effective utilization of material)
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 6
The New OPEL Corsa
Less Variants in Zaragoza
Corsa
Bodystyle LHD/ RHD R/End Carr. Sunroof
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 2
The New OPEL Corsa
Key Drivers For Body
Development Timing Passive Safety Body Targets Manufacturing
The New OPEL Corsa
Body Targets - Weight Efficiency
Old Corsa 3-DR MJ 2000 New Corsa 3-DR MJ 2007
-33%
0,0 1,0 2,0 3,0 4,0 5,0 6,0 7,0
Weight Efficiency [(kg/(kNm/grd*m2))]
Body structure efficiency =
m KT ⋅ A
deg ⋅ s 2 3 m 4 ⋅ 10
KT =
M T F ⋅ L Nm = α α deg
m [kg]: Kt [kNm/deg]: A [m2]:
BIW mass included bolted elements, glued windscreen and front sub frame Torsional stiffness of BIW included bolted elements and glued windscreen Wheel Base x Tread
Old Corsa Body 232 kg
New Corsa 279,6 kg
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 9
The New OPEL Corsa
The New OPEL Corsa Body
EuroCarBody 2006 K.P. Manns S. Zielke
GME Engineering
1
The New OPEL Corsa
Corsa Positioning For spirited & fun loving individuals, the seductive Corsa with its athletic dynamic styling, puts the fun into driving
The New OPEL Corsa
Weight Reduction - Figures
Weight increase mainly driven by: by: • Dimensions • Safety Requirements; Requirements; Ped Pro • NVH and Fatique Doors Hood Tailgate Total 37,6 kg 13,7 kg 8,1 kg 291,5 kg 43,7 kg 10,7 kg 8,6 kg 342,6 kg • Manufacturing Strategies Main mass reduction activities: activities: • PHS B-Pillar Reinf. Reinf. • PHS A-Pillar Reinf. Reinf. • Hybrid Front • Usage of Thin Metal • Usage of HSS Steel -4,5kg -3,0kg -1,5kg -5,2 kg -8,9kg
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 4
The New OPEL Corsa
Innovations
Panorama Sunroof FlexFlex-Fix®
• Underlines the progressive exterior design • 25 % more opening vs. previous Corsa
Simulation Areas
UTM PTC HVAC Closures Aerodynamics Crash Statics Dynamics
High Freq. Acoustics
Veh. Veh. Fatigue Ride/Steering Overall
Class Leading Driving Dynamics Set new standards in respect to handling, agility and response. To reach this ambitious targets, the new Corsa has a completely newly designed chassis with improvements and innovative design solutions in all areas. Improvement of mobilities for all chassis attachment points Crash Excellent Overall Crash performance, very good 5- Star EuroNCAP rating and improved Insurance classification
GME Engineering
EuroCarBody 2006
Program Notebook
The New OPEL Corsa Body
Monday, 25 September 2006 / 11
The New OPEL Corsa