HAVAL COUPE Body Lightweight Design and Attribute

Integration

Dr. Lei Shi

Technical Director

R&D of Great Wall Motor

April 15, 2015

Detroit, MI USA

� Background

� Design Approach

� Lightweight Design

Agenda

� Attributes- NVH

- Safety

- etc.

� Summary

2

Overview

- We are China’s largest SUV and pickup manufacturer, with over 30 holding subsidiaries, more than 60,000

employees, four vehicle production bases and a production capacity of 800,000 units.

- We own Haval and Great Wall brands, covering products range of SUV, passenger car and pickup.

- Our assets had amounted to 61.345 billion RBM by Dec. 31, 2014.

- We persist in focused development, uphold the brand concept of "focus, dedication and specialization"

SUV

Our products: SUV, Pickup and Sedan

What we are?

31.59

23.74 25

30

35Unit: 10, 000

2014 SUV Top-ten Sales Ranking in China

HA

VA

L

Top one: HAVAL

- First produce economic type of SUV in domestic.

- Hover H6 got “China annual SUV prize” in 2012,

which sales so popular and even hard to meet the

purchase requirement.

HAVAL H8 HAVAL H6 HAVAL Coupe-c HAVAL Coupe HAVAL H9 HAVAL H6 Update HAVAL H2

3

16.82 14.53 13.60 12.47 11.45 10.70 10.06 9.87

0

5

10

15

20

HA

VA

L

Overview

What we are?

- Domestic sales for GW pickup gains No.1 in 14 continually years.

- Together with Toyota, Ford pickup named as “World three pickup”.

- Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas.

Pickup

- First made the saloon car in 2007, got No 2 in terms of sales quantity in 2011.

- First pass EWVTA as Chinese self-owned saloon brand manufacture.

- Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas.

Saloon car C50 C30 C2OR C50 Update

4

Overview

What we are?

- Domestic sales for GW pickup gains No.1 in 14 continually years.

- Together with Toyota, Ford pickup named as “World three pickup”.

- Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas.

Pickup

- First made the saloon car in 2007, got No 2 in terms of sales quantity in 2011.

- First pass EWVTA as Chinese self-owned saloon brand manufacture.

- Trusted by 700,000 vehicle owner, and sales for more than 100 Countries and areas.

Saloon car C50 C30 C2OR C50 Update

5

Europe

North AmericaJapanChina

长城汽车新技术中心GWM New R&D Center

Overview

What we are?

长城汽车北美技术分中心长城汽车欧洲技术分中心 长城汽车日本技术分中心GWM European R&D Center GWM Japan R&D Center GWM North America R&D Center (On-going)

6

Goal of R&DBackground | Design Approach | Lightweight Design | Attributes

The goal of R&D activities:

Style Freeze •T/Section

•Ext/Int

•S.E.

•Feasibility

Report

Data Freeze•M/Section

•CAE & Physical

Test

•S.E..

•Neighbor Parts

Status Through

CAECAEOptimum-Optimum-

Over-

design

Over-

design

Data

ReduceStyle Change &

Data Change

CAECAEverification

Optimum-

design

Optimum-

design

Under-

design

Under-

design

Data

Freeze

How to freeze data?

7

Goal of R&DBackground | Design Approach | Lightweight Design | Attributes

The goal of R&D activities:

Design ChangeDesign ChangeDesign ChangeDesign ChangeCutCut--offoff

Reach Performance Target

within given cost and weight

Weight Cost Performance+ =

8

Roadmap of WRBackground | Design Approach | Lightweight Design | Attributes

Co

st

AD

Conventional Material & ProcessAdvanced Steel & Process& More Light Material

Ideal Line

Maximum use of HSS & Process

Trad. Line

WeightWeight

Target

Co

st

Targ

et Opt. Body Performance

B

C

Ideal Line

Optimum Design Process withmultiple iteration of CAE

Lightweight Design Cost & Weight saving Design

9

CAE iteration

Roadmap of WRBackground | Design Approach | Lightweight Design | Attributes

Strategy: Sequential effect/benefit for lightweight design

We

igh

t

red

uct

ion

(K

g)

-A Kg -B Kg -C Kg -D Kg -E Kg

Tota

l W

R

Fu

el

eff

icie

ncy

imp

rov

em

en

t

By weight

reduction

Tota

l F

EI

By thermal

losses reduction

By aerodynamics

resistance reduction

By secondary

weight reduction

Starting

points

10

Efficiency benefit sequence: Mass reduction of passenger cabin and ripple effect

will lead to greater fuel efficiency and secondary mass reduction

Roadmap of WRBackground | Design Approach | Lightweight Design | Attributes

Strategy: Sequential effect/benefit for lightweight design

We

igh

t

red

uct

ion

(K

g)

-A Kg -B Kg -C Kg -D Kg -E Kg

Tota

l W

R

Fu

el

eff

icie

ncy

imp

rov

em

en

t

By weight

reduction

Tota

l F

EI

By thermal

losses reduction

By aerodynamics

resistance reduction

By secondary

weight reduction

Starting

points

11

Strategy of WR for Body Structure

For a given set of conditions & For a given set of conditions &

loads, find the lightest & efficient loads, find the lightest & efficient

structure that is able to meet structure that is able to meet

design targets.design targets.

Right

topology

Right

size

Predecessor

architecture

BIW mass

Background | Design Approach | Lightweight Design | Attributes

design targets.design targets.

Right

Design

details

Right

material

New vehicle

BIW mass

12

Strategy of WR for Body StructureBackground | Design Approach | Lightweight Design | Attributes

What is MDO? Multidisciplinary Design Optimization (MDO) is a methodology for improving design of engineering

systems, e.g., automobile, aircraft, or spacecraft, in which everything influences everything else.

NVH: Torsion, Bending,

Dynamic stiffness

A MDO platform integrating all the vehicle attributes is developed to achieve the

weight target under CAE environments

13

偏置碰:

64kph

正碰：

35mph

Madymo:

FC1-USNCAP

FC2-EuroNCAP

Offset

impact

Frontal

Door-ring StructureBackground | Design Approach | Lightweight Design | Attributes

Hot stamping process

1. Blanking 2. Blank heat up (over 900 degrees) 3. Forming &

quenching 4. Post form

operations

Remove

Weld Line

Predecessor HAVAL Coupe

14

Weld Line

Roof Cross-member DesignBackground | Design Approach | Lightweight Design | Attributes

Weld Line

Predecessor HAVAL Coupe

15

MDO- based Lightweight Design

BIW Trimmed-body Safety

Trimmed-body

VTF/NTF/IPI

BIW NM

Full Frontal

MDOIntegration

Background | Design Approach | Lightweight Design | Attributes

16

Trimmed-body

Acoustic Mode

Trimmed-body

Bending Mode

Trimmed-body

Torsion Mode

Bending Stiff

Torsion Stiff

BIW IPI

40% Offset

Side Impact

Roof Crush

To achieve 3.0 Kg weight saving per

vehicle

Front SeatBackground | Design Approach | Lightweight Design | Attributes

17

Closure-LiftgateBackground | Design Approach | Lightweight Design | Attributes

To achieve 1.71 Kg weight saving per

vehicle while meeting design target

requirements

18

We

igh

t

Lightweight Index

3.96

Background | Design Approach | Lightweight Design | Attributes

19

0 Kg

We

igh

t

0

Weight reduction Lightweight index

-21.3 Kg

3.96

LWI

0

3.673.74

Competitor

Predecessor

HAVAL Coupe

HAVAL Coupe

Predecessor

Attributes Available Space (AAS):

−= ∑

esetAttributT

esetAttributTributesVehicleAttmeanAAS

arg

arg

0 0

Attributes Improvement

HAVAL CoupePredecessor HAVAL CoupePredecessor

Background | Design Approach | Lightweight Design | Attributes

20

-22%

-29%

-18%

-26%AA

S

Safety attributes NVH attributes

+8%+7%

Weight reduction summary:

Weight ReductionBackground | Design Approach | Lightweight Design | Attributes

-5.09

-1

0 Kg

We

igh

t

0Predecessor

HAVAL Coupe

We

igh

t

0Closures Seat IP

21

To achieve 33.5 Kg weight reductionw/o using light alloys

-6.11

-5.09

Total: 12.2 KgBIW WR

-21.3

Summary

• Successfully developed a platform to integrate all vehicle attributes to achieve weight targets while meeting design requirements

• Weight reduction:

Totally achieve 33.5 Kg weight reduction w/o using light alloys

Lightweight index has been improved 7.3% (through optimization of the body structure) as well as outperformed the competitor

• Vehicle attributes:

22

• Vehicle attributes:

Body rigidity-top class body rigidity performance through improvement of joint efficiency in all areas of the cabin

Also, safety and NVH attributes are improved (w/ 7-8% enhancement)

• Almost 40 RBM cost saving per vehicle with structural adhesive usage optimization

Thanks!

Questions/Comments?

2323