Safety Cage Design in the Volvo XC90 Jonas Bernquist Volvo Car Corporation www.autosteel.org Presentation overview • General • Body structure – Safety cage – XC90: New structural solutions • Materials – General – XC90: Materials • Sum-up www.autosteel.org General The first Volvo SUV? 1943 www.autosteel.org 2002 General Key attributes SIZE [mm] Weight [kg] Length Width Height P28 4798 1890 1740 Body shell incl frt bumper (BMW painted) 407 Total hang on (BMW painted) 113,0 Paint and sealings 16,4 Body complete incl closures Body complete incl 2nd row subframe 536,4 17,6 554,0 Static Torsional Stiffness BIG [kNm/deg] 1st Dynamic Torsion mode BIG [Hz] 1st Dynamic Lateral Bending mode BIG [Hz] 1st Dynamic Vertical Bending mode BIG [Hz] 21,4 33,6 44,1 47,4 2nd row seat subframe (structural part) Attributes www.autosteel.org General Advanced Body Engineering www.autosteel.org Body structure Safety cage 1 “A rigid framework surrounding the occupants which creates a support for the interior safety equipment and provides a survival space for the vehicle occupants in case of a crash” www.autosteel.org Body structure Safety cage 2: SIPS Side Impact Protection System – Introduced in 1991 – The structure minimises the intrusion by the: • • • • • very strong B-pillars rigid rockers transverse floor/roof members SIPS-box framework of the front seats www.autosteel.org Body structure New structural solutions The XC90 BIW challenge S80 • • • • • V70 S60 Increased front crash demands Compatibility small cars Rollover protection Protection 3rd row Increased side-impact protection P2x-platform Body implications: New structural and material solutions! www.autosteel.org Body structure XC90 dimensions XC90 Comparison with other cars on the P2x-platform S80 1582 1832 4822 V70 931 1563 1804 1563 1804 1024 4710 (XC 4733) S60 887 974 4576 Width (mm) S80: 1832 V70: 1804 S60: 1804 Length (mm) S80: 4822 V70: 4710 Kerb weight: 2070kg S60: 4576 www.autosteel.org Kerb weight (kg) 1631 1670 1574 Height (mm) 1434 1488 (XC1562) 1428 Body Structure New structural solutions: Front New front structure Three leg support • To handle higher forces and weight • Centre floor is carry over P2 platform • “Three leg support” • Cross member firewall Compatibility • SUV hitting car • Different side rail heights • Engine sub frame (cradle) reinforced and extended forward • Height aligned with car rail height www.autosteel.org Body Structure New structural solutions: Safety cage - Side 1st attempt Low hit New demands… Side impact common accident type SUV hit by SUV Side impact + higher rollover requirement Controlled deformation Preferred B-pillar intrusion and deformation mode Roof bow collapse B-pillar collapse Too big intrusion High hit Reinforced side- and roof structure Strong B-pillar, B roof bow and seat belt bracket Dual piece sunroof frame clinched together New seat crossmbr www.autosteel.org EuroNCAP ! Body Structure New structural solutions: Safety cage - Roof Force F kN Rollover accidents Increased req's rollover impact Heavy vehicle Strong structure Packaging New demands… Roof bow collapse A-pillar collapse Seat belt bracket collapse B-pillar collapse Reinforced side- and roof structure No structural collapse allowed. Strong B-pillar, B roof bow and Apillar upper Dual piece sunroof frame clinched together EHSS-reinforced A-pillar www.autosteel.org Result: No structural collapse! Materials General: Why HSS/EHSS/UHSS? 100 HSS, EHSS & UHSS (Body Structure) 90 Zink coating 80 Parts weight% 70 60 50 40 30 20 10 0 240 240 740 740 940 940 850 850 S40 S40 S80 S80 V70 V70 XC90 S40+ XC90 S40+ Annual total weight increase of 10 kg, platform to platform! www.autosteel.org Materials General: High strength steels at VCC Tensile strength, Rm • HSS: Rephosphorized & HSLA steels. VCC “standard qualities for high strength material. Slightly better formability with Rephos. MS HSS EHSS UHSS (MPa) max 270-390 min 340 min 600 min 800 Boron steel DP HSLA Rephos • HSS/EHSS: Dual phase steels, used for reinforcements. Boron steel DP HSLA Rephos • UHSS: Boron steel. Used for reinforcements subjected to extreme load cases. max 170-280 min 220 min 280 min 400 Yield strength, Re Using HSS/EHSS/UHSS for cost efficient weight reduction ! www.autosteel.org (MPa) Materials XC90: Side-impact & roll-over Boron Steel DP600 Rephos (σtensile min = 380 MPa) B roof bow Cantrail ext. W-screen mbr Rear seat frame (rear part) roll formed boron steel A-pillar upper B-pillar Rocker General thickness ~1,2-2 mm www.autosteel.org Materials XC90 BIW Material distribution Rmmax≅300 MPa Rmmin>340 MPa (DP, HSLA el Rephos) Rmmin>380-420 MPa (DP, HSLA el Rephos) Rmmin>600 MPa (DP600) Rmmin>1400 MPa (Boron steel) •Body structure •Body structure on •Hang parts •Hang onparts tailgate •Polymer •Polymer tailgate MS 42% HSS 36% EHSS UHSS Al 14,5% 6,5% 1% 407 407 kg kg 113 kg 113 kg ~11 ~11 kg kg www.autosteel.org EHSS Sum-up Ratings Europe Front Side www.autosteel.org USA Sum-up • XC90 incorporated several, for Volvo, new structural concepts and material applications • High degree of HSS-material in the body structure (HSSÎEHSSÎUHSS) • Extremely strong upper body structure for good rollover properties www.autosteel.org Thank you for your attention! www.autosteel.org