Lightweight parts with load and function-optimized material usage
Implementation
Flexible Cold-Rolling Process Flat material with repeated, varying thickness runs and harmonious transition zones
An increased number of thickness zones for an optimized TRB solution results in minimal lightweight cost
Targets / Benefits
Weight reduction Part integration
Functional Improvement
CAE model information
Re-engineered model
Five passenger CUV ; model year 2010
Updated material for the Door-Ring and Rear
Rails to state of the art
Curb weight: 4,000 lbs
Dimensions
– Length: 189”
– Width: 75”
– Height: 63”
Less deformation concerning the B-Pillar
Slightly lower SWR because of more deformation of the Roof Rail
Independent thickness run without requiring a symmetry line
More homogeneous distribution of the crash energy
High material utilization
Weight reduction up to 17 %
Potential of a TRB ® Rear Rail Design
Simulation with generic vehicle
– FMVSS 301 Rear Crash
– Understructure deformation
– Plastic strain at Fuel Tank
– Door opening
– Stiffness comparison
Harmonic load distribution due to transition zones
Reduced production and assembly costs by part integration
10 % weight reduction + 1 part integration with TRB ® I
21 % weight reduction + 3 parts integration with TRB ® II
