EuroCarBody2020 Benchmark Data Isuzu D-Max

EuroCarBody 2020 22nd Global Car Body Benchmarking Conference

Car body benchmarking data summary General vehicle data0

Isuzu D-MAX

1. General vehicle and platform data

Comments

Generation No.: 3 D-MAX series

Consecutive derivative number on the platform (incl. all company brands)

9 Pickup truck

Internal OEM denomination:

SOP (year-month): 2019-10

Vehicle segment (A, B, C, D, E, F, S, M, J) M Pickup truck

(European Commission 2002)

Vehicle dimensions:

Length (mm) 5265

Width (mm) 1870

Height (mm) 1810

Track, front (mm) 1570

Track, rear (mm) 1570

Wheelbase (mm) 3125

Contact area (m2) 4.906

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

Platform boundaries:

Platform name: n.sp.

Platform description:

Range

From to

Vehicle lengths (mm) 5020 5325 Regular, Space, Crew Cab

Vehicle widths (mm) 1870 1870 Regular, Space, Crew Cab

Vehicle wheelbases (mm) 3125 3125 Regular, Space, Crew Cab

Vehicle tracks (mm) 1555 1570 Regular, Space, Crew Cab

Gross vehicular weights (kg) 2700 3100 Regular, Space, Crew Cab

EuroCarBody 2020, Car Body Benchmark Data, Isuzu D-MAX

2. Battery frame data and concept Not applicable

3. Weights and images Comments

Total weight of the car body 426.4 kg

including doors and closures, as well as all parts that are fitted in the body shop (e.g. integrated bumper beams), excluding paint.

Weight of the car body structure 322 kg

= Weight of the car body without

Front doors, rear doors Hood Tailgate/Liftgate/Decklid Front fenders Hinges, fasteners, etc.

(as stated below)

Weights of modules (all values in kg) Hang-On parts

Front doors (both) 34.2

Rear doors (both) 26.3 Hood 18.2 Tailgate/Liftgate/Decklid 13.8 Front fenders (both) 6.8 Hinges, fasteners, etc. 5.1 Architectural Modules

Underbody complete 103.1

Front end module/structure 11.3 Front bumper and crush cans Rear bumper and crush cans Other bolt-on underbody braces Other standard modules

Front subframe

Rear end Rear subframe IP beam


Images (The colour scheme of the images makes use of the RGB colour code suggested for the material classification, see section 2.)

Full car body (including hang-on parts and outer panels)


Car body structure (without hang-on parts and outer panels)


Exploded views


Hang-on parts Front doors Rear doors Hood Tailgate/liftgate/decklid Front fenders

Architectural modules Underbody complete* * Underbody complete body shop assembly, including rocker inner, cowl side and lower hinge pillar inner. Front end module/structure


4. Material mix in the body-in-white including doors and closures

Based on metallurgical/chemical material classes. (Complete car body incl. doors and closures = 100%)

Comments:

Materials RGB colour code Wt % Metallurgical

classes Wt %

Ste

els

Low strength steels R 153, G 204, B 255 63.7 Mild steels 63.7

High strength steels (HSS) R 051, G 102, B 255 19.3 HSIF, BH 2.3

HSLA, CMn 17.0

Advanced high strength steels (AHSS)

R 255, G 153, B 204 15.4

1st Gen.: DP, TRIP 15.4

2nd Gen.: TWIP

3rd Gen: TBF, Q&P

Austenitic stainless steels R 051, G 051, B 153

Ultra-high strength steels (UHSS) R 204, G 153, B 255 CP

MS

Press hardened steels (PHS) R 128, G 000, B 128 1.6

All steels 100.0

Alu

min

ium

Aluminium sheet, 7xxx series R 051, G 204, B 153



Aluminium extrusions, 7xxx series R 153, G 204, B 000

Aluminium extrusions, 6xxx series R 220, G 255, B 153

Aluminium castings, high pressure R 051, G 153, B 102

Aluminium castings, low pressure R 040, G 120, B 080

All aluminium

Magnesium R 255, G 255, B 000

Pla

stic

s

Fibre reinforced plastics R 255, G 000, B 000

Duroplastics, including SMC R 255, G 153, B 000

Thermoplastics R 153, G 051, B 000

Elastomers R 255, G 204, B 204

All plastics

Other materials R 192, G 192, B 192

Namely:


5. Stiffness data Comments

Measured or Calculated 1st Eigenfrequency trimmed body (Hz): 17.0 C

2nd Eigenfrequency trimmed body (Hz): 18.9 C 1st Eigenfrequency body* (Hz): 30.2 C 2nd Eigenfrequency body* (Hz): 34.7 C *List of the parts included in the measurement or

calculation of the trimmed body frequencies:

n.sp.

Static torsional stiffness (kNm/°): 16.7

Static bend stiffness (kN/mm): n.sp.


6. Joining processes used in the body shop…

... including all bought-in parts and sub-assemblies…

Unit

…in the body

structure +

…in the hang-on

parts =

…in the complete car

body

Thermal Joining

Spot welding

Conventional spot welds

Steel 3504 + 349 = 3853

Aluminium + =

Stud welds Steel 58 + = 58

Aluminium + =

Projection welds

sheet/sheet + =

sheet/standard part 353 + 36 = 389

Friction stir spot welds + =

Friction element welds +

Arc welding

MAG welding (steel) mm 292 + 325 = 617

MIG/TIG welding (aluminium) mm + =

CMT mm +

MIG brazing mm + =

Laser welding

Conventional laser welding

Steel mm + =

Aluminium mm + =

Remote laser welding

Steel mm + =

Aluminium mm +

Laser brazing, steel mm + =

Friction stir welding mm + =

Non-thermal Joining

Riveting

Semi-tubular rivet / SPR + =

Punch rivet + =

Grip Punch Rivets +

Blind Rivets +

Clinching + =

Hemming mm + 25007 = 25007

Screws and nuts

Screw / nut (metric) + =

Insert nut / Stud + =

Glued studs

Flow drill screws + =

Adhesive bonding

structural adhesive mm 1502 + 99 = 1601

supporting adhesive mm + =

hemming adhesive mm + 24434 24434

gap sealing adhesive mm 3140 + 11770 = 14910

Additional joining technologies

+ =

+ =

+ =

Number of different joining technologies used: 8

Comments:


7. Production concept

Comments

Process stability/availability (%) 90 Samrong plant

= total up-time in the body shop

Re-tooling or re-use factor (%) 0

= 100 (1 −𝑃𝑟𝑜𝑗𝑒𝑐𝑡 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑐𝑜𝑠𝑡𝑠

”𝑎𝑙𝑙 𝑛𝑒𝑤” )

with “all new” = value of the total installed investment

Degree of mechanisation (%) 100 Samrong plant

= 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

No. of production sites 2

namely in Samrong, TH Gateway, TH

Car body production lead time (minutes): 77.6 Samrong plant

= 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, seconds) 82 Samrong plant

Degree of material utilisation (%) 62.9

= 100% - scrap rate

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

Number of parts in the car body 429

incl. doors and closures, excluding baffles and standard parts (e.g. screws, nuts, bolts, rivets), all assemblies broken down into their component parts.

+ Number of acoustic baffles 8

+ Number of structural baffles 0

= Total number of parts in the car body 437


8. Development strategies / initial propositions Comments Origin of build Thailand

= production site of the specific car body exhibited at EuroCarBody

Specific aims of the development

To improve NVH and safety performance with light weight BIW

Specific improvements over the predecessor

Improved torsion stiffness and local dynamic stiffness, rough road durability and roof strength

9. Damage and repair strategy Comments Qualitative description of the repair strategy

n.sp.

Engine variant Insurance classification

3.0L turbo diesel 1.9L turbo diesel

n.sp.

10. Crash performance Comments Public test results: Done,

results available

(will be) done, results

not yet available

not done

Euro NCAP X

US NCAP X

IIHS X

JNCAP X

KNCAP X

C-NCAP X Others, namely:

ANCAP X

ASEAN NCAP X

Documents

EuroCarBody2020 Benchmark Data Isuzu D-Max