2017-Euro-Carbody-VW-POLO

EuroCarBody201719thGlobalCarBodyBenchmarkingConferenceCarbodybenchmarkingdatasummaryGeneralvehicledata0VWPolo0.Generalvehicledata,dimensionsCommentsGenerationNo.:6InternalOEMdenomination:VW270SOP(month/year):06/2017Vehiclesegment(A,B,C,D,E,F,S,M,J)AA0(EuropeanCommission2002)Vehicledimensions:Length:4053mmWidth:1751mmHeight:1446mmTrack,front:1525mmTrack,rear:1505mmWheelbase:2564mmContactarea3.884m2=(Track,front+Track,rear)/2xwheelbaseEuroCarBody2017,CarBodyBenchmarkData,VWPolo1.WeightsandimagesCommentsTotalweightofthecarbody322.4kgincludingdoorsandclosures,aswellasallpartsthatarefittedinthebodyshop(e.g.integratedbumperbeams),excludingpaint.WeightsofstandardmodulesFrontdoors(both)32.6kgReardoors(both)22.1kgHood13.6kgTailgate/Liftgate/Decklid11.8kgFrontfenders(both)3.2kgHinges,fasteners,etc.4.1kgFrontendFrontsubframe9.0kgFrontbumperbeamRearendRearsubframeRearbumperbeamIPbeamWeightsoffurthermodulesDVDincl.adhesiveandacousticbaffles1.4kgWeightofthebody-in-white235.0kg=WeightofthecarbodywithoutFrontdoors,reardoorsHoodTailgate/Liftgate/DecklidFrontfendersHinges,fasteners,etc.(asstatedabove)EuroCarBody2017,CarBodyBenchmarkData,VWPoloImages(ThecolourschemeoftheimagesmakesuseoftheRGBcolourcodesuggestedforthematerialclassification,seesection2.)CarbodystructureEuroCarBody2017,CarBodyBenchmarkData,VWPoloHang-onpartsDoorsHoodTailgateFendersEuroCarBody2017,CarBodyBenchmarkData,VWPolo2.Materialmixinthebody-in-whiteincludingdoorsandclosuresBasedonmetallurgical/chemicalmaterialclassesComments:MaterialsRGBcolourcodeWt%MetallurgicalclassesWt%SteelsLowstrengthsteelsR153,G204,B25530.3Mildsteels30.3Highstrengthsteels(HSS)R051,G102,B25538.2HSIF,BH9.7HSLA,CMn28.5Advancedhighstrengthsteels(AHSS)R255,G153,B2049.21stGen.:DP,TRIP9.22ndGen.:TWIP3rdGen:TBF,Q&PAusteniticstainlesssteelsR051,G051,B153Ultra-highstrengthsteels(UHSS)R204,G153,B2551.3CPMS1.3Presshardenedsteels(PHS)R128,G000,B12821.0Allsteels100.0AluminiumAluminiumsheet,7xxxseriesR051,G204,B153Aluminiumsheet,6xxxseriesR000,G255,B000Aluminiumsheet,5xxxseriesR204,G255,B204Aluminiumextrusions,7xxxseriesR153,G204,B000Aluminiumextrusions,6xxxseriesR220,G255,B153Aluminiumcastings,highpressureR051,G153,B102Aluminiumcastings,lowpressureR040,G120,B080AllaluminiumMagnesiumR255,G255,B000PlasticsFibrereinforcedplasticsR255,G000,B000Duroplastics,includingSMCR255,G153,B000ThermoplasticsR153,G051,B000ElastomersR255,G204,B204AllplasticsOthermaterialsR192,G192,B192namelyEuroCarBody2017,CarBodyBenchmarkData,VWPolo3.StiffnessdataCommentsMeasuredOrCalculated1stEigenfrequencytrimmedbody:33.0HzC32Hzand33Hzforopenroof2ndEigenfrequencytrimmedbody:33.0HzC1stEigenfrequencybody*:47.0HzC46Hzand47Hzforopenroof2ndEigenfrequencybody*:48.0HzC*Partsincludedinthemeasurement/calculationofthebodyfrequencies:bodyinwhitewithwindshield,frontbumperbeamandfrontaxlebeamStatictorsionalstiffness25.2kNm/°20.5kNm/°foropenroofStaticbendstiffnessn.sp.EuroCarBody2017,CarBodyBenchmarkData,VWPolo4.Joiningprocesses...usedinthebodyshop,includingallbought-inpartsandsub-assemblies…Unit…inthebodystructure…inthehang-onparts…inthecompletecarbodyThermalJoiningSpotweldingConventionalspotweldsSteel4175+212=4387Aluminium+=StudweldsSteel140+=140Aluminium+=Projectionweldssheet/sheet+=sheet/standardpart62+=62Frictionstirspotwelds+=ArcweldingMAGwelding(steel)mm2910+527=3437MIG/TIGwelding(aluminium)mm+=MIGbrazingmm+=LaserweldingConventionallaserweldingSteelmm+921=921Aluminiummm+=Remotelaserwelding,steelmm+=Laserbrazing,steelmm3205+=3205Frictionstirweldingmm+=Non-thermalJoiningRivetingSemi-tubularrivet/SPR8+=8Punchrivet+=Clinching8+28=36Hemmingmm+6090=6090ScrewsandnutsScrew/nut(metric)28+4=32Insertnut/Stud54+5=59Flowdrillscrews+=Adhesivebondingstructuraladhesivemm54170+4294=58464supportingadhesivemm2905+4569=7474hemmingadhesivemm+14879=14879gapsealingadhesivemm1682+=1682Additionaljoiningtechnologies+=+=+=Numberofdifferentjoiningtechnologiesused:15Comments:EuroCarBody2017,CarBodyBenchmarkData,VWPolo5.ProductionconceptCommentsProcessstability/availability85%90%technical,85%overall=totalup-timeinthebodyshopRe-toolingorre-usefactor15%onlyinstallationwithoutstructure=100(1−𝑃𝑟𝑜𝑗𝑒𝑐𝑡𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛𝑎𝑙𝑐𝑜𝑠𝑡𝑠”𝑎𝑙𝑙𝑛𝑒𝑤”)with“allnew”=valueofthetotalinstalledinvestmentDegreeofmechanisation92%=Automatedworkcontent/TotalworkcontentWorkcontentreferstothesumofStandardizedWorkContentsinthebodyshop,calculatedaccordingtotheHarbourReportsystem,excludinglay-inoperations,handlingofparts,logisticoperationsNo.ofproductionsites10namelyinPamplona,ES;Anchieta,BR;Kaluga,RU;Urumqi,CN;Chengdu,CN,Pune,IN,Uitenhage,ZA,Pekan,MY;Yizheng,CN;Anting,CNIntendedproductionvolume(units/year)350,000Carbodyproductionleadtime:1143.0minutes=thetimespentbytheunitinthebodyshop,fromthestartofthefirstunderbodypartstothehandingoverofthebody-in-whitetothepaintshop,includingcarbodyinterimstorage.Moreaccuratedefinition(Harbour):Startcountingwhenworkbeginsatthefirststationoftheunderbody(motorcompartmentorrearfloor,whicheverstationbeginsfi