Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
of the
New C-Class
Development
Planning
Production
Development Planning Production
Active and
passive safety
Impression of
value Consumption
Telematics,
entertainment,
assistance systems Design of
interior and exterior
Drivability
Comfort
agility
Development Planning Production
Different wheelbase
• New architecture in the high-volume model series of Mercedes-Benz
• C-Class sedan car as lead vehicle
• Highly efficient use of derivatives
Sedan short wheelbase Sedan long wheelbase Derivatives
• More than 10 additional derivatives on this architectural basis
Different bodies
Station
Wagon
Derivatives
Coupé
Development Planning Production
1,442 (+-5)
790 (+15) 2,840 (+80) 1,056 (0) 1,588 (+41)
1.404 (+14)
1.454 (+14)
SPORTS GRILL
LARGE AND UPRIGHT
DROPPING LINE
DISTINCT
SHOULDER
LUXURY GRILL,
UPRIGHT, WITH
DETACHED; TAPERING
FINS
New benchmark in coefficient of drag of 0.24 in the compact sedan car segment
I. Safe driving II. Dangerous situations III. During an accident IV. After the accident
avoiding danger, Prevention action providing suitable preventing a
providing plenty of timely with PRE-SAFE® and protection deterioration of the
warning and offering driver assistance situation and offering fast
assistance systems assistance
Optimal design configuration of the load paths is the basis for the highest level of crash performance
Front Side
The vehicle has four independent Optimized transition of force into the floor structure
load paths for the frontal impact Including the side opposite the crash; rigid sidewall
structure
Development Planning Production
More than 150 trial tests were conducted to confirm the crash-related functions of the lead vehicle
Mercedes-Benz
Rating
Legislation
2
6
2
10 5
7 1
3
92
92% 84 %
84% 77
77%% 70
70%%
Side MDB 8.000 Vehicle based 9.000 Upper legform 0.800 ESC 3.000
Side pole 6.730 CRS installation 12.000 Lower legform 5.930 SAS 1.333
Normalised score 92 84 77 70
80 75 60 65
70 60 50 55
14
Development Planning Production
New C-Class body is designed to meet small overlap (IIHS rating) requirements
A highly rigid body forms the basis for an optimal comfort setup
Discharge points
NVH load paths
Development Planning Production
1 st torsion 1 st bending
frequency frequency
58.0
56.0
54.6
51.6
Realisation of an efficient ring structure concept with assembly braces and front-end design
Rigidity [N/mm]
+300
%
Frequency [Hz]
Development Planning Production
• High torsional rigidity • Integrated 4-link • Increasingly stringent crash • Flexible integration of • Integrated panoramic
front suspension requirements in different markets drive components sliding sunroof
• Optimised initial
rigidity • Integrated air - IIHS side collision • Protection for • Integrated Frontbass
suspension - ECE R95 (new) accumulator and high- audio system
- Pole impact, FMVSS214 (new) voltage components
- Small Overlap (IIHS rating)
Added weight of approximately 30 kg resulting from increased body requirements is compensated by an integral lightweight design
approach
Development Planning Production
1 Design/aerodynamics
Benchmark standard amongst the
competition
2 Integral Safety/function
Highest priority when it comes to occupant
1 3 protection
3 Lightweight design
Utilising hybrid technology
The right material at the right location
Development Planning Production
Exterior shell
Rear-axle suspension
Aluminium sheetmetal
14.4 %
Low-carbon steel
18.4 %
Material concept:
• Different sheet metal thicknesses that
target specific requirements
e.g. center as an single-piece area optimized for
pedestrian protection.
Joining concept:
• Clinching and bonding
Development Planning Production
Material concept
• Aluminium sheet metal 1.15 mm
Joining concept
• body-in-white production station:
Automated positioning of roof panelling in
body-in-white via screws and “plastic
spacers”
Weight was reduced by more than 30% while meeting increased crash requirements
Material concept
• Aluminium monocoque design
• Door hinges made from aluminium
• Structure components made from extruded
aluminium profiles
Joining concept:
• Laser welding at the door frame
• Self-piercing riveting, spot welding and bonding
Development Planning Production
Aluminium outer skin – A challenge for realising small gaps and radii
3.0 mm
2.0 mm
F3 W204 W205 F4 W204 W205 F5 W204 W205 F6 W204 W205 F7 W204 W205
Development Planning Production
Diecast aluminium console for rigid and adjustable connection for the trunk lid hinge bracket
+2,25 +3
-3 • Independent X and Z-adjustment
+5 -1,25
Development Planning Production
Per vehicle weight reduction of 2.8 kg and component reduction from 10 to 2 components
Material concept:
• Two-stage heat treatment in line with ductile and rigidity requirements
• Weight reduction: 2.8 kg per vehicle
Joining concept:
• Self-piercing riveting and bonding
Development Planning Production
Per vehicle weight reduction of 3.1 kg and component reduction from 8 to 2 components
Material concept
• Diecast aluminium
• Two-stage heat treatment in line with ductile and rigidity requirements
Joining concept
• Self-piercing riveting, bonding and ImpAcTing
Development Planning Production
Per vehicle weight reduction of 4.5 kg and component reduction from 14 to 2 components
Material concept
• Diecast aluminium
• Two-stage heat treatment in line with ductile and
rigidity requirements
Joining concept
• Self-piercing riveting, bonding, flow-drill screwing,
ImpAcTing
Development Planning Production
Per vehicle weight reduction of 3 kg and targeted deformation in the lower region
Material concept
• Partially hot-formed steel with ductile area below the beltline.
Joining concept
• Spot welding and bonding
Development Planning Production
+2.2 kg -10.2 kg
∑+30,4 kg Corrosion Lightweight ∑ -71,4 kg
protection design
Other -6.7 kg
+8.4 kg Hot-forming
scopes
Design -13.2 kg
Vehicle dimensions Aluminium
Packaging structure
-41.3 kg
+15.6 kg
Aluminium add-
Function
on parts
+4.2 kg Aluminium doors
LC measure
403 kg
362 kg
-41 kg
W204 W205
G * Aproj.
Lightweight index: L= m
Weight [kg]
Torsional stiffness 378 kg
[kNm/°] 400
374 kg
30 kNm/° 372
370 kg 4%
28.8 W205
366 kg
20 kNm/° 348
350
334
10 kNm/°
Projected area [m2]
4.5 m2 4.5
4.4 m2
4.3 m2 250
W205 W204 W205
Increase of the lightweight index
Weight as per OEM lightweight quotient
Entwicklung Planung Produktion
Project
start QG I QG H QG G QG F QG E QG D QG C QG B QG A
Quality Gates
• Design/shape/aerodynamics
• Function (crash /durability/NVH …..) Costs • PPG workshops
• Lightweight design, concepts Costs
Function • Manufacturing feasibility
• Corrosion protection • Part release process
Weight Time
• Modular integration • Joining method validation
• Digital validation Maturity
• Preproduction supply from series
production equipment
Development Planning Production
Planning premises
• Consistently implement mechanical and electrical standards at all plants.
• Use proven technology where possible.
• Validate new joining methods by carrying out preliminary trial tests in series operation.
Development Planning Production
• LOG concept:
Delivery of parts by trucks via ramps;
one LOG area for the overall body-in-white production.
Development Planning Production
Time schedule:
Start of hall ext.: 10/2011 Start commissioning : 4/2012 PRO1 W205 bodies., 6/2013 Job #1 W205 body-in-white, 12/2013
Development Planning Production
W204 W205
Spot welding 4,818 (units)
(steel) 4,441 + 316 (units)
(steel + aluminium)
RobScan 507 (units) 180 (units)
ImpAcT 0 80 (units)
• Aluminium-steel hybrid construction in rear end with steel, aluminium sheet and diecast
aluminium.
Optimization of tack
supply systems
Mass production
C-Class
Tape feed Blow feed Magazine feed
2007 2014
Basic research
Operational tests:
• Validation of "mass production capability of joining systems“ in rear end of E-Class
• Validation of "focus on aluminium" in rear end of SL-Class
Development Planning Production
• Application for complex systems (e.g. framers) but also for validation of new joining
methods (e.g. ImpAcT).
• Validated offline programs from robot and PLC prior to start of programming, fast
commissioning and acceptance/approval of special functions.
• Aluminium-steel hybrid construction in rear end with steel sheet, aluminium sheet and
diecast aluminium.
• Use of self-piercing riveting together with structural adhesive for joining operations with
two-sided accessibility.
• Weight reduction due to trimming of the flanges and the application of laser fillet welding.
• Technological challenge:
Clamping technology for RobScan requires two-sided accessibility, i.e. laser process clamping
during the welding process on the outside and inside the longitudinal member assembly.
• Solution:
Validate using series clamping technology from prototype vehicle phase, coordinate laser
process clamping components welding parameters.
Development Planning Production
Z1 line:
• Robot transport – Proven standardised concept for the S-Class,
E-Class and C-Class
• Product supplied via "collective overhead monorail conveyor"
• Conventional joining methods (spot-welding, adhesive bonding,
stud welding)
Front end:
• In-line sequencing from front end assembly
• Multi-joining method (laser, self-piercing riveting, adhesive bonding,
spot-welding)
Main floor:
• Conventional production (spot-welding, bonding)
Rear end:
• Multi-joining method (ImpAcT, flowdrill, self-piercing riveting, adhesive bonding, spot-welding)
Development Planning Production
Carryover of production concept from predecessor model series & high-speed conveyor as a process innovation
Z2 line:
• Primarily conventional production (spot-welding, adhesive bonding, flowdrill, self-piercing
riveting)
• Chassis punch due to multi-link axle
• Standard framer, proven concept from predecessor
• "High-speed conveyor" innovation reduces transport time and creates more time for value-
added content.
• Assembly-joined aluminium roof => Roof bolted in body-in-white for paint thru-sequence
due to Δ problem.
Development Planning Production
Z3 line (4 types):
• Line as standard concept
(automated hang-on parts assembly with best fit).
• "High-speed conveyor" conveyor system.
• No need for boot lid preadjustment in body-in-white, fine adjustment is carried out in assembly.
Development Planning Production
• Consumption-optimised operation
(Deactivation of robots during breaks by Profi Energy, deactivation of technologies
and components, automatic and consumption-governed shutdowns.
7 start-ups in 3 years
2014
Optimisation Cross-
of series functional
Product workshops
maturity
Development Planning Production
• Installation of 9 sample cells with all key technologies, e.g. laser welding, ImpAcT more than
2 years prior to start-up
• Coordination/alignment of technical standards
• Qualification of employees at all international production locations at the Bremen plant
• 25 technology training seminars, 50 trainers, 15 interpreters and 2,400 man days of training
• Involvement of production employees during line installation
• Extensive expert qualification of all locations during production testing in Bremen
Development Planning Production
Bremen
Tuscaloosa Beijing
East London
Development Planning Production
2,0
Downtime in minutes
Downtime overview
1,0
per body (ImpAcT)
0,0
0 8 16 24 32 40 48
CW in 2014
Development Planning Production
Sindelfinge
n
Development Planning Production
Tuscaloosa
• Frequent on-site workshops with foreign plants every
Beijing 2 months; personal networking ensures optimal
transfer of knowledge
Bild-Zeitung:
„Bild Urteil: S-Klasse im C-Format.“
edmunds.com
“Like the rest of the car, the features available inside
the C-Class are all at the forefront of technology.”
Autobild.de:
„So viel Varianz bietet in dieser Klasse keiner…“
„Der Konkurrenz mindestens um eine halbe
Klasse voraus…
caranddriver.com:
„This is a strikingly elegant car.”
Focus.de:
„So vornehm wie das Ambiente ist auch
das Fahrverhalten…“
Autoblog.com:
“It might be so good that there's no
need to climb any higher.”
Auto Zeitung:
„Fazit: Die neue C-Klasse passt.
Leistungsstark, effizient, komfortabel, dynamisch
– Mercedes lässt keine Wünsche unbefriedigt.“