BMW_B

EuroCarBody 2012

14th Global Car Body Benchmarking Conference

Car body benchmarking data summary

BMW 3 Series

0. General vehicle data, dimensions

Generation No.: 6 Internal OEM denomination: F30 SOP (month/year): 10/2011

Vehicle segment according to European Commission 2002:

(A, B, C, D, E, F, S, M, J) D Vehicle dimensions:

Length: 4.624 m Width: 1.811 m Height: 1.429 m Track, front: 1.531 m Track, rear: 1.572 m Wheelbase: 2.810 m Contact area

= (Track, front + Track, rear)/2 x wheelbase 4.3597 m2

1. Weights

Total weight body-in-white: 402.00 kg Defined as the total weight of the car body including doors and closures, as well as all parts that are fitted in the body shop (e.g. integrated bumper beams), excluding paint.

Corresponding view:

(The colour scheme of the parts shown makes use of the RGB colour code for the material classification, see section 2.)

Additional views of the car body structure and outer skin using the same colour scheme:

Weights of separate subframes, front end modules, etc.

Part description Corresponding view Weight

Subframe(front): 17.3 kg

Subframe (rear): 17.4 kg

Front end: 11.5 kg

Struts and mounted braces: 7,2 kg

Body-in-white weights of doors, closures and fenders

Front doors (both): 29,896 kg Rear doors (both): 25,220 kg Hood: 23,440 kg Liftgate/deck lid: 16,260 kg Front fenders (both): 5,560 kg Front end modules: 11,500 kg Total weight body-in-white without doors, closures and fenders: 301,3 kg

Based on metallurgical/chemical material classes

Materials: corresponding metallurgical classes

RGB colour code

% S t e e l s

Low Strength Steels: Mild steels

R 153, G 204, B 255 25 High Strength Steels (HSS):

High Strength Interstitial-free Steels (HSIF), Bake Hardening Steels (BH), High Strength Low Alloy Steels (HSLA) R 051, G 102, B 255

54 Advanced High Strength Steels (AHSS):

Dual Phase Steels (DP), Transformation Induced Plasticity Steels (TRIP)

R 255, G 153, B 204 9 Stainless steels: Austenitic stainless steels R 051, G 051, B 153 Ultra High Strength Steels (UHSS):

Complex Phase Steels (CP), Martensitic Steels (MS) R 204, G 153, B 255 4 Press Hardened Steels (PHS) R 128, G 000, B 128 3 A l u m i n i u m

Aluminium sheets: 7xxx series R 051, G 204, B 153 Aluminium sheets: 6xxx series R 000, G 255, B 000 Aluminium sheets: 5xxx series R 204, G 255, B 204 Aluminium extrusion profiles R 153, G 204, B 000 Cast aluminium R 051, G 153, B 102 Magnesium R 255, G 255, B 000 P l a s t i c s

Fibre reinforced plastics

R 255, G 000, B 000 Duroplastics, including Sheet Molding Compound (SMC) R 255, G 153, B 000 Thermoplastics

R 153, G 051, B 000 Other materials, namely: hinges, bars, bushings, etc,… R 192, G 192, B 192

5

The following graph may serve as a guide to locate the properties of the metallurgical steel classes:

Measured / Calculated 1st Eigenfrequency trimmed body: 31.0Hz

2nd Eigenfrequency trimmed body: 32.0Hz

1st Eigenfrequency body*: 50.0Hz

2nd Eigenfrequency body*: 53.0Hz

*Parts included in the measurement/calculation of the body frequencies:

Body in white, front subframe, rear subframe, struts, instrument panel support structure, front and rear screen, front and rear bumper carrier, frontend.

Static torsional stiffness 26,000 Nm/°(Measured)

Static bend stiffness11,700 N/mm (Measured)

4. Joining processes

used in the body shop, including all bought-in parts and sub-assemblies

Joining technique Number of joints Weldspot Calculation

or length of seams equivalents

(WSE)

Spot welds 5.846 5.8461:1 Arc welding 0.86 m 4320 mm = 1 WSE Laser welding 2.6 m 17315 mm = 1 WSE Conventional brazing 20 mm = 1 WSE Laser brazing 1,2 m 4030 mm = 1 WSE Adhesive joining 54.5 m 109050 mm = 1 WSE Rivets 1 joint = 1 WSE Clinch-spots 6 6 1 joint = 1 WSE Screws (incl. flow drills) 64 64 1 joint = 1 WSE

Total WSE 7.262

Process stability/availability: 85 % = total up-time in the body shop

Re-tooling or re-use factor:

10 %

= [1 – Project investment excluding operational costs / “all new“] x 100

with …all new“ = Value of the total installed investment

Degree of mechanisation:

99 %

= Automated Work Content* / Total Work Content*

* Work Content refers to the sum of Standardized Work Contents in the Body Shop, calculated according to the Harbour Report system, excluding lay-in operations, handling of parts, logistic operations

Bodyshop-Index BSI 510 [€ x hour/car unit /WSE]

*

model the of WSE Total ]units/hour [car model the of production net [€] model specific the for investment additional [€]re architectu ,investment project ×+=

* as calculated in section 5

No. of production sites: 4

namely in: Munich, Regensburg (Germany), Tiexi (China), Rosslyn (South Africa) Intended production volume: >340,000 units/year

Car body production lead time: 608 minutes = the time spent by the unit in the body shop, from the start of the first underbody parts to the handing over of the body-in-white to the paint shop, including car body interim storage**

** More accurate definition (Harbour):

? Start counting when work begins at the first station of the underbody (motor compartment or

rear floor, whichever station begins first).

? The end of the measurement is the beginning of the delivery from body in white to the paint

shop. If the vehicle changes skids or pallets, the process ends as soon as the vehicle leaves the original pallet. If the vehicle is going on a lift to transfer to the paint shop, the process ends as soon as the body in white is in final position to begin transfer.

Cycle time (mainline bodyshop):

64 seconds

Degree of material utilisation: 58 %

= 100% - scrap rate

(Sheet only, inhouse parts only, not including laser welded blanks)

Total number of parts in the BIW:

452 Number of parts, including external parts, in weight classes < 100 g: 124 100 g - 1 kg: 219 1 kg - 5 kg: 94 > 5 kg:

15

(all assemblies broken down into their component parts)

6. Targeted market regions and origin of build…

….of the vehicle presented at the EuroCarBody:

Targeted market region(s): world: Europe, China, Asia, North/South-America; etc. Origin of build: Munich, Germany 7. Development strategies /initial propositions

Specific aims of the development:

Emotional unique design combined with functionality. Perfect dynamic handling and increased ride comfort, pronounced driver orientation, benchmark in efficiency. Enlargement of fond interior width and loading capacity. Technical lead and backbone definition for the BMW product-lines.

Specific improvements reached compared to the predecessor:

Increase of global and local static stiffness; improvement of homogeneous Body Stiffness Distribution; more spacious interior; about 45kg less weight,

Specific comparisons to direct competition in the market:

n.sp.

8. Damage and repair strategy

Qualitative description of the repair strategy:

Use of bonding and riveting repair-method in combination with classic welding process. Bonding and riveting: Rear quarter panel, tail panel, roof panel, front wheel arch. Welding: engine carrier, A- and B-pillar.

Engine variant Insurance classification 316d, 318d, 320d (135KW) VK 24 320i VK 22 330d, 335i, 320d (147KW) VK 26 335i (hybrid) VK 26 RCAR basket of parts*:

Front: Bonnet, upper bumper carrier, absorber foam, deformation device bottom left, lower bumper carrier, vertical connection left, adapter plate to subframe, left part of BMW-brand–grill, bumper cladding, harness front end, cover part bottom left, brake air duct on the left (front), upper part of bonnet lock

Rear: Bumper cladding, carrier bumper, rear bumper carrier

* Parts to be repaired after a standardised RCAR low speed (15 km/h) offset insurance crash (front and rear, respectively). See https://www.wendangku.net/doc/3319097046.html,/Papers/Procedures/rcar_test_protocol_angled_barrier.pdf

9. Additional information:

Crash performance data:

Euro NCAP

No. of stars 5

Total percentage

Adult 34 Pts. = 95 %

Front 15.8 Pts.

Side 8.0 Pts.

Pole 7.4 Pts.

Rear 3.1 Pts.

Child 41 Pts. = 84 %

Pedestrian 28 Pts. = 78 %

Safety Assist 6 Pts. = 86 %

Other test results:

US-NCAP: 5 stars

IIHS: TOP SAFTY PICK

Development time:16 months = time from design freeze to SOP/job one

Life cycle analysis data: not available