The document provides details on benchmarking activities conducted to assist in developing targets for a new vehicle body configuration called Project SP2. Static benchmarking was performed on various vehicles to analyze their body types, including the Kia Cerato, Renault Mégane II, Renault Logan, Nissan Teana, Nissan Qashqai, and Peugeot 206. This provided advantages and disadvantages of each component and information to define characteristics for SP2's market position. Scenario 1 is proposed which uses the Renault Logan platform as the base, modifying it according to different body types while maintaining common front ends and production processes to reduce time, cost and investment.

1. Project: SP2
Prepared by:
F.Hesami
2011/Jun

2. 1. Introduction:

3. • to provide resting space for customers,
• to serve as a bridge between front and rear subsystems,
• to provide a passageway for powertrain and exhaust
components,
• to protect vehicle against water intrusion,
• to connect major load-carrying members - rails, cross
members, rockers, etc.,
• to enable seats, restraints, etc.
• to be attached to the body,
• to provide roomy interior and rest space for customer's legs,
• to prevent heat and noise intrusion from the engine into the
passenger compartment,
• to provide attachments to the instrument panel and steering
subsystem,
• to provide attachments to the plenum,
• to protect customers in the event of roof crush,
• to directly protect customers from rain, snow, sunshine, and
other hazards,
• to improve windnoise, vibration and harshness characteristics,
• to connect the pillars to the lower half of the vehicle,
• to provide attachment for seat belts,
• To connect the roof, front structure, underbody and rear end
• to form the complete body structure,
• to provide attachments for the doors and windows,
• to add several reinforcements to improve upon the rigidity of
the body system,
• to provide surfaces (interior and exterior) for trim and
ornamentation,
• to provide attachments for rear seats,
• to improve sound quality (attachment for speakers),
• to attach to rear bumper,
• To provide storage space (cargo/spare tire),
• to protect customers in rear impact,
• to provide attachments for lights and ornamentation,
• to provide towing and coupling attachments,
• to support the engine and the subframe (rails), front
suspension and steering gear,
• to support the radiator,
• to provide housing for front wheels,
• to provide attachment for steering subsystems and cowl,
• to support the bumper subsystem,
• to provide protection in frontal crash,
• to provide attachment for engine compartment components,
• to support the battery/battery tray.
1.1 Body functions :
The primary functions of the Underbody - Body Structure are:

4. 2. Benchmarking

5. 2.1 Benchmarking Body :
To ensure efficient development work on vehicle body configurations from the
point of view of;
• static,
• structural dynamics
• and optimum weight,
The definition targets as input data for the development process is required at a
very early stage.
These targets are obtained by continuously converting what are often only
subjective demands on the vehicle body into quantitative targets.
Benchmarking allows the characteristic data to be defined for a new product and
therefore assists in determining its market position .
Benchmarking activities were conducted in two stages to assists the process
1. Static benchmarking
2. Dynamic benchmarking (not used within the BIW process hence not
mentioned within the report)

6. 2.2 Static Benchmarking:
Benchmarking activities were conducted using vehicles or information which were at our
disposal or were easily available through the company A network
 company A
 Kia-Cerato
 PARS KHODRO
 Mégane II
 Renault Logan
 Nissan Teana
 Nissan Qashqai
 Others (data available)
 Peugeot 206

7. Vehicle Picture Type Advantages Disadvantages
Kia-
Cerato
Front Frame
assy
•Ease of manufacturing
•Ideal shape for controlling
deformation
•Integrated bracket to
support powertrain sub-
frame
•Weight – excessive
•Material - unknown
Kia-
Cerato
Firewall
•Ease of manufacturing •Irregular shape – complex
•Weak structure compared with
other benchmarked BIW’s e.g.
lack of cross members
Kia-
Cerato
Panel floor
•Ease of manufacturing •One piece stamping – cannot be
used for other variants e.g. pick-up
•Tunnel section to narrow e.g.
cannot pass exhaust & prop-shaft
together
Kia-
Cerato
Rear cross-
member
•Ease of manufacturing
•Simple design
•Initial assumptions – good
for rear impact i.e.
controlled deformation

8. Vehicle Picture Type Advantages Disadvantages
Mégane II Front Frame
assy
•Powertrain packaging
environment & space
•Up to date technology &
material deployed
•Minimum sub- assemblies
•Ease of manufacturing
Mégane II Firewall
•One piece x-member
•Brackets controlling
longitudinal
•Ease of manufacturing
•Up to date technology &
material deployed
Mégane II Panel floor
•Ease of manufacturing
•Up to date technology &
material deployed
•3 piece floor panel
•HSS used for seat brackets
Mégane II Rear
crossmember
•Composite spare wheel
carrier – light weight
•Rear beams – strong

9. Vehicle Picture Type Advantages Disadvantages
Renault
Logan
Front Frame
assy
•Powertrain packaging
environment & space
•Minimum sub- assemblies
•Ease of manufacturing
•Old Technology & material
deployed
•Front longitudinal not ideal for
frontal impact i.e. deformation can
not be controlled
Renault
Logan
Firewall
•One piece x-member
•Brackets controlling
longitudinal
•Ease of manufacturing
Renault
Logan
Panel floor
•Ease of manufacturing
•3 piece floor panel
Renault
Logan Rear
crossmember
•Rear beams – simple •Rear impact capabilities -
unknown

10. Vehicle Picture Type Advantages Disadvantages
Nissan
Teana
Front Frame
assy
•Powertrain packaging
environment & space
•Up to date technology &
material (AHSS) deployed
•Design – fit for today's
requirements
• many sub- assemblies
•Manufacturing – complicated
Nissan
Teana
Firewall
•One piece x-member
•Brackets controlling
longitudinal
• Manufacturing – complicated
Nissan
Teana
Panel floor
•Ease of manufacturing
•Up to date technology &
material deployed
•3 piece floor panel
•HSS used for seat brackets
Nissan
Teana Rear
crossmember
•Simple & strong rear end
•HSS material used for the
main beams
•Ease of manufacturing

11. Vehicle Picture Type Advantages Disadvantages
Nissan
Qashqai
Front Frame
assy
•Powertrain packaging
environment & space
•Up to date technology &
material (AHSS) deployed
•Longitudinal shape – ideal
for crash control
•Simple sub-frame
mounting design
Nissan
Qashqai
Firewall
•One piece x-member
•Brackets controlling
longitudinal
•Up to date technology &
material (HSS) deployed
•Ease of manufacturing
Nissan
Qashqai
Panel floor
•Ease of manufacturing
•Up to date technology &
material deployed
•3 piece floor panel
•AHSS used for seat
brackets
Nissan
Qashqai
Rear
crossmember
•Simple & strong rear end
•HSS material used for the
main beams
•Ease of manufacturing
•Many sub assemblies

12. Vehicle Picture Type Advantages Disadvantages
Peugeot
206
Front Frame
assy
•Powertrain packaging
environment & space
•Up to date technology &
material (HSS in specific
areas) deployed
•Longitudinal shape – ideal
for crash control
Peugeot
206
Firewall
•One piece x-member
•Brackets controlling
longitudinal
•Ease of manufacturing
Peugeot
206
Panel floor
•Ease of manufacturing
•Up to date technology &
material deployed
•2 piece floor panel
•Longitudinal beams not used
Peugeot
206 Rear
crossmember
•Simple & strong rear end
•Ease of manufacturing

13. 3-Targets setting

14. Attribute Comments (based on target vehicle-Logan)
1. Safety
•Body Deformation &
Occupant Injuries
Improve on the current front structure - improve shape, sections & technology
•Design Of Interiors &
Safety Equipment
New materials proposed
2. Security
•Valuable Devices introduce small deflector panels
•Theft of Vehicle
Contents
spare wheel inside trunk (all except), (pick-up) behind passenger seat, (MPV)
under floor (theft proof cage)
3. Packaging and Ergonomics
•All related requirements Concepts completed with dictated packaging dimensions
4. Thermal & Aerodynamics – Not related
5. Vehicle dynamics
•Handling provide a stiff platform to ensure adequate handling
6. Protecting Environment
•Emission Reduce BIW weight
•Recyclability Usage of recyclable material

15. Attribute Comments (based on target vehicle-Logan)
7. Performance/ Fuel economy
•Performance &
Drivability
Reduce BIW weight
•Economy Reduce BIW weight
•Energy Utilization Petrol only (to date)
•Transmission packaging space provided
8. NVH
•NVH ensure BIW NVH sensitivity is sufficient
9. Electrical/Electronics
•Facilities Provide space for modules
10. Interior climate comfort
•ventilation, heating and
cooling
HVAC module packaged
11. Weight
•Mass & Dimension Reduce BIW weight

16. Attribute Comments (based on target vehicle-Logan)
12. Product/ Process Design
•Product/ Process Design
(platform)
High commonality considered
13.Customer Life cycle
•Serviceability
/Reparability
Same practices as target vehicle used
•Durability / Reliability sufficient torsion & bending stiffness's identified to ensure durability of the
BIW.
•Corrosion Coated material used where possible
14. Electrical/Electronics
•Facilities Provide space for modules
15. Interior climate comfort
•ventilation, heating and
cooling
HVAC module packaged
16. Weight
•Mass & Dimension Reduce BIW weight

17. 4-New Platform Scenarios

18. 4.1 Ideal strategies for new platform solution:
• Create a new platform by modifying it according to type maintaining
common front end and front floor for all type.
• Usage of Logan & Other company A product parts bin .
• Usage of current production facilities/Process (Updating where required).
Vehicle Class Comments
Pride B Not in the same class of PF2 but parts bin may be used
Xantia D Phased out - CKD from PSA
Rio C Not in the same class of PF2 - CKD from KIA
Tiba C Not in the same class of PF2 but parts bin may be used
Megan D CKD from Renault Turkey
Logan C PROPRIETARY design by Renault

19. 4.2 Scenario 1
Using the base from a existing model & updating it to suit company A’s
requirements
Ideal Potential – Logan
Using parts and production facilities of Logan & Creating a new platform by
modifying it according to body type maintaining main features:
•New style themes for PF2
1-Sedan
2-Hatch back
3-SUV
4-MPV
5-Pickup
•Common front end for all types
•Modifying floor area for specific body type
•Production facilities & processes available

20. Advantages
1. ‘C’ Class
2. Proved out technology (i.e. crash ENCAP 3 – pre-2009)
3. High commonality with Logan
4. Usage of existing parts bin
5. Time & cost during development
6. Low investment
Disadvantages
1. Renault/Nissan may not allow this platform to be used i.e. SR project
still under review (by owners of platform) after 3 years of negotiation.
2. No independency for company A.
3. Lack of information regarding commonality (refer to Next Slide)
4. May not be suitable for variable body type as proposed by PF2
5. Logan has had many updates during its time at Company. The platform
(vehicle) currently produced in IRAN the design is at least a year behind
the ones produced in other area such as Russia, India..
Owners of Logan changes parts & design at will – updates unknown
6. Supplier may not be local or localization may not be possible
Scenario 1 cont.

21. From previous slide disadvantages
Item 3. Lack of information regarding commonality
Scenario 1 cont.
Vehicle
Wheel
Base
Length
Ground
clearance
SEDAN 2630 4250 155
H/Back 2588 4020 N/A
MPV 2905 4450 160
SUV 2673 4315 205
Pickup 2905 4496 N/A

22. 4.3 Scenario 2
New Platform to suit company A’s future requirements
• Platform
• common modular systems and components
• maximise structural commonality
• maintain power-train mounting points
• maintain rear suspension mounting points
•Suitable for all type of variation
1-Sedan
2-Hatch back
3-SUV
4-MPV
5-Pickup
• company A parts bin can be used where possible .
• Production facilities/Process modified to suit, increasing local supplier
potential .

23. Advantages
1. Deploying new trends & technologies
2. Idea comprise between development and cost .
3. company A owned platform - No royalties
4. Commonality through out the variable body type (refer to next slide)
5. New knowledge acquired - How to design and development a platform
6. Facelifts or model year changes possible when needed .
Disadvantages
1. Investment for development & manufacturing required
2. New technologies to be acquired
Scenario 2 cont.

24. company A Owned Platform
New design (max usage of company A’s Parts Bin)
Proceeding forward using the benchmarking data gathered
(advantages & disadvantages)
Vehicle
Wheel
Base
Length
Ground
clearance
SEDAN 2650 4595 180
H/Back 2650 4345 180
MPV 2650 4435 180
SUV 2650 4435 280
Pickup 2900 4625 280

25. Way Forward
From the previous slides the 2 scenarios presented, both have advantages &
disadvantages.
With the knowledge gained it is obvious that the way forward for the company A group is
to have an independently owned platform i.e. scenario 2 (linked closely to scenario 1
using base knowledge from Logan)
From this point forwards all the discussion are based on a newly developed Platform

26. 5. Platform and first vehicle
proposal &Configuration

27. 5.1 Structural concept:
•Wants from Platform.
•Primary concept.
•BIW - Underbody concept layout.
•Front rail & Eng. Compartment.
•Panel dash Lwr assy.
•Front floor assy.
•Rear floor assy.
Top
View
Bottom
View

28. Wants from Platform.
Top View
Bottom View
Front-suspension system
Concept from Logan
Corporate seating
system (i.e. Megane/Rio)
Rear-susp. system
Concept from
•FWD - Logan
•4WD - Qashqai
Safety requirements
to meet (2015 -2020)
Safety requirements to
meet (2015 -2020)
Safety requirements to
meet (2015 -2020)
Rear cargo space
leader in its class
Capable of
packaging a variety
of power-trains

29. Primary concept:
•The fundamental tasks for PF2 body structures is that they meet the program targets:
1. Safety & Crashworthiness.
2. Lightweight design concept to contribute towards the reduction of;
i. CO2-emission
ii. Fuel consumption
3. Vehicle dimension to meet packaging requirements.
4. Commonality and modularity.
5. CNG packaging capability.
6. Utilization of existing parts (where/possible) company A’s Parts Bin.
7. Using new technologies during process (where possible – availability & cost)
i. tailor welded blanks for optimum rail performance.
8. Body structure designed using benchmarked vehicles (Nissan C platform and Renault
B0 platform)

30. Eng. Compartment & Front rails:
• to support the engine and the subframe (rails), front suspension and steering gear,
•to support the radiator,
•to provide housing for front wheels,
•to provide attachment for steering subsystems and cowl,
•to support the bumper subsystem,
•to provide protection in frontal crash,
•to provide attachment for engine compartment components,
•to support the battery/battery tray.
Engine/suspension
sub-frame attachment
Bumper crash
box/can
Longitudinal
front rails

31. Bumper beams:
• Crash energy management system.
• Energy absorption without foam (intrusion reduced)
• Direct air flow to the heat exchangers (radiators etc..).
• Choice of material (weight reduced)
Bumper crash
box/can

32. DASH LWR CROSS CTR
DASH LWR CROSS MBR
REINF
DASH LWR
PANEL DASH LWR ASSY :
•To connect major load-carrying members - rails, cross members, rockers, etc.
•To enable seats, restraints.
•To provide roomy interior and rest space for customer's legs.
•To prevent heat and noise intrusion from the engine into the passenger compartment.
•to provide attachments to the instrument panel and steering subsystem.
•To improve
•torsion stiffness •Firewall intrusion criteria
•To absorb & distribute loads from the suspension into the body structure.

33. FRONT SIDE MBR
MBR ASSY SIDE CTR
CROSS MBR ASSY
FRONT FLOOR CTR
FRONT FLOOR ASSY :
•To improve
•bending stiffness.
•To transfer load from the front rail to Rear floor assy.

34. FLOOR ASSY
MBR ASSY
Bumper crash
box/can
CROSS
MBR ASSY
REAR FLOOR ASSY :
•To provide storage space (cargo/spare tire).
•To protect customers in rear impact.
•To attach to rear bumper.

35. BIW concept layout:
SECTION 1-1
SECTION 2-2
SECTION 3-3
SECTION 4-4
SECTION 5-5
SECTION 6-6
SECTION 7-7
SECTION 8-8
SECTION 9-9
SECTION 1-1
SECTION 2-2
SECTION 3-3 SECTION 3-3SECTION 4-4 SECTION 5-5 SECTION 6-6
SECTION 7-7 SECTION 8-8
SECTION 9-9

36. BIW concept layout:
SECTION 11-11
SECTION 10-10
SECTION 10-10
SECTION 11-11
SECTION 12-12
SECTION 12-12
SECTION 13-13
SECTION 13-13
SECTION 14-14
SECTION 14-14
SECTION 15-15
SECTION 15-15

37. 5.2 Assembly concept :
5.2.1 All variants (other than Pick-up)
Assembly level 1
Assembly level 2Assembly level 3
•Sedan.
•Hatchback.
•SUV.
•MPV.
•Pickup

38. Assembly level 1:
Common on all except SUV
Common on all

39. Assembly level 2:
Common on all

40. Assembly level 3:
Different on all models(same geometry, different length)
Common on all

41. Assembly level 4
5.2.2 Pick-up only
•Sedan.
•Hatchback.
•SUV.
•MPV.
•Pickup

42. 5.3 Material concept :
•Material specifications.
•Tailored Blanks.
•Engine Compartment & Front rails concept.
•Front floor concept.
•Rear floor concept.

43. Automotive Steel Families:
Family Quality AM offer Eu Norm Exemple of application
Drawing DC01- DC07
ArcelorMittal 01-07
ArcelorMittal 51-57
EN10111
EN10130
EN10152
EN10327
Bodyside, roof, floor, hood
panels, crossmembers
High Strength steels
IFHSS IF180 – IF300 EN10268
EN10292
EN10152
EN10149
Door, hood, decklid outer
panels
Members, crossmembers
BH 180BH – 300BH
Rephosphorized H220 – H300
Isotropic E220i – E260i
HSLA
CR HSLA 260 – 420
HR HSLA 320 -550
Advanced High
strength steels
Dual Phase
Complex Phase
TRIP
Martensitic
DP450 -1180
DP HY and HHE
TRIP 690 – 780
MS1200
EN10336
prEN10338
A, B, C Pillar R/F
Member R/F
Bumper, door beams
Rocker panel
Press hardened steels
22MnB5
USIBOR
22MnB5
USIBOR1500AS
A Pillar, member, bumper
beam
Composite steels
Vibration damping
structural
Quietsteel
smoosteel
Dash panel, engine cover, oil
pan

44. 5.3.1 : Scenario 1 :
Current Logan utilizing the following materials:
•6% high strength steel
•94% mild steel
<10% high strength steel in body structure
EuroNCAP 3-star crash rating (old rating)
Deformation in
upper A-pillar
and roof

45. Eng. Compartment & Front rails concept:
HE450
Th:1.0
DC04
Th:0.7
DC04
Th:1.8
DC04
Th:2.0
DC04
Th:1.0
DC04
Th:0.7
DC04
Th:1.0
DC04
Th:0.7
DC04
Th:0.7
DC04
Th:1.4 DC04
Th:2.5
DC04
Th:0.7
DC04
Th:0.7
DC04
Th:1.0
DC04
Th:1.0
DC04
Th:1.2
DC04
Th:0.7
DC04
Th:2.0
HE450
Rear Th:2.0
HE450
Front Th:1.7
DC04
Th:1.5
DC04
Th:2.0
DC04
Th:2.0
DC04
Th:2.0
Th:1.0
DC04
Th:1.2
Refer to slide 45 – table of materials

46. Front floor concept :
DC04
Th:1.0
DC04
Th:1.5
DC04
Th:1.5 DC04
Th:1.5
DC04
Th:1.5
DC04
Th:1.5
DC04
Th:1.2
Refer to slide 45 – table of materials

47. Rear floor concept :
DC04
Th:1.0
DC04
Th:0.7
DC04
Th:1.5
DC04
Th:1.5
DC04
Th:1.0
DC04
Th:1.7
DC04
Th:2.0
DC04
Th:1.6
DC04
Th:1.0
DC04
Th:1.6
DC04
Th:1.7
DC04
Th:0.7
DC04
Th:0.7
DC04
Th:0.7
DC04
Th:2.0
DC04
Th:1.0
DC04
Th:2.0
DC04
Th:0.7
DC04
Th:2.0
Th:1.0
Refer to slide 45 – table of materials

48. 5.3.2: Scenario 2 :
Advanced steels used in
constructing Body-in-White
>70% high strength steel in body structure
EuroNCAP 5-star crash rating (new rating)
 AHSS  HSS
To achieve the ratings set by PF2 the following example defines the direction to be
adopted:
Using latest available materials as suggested/available by the supplier (POSCO)
No deformation
of passenger
cell

49. Eng. Compartment & Front rails concept :
DP590
Th:1.0
HSLA-250
Th:0.7
DP600
Th:1.8
DP500
Th:2.0
DP590
Th:1.0
HSLA320
Th:0.7
BH300
Th:1.0
BH210
Th:0.7
BH210
Th:0.7
DP590
Th:1.4 HSLA320
Th:2.5
BH500
Th:0.7
BH210
Th:0.7
DP500
Th:1.0
DP500
Th:1.0
HSLA320
Th:1.2
DP500
Th:0.7
HSLA550
Th:2.0
DP600
Rear Th:2.0
DP600
Front Th:1.7
DP600
Rear Th:2.0
DP600
Front Th:1.7
DP500
Th:1.5
DP500
Th:2.0
DP-600
Th:2.0
DP600
Th:2.0
Th:1.0
DP590
Th:1.2
Refer to slide 45 – table of materials

50. Front floor concept :
DP600
Th:1.0
DP590
Th:1.5
DP500
Th:1.5 DP- 450
Th:1.5
DP590
Th:1.5
DP590
Th:1.5
DP500
Th:1.2
Refer to slide 45 – table of materials

51. Rear floor concept :
DC04
Th:1.0
DC04
Th:0.7
HSLA550
Th:1.5
DP500
Th:1.5
DP500
Th:1.0
DP500
Th:1.7
DP500
Th:2.0
DP500
Th:1.6
HSLA320
Th:1.0
DP590
Th:1.6
DP500
Th:1.7
BH210
Th:0.7
BH210
Th:0.7
DP590
Th:0.7
DP500
Th:2.0
DP500
Th:1.0
DP500
Th:2.0
DC04
Th:0.7
DP600
Th:2.0
Th:1.0
Refer to slide 45 – table of materials

52. Tailored Blanks :
•Advantages of Tailored Blanks:
Weight Parts Stability
Overlap
joints
Reduction
•Material
•Mass
•Transported
Reduction
•Tool costs
•Press shop costs
•Assembly costs
•Material costs
•Logistic costs
Improvement
•Fatigue values
•Crash behaviour
Reduction
•overlap joints
Improvement
•corrosion

53. Tailored Blanks cont.
•Concepts for PF2:
Laser weld seam
Laser weld seam
Laser weld seam

54. 5.7 Recommendation for joining technologies :
•Joining
Crimping
seam
Riveted
joints
Laser-
welded
seam
Resistance
spot
welding
Welding
bolts
MAG
welded
seam
Projection
welded
joints

55. FARSHID HESAMI
Email Address : farshidhesami@gmail.com
BIW EXPERT ENGINEER
https://www.linkedin.com/in/farshid-hesami-33a09529/
Cellphone : +989123387563