Project #06

This project has been a 2 Door and 4 Door pickup cab derived from an existing SUV separated frame. The BIW and the under body structure have been redesigned to save as much part as possible from the existing vehicle. The rear door for the 4 doors version, have been improved to reduce noise and the solution have been applied also to the existing vehicle.

Product description:

This project has been a 2 Door and 4 Door pickup cab derived from an existing SUV separated frame. The BIW and the under body structure have been redesigned to save as much part as possible from the existing vehicle. The rear door for the 4 doors version, have been improved to reduce noise and the solution have been applied also to the existing vehicle.

Objective:

Product development from Style support, Stile surfacing up to detail design and 3d annotation for SC (single cab), DC (double cab) and for the following systems:

  • BIW
  • Under body
  • Side door
  • Glasses
  • Sealing
  • Tool box
  • Cargo
  • Air extractor
  • HMSL (High Mount Stop light)
  • Seating integration
  • Exterior applique (on SC body side panel)

Key activities:

Product development from Style support up to detail design of Upper and under body, Closures, Interior and Exterior trim.

  • Project management
  • Style feasibility
  • Homologation verifications
  • Typical sections
  • Stile surfacing up to A class
  • Detail design
  • Style verification for manufacturability
  • Packaging definition
  • Ergonomics definition
  • Welding feasibility and Assembly sequence proposal in agreement with assembly team direction
  • Tolerances calculation
  • OEM interaction for part manufacturability and performances
  • CAE back-up solution verifications
  • Tools and Jack storing box integrated into BIW

Inputs:

  • CAS surfaces/ sketches
  • Program macro Time plan
  • Underbody and parent vehicle parts
  • Manufacturing Process constrains

Output:

  • CAS surfaces feasibility studies
  • BOM, FMEA
  • CAE results
  • 3D data and annotation of parts and assemblies
  • Clash and clearance Analysis (DMU)
  • Modification management

KPI’s:

  • Weight
  • Parts commonality
  • Target Performance without the application of High strength steel (HSS)
  • Process duration – July 2008 – December 2008

MGRD added value and achievement:

  • Door NVH improvement. Solution has been applied also to the existing vehicle.
  • Toolbox integration study on BIW and below the Rear door/ rear lover corner. This study have not been produced but protected by the structure. Solution patented by customer.
  • BIW rear pillar structure performance without HSS material and add-on reinforcement.


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