a winner: car body design development of the hyundai...

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A Winner: Car Body Design Development of the Hyundai Sonata

Carsten Höfer Hyundai Motor Europe Technical Center

• Background • History • Customer proposition • Styling • Practicality • Performance • Efficiency

• Development process • Platform strategy • Weight optimization • Stiffness • Material • Safety

• Overview of Ulsan Plant • Manufacturing strategy • Flexible production system • Productivity • Quality

Hyundai Sonata at GDIS Conference 2013

Product Concept BIW Concept /

Product Concept

• Background • History • Customer proposition • Styling • Practicality • Efficiency

• Development process • Weight optimization • Stiffness • Material • Safety

BiW Concept

i40 intro.m4v

Product Concept Hyundai Sonata at GDIS Conference 2013


7

2010 Sedan 2011 Sedan & Wagon

2004

1998




Product Concept

• Best in class roominess • Class leading practicality

• Sporty and emotional • Modern interior

• Target best in TCO • Competitive pricing

• 3 USPs: rear seat reclining, auto defog, heated steering wheel

• Best in class with 113g CO2/km


Product Concept BIW Concept

Product Concept

• Cargo capacity 19. 5 cu. ft. (553 liters) with the rear seats occupied • Up to 60.7 cu. ft. (1718 liters) with the rear seats folded down


/

Product Concept

0.32

0.29 0.30

0.29

Predecessor i40 Competition

Cd

8,013

8,878 8,840


10,082 22%

132

155 148


CO2 (g/km)

214




BIW Concept Hyundai Sonata at GDIS Conference 2013


BIW Concept

SOP

SOP

-6 -4 -2

Full schedule predecessor 24M

Full schedule i40 18M

Model Fix

Design

Design Model Fix

Test

Test



BIW Concept

• Achieved a 7.6% reduction in BIW weight compared to predecessor.

438kg

Design concept Final drawings

456.3kg

Competition

438kg

EVI process

Design optimization -27.3kg


BIW Concept

• Rearranging the part assembly allowed for a reduction of the material thickness • From single part with uniform thickness to three parts with different, optimized thickness



BIW Concept

• Change of the form from linear interior to radial interior lead to a material thickness reduction • Divergence angle to improve airflow and NVH performance



Spare Member (0.8 ) Spare Member (1.0 )

BIW Concept

• Increased the torsional stiffness by 141% and the bending stiffness by 19%. • Achieved 11% more torsional and 23% more bending stiffness compared to competition

0.32

24

14.6 0.29

Predecessor i40

28.6 35.3



a winner: car body design development of the hyundai...

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