frame - Abdullah Demir

Transkript

MARMARA ÜNİVERSİTESİ
TEKNOLOJİ FAKÜLTESİ
TAŞIT TEKNOLOJİSİ
ŞASİ, ÇERÇEVE ve
GÖVDE - KAROSER/İ
-GİRİŞVehicle Structure
Frame, Body, and Chassis
Yrd. Doç. Dr. Abdullah DEMİR
According to a prediction by British Petroleum
(BP), the number of vehicles worldwide will
increase from 800 million today to 2 billion in
the year 2050 [a]. Global demand for energy will
increase by 60 % between now and the year 2030.
It is estimated that global fossil fuel reserves will
last between 40 and 50 years.
a) Goeudevert, D.: Die Automobilindustrie ist nicht innovativ.
VDI-Nachrichten, Ausgabe 24.3.2006. Düsseldorf, 2006
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics,
Components, Mechatronics, Perspectives, 2011.
This statistic shows the number of passenger cars and commercial vehicles in
use worldwide from 2006 to 2012. In 2012, around 833 million passenger cars
and 310 million commercial vehicles were registered worldwide.
http://www.statista.com/statistics/281134/number-of-vehicles-in-use-worldwide/
It can take up to seven years to develop a new vehicle from an initial
concept to full series production. Most vehicles remain in series
production for approximately seven years. After initial production,
passenger vehicles are expected to remain in service for at least ten
years and should maintain a high resale value throughout their service
life. Engineers and designers must therefore consider a time frame of
approximately 25 years starting from the beginning of the concept
phase.
Bernd Heißing | Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011.
It should be noted that every automobile is a highly complex machine
which consists of 25 to 30 systems, about 500 modules, and more than
50,000 individual parts.
Vehicle function levels
The V model can be applied to different levels of vehicle development. To
facilitate this, the vehicle is divided into different systems, subsystems,
modules, etc., until the most basic component level is reached
Chassis structures can be separated from the body, as in industrial
vehicles and some commercial and off-road vehicles, or they can be
integrated, as found in unitized bodies. In this case, auxiliary
structures are sometimes applied, to better distribute local loads to
the body, supporting suspension mechanisms, engine or power train,
transmission and final drive.
Chassis structures in these three cases are also called, respectively,
frames, underbodies and subframes.
G. Genta and L. Morello, The Automotive Chassis, Volume 1: Components Design, 351 Mechanical Engineering Series, 2009
Note: Today, automakers only manufacture about 30 % of each
car themselves. The remaining 70 % of the components are
purchased from suppliers.
Temel Kavramlar
The vehicle’s main components and sub - systems can be categorically
listed as: Power-train, chassis, exterior and interior trims, and the
body in white (BiW) or vehicle body - shell.
body in white: Beyaz gövde. Bir otomobilin motor vb gibi ana parçaları ile trim
donanımı öncesi ana yapısıdır.
2004 5 series
http://www.forocoches.com/foro/showthread.php?t=3781364
2013-SL-Class_body_in_white
http://www.forocoches.com/foro/showthread.php?t=3781364
Bütün taşıtlar kendilerini ve üzerlerindeki yükü taşıyan bir gövdeye
sahiptir. Kullanım amaçlarına göre farklı olmakla birlikte taşıtların
gövdeleri genel olarak iki ana kısımdan oluşur.
1. Şasi
2. Karoseri
A typical BiW consists of about 300 – 400 stamped pieces, however, only a few main
panels affect the overall geometry, fit and finish. These panels are the roof, the trunk
(inner, outer, and pan), the hood (inner and outer), the under - body, the wheel house, the body - side, A and B pillars, the floor pan, the front module (engine
cradle, crush zones, shock towers), the quarter panels, and doors (inner, outer).
A-pillar: A-direği / sütunu, Adikmesi.
Quarter panel: Arka kelebek
panel, çamurluk panel
Stamped pieces:
Preslenmiş
parçalar
Figure : The different panels of the vehicle structure
Mohammed A. Omar, The Automotive Body Manufacturing Systems and Processes, © 2011 John Wiley & Sons Ltd. ISBN: 978-0-47097633-3
OKUMA PARÇASI: Şasi ve karoseri, otomobilin gövdesini
oluşturur. Şasi çerçevesi (Şasi çatkısı), aracın bütün parçalarını
üzerinde taşıyan, motora, karoseriye ve güç aktarma
organlarına desteklik eden bir temeldir. Karoseri ise aracın
kaporta ya da gövde diye tabir edilen sac aksamıdır.
Günümüz araçlarında en genel anlamda iki tür şasi çerçevesi
bulunmaktadır. Bunlar ayrı şasi çerçevesi ve birleşik şasi
çerçevesidir.
Eğer şasi çerçevesi sonradan karoseriye cıvatalarla tutturulacak
şekilde yapılmışsa ayrı şasi çerçevesi olarak isimlendirilir. Şasi
çerçevesi oldukça katı ve sağlam bir yapıya sahip olmalıdır.
Günümüz otomobillerinde pek kullanılmamaktadır. Daha çok
ağır ticari araçlarda kullanılır.
Birleşik şasi çerçevesinde ise; şasi çatkısında parçalar
kaynakla tutturulmuştur. Bazı birleştirme yerlerinde
kuvvetlendirmeler yapılmak zorundadır. Onun için birleşik
karoseri-şasilerin çeşitli bölümlerinde birbirini kuvvetlendiren,
tüm gövdeyi birlikte destekleyen bir yapı özeliği vardır.
…
Chassis
•
•
Consists of the vehicle’s
frame
and
everything
attached to it except the
body
Includes the tires, wheels,
engine, transmission, drive
axle assembly, and frame
Russell Krick, “Modern Automotive Technology” Sunumu, The
Goodheart-Willcox Co.
Chassis Frames
The chassis frame is the commercial
vehicle's actual load-bearing element. It is
designed as a ladder-type frame,
consisting of side and cross members. The
choice of profiles decides the level of
torsional stiffness. Torsionally flexible
frames are preferred in medium- and
heavy-duty trucks because they enable the
suspension to comply better with uneven
terrain. Torsionally stiff frames are more
suitable for smaller delivery vehicles and
vans.
Reff: Automotive Handbook
•
•
•
Chasis is a French term
which denotes the whole
vehicle except body in case of
heavy vehicles.
In case of light vehicles of
mono construction it denotes
the whole body except
additional fitting in the body.
Chassis consists of engine,
brakes, steering system &
wheel mounted on the frame,
differential, suspension.
•
•
•
•
•
ITS PRINCIPAL FUNCTION:
To safety carry the maximum
load.
Holding all components together
while driving.
Accommodate twisting on even
road surface.
Endure shock loading.
It must absorb engine - driveline
torque.
«INTRODUCTION TO AUTOMOBILE» Sunumu, SAEINDIA.
FRAME
•
•
Frame is the main part of chassis on
which remaining part of chassis are
mounted.
Frame should be extremely rigid and
strong so that it can withstand
shocks,
twist,
stresses
and
vibrations when vehicle is moving on
road.
unibody (or monocoque)
 Strong metal structure that provides a
mounting place for other parts of the
vehicle
 Body-over-frame construction
 chassis parts and body bolt to the
frame
 Unibody (unitized) construction
 sheet metal body panels are welded
together to form the body and frame
Binek otomobilleri eskiden şasili olarak
yapılırlardı. Ancak günümüzde takviye
edilmiş karoseri yekpare gövde ile
birlikte yapılmaktadırlar. Kendi kendini
taşıyan karoseri (şasisiz taşıyıcı gövde ve
hücre
tip
karoseri),
tabanı
kuvvetlendirilmiş bir yapıdadır. Saç
gövde gerekli takviyelerle ve şekil
mukavemeti yardımı ile dayanıklı hale
getirilmektedir
Kaynak: “Şase ve Karoseri” Sunumu, TÜVTURK, 08/03/2006.
Ağır kamyonlar ve yük
taşıyan taşıtlar şasilidir ve
üzerinde sürücü kabini ile
yükleme
yapılan
kasası
vardır.
Karoserinin görevi: Taşıta
şekil veren, fonksiyonları
yerine getirmesi için ana
hacim sağlayan kısmıdır.
 Made
of
steel,
aluminum,
fiberglass, plastic, or composite
materials
 Forms the outside of the vehicle
 Serves as an attractive covering for
the chassis
Russell Krick, “Modern Automotive Technology” Sunumu, The Goodheart-Willcox Co.
Automobile Body Parts
Kaynak: Toyota
Şasi, Çerçeve ve
Gövde - Karoser/i
Şasinin
görevi:
İnsan
vücudundaki iskelet gibi ana
taşıyıcılık görevini yerine getirir.
Taşıtın
birçok
elemanını
üzerinde taşır.
The Rolling/Driving Chassis
Vehicles with ladder-frame chassis
configurations (mostly light trucks
for the US market) are often
preassembled as a rolling chassis
including the fuel system, driveline,
and other running gear (Figure). This
rolling chassis can be assembled by a
system supplier and rolled or
otherwise transported to the OEM’s
final assembly line.
Rolling chassis (DANA Corp.) [13]
Merdiven Tipi Şasi (Paralel
Kollu Şasi): Kamyon ve
otobüslerde
yaygın
olarak
kullanılan şasi tipidir. Paralel
iki kol ve bu iki kola bağlanmış
kuşaklardan
oluşur.
Kollar
genelde U, kare, dikdörtgen ve
daire kesitli olarak preste
yapılırlar. Kuşaklar ve üst yapı,
kaynak, perçin ve cıvata ile şasi
kollarına bağlanır.
• The ladder frame is the
simplest and oldest of all
designs.
• It consists merely
symmetrical rails, or
of
two
• This design offers good beam
resistance because of its
continuous rails from front to
rear
• poor resistance to torsion
Paralel Kollu Şasi
(Merdiven Tipi Şasi)
Kaynak:
“Şase ve Karoseri”
TÜVTURK, 08/03/2006.
Kaynak: VW, Otomobil Teknolojisinin Temelleri
Sunumu,
Çapraz Kollu (X Tipi)
Şasi: Oldukça hafif bir
yapısı vardır. Daha çok
kamyonetlerde
tercih
edilir.
Tek Kollu (Platform)
Şasi: Ortada tek bir kol ve
buna bağlanmış kuşaklar,
bazen de taban sacı ile bir
bütün olarak yapılırlar.
Otomobillerde
tercih
edilir.
Çatal Kollu Şasi: Taşıt
motorunun bağlanmasına
ve destek oluşturmasına
elverişli bir şasi tipidir.
Kamyonetlerde ve
otomobillerde tercih
edilir.
Gövde Tipleri
Body Types
Vehicle Classification
Vehicle
Type
Body Style
Power Train
Suspension
Passenger Car
2D/3D/4D/5D UniBody
Engine: 1.0-3.0L
Trans: 5spd/Auto
Driveline: FWD
Front: McPherson
Rear: Multi-link
MPV
4D/5D UniBody
Engine: > 2.0L
Trans: Auto
Driveline: FWD
Front: McPherson
Rear: Multi-link
SUV
5D Unibody or Body on
Frame
Engine: 1.8-5.0 L
Trans: Auto
Driveline:
FWD/RWD/AWD
Front: McPherson/SLA
Rear: Multi-link/Solid Axle
Luxury Car
4D Unibody or Body on
Frame
Engine: >2.5 L
Trans: Auto
Driveline: FWD/RWD
Front: SLA
Rear: Multi-link
Sports Car
2D/3D Unibody
Engine: >3.5 L
Trans: 5Spd
Driveline: RWD
Front: McPherson
Rear: Multi-link
Pickup Truck
2D/4D Body on Frame
Engine: >2.5 L
Trans: Auto
Driveline: RWD/AWD
Front: SLA
Rear: Solid Axle
Commercial
Truck
2D Body on Frame
Engine: >5 L
Trans: Auto
Driveline: RWD
Front: SLA
Rear: Solid Axle
Fundamentals of Vehicle Design; Dr. Shirish P Patil & Dr. Kamarul Tawi
The purpose of body design is to achieve the following:
• Aesthetics: to provide a pleasing overall appearance, surface quality and
consistent details.
• Structural function: to support the weight of the transported passengers
and load as well as the mechanical parts required for vehicle propulsion,
control and other system functions, so withstanding mechanical stresses
from multiple sources.
• Ergonomy and roominess: to supply easy access and adequate room for
the driver, passengers and transported goods.
• Safety: to ensure integrity of passenger compartment in the event of a
crash, while absorbing the impact energy as well as to reduce injuries to
vulnerable road users (pedestrians, wheelers), in case of collision.
• Aerodynamics: to minimize drag due to air impact; to control air flow
effects on tyre-road contact and vehicle stability.
• Insulation: to minimize noise, vibration and thermal transmission,
generated by body walls, by lack of sealing between compartment and
movable parts and by thermal radiation from the surfaces of passengers
compartment.
• Visibility: to provide the highest possible day and night visibility on the
environment and to host the lighting devices in the most effective way.
Lorenzo Morello, Lorenzo Rosti Rossini, Giuseppe Pia, Andrea Tonoli, The Automotive Body, Volume I: Components Design, e-ISBN 978-94-007-0513-5
The interior and exterior
trims compose the front
and rear ends, the door
system, and the cockpit
trim.
Finally, the body in
white is made up of the
closures (doors, hood,
tail-gate) and the frame,
see Figure 1 ).
emmesei.com
Body Types
Automobiles are available in
several body types, including:
• sedan
• hardtop
• convertible
• hatchback
• station wagon
• minivan
• sport-utility vehicle
Sedan
A sedan is a car with a four-door body configuration and a
conventional trunk or a sloping back with a hinged rear cargo hatch
that opens upward.
Sedan is the most
common body style that
are cars with four or
more seats and a fixed
roof that is full-height up
to the rear window.
Sedans can have two or
four doors.
Uses center body pillars, or “B” pillars, between the
front and rear doors. A hardtop does not use “B” pillars.
Convertible
A convertible is
a car with a
removable
or
retractable top.
Uses a vinyl or cloth top that can be raised and
lowered
Hatchback
The large rear door allows easy access when hauling
items
Station Wagon
A wagon is a car
with an extended
body and a roofline
that extends past the
rear doors.
Station wagon or
wagon is a car with
a full-height body all
the way to the rear;
the
load-carrying
space created is
accessed via a rear
door or doors.
Provides a large rear interior compartment
Minivan
Has a higher roofline for more headroom
and cargo space
A minivan/van is a
vehicle with a box-shaped
body enclosing a large
cargo or passenger area.
The identified gross weight
of a van is less than 10.000
lb ≈ 4,500 kg. Vans can be
identifiable
by
their
enclosed
cargo
or
passenger area, short
hood, and box shape. Vans
can be divided into mini
van, small van, midsize
van, full-size van, and large
van. The van subdivision
has the same specifications
as SUV subdivisions.
Minivans are boxy wagon cars usually containing three
rows of seats, with a capacity of six or more passengers
and extra luggage space.
Sport-Utility Vehicle
An SUV (sport utility
vehicle) is a vehicle with
off-road capability. SUV is
designed for carrying ten
or fewer persons, and
generally considered a
multi-purpose
vehicle.
Most SUVs are four-wheeldrive with and increased
ground clearance. The
SUV is also known as 4by-4, 4WD, 4 × 4 or 4x4.
SUVs can be divided into
mini, small, midsize, fullsize, and large SUV.
Provides the comfort of a passenger car, the interior space of a
station wagon, and the durability of a truck
An MPV (multi-purpose vehicle) is
designed as large cars or small buses having
off-road capability and easy loading of
goods. However, the idea for a car with a
multi-purpose application can be seen in
other classes, especially SUVs.
Tam Taşıyıcı Karoseri:
Günümüzde binek otomobiller şasisiz olarak imal
edilmektedirler. Gövde kendi kendini taşıyan bir formda dizayn
edilmektedir. Genellikle karoseri gövdesi hücre tip dediğimiz
gövdedir. Bilgisayarlar yardımı ile orijinal yapının ve istenilen
bölge veya parçaların tek tek deformasyon ve gerilmeleri
hesaplanabilir.
Hücre Tipi Karoseri: Taşıt gövdesi ayrı hücrelerden oluşur.
Yolcu bölümü taşıtın ön ve arkasına göre korunmaya
alınmıştır. Çarpışma anında ön ve arka hücreler daha elastik
yapıldıkları için yolculara gelecek darbe minimuma
indirilmiştir. Binek otomobillerde genellikle uygulanan bir
gövde tipidir.
Karma Tip Karoseri: Şasi ve karoserinin bir nevi
kombinasyonundan meydana gelmiştir. Taşıt, bir platform şasi
veya çatal şasi ile gövde saçının kaynakla veya cıvata ile
birleştirilmesinden oluşur. Otomobil ve otobüslerde
uygulaması vardır.
Audi Space Frame
When it introduced the first A8 in 1994, Audi had not only developed the radically new
ASF design and put it into series production, it had also developed all of the steps required
for its production. The launch was preceded by a development process lasting 12 years.
Since this time Audi has built on its competitive edge step by step. The arc spans three
generations of the A8 and also includes the A2 along with its legendary three-liter version,
the A2 1.2 TDI. By the end of 2010 alone, the company had produced some 550,000 vehicles
with the ASF body – far more than any other manufacturer in the world.
ASF olarak bilinen Audi Space Frame (Audi Uzay Kafesi), hafif gövde yapısı
sayesinde daha fazla performans ve daha düşük yakıt tüketimi gibi avantajlar
sunmaktadır.
http://www.audi-technology-portal.de/en/body/aluminium-bodies/audi-spaceframe-en
Şasisiz Otobüs Gövdeleri: Otobüs
imalinde şasisiz gövdeye örnek
olarak gösterilen iki ana grup vardır.
Bunlar:
1. Platform takviyeli otobüs gövdesi
2. Tam taşıyıcı otobüs gövdesi
Her iki yapı tipide şasili tipe nazaran
hafiftir. Taşıt ağırlığında azalma tam
taşıyıcı otobüs gövdesinde daha
fazladır. Ağırlık azalması şasinin
çıkması ile %8 civarında olur. Ancak
bunun bir kısmı mukavemet
arttırmak amacı ile tekrar kullanılır.
Taşıtın boş ağırlığı ne kadar az ise
işletme şartları da o oranda
ekonomik olur.
Ek Okuma ve
İnceleme Bölümü
Moreover, the body must satisfy a series of prerequisites:
• high reliability (to maintain design functions vehicle life along),
• low cost (to minimize production investment, process and material
cost),
• high material recyclability (by rapid disassembling and
straightforward division of heterogeneous materials).
These functions ere required by the completely assembled body and are
achieved through the individual contribution of body components and
several body systems.
Fig. 1: Common body and chassis configurations.
A) Unitized body or unibody, in which the chassis parts cannot be physically
removed from the upper body parts. In this case, suspensions and other mechanical
parts are directly fitted (using brackets) to body frame. The main advantage of such
solution is relatively low weight, while the main disadvantage is a lower dimensional
precision of suspension attachment, due to body tolerance and the lower filtering
performance of suspension fittings, reducing the insulation of vibrations due to
road-wheel excitation.
B) Body on frame, where the chassis frame is connected to upper body frame by
bolts with or without the inter-position of rubber bushes. Such a solution offers the
main advantage of allowing the adoption of one chassis for different body shapes,
providing benefits in terms of mechanical parts standardization and simplification of
the assembly process of a mechanical chassis, before being matched to the upper body.
This kind of solution is commonly used for cargo vehicles, off-road and SUV. The
main disadvantage is the increased weight with respect to configuration A).
Farklı ifade biçimleri:
Unitized body: Unibody (or monocoque)
Body on frame: Body-over-frame
Unibody Construction
The frame is an integral part of the body
Body-over-Frame Construction
The body bolts to a thick steel frame
The frame can be of a uni - body design (Figure 1.1 (a) uni - body), a body - on - frame
(Figure 1.1 (b)), or a space - frame (Figure 1.1 (c)). The uni-body design features
stamped panels, while the space - frame is made up of extrusions and cast parts. The
BiW closures are selected based on the vehicle’s constituent material dent resistance properties (i.e. yield strength) while the frame is designed to provide
specific torsional and bending stiffness.
Figure 1.1: Top left: (a) a uni - body design, top, right: (b) truck platform;
and bottom right: (c) space - frame design
Reading text:
Unitized (self-supporting)
(Standard design)
body
The conventional unitized (self-supporting) body is
built up of hollow sheet-steel components onto which
body panels are welded by welding robots or in multispot welding units. Individual parts can also be glued
in position.
Depending upon vehicle type, roughly 5000 spot
welds must be made along a total flange length
of 120...200 m. The flange widths are 10...18 mm.
Other parts (front fenders, doors, hood and luggagecompartment lid) are bolted to the supporting
structure of the body. Other types of body
construction include frame and sandwich designs.
Reff: Automotive Handbook
C) Body with ancillary subframes, for powertrain and suspension systems; connections
between the subframe and the body can be either rigid or through elastic bushes. The main
advantages are modularity and the division of the assembly process between parallel lines,
enabling components to be mounted on the sub-frames. The resulting sub-assemblies can be
tested before integration with main body. Moreover, the relative ease in which elastic and
damping devices between subframe and body can be inserted, provide an improved insulation
from noise and vibration. Again, the main disadvantage is increased weight, but to a lower
extent than configuration B).
D) Dual frame body, in which body and chassis are separate and connected through elastic
and damping bushes. In this configuration, the structural, safety, propulsion and driving
functions are concentrated and optimized in the chassis, with priority to front and rear crash
absorption, torsional stiffness and resistance to stress induced through the suspension and
powertrain stiff and precise, since the filtering of road-surface induced excitation is achieved by
incorporating elastic connections between chassis and body. The weight of upper body can be
reduced, since the structural task is limited to its own inertial stresses and to those induced by
transported components, people and load. The same chassis can also be adopted by different
bodies of similar inertia properties. Although the increase of chassis weight remains a
disadvantage, it is partially counterbalanced by the reduction in the weight of upper body.
Ladder Chassis: Ladder chassis is considered to be one of the oldest
forms of automotive chassis or automobile chassis that is still used by
most of the SUVs till today. As its name connotes, ladder chassis
resembles a shape of a ladder having two longitudinal rails inter linked
by several lateral and cross braces.
Monocoque Chassis: Monocoque Chassis is a one-piece structure
that prescribes the overall shape of a vehicle. This type of automotive
chassis is manufactured by welding floor pan and other pieces
together. Since monocoque chassis is cost effective and suitable for
robotized production, most of the vehicles today make use of steel
plated monocoque chassis.
Backbone Chassis: Backbone chassis has a rectangular tube like
backbone, usually made up of glass fibre that is used for joining front
and rear axle together. This type of automotive chassis or automobile
chassis is strong and powerful enough to provide support smaller
sports car. Backbone chassis is easy to make and cost effective.
M. Ravi Chandra1, S. Sreenivasulu2, Syed Altaf Hussain3; Modeling and Structural analysis of heavy vehicle chassis made of polymeric composite material by three
different cross sections; International Journal of Modern Engineering Research (IJMER) Vol.2, Issue.4, July-Aug. 2012 pp-2594-2600 ISSN: 2249-6645
KISA… KISA… KISA…
(A) Unibody construction welds major body panels together to form the frame for attaching
the engine, drivetrain, suspension, and other parts. This type of construction is commonly
used on cars.
(B) With body-over-frame construction, a thick gauge steel frame provides the foundation for
holding other parts. This type of construction is commonly used on large trucks and SUVs.
Figure 1: Two very different methods used to construct modern vehicles: unibody and bodyover-frame construction
Chapter 9 Vehicle Construction, Thomson
Figure 2: Note the space frame construction. Composite (plastic) panels fasten to a
metal inner body structure. Composite panels can be made flexible to resist door
dings and small dents.
Figure 3: This top view of unibody construction shows how
structural members are added to support the engine suspension
and other mechanical systems.
Figure 4: Doors normally have strong steel beams under the door skin to
protect people during side impact collisions.
Summary
 Vehicle classification relates to construction, size,
shape, number of doors, type of roof, etc.
 Three main types of frame construction
 Body-over-frame, unibody, and space frame
 Vehicle commonly divided into 3 body sections
 Front section, or nose section
 Center section, or midsection
 Rear section, tail section, or rear clip
 Vehicle sizes: compact, intermediate, full size

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