Concept Development Lecture (FAU Erlangen 2024) PDF

Lecture “Concept Development" at FAU Erlangen in the summer semester 2024 Dr.-Ing. Stefan Dengler Erlangen, 14.05.2024  3 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Lecture content 1 Introduction 2...

Lecture “Concept Development" at FAU Erlangen in the summer semester 2024 Dr.-Ing. Stefan Dengler Erlangen, 14.05.2024  3 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Lecture content 1 Introduction 2 Presentation of concept design 3 Modular and platform development 4 Hat development INTERNAL  4 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Classification "Concept Design" in "Development Cycle" INTERNAL  5 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Insights into the everyday life of vehicle development – or something like that... What the customer How it is the How it is the What the design is How it is the How it is wants to have. sales development all about production Marketing introduces. introduces. introduces. introduces. introduces. "1.5 million regional market Departmental "Artists" Production site incl. Brand customers" requirements Strategy equipment Surface design Communication Importer requests Complexity Production times strategy Materiality... Effort Manufacturing...... plants Cost... Laws... INTERNAL  6 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Insights into the everyday life of vehicle development – or something like that... What the customer How it is the How it is the What the design is How it is the How it is wants to have. sales development all about production Marketing introduces. introduces. introduces. introduces. introduces. "1.5 million regional market Departmental "Artists" Production site incl. Brand customers" requirements Strategy equipment Surface design Communication Importer requests Complexity Production times strategy Materiality... Effort Manufacturing...... plants Cost... Laws... User Stories Require- Requirements architecture- User Journeys ments and specific Use Cases architecture discipline INTERNAL  7 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Systems Engineering using the example of the "swing" Problem room Solution space Requirements Requirements Architecture The product is intended to... › can be used by one person, › can be attached to a horizontal branch, › enable stable sitting, › enable swinging back and forth, › two ropes: › do not damage the tree, length, material, cross- section, fastening concept ›... › Seat: dimension, material,... ›... INTERNAL  8 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Design – Technic - Converging INTERNAL  9 INTERNAL  10 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Showcar IAA 2021 Audi Grandsphere Concept INTERNAL  11 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Showcar IAA 2021 Audi Grandsphere Concept INTERNAL  12 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Examples of the "birth" of new vehicle concepts. The birth of the BMW Touring The beginnings of the KTM X-Bow Source: https://www.bimmertoday.de/2015/05/14/erfinder-des-bmw-3er-touring-max- reisbock-im-interview/ Source: www.netcarshow.com INTERNAL  13 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Lecture content 1 Introduction 2 Presentation of concept design 3 Modular and platform development 4 Hat development INTERNAL  14 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Challenges in concept design E-E Architecture EU7 Interior FASIS Portolio extension 1. MODULAR SYSTEM MLB first E-vehicle construction kit E-vehicle Pedestrian protection 2005 2010 2015 2020 2025 INTERNAL  15 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development The concept design is part of the requirements and architecture management of the entire vehicle. E E1... E5 EG ED EM ER ET EV About. 10,000 employees EG-P EG-A EG-I EG-Q EC-F EG-1 EG-2 EG-3 EG-8 About. 1,000 employees EG-AA EG-AB EG-AC EG-AD EG-AE EG-AF About. 150 employees Ergonomics Architecture/ Functional Concepts Concepts and Special Requirement architecture Platforms Hats measuremen vehicles s t concepts "Concept design“ INTERNAL  16 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Phases of product development approx. 5 years approx. 3 years before SOP before SOP Project Concept start freeze Start ofProduction Pre-PP Concept/series preparation phase Series development Base feasability Product INTERNAL  17 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development New vehicle ideas are brought to a decision as part of a "rough satisfaction". Coarse satisfaction "Filter" Portfolio Team Design Start of product development Sales Board Concept- Showar Development... No Monitoring INTERNAL  18 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Early project phase has a great influence on the success of the project due to cost influence and error prevention. › in the early project phase, most of the controllable costs are › in addition: the error costs increase exponentially after the project determined, at the same time relatively low costs are triggered phase ("rule of 10") › the greatest costs arise with the start of production preparation and production Source: https://www.cadenas.de Source: https://www.sixsigmablackbelt.de INTERNAL  19 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Central "products" of the concept design are seating plan, ergoplan, operating layout plan, ergo model, common parts concept, section folder, DMU package Seating plan Ergoplan, operating layout plan Ergomodel Dachmodul Kombi Cockpit links Cockpit rechts & Mittelkonsole Bereich Lenkrad Fußraum) Bereich Beifahrer Türverkleidung Tunnelkonsole Sitz Fond Common parts concept Section folder DMU Package COP modifiziert Neuteil Übernahme INTERNAL  20 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Lecture content 1 Introduction 2 Presentation of concept design 3 Modular and platform development 4 Hat development INTERNAL  21 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Motivation for modules/kits/platforms 1 2 3 4 2015 INTERNAL Source: internal  22 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Improved results through standardization and multiple use INTERNAL Source: internal  23 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Connection of vehicle kits and platforms INTERNAL  24 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Vehicle kits: Powertrain architecture determines the assignment of a vehicle to the modular system. INTERNAL  25 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development An Audi consists of the 4 parts types platform part, modular module, single module and individual component. 100% vehicle = Modular modulesParts used in several platforms of the modular system + Platform partsParts used in specific platform + Individual modulesParts used in various construction kits + Individual component in specific. Vehicle (family) parts used e.g. powertrain, chassis e.g. platform body e.g. roof handle, interior mirrors e.g. sheet metal outside, bumpers Modular and platform parts Hat components INTERNAL  26 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development MlB modular system and platforms MLB Modular System Platform MLB49 PF MLB42 PF MLB58 PF MLB53 PF MLB65 A4 Family A5 Family INTERNAL  27 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Structure kit using the example of MQB Unified architecture Uniform body Uniform modules INTERNAL Source: VW intern, Modular Management, 11.06.2015  28 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Modular idea: Keeping cost-intensive assemblies the same direct costs INTERNAL Source: VW intern, Modular Management, 11.06.2015  29 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Modular idea: Keeping cost-intensive assemblies the same Costs of parts INTERNAL Quelle: VW intern, Modul-Baukastenmanagement, 11.06.2015  30 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Platforms are characterized in production by the same joining and assembly sequence and by standardized connection concepts! Same joining and assembly sequence Standardized connection concepts INTERNAL Source: VW intern, Modular Management, 11.06.2015  31 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Example of a common part concept of a platform variant Characteristics of platform variants: same structures and load paths Modifications for specific coordination scopes INTERNAL  32 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Integration of parts and modules i.g. at the A3 PHEV. INTERNAL  33 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Unified architecture MLB INTERNAL  34 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Modular development precedes product development and overlaps by about 2 years. Modular development approx. 5 years approx. 3 years before SOP before SOP Project Concept Start Start of start freeze Production Pre-PP Concept/series preparation phase Series development Base feasability Product INTERNAL  35 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Modular and platform development requires the advance relocation of content from vehicle development. Electrical-Electronics Architecture Moving content forward Modular system and Vehicles Vehicle platforms Vehicle INTERNAL  36 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development A modular system enables the representation of vehicles with the widest possible range of properties at the lowest possible cost (EK, expense). Requirements and premises of vehicles ▪ Project o Wheel diameter o 0-100km/h o SOP o Customs o Vmax o Customer Expectations Segment ▪ Weight ▪ Load o Volume o Materiality o Loading speed ▪ Dimensional concept ▪ Range ▪ Further o Length o WLTP, EPA, CLTC o HAF level o Width ▪ Performance ▪ Technology o Height o Performance Levels o e.g. air spring, HAL A modular system forms the technical basis Kit for defined products. It consists of modular modules and Modular modules Platforms + platforms. By exploiting synergies , a modular system Battery Axle Chassis E/E TMM PF1 PF2 PF3... PF n enables an optimum of spread and costs. modules drives modules Modules Module optimum , e.g. from Platformoptimum e.g. from ▪ time availability ▪ time availability ▪ Property Spread ▪ Consideration of modules/components ▪ EC, expense ▪ EC, expense ▪ Dimension ▪ Weight INTERNAL  37 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development The basis for modular and platform development is a first architectural step in the vehicle. Vehicle (Level 1) Modular modules/Platforms Problem room Solution space Vehicles Vehicle requirements Vehicle Anfo Vehicle Architecture Modular modules Modular Anfo Modular architecture Platform Platforms Platform-Anfo Architecture in the user brand in the modular system / in the platform INTERNAL  38 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development The basis for modular and platform development is a first architectural step in the vehicle. Vehicle Project/Needs Request Architecture Range Range Modular modules/Platforms (WLTP, Single/RW- (WLTP, Single/RW- Fzg.) Fzg.) Anfo Architecture Hat shape Hat shape Vehicle dimensions Vehicle dimensions Vehicle dimensions (length, width, height, (length, width, height) (length, width, height) wheel-⌀) cW, A HV Energy Rim size Rim size Rim size Retention RoWi HV battery net driven axles driven axles Concept Consumption HV battery gross BNL SOC By-Wire Assistance Assistance Weight FAS/HAF level View View Display concept Sit Sit Seating concept Seating Seating Material concept INTERNAL  39 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development A platform is defined by the temporal/geometric spread and the spread of the modular modules taken into account. Platform... Platform n temporal spread SOP of the respective initial inserters maximum 2 to 3 years geometric spread maximum over 2 customer segments (e.g. B/C) Modular module spread uniform concept (e.g. exclusively ML) › Batteries Scalable › Axle drives › Chassis Scope of unit and application › TMM › E/E ›... INTERNAL  40 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Construction kits and platforms Shoot or blessing? Benefits Disadvantages › higher volume › Compromises in installation space distribution: Consideration of the maximum installation space (e.g. for high performance › thus quantity effect on direct costs classes) › thus reduction of relative expense e.g. for development, › Compromises in properties, both in terms of those directly validation, procurement perceptible by the customer (e.g. dimensions/proportions), and in indirect properties (e.g. weight, installation space › Basis for joint production ("on the same line"), high synergies in requirements) joint production › thus also lower spreadability of the products from each other ›... ›... Vehicles on modular system solitary vehicles INTERNAL  41 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Lecture content 1 Introduction 2 Presentation of concept design 3 Modular and platform development 4 Hat development INTERNAL  42 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development An Audi consists of the 4 parts types platform part, modular module, single module and individual component. 100% vehicle = Modular modulesParts used in several platforms of the modular system + Platform partsParts used in specific platform + Individual modulesParts used in various construction kits + Individual component in specific. Vehicle (family) parts used e.g. powertrain, chassis e.g. platform body e.g. roof handle, interior mirrors e.g. sheet metal outside, bumpers Modular and platform parts Hat components INTERNAL  43 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Dimensional design → Space 4 → Visibility Greenhouse 2 1 3 2 Frontend Wheels Seating positions Hedgeend and and steering surface wheel position → External dimensions → External dimensions → Seating positions → External dimensions → Transport comfort INTERNAL  44 Maßkonzeption INTERNAL  45 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Ergonomics System Anthropometry ergonomics System ergonomics Assistenz Information Unterhaltung ERGONOMICS- CONCEPTS Vernetzungsebene Methods and tools Mockup Driving simulator virtual seat box Ergomodel INTERNAL  46 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Identical parts concept hats exterior Example first inserter Example follow-up inserter COP COP modifiziert modifiziert Neuteil Neuteil Übernahme Übernahme INTERNAL  47 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Same parts concept hats interior Example first inserter Example follow-up inserter COP Modified New part Acquisition INTERNAL  48 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Example of cross-brand identical parts in the exterior. VW Touareg MJ 2003 Porsche Cayenne MJ 2003 Source: www.netcarshow.com INTERNAL  49 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Principle cuts INTERNAL  50 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Example principle cut: x-cut head 1st row of seats INTERNAL  51 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Example for design requirement: Optics rear window Konzept klassisch Konzept neu Bodensicht neu Bodensicht alt INTERNAL  52 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Design-technology convergence Design n Models 4 models Design- 2 Models 1 model Freeze Technology Concept area Strak Exterior / Interior Exterior / Interior INTERNAL  53 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Design-technology convergence using the example of A3 headlights Audi A3 Concept (2011) Audi A3 MJ 2014 Design Laws Space Manufacturability Functionality Quality Cost INTERNAL  54 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Design-technology convergence using the example of A3 headlights Zone Vorderwagen Designpass Bezeichnung: Y-687_ABBLENDLICHT Zone VoWa Designpass Bezeichnung: Y-687_ABBLENDLICHT Zone VoWa Designpass Bezeichnung: Y-687_ABBLENDLICHT Schnittenummer:005 Schnittenummer:005 Schnittenummer:005 KW44 - 2015 KW04 V2 – 2016 KW25 - 2016 Huerta links 26.01.2016 Huerta rechts 26.01.2016 Chirek rechts 29.01.2016 Huerta links 24.06.2016 Chirek links 29.01.2016 Chirek links 24.06.2016 30 31 32 KW 33/15 KW 44/15 KW 33/15 KW 44/15 KW 04/16 KW 33/15 KW 44/15 KW 04/16 KW 25/16 Zone VoWa Designpass Bezeichnung: Y-687_ABBLENDLICHT Zone Vorderwagen Designpass Bezeichnung: Y-687_ABBLENDLICHT Zone Vorderwagen Designpass Bezeichnung: Y-687_ABBLENDLICHT Schnittenummer:005 Schnittenummer:005 Schnittenummer:005 KW27 - 2016 KW41 - 2016 KW03 - 2017 Huerta links 04.07.2016 Chirek links 05.07.2016 Huerta 11.10.2016 Huerta 17.01.2017 Chirek rechts 05.07.2016 Strak 11.10.2016 Strak 22.12.2016 33 34 35 KW 33/15 KW 44/15 KW 04/16 KW 25/16 KW 27/16 KW 33/15 KW 44/15 KW 04/16 KW 25/16 KW 28/16 KW 41/16 KW 33/15 KW 44/15 KW 04/16 KW 25/16 KW 28/16 KW 41/16 KW 03/17 INTERNAL  55 Zone front end DesignPass Part 1 Designation: Y-680_ABBLENDLICHT Section number:005 KW33 - 2015 Hirzel 10.08.2015 Huerta 15.08.2015 Roybal 11.08.2015 Paruch 11.08.2015 DCC - L DCC - R INTERNAL CW 33/15 CW 44/15 CW 04/16 CW 25/16 CW 41/16  56 Zone front end Design Pass Part 2 Designation: Y-680_ABBLENDLICHT Section number:005 KW33 - 2015 Guo 11.08.2015 Christ Guo 11.08.2015 11.08.2015 Chirek Christ 11.08.2015 Mueller Chirek Mueller INTERNAL CW 33/15 CW 44/15 CW 04/16 CW 25/16 CW 41/16  57 Zone front end Design Pass Designation: Y-687_ABBLENDLICHT Section number:005 KW44 - 2015 Huerta 30.10.2015 Roybal 30.10.2015 Chirek 30.10.2015 Christ 30.10.2015 INTERNAL CW 33/15 CW 44/15 CW 04/16 CW 25/16 CW 41/16  58 Zone front end Design Pass Designation: Y-687_ABBLENDLICHT Section number:005 KW04 V2 – 2016 Huerta links 26.01.2016 Huerta rechts 26.01.2016 Chirek rechts 29.01.2016 Chirek links 29.01.2016 INTERNAL CW 33/15 CW 44/15 CW 04/16 CW 25/16 CW 41/16  59 Zone front end Design Pass Designation: Y-687_ABBLENDLICHT Section number:005 CW25 - 2016 Huerta links 24.06.2016 Chirek links 24.06.2016 INTERNAL CW 33/15 CW 44/15 CW 04/16 CW 25/16 CW 41/16  60 Zone front end Design Pass Designation: Y-687_ABBLENDLICHT Section number:005 KW41 - 2016 Huerta 11.10.2016 Strak 11.10.2016 INTERNAL CW 33/15 CW 44/15 CW 04/16 CW 25/16 CW 41/16  61 Zone front end Design Pass Designation: Y-687_ABBLENDLICHT Section number:005 CW03 - 2017 Huerta 17.01.2017 Strak 22.12.2016 INTERNAL CW 33/15 CW 44/15 CW 04/16 CW 25/16 CW 41/16 CW 03/17  62 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Result Design-technology convergence using the example of headlights A3 Audi A3 MJ 2014 Audi A3 MJ 2021 INTERNAL  63 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development Derivatization: Derivative is determined by the 4 parametershat shape, seating, seat height and dooriness. 2-door Dooriness 4-door SAV High-seater SUV Seat "Crossover" Hatchback Mainstream Hat shape Hatchback 3-Box Flat seater Sportscar 2-seater Seating 2-/4-/5-seater 4-/5-/7-/8-seater INTERNAL  64 AUDI AG Dr. S. Dengler I/EG-Z Lecture Series Complete Vehicle Development "Exotic" vehicle concepts Derivative = f(hat shape, seating, seat height, door) INTERNAL Thank you very much