Safety Cage Design in the Volvo XC90
Safety Cage Design in the Volvo XC90
Safety Cage Design in the Volvo XC90
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<strong>Safety</strong> <strong>Cage</strong> <strong>Design</strong> <strong>in</strong> <strong>the</strong> <strong>Volvo</strong> <strong>XC90</strong><br />
Jonas Bernquist<br />
<strong>Volvo</strong> Car Corporation<br />
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• General<br />
• Body structure<br />
– <strong>Safety</strong> cage<br />
– <strong>XC90</strong>: New structural solutions<br />
• Materials<br />
– General<br />
– <strong>XC90</strong>: Materials<br />
•Sum-up<br />
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Presentation overview
1943<br />
The first <strong>Volvo</strong> SUV?<br />
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2002<br />
General
SIZE<br />
[mm]<br />
Weight<br />
[kg]<br />
Attributes<br />
Length<br />
Width<br />
Height<br />
Body shell <strong>in</strong>cl frt bumper (BMW pa<strong>in</strong>ted)<br />
Total hang on (BMW pa<strong>in</strong>ted)<br />
Pa<strong>in</strong>t and seal<strong>in</strong>gs<br />
Body complete <strong>in</strong>cl closures<br />
2nd row seat subframe (structural part)<br />
Body complete <strong>in</strong>cl 2nd row subframe<br />
Static Torsional Stiffness BIG [kNm/deg]<br />
1st Dynamic Torsion mode BIG [Hz]<br />
1st Dynamic Lateral Bend<strong>in</strong>g mode BIG [Hz]<br />
1st Dynamic Vertical Bend<strong>in</strong>g mode BIG [Hz]<br />
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P28<br />
4798<br />
1890<br />
1740<br />
407<br />
113,0<br />
16,4<br />
536,4<br />
17,6<br />
554,0<br />
21,4<br />
33,6<br />
44,1<br />
47,4<br />
General<br />
Key attributes
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General<br />
Advanced Body Eng<strong>in</strong>eer<strong>in</strong>g
“A rigid framework<br />
surround<strong>in</strong>g <strong>the</strong><br />
occupants which creates<br />
a support for <strong>the</strong> <strong>in</strong>terior<br />
safety equipment and<br />
provides a survival space<br />
for <strong>the</strong> vehicle occupants<br />
<strong>in</strong> case of a crash”<br />
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Body structure<br />
<strong>Safety</strong> cage 1
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Body structure<br />
<strong>Safety</strong> cage 2: SIPS<br />
Side Impact Protection System<br />
– Introduced <strong>in</strong> 1991<br />
– The structure m<strong>in</strong>imises <strong>the</strong><br />
<strong>in</strong>trusion by <strong>the</strong>:<br />
• very strong B-pillars<br />
• rigid rockers<br />
• transverse floor/roof members<br />
• SIPS-box<br />
• framework of <strong>the</strong> front seats
V70<br />
The <strong>XC90</strong> BIW challenge<br />
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Body structure<br />
New structural solutions<br />
S80 • Increased front crash demands<br />
S60<br />
P2x-platform<br />
Body implications:<br />
• Compatibility small cars<br />
• Rollover protection<br />
• Protection 3rd row<br />
• Increased side-impact protection<br />
New structural and material solutions!
<strong>XC90</strong><br />
Kerb weight: 2070kg<br />
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Body structure<br />
<strong>XC90</strong> dimensions<br />
Comparison with o<strong>the</strong>r<br />
cars on <strong>the</strong> P2x-platform<br />
S80<br />
V70<br />
931<br />
S60<br />
4822<br />
4710 (XC 4733)<br />
4576<br />
1024<br />
887 974<br />
1582<br />
1563<br />
1563<br />
1832<br />
1804<br />
1804<br />
Width (mm) Kerb weight (kg)<br />
S80: 1832 1631<br />
V70: 1804 1670<br />
S60: 1804 1574<br />
Length (mm) Height (mm)<br />
S80: 4822 1434<br />
V70: 4710 1488 (XC1562)<br />
S60: 4576 1428
New front structure<br />
• To handle higher forces and weight<br />
• Centre floor is carry over P2 platform<br />
• “Three leg support”<br />
• Cross member firewall<br />
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Body Structure<br />
New structural solutions: Front<br />
Three leg support<br />
Compatibility<br />
• SUV hitt<strong>in</strong>g car<br />
• Different side rail heights<br />
• Eng<strong>in</strong>e sub frame (cradle) re<strong>in</strong>forced and<br />
extended forward<br />
• Height aligned with car rail height
1st attempt<br />
Low hit<br />
Preferred B-pillar <strong>in</strong>trusion<br />
and deformation mode<br />
Body Structure<br />
New structural solutions: <strong>Safety</strong> cage - Side<br />
Side impact common<br />
accident type<br />
SUV hit by SUV<br />
Side impact + higher<br />
rollover requirement<br />
Controlled deformation<br />
Re<strong>in</strong>forced side- and<br />
roof structure<br />
Dual piece sunroof<br />
frame cl<strong>in</strong>ched toge<strong>the</strong>r<br />
Strong B-pillar, B<br />
roof bow and seat<br />
belt bracket<br />
New seat<br />
crossmbr<br />
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New demands…<br />
Roof bow<br />
collapse<br />
B-pillar<br />
collapse<br />
High hit<br />
EuroNCAP<br />
Too big<br />
<strong>in</strong>trusion<br />
!
No structural<br />
collapse<br />
Force<br />
FkN<br />
Body Structure<br />
New structural solutions: <strong>Safety</strong> cage - Roof<br />
Rollover accidents<br />
Increased req's rollover<br />
impact<br />
Heavy vehicle<br />
Strong structure<br />
Packag<strong>in</strong>g<br />
Re<strong>in</strong>forced side- and<br />
roof structure<br />
Dual piece sunroof<br />
frame cl<strong>in</strong>ched toge<strong>the</strong>r<br />
Strong B-pillar, B<br />
roof bow and Apillar<br />
upper<br />
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New demands…<br />
A-pillar<br />
collapse<br />
EHSS-re<strong>in</strong>forced A-pillar<br />
Seat belt<br />
bracket<br />
collapse<br />
allowed. Result:<br />
Roof bow<br />
collapse<br />
B-pillar<br />
collapse<br />
No structural<br />
collapse!
Parts weight%<br />
100<br />
90<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
0<br />
HSS, EHSS & UHSS (Body Structure)<br />
Z<strong>in</strong>k coat<strong>in</strong>g<br />
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Materials<br />
General: Why HSS/EHSS/UHSS?<br />
240 740 940 850 S40 S80 V70 <strong>XC90</strong> S40+<br />
Annual total weight <strong>in</strong>crease of 10 kg, platform to platform!
• HSS: Rephosphorized &<br />
HSLA steels. VCC “standard<br />
qualities for high strength<br />
material. Slightly better<br />
formability with Rephos.<br />
• HSS/EHSS: Dual phase<br />
steels, used for re<strong>in</strong>forcements.<br />
• UHSS: Boron steel. Used for<br />
re<strong>in</strong>forcements subjected to<br />
extreme load cases.<br />
Materials<br />
General: High strength steels at VCC<br />
Tensile strength, R m<br />
MS HSS EHSS UHSS<br />
max 270-390 m<strong>in</strong> 340 m<strong>in</strong> 600 m<strong>in</strong> 800<br />
HSLA<br />
Rephos<br />
Rephos<br />
DP<br />
HSLA<br />
max 170-280 m<strong>in</strong> 220 m<strong>in</strong> 280 m<strong>in</strong> 400<br />
Yield strength, R e<br />
Us<strong>in</strong>g HSS/EHSS/UHSS for cost efficient weight reduction !<br />
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DP<br />
(MPa)<br />
Boron<br />
steel<br />
Boron<br />
steel<br />
(MPa)
Boron Steel<br />
DP600<br />
Rephos (σ tensile m<strong>in</strong> = 380 MPa)<br />
W-screen mbr<br />
A-pillar upper<br />
B-pillar<br />
General thickness ~1,2-2 mm<br />
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Materials<br />
<strong>XC90</strong>: Side-impact & roll-over<br />
B roof bow<br />
Cantrail ext.<br />
Rear seat frame<br />
(rear part)<br />
roll formed boron steel<br />
Rocker
Rmm<strong>in</strong> >340 MPa<br />
(DP, HSLA el Rephos)<br />
Rmm<strong>in</strong> >380-420 MPa<br />
(DP, HSLA el Rephos)<br />
Rmm<strong>in</strong> >600 MPa<br />
(DP600)<br />
Rmm<strong>in</strong> >1400 MPa<br />
(Boron steel)<br />
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Materials<br />
<strong>XC90</strong> BIW Material distribution<br />
MS<br />
Rm max ≅300 MPa 42%<br />
HSS<br />
EHSS<br />
UHSS<br />
Al<br />
•Body structure 407 kg<br />
•Hang on parts 113 kg<br />
•Polymer tailgate ~11 kg<br />
36%<br />
14,5%<br />
6,5%<br />
1%<br />
EHSS
Rat<strong>in</strong>gs<br />
Front<br />
Side<br />
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Europe USA<br />
Sum-up
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Sum-up<br />
• <strong>XC90</strong> <strong>in</strong>corporated several, for <strong>Volvo</strong>, new<br />
structural concepts and material applications<br />
• High degree of HSS-material <strong>in</strong> <strong>the</strong> body<br />
structure (HSS�EHSS�UHSS)<br />
• Extremely strong upper body structure for<br />
good rollover properties
Thank you for your attention!<br />
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