MARMARA ÜNİVERSİTESİ TEKNOLOJİ FAKÜLTESİ

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1 MARMARA ÜNİVERSİTESİ TEKNOLOJİ FAKÜLTESİ TAŞIT TEKNOLOJİSİ ŞASİ, ÇERÇEVE ve GÖVDE - KAROSER/İ -GİRİŞ- Vehicle Structure Frame, Body, and Chassis Abdullah DEMİR, Yrd. Doç. Dr.

2 Kısa Ufuk Turu

3 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. Bernd Heißing Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011.

4 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.

5 Today, automakers only manufacture about 30 % of each car themselves. The remaining 70 % of the components are purchased from suppliers. Bernd Heißing Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives,

6 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 Bernd Heißing Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011.

7 Superimposed trends: trends based on the extrapolation of the past, present trends, and future trends Bernd Heißing Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011.

8 Şasi, Çerçeve ve Gövde - Karoser/i

9 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 series

10 2013-SL-Class_body_in_white

11 Body in White indianautosblog.com - Mercedes Benz C-Class

12 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

13 A typical BiW consists of about 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, A- dikmesi. 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:

14 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

15 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.

16 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 "Introduction To Automobile" Sunumu, Saeindia.

17 Şasinin görevi: İnsan vücudundaki iskelet gibi ana taşıyıcılık görevini yerine getirir. Taşıtın birçok elemanını üzerinde taşır. Kaynak: Şase ve Karoseri Sunumu, TÜVTURK, 08/03/

18 Merdiven Tipi Şasi (Paralel Kollu Şasi): Kamyon ve otobüslerde yaygın olarak kullanılan şasi tipidir. Paralel iki kol ve bu iki kola bağlanmış kuşaklardan/traverslerden oluşur. Kollar genelde U, kare, dikdörtgen ve daire kesitli olarak preste yapılırlar. Kuşaklar ve üst yapı, kaynak, perçin ve cıvata ile şasi kollarına bağlanır. Kaynak: Şase ve Karoseri Sunumu, TÜVTURK, 08/03/2006.

19 Ağır kamyonlar ve yük taşıyan taşıtlar şasilidir ve üzerinde sürücü kabini ile yükleme yapılan kasası vardır. Kaynak: Şase ve Karoseri Sunumu, TÜVTURK, 08/03/2006.

20 The ladder frame is the simplest and oldest of all designs. It consists merely of two symmetrical rails, or This design offers good beam resistance because of its continuous rails from front to rear poor resistance to torsion "Introduction To Automobile" Sunumu, Saeindia.

21 Kaynak: VW, Otomobil Teknolojisinin Temelleri Şase ve Karoseri Sunumu, TÜVTURK, 08/03/2006.

22 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.) Bernd Heißing Metin Ersoy (Eds.), Chassis Handbook Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives, 2011.

23 Çapraz Kollu (X Tipi) Şasi: Oldukça hafif bir yapısı vardır. Daha çok kamyonetlerde tercih edilir. Şase ve Karoseri Sunumu, TÜVTURK, 08/03/2006.

24 Tek Kollu (Platform) Şasi: Ortada tek bir kol ve buna bağlanmış kuşaklar, bazen de taban sacı ile bir bütün olarak yapılırlar. Otomobillerde tercih edilir. Şase ve Karoseri Sunumu, TÜVTURK, 08/03/2006.

25 Çatal Kollu Şasi: Taşıt motorunun bağlanmasına ve destek oluşturmasına elverişli bir şasi tipidir. Kamyonetlerde ve otomobillerde tercih edilir. Şase ve Karoseri Sunumu, TÜVTURK, 08/03/2006.

26 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. Şase ve Karoseri Sunumu, TÜVTURK, 08/03/2006.

27 Tam Taşıyıcı Karoseri Günümüzde binek otomobiller şasisiz olarak imal edilmektedirler. Gövde kendi kendini taşıyan bir formda dizayn edilmektedir. Genellikle karoseri hücre tip dediğimiz gövdedir. Bilgisayarlar yardımı ile orijinal yapının ve istenilen bölge veya parçaların tek tek deformasyon ve gerilmeleri hesaplanabilir. Şase ve Karoseri Sunumu, TÜVTURK, 08/03/2006.

28 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. Şase ve Karoseri Sunumu, TÜVTURK, 08/03/2006.

29 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 (Kendini Taşıyıcı Yapı Biçimi) Her iki yapı tipide şasili tipe nazaran hafiftir. Taşıt ağırlığında azalma tam taşıyıcı otobüs gövdesinde daha fazladır. Şasinin çıkarılması ile araçta yaklaşık %8 ağırlık azaltılmış 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. Bu nedenle taşıtın ağır olması istenmez.

30 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 bağlama yöntemleriyle 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 birleştirme yöntemleri kullanılarak tutturulmuştur. Bazı birleştirme yerlerinde kuvvetlendirmeler yapılmak zorundadır. Onun için birleşik karoserişasilerin çeşitli bölümlerinde birbirini kuvvetlendiren, tüm gövdeyi birlikte destekleyen bir yapı özeliği vardır.

31 Gövde Tipleri Body Types

32 Karoserinin görevi: Taşıta şekil veren, fonksiyonları yerine getirmesi için ana hacim sağlayan kısmıdır. Kaynak: Şase ve Karoseri Sunumu, TÜVTURK, 08/03/2006. 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.

33 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

34 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. Lorenzo Morello, Lorenzo Rosti Rossini, Giuseppe Pia, Andrea Tonoli, The Automotive Body, Volume I: Components Design, e-isbn

35 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 ). Hatırlatma: "Body in white" nedir? Beyaz gövde. Bir otomobilin motor vb. gibi ana parçaları ile trim donanımı öncesi ana yapısını ifade eder. Mohammed A. Omar, The Automotive Body Manufacturing Systems and Processes, 2011 John Wiley & Sons Ltd. ISBN:

36 Body Types Automobiles are available in several body types, including: sedan hardtop convertible hatchback station wagon minivan sport-utility vehicle Russell Krick, Modern Automotive Technology Sunumu, The Goodheart-Willcox Co.

37 Automobile Body Parts Russell Krick, Modern Automotive Technology Sunumu, The Goodheart-Willcox Co.

38 emmesei.com

39 Toyota

40 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. Russell Krick, Modern Automotive Technology Sunumu, The Goodheart-Willcox Co.

41 Convertible A convertible is a car with a removable or retractable top. Uses a vinyl or cloth top that can be raised and lowered Russell Krick, Modern Automotive Technology Sunumu, The Goodheart-Willcox Co.

42 Hardtop A Volvo C70 with retractable hardtop A hardtop is a rigid form of automobile roof. They may be detachable for separate storing, retractable within the vehicle itself, or permanently attached to an auto lacking a center side-support known as a B-pillar. The term is also used to describe such vehicles, principally the last. Hardtops may be either two-door or four-door, and tend to be more expensive and collectible than sedan models of the same vehicle.

43 Hatchback The large rear door allows easy access when hauling items Russell Krick, Modern Automotive Technology Sunumu, The Goodheart-Willcox Co.

44 Station Wagon Provides a large rear interior compartment 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 fullheight body all the way to the rear; the loadcarrying space created is accessed via a rear door or doors. Russell Krick, Modern Automotive Technology Sunumu, The Goodheart-Willcox Co.

45 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 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. Russell Krick, Modern Automotive Technology Sunumu, The Goodheart-Willcox Co.

46 Sport-Utility Vehicle Provides the comfort of a passenger car, the interior space of a station wagon, and the durability of a truck 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 multipurpose vehicle. Most SUVs are four-wheeldrive with and increased ground clearance. The SUV is also known as 4- by-4, 4WD, 4 4 or 4x4. SUVs can be divided into mini, small, midsize, fullsize, and large SUV. An MPV (multi-purpose vehicle) is designed as large cars or small buses having offroad capability and easy loading of goods. However, the idea for a car with a multipurpose application can be seen in other classes, especially SUVs. Russell Krick, Modern Automotive Technology Sunumu, The Goodheart-Willcox Co.

47 Ek Okuma ve İnceleme Bölümü

48 Fig. 1: Common body and chassis configurations. Lorenzo Morello, Lorenzo Rosti Rossini, Giuseppe Pia, Andrea Tonoli, The Automotive Body, Volume I: Components Design, e-isbn

49 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). Lorenzo Morello, Lorenzo Rosti Rossini, Giuseppe Pia, Andrea Tonoli, The Automotive Body, Volume I: Components Design, e-isbn

50 Reading Text Unitized (self-supporting) body (Standard design) 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 multi-spot 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 m. The flange widths are mm. Other parts (front fenders, doors, hood and luggage-compartment lid) are bolted to the supporting structure of the body. Other types of body construction include frame and sandwich designs. Reff: Automotive Handbook Note: Unitized Body = Unibody = Self-supporting Body

51 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 unibody 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 Mohammed A. Omar, The Automotive Body Manufacturing Systems and Processes, 2011 John Wiley & Sons Ltd. ISBN:

52 Unibody Construction The frame is an integral part of the body Russell Krick, Modern Automotive Technology Sunumu, The Goodheart-Willcox Co.

53 Body-over-Frame Construction The body bolts to a thick steel frame Russell Krick, Modern Automotive Technology Sunumu, The Goodheart-Willcox Co.

54 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). sub-frame: takviye şasi, tali çerçeve Lorenzo Morello, Lorenzo Rosti Rossini, Giuseppe Pia, Andrea Tonoli, The Automotive Body, Volume I: Components Design, e-isbn

55 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. Lorenzo Morello, Lorenzo Rosti Rossini, Giuseppe Pia, Andrea Tonoli, The Automotive Body, Volume I: Components Design, e-isbn

56 Referring to body missions previously listed, the different configurations result in variations of upper body contribution for just a limited number of functions, in which the characteristics of body connection with the chassis is highly relevant: structural function, insulation and isolation, safety and, partially, aerodynamics (due to floor contribution). The remaining functions are not directly affected. Focusing on the most common body configuration (C), through the example of a 2 box mass production body in white with spot welded steel stamped sheets, it is appropriate to consider the main stamped parts and follow a typical assembling process step-by-step, to gain a deeper understanding of the process used to manufacture the body, widely applied today. Lorenzo Morello, Lorenzo Rosti Rossini, Giuseppe Pia, Andrea Tonoli, The Automotive Body, Volume I: Components Design, e-isbn

57 Kaynak: VW, Otomobil Teknolojisinin Temelleri

58 ASF - Audi Uzay Kafesi yüksek mukavemetli bir alüminyum kafestir. Alüminyum kullanımı önemli bir ağırlık tasarrufu sağlayarak yakıt tüketimini azaltır ve verimliliği arttırır. Not: İlk kez 1994 yılında Audi A8 de kullanılmıştır.

59 İlgili Videolar Unibody vs Body On Frame Explained: Mercedes-Benz Production A-Class - Body Shop: BMW 3 Series Production, BMW Munich Plant Body Shop: Audi Space Frame (ASF) - Audi A8:

60 KISA KISA KISA

61 (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

62 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. Chapter 9 Vehicle Construction, Thomson

63 Figure 3: This top view of unibody construction shows how structural members are added to support the engine suspension and other mechanical systems. Chapter 9 Vehicle Construction, Thomson

64 Figure 4: Doors normally have strong steel beams under the door skin to protect people during side impact collisions. Chapter 9 Vehicle Construction, Thomson

65 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 Chapter 9 Vehicle Construction, Thomson