宝时捷总布置设计过程资料

1、Engineering Services, Inc.3.ULSAB Phase 2 PackageEngineering Services, Inc.3. ULSAB Phase 2 Package3.1. General ApproachDiscussions with OEMs about Phase 1 findings provided valuable input and guidance for the more detailed Phase 2 package layout created at the start of Phase 2. The Phase 2 package

2、was defined as a modification of the Phase 1 package without being too specific so the package findings could apply to morethan one body structure concept.The most important components, spacedefinitions and dimensions had to be considered by either defining them using engineering judgment, or by usi

3、ng actual component dimensions. Furthermore, secondary mass savings were not considered in order to take a more conservative and more credible approach. This is also reflected in component size and mass, as well as in the crash mass used for the crash analysis.3.2. Package DefinitionThe first step i

4、n the package phase was to define the vehicle concept type, exterior dimensions, interior dimensions and the main components. With these package definitions, package drawings were revised and structural hard points defined.3.2.1. Vehicle Concept TypeIn Phase 2 the same concept type definition was us

5、ed as in Phase 1, five passenger and four door midsize sedan.Chapter 3 - Page 1Engineering Services, Inc.3.2.2.Exterior Dimensions*SAE J1100 Revised May 95Chapter 3 - Page 2Ident.*DefinitionMeasurementsW101Tread - front1560 mmW102Tread - rear1545 mmW103Vehicle width1819 mmW117Body width at SgRP - fr

6、ont1767 mmL101Wheelbase2700 mmL103Vehicle length4714 mmL104Overhang - front940 mmL105Overhang - rear1074 mmL114Front wheel centerline to front SgRP1447 mmL123Upper structure length2631 mmL125Cowl point - X coordinate2016 mmL126Front end length1281 mmL127Rear wheel centerline - X coordinate4295 mmL12

7、8Front wheel centerline - X coordinate1595 mmL129Rear end length654 mmH101Vehicle height1453 mmH106Angle of approach14H107Angle of departure15H114Cowl point to ground1001 mmH121Backlight slope angle61H122Windshield slope angle59H124Vision angle to windshield upper DLO15H136Zero Z plane to ground - f

8、ront112 mmH138Deck point to ground1091 mmH152Exhaust system to ground170 mmH154Fuel tank to ground188 mmH155Spare tire well to ground311 mmEngineering Services, Inc.3.2.3.Interior Dimensions*SAE J1100 Revised May 95Chapter 3 - Page 3Ident.*DefinitionMeasurementsW3Shoulder room - front1512 mmW4Should

9、er room - second1522 mmW5Hip room - front1544 mmW6Hip room - second1544 mmW7Steering wheel center - Y coordinate350 mmW9Steering wheel maximum outside diameter370 mmW20SgRP - front - Y coordinate350 mmW25SgRP - second - Y coordinate335 mmW27Head clearance diagonal - driver79 mmW33Head clearance diag

10、onal - second83 mmW35Head clearance lateral - driver136 mmW36Head clearance lateral - second132 mmL7Steering wheel torso clearance418 mmL11Accelerator heel point to steering wheel center412 mmL13Brake pedal knee clearance573 mmL30Front of dash - X coordinate1942 mmL32SgRP - second to rear wheel cent

11、erline473 mmL34Effective leg room - front1043 mmL38Head clearance to windshield garnish - driver266 mmL39Head clearance to backlite garnish21 mmL40Torso (back) angle - front25L41Torso (back) angle - second25L42Hip angle - front93L43Hip angle - second86L44Knee angle - front118L45Knee angle - second88

12、L46Foot angle - front78L47Foot angle - second113L50SgRP couple distance780 mmL51Effective leg room - second894 mmL52Brake pedal to accelerator48 mmL53SgRP - front to heel832 mmEngineering Services, Inc.3.2.3.Interior Dimensions (Contd)*SAE J1100 Revised May 95Chapter 3 - Page 4Ident.*DefinitionMeasu

13、rementsH5SgRP - front to ground519 mmH6SgRP - front to windshield lower DLO495 mmH10SgRP - second to ground529 mmH11Entrance height - front798 mmH12Entrance height - second810 mmH13Steering wheel to centerline of thigh67 mmH14Eyellipse to bottom ofide rearview mirror40 mmH17Accelerator heel point to

14、 steering wheel center645 mmH18Steering wheel angle23H25Belt height - front446 mmH26Interior body height - front at zero Y plane1011 mmH27Interior body height - front at SgRP Y plane1220 mmH29Interior body height - second at SgRP Y plane1033 mmH30SgRP - front to heel245 mmH31SgRP - second to heel303

15、 mmH32Cushion deflection - front49 mmH33Cushion deflection - second66 mmH35Vertical head clearance - driver75 mmH36Head clearance vertical - second49 mmH37Headlining to roof panel - front7 mmH38Headlining to roof panel - second7 mmH40Steering wheel to accelerator heel point468 mmEngineering Services

16、, Inc.3.2.3.Interior Dimensions (Contd)*SAE J1100 Revised May 95Chapter 3 - Page 5Ident.*DefinitionMeasurementsH41Minimum head clearance - driver88 mmH42Minimum head clearance - second21 mmH49Eyellipse to top of steering wheel17 mmH50Upper-body opening to ground - front1317 mmH51Upper-body opening t

17、o ground - second1339 mmH53D-point - front to heel137 mmH54D-point - center passenger - front to tunnel105 mmH55D-point - center passenger - second to tunnel43 mmH56D-point - front to floor182 mmH57D-point - second to floor72 mmH60D-point to heel point - second19 mmH61Effective head room - front1019

18、 mmH63Effective head room - second972 mmH64SgRP - front to windshield upper DLO796 mmH69Exit height - second743 mmH70SgRP - front - Z coordinate631 mmH71SgRp - second - Z coordinate641 mmH75Effective T-point head room - front994 mmH76Effective T-point head room - second932 mmH77Seatback height - fro

19、nt868 mmH78Seatback height - second781 mmH94Steering wheel to cushion - minimum223 mmEngineering Services, Inc.3.2.4.Main Component DefinitionChapter 3 - Page 6ComponentDescriptionRemarksEngineV6 3000 ccmAverage sizeEngine MountsTotal of 32 on top of front rail 1 on subframeRadiator Size.252 m2With

20、single fanExhaust SystemSingle routing,1 catalytic converter,1 mufflerVol 2.8 catalytic converter 21 ltr. muffler, LHSBattery L x W x H280mm x 170mm x 170 mmLHS front of engine compartmentDrive TrainTransverse front wheel driveTransmissionAutomatic - manualG-shift for manual included in packageSuspe

21、nsion Type, FrontMcPhersonMounted to front subframeSuspension Type, RearTwist beamWith separate spring shock absorberTire Size Front-Rear195/60R15Winter tires 185/60R15Spare TireSpace saverTub to fit full size tireFuel Tank volume65 ltrLocated under rear seatFuel FillerOn RHSRouting in packageBumper

22、 Front-RearBolt-onCrash boxes includedSteeringRack & pinionSteering rack housing on top of crossmember dashCargo Volume490 ltrVDA method with 200 x 100 x 50 mm moduleHingesSimilar to Porsche 911 / BoxsterWeld through typeHead LampsPart of front end moduleInteriorFront and rear seat conceptIn package

23、 drawingCockpitBasic concept with I/P beamIn package drawingPedalsUnit with integrated foot-parking-brakeIn package drawingEngineering Services, Inc.3.2.5. Underfloor ClearanceThe underfloor clearance of a vehicle depends on the vehicle load. The determination of the underfloor clearance relative to

24、 the road surface was crucial for the body structure design, styling, selection of components and their positioning in the vehicle structure. Underfloor clearance is defined as the summary of five different parameters. These are:Curb Clearance Front / Rear Angle of Approach / Departure Ramp Brakeove

25、r AngleOil Pan Clearance Ground ClearanceTo define these parameters, three vehicle positions, which then depended on three specific load cases, needed to be determined. The three load cases applied to thevehicle were:Curb weight:The weight of a vehicle equipped for normal driving conditions. This in

26、cludes fluids such as coolant, lubricants and a fuel tank filled to a minimum of 90%. Also included are the spare tire, tool kit, and car jack.Design weight:Vehicle curb weight plus the weight of three passengers (68 kg each, with luggage 7 kg each) with 2 passengers in the front seat and 1 passenge

27、r in the rear seat.Gross vehicle weight:Vehicle curb weight plus maximum payload (5 passengers plus luggage).Chapter 3 - Page 7Engineering Services, Inc.To determine the vehicle position relative to the road surface under these load conditions, the vehicle is positioned relative to zero grid Z-plane

28、.ZR1AR2BGroundXFigure 3.2.5-1 ULSAB Vehicle Position Relative to Zero Grid Z-PlaneUsing the ULSAB data and the weights of the three load cases, the road surface positions relative to the zero grid Z-plane and to the vehicle were calculated.Calculation of Road Surface Positions Relative to the Vehicl

29、eChapter 3 - Page 8Load CaseDistance from Zero Grid Z-PlaneStatic Tire RadiusWeightA (mm)B (mm)R1 (mm)R2 (mm)Curb Weight Design WeightGross Vehicle Weight3954134153924174623013013033083053001350 kg1575 kg1850 kgULSAB DataNumber of Seats5Wheelbase2700 mmTiresFront Rear195/60-R15195/60-R15PressureFron

30、t Rear2.5 bar2.5 barEngineering Services, Inc.Gross Vehicle Weight Design WeightCurb WeightFigure 3.2.5-2Road Surface Relative to VehicleWith the road surface positions relative to the vehicle, the underfloor clearance wasdetermined.170 mm190 mmGross Vehicle WeightDesign WeightFigure 3.2.5-3Curb Cle

31、arance Front/Rear1415Design WeightFigure 3.2.5-4Angle of Approach/DepartureChapter 3 -Page 9Engineering Services, Inc.14Gross Vehicle WeightFigure 3.2.5-5Ramp Breakover Angle185 mmDesign WeightFigure 3.2.5-6Oil Pan Clearance143 mmGr oss Vehicle W eightFigure 3.2.5-7Ground ClearanceChapter 3 - Page 1

32、0Engineering Services, Inc.3.2.6. Seating PositionAt first the 2-D manik(spelling taken from SAE) were aligned in a comfortableseating position taking into consideration the angles between joints such as hip, knee, and foot. When the seating position was defined, verification was made thatthe operat

33、ingparts like steering wheel, gearshift lever and pedal were in reach.This was important for ergonomic reasons. Two types of 2-D manikwere used:The small female, 5th percentile with a height of 147.8 cm; and the tall male, 95th percentile with a height of 185.7 cm. (5th percentile means that 5% of t

34、hepopulation is smaller or equalize and 95% is taller. 95th percentile means that95% of the population is smaller or equalize and 5% is taller.)For the dash panel layout the tall male 2-D manikin was used because it is more difficult to reach, since the seat position of the taller person is more rea

35、rward than itis for a shorterperson.Figure 3.2.6-1Distance to Operating Parts of the 5% Female and the 95% MaleChapter 3 - Page 11Engineering Services, Inc.3.2.7. Visibility Study. Horizontal and Vertical ObstructionFor the study of horizontal, vertical and A-pillar obstruction of the drivers

36、 visibility, the following positions needed to be defined:Seating Reference Point (SgRP)It was necessary to determine the seating reference point (SgRP) in order to position the eyellipse (spelling taken from SAE) template and the eyepoints V1 / V2. For adjustable seats, the SgRP is defined as the h

37、ip- point (H-Point) relative to the driving seat in its most rearward position. The H-point is defined as the pivot center of the torso and thigh center lines.Eyepoints V1, V2EyellipseTorso LineThigh CenterlineSgR-PointAccelerator Heel PointFigure 3.2.7-1 SgRP, Eyellipse, EyepointsEyellipse (SAE J94

38、1)The eyellipse is a tool to describe the vision of a driver. The template with the eyellipse is positioned with its horizontal reference line 635 mm above the SgRP and with the vertical reference line through the SgRP. Two types of templates, with two eyellipses, take the different seat track trave

39、lChapter 3 - Page 12Engineering Services, Inc.ranges into consideration. For the ULSAB vehicle, with a seat track travel of 240 mm, a template for seat track travel of more than 130 mm was used.Eye Points V1 / V2 (RREG 77/649)The coordinates of the eye points V1 / V2 relative to the SgRP were determ

40、ined by using the following dimensions:Using vision lines through the eye points, the following vision areas are described:V1Horizont View Through V1V2Steering Wheel Rim Obscuration 1 Through V2 (77/649/EWG)Figure 3.2.7-2Horizontal VisionChapter 3 - Page 13PointV1 V2X6868Y-5-5Z665589Engineering Serv

41、ices, Inc.V1, V2YXFigure 3.2.7-3 Vertical Vision. A-Pillar ObstructionIn order to determine the A-pillar obstruction, points P1 and P2 have to be determined first. The coordinates for these points related to the SgR-point are:The ULSAB structure has a seat track travel of 240 mm. Therefore th

42、e X-value has to be corrected by -48 mm.Since the torso back angle is 25 degrees, no further correction is necessary for the X- value and Z-value.The new coordinates for the P-points are:Chapter 3 - Page 14PointXYZP1 P2-13 mm+15 mm-20 mm47 mm627 mm627 mmPointXYZP1 P235 mm63 mm-20 mm47 mm627 mm627 mm

43、Engineering Services, Inc.YP2 +15 mmSgRPPm+47 mmHorizontal Line-20 mmP1 -13 mmXFigure -4Distance of the P-Points Relative to the SgR-PointTwo planes are cutting the A-pillar in an angle of 2 and 5 degrees. In the front most intersection, the horizontal planes S1 and S2 cut the A-pillar (Figur

44、e 3.2.7-5).S1S1PmS2S225SgRPFigure -5 Determination of the Sections S1 and S2Chapter 3 - Page 15627 mmEngineering Services, Inc.The sections in the plan view are shown in Figure 3.2.7-6.P2PmV1, V2P1S1S2Figure 3.2.7-6 Sections S1 and S2 in Plan ViewThe point P1 is necessary to determine the A-p

45、illar obscuration for the left side (for a left hand drive vehicle). P2 is necessary for the right side. If P1 fulfills the requirements, it is not necessary to determine the obscuration for the right A-pillar, since the right pillar is farther away from the driver.The template to determine the obst

46、ruction is shown in Figure 3.2.7-7.P1E2E1aFigure 3.2.7-7 Template for A-Pillar ObstructionChapter 3 - Page 16Engineering Services, Inc.The point P1 on the template is aligned to the point P1 on the drawing. The line “Section S2 Outer” is laid tangent to the most outer edge of the A-pillar section (S

47、2), including trim, door frame and door seal.The second tangent line “Section S1 inner” is laid to the most inner edge of the A-pillar section (S1), including trim, sealand dot matrix. (Figure 3.2.7-8).P11Figure 3.2.7-8Template in Position3.2.8. Gear Shift Lever PostionThe position of the gearshift

48、lever depends on the SgRP-position and on the torso back angle. The position of the gearshift lever in the side view is shown in Figure3.2.8-1.220 mm340 mmFigure 3.2.8-1Distance of Gearshift Lever Relative to SgR-PointChapter 3 - Page 17Engineering Services, Inc.3.2.9. Pedal Position98 mm59 mm58 mmS

49、eating Reference Point201 mmFigure 3.2.9-1 Pedal Position SideFigure 3.2.9-2 Pedal Position Rear3.2.10. Bumper Height DefinitionECE R42 for the bumper height definition requires a pendulum 445 mm above the curb weight vehicle position and the design weight vehicle position. At the same time an overlapping of 35 mm of the pendulum to the bumper is required.CDABFigure 3.2.10-1 Pendulum in the Extreme Height Posit