MARMARA ÜNİVERSİTESİ TEKNOLOJİ FAKÜLTESİ · Chassis structures can be separated from the body, as in industrial vehicles and some commercial and off-road vehicles, or they

MARMARA ÜNİVERSİTESİ TEKNOLOJİ FAKÜLTESİ

TAŞIT TEKNOLOJİSİ

Yrd. Doç. Dr. Abdullah DEMİR

ŞASİ, ÇERÇEVE ve GÖVDE - KAROSER/İ

-GİRİŞ- Vehicle Structure

Frame, Body, and Chassis

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

According to a prediction by British Petroleum (BP), the number of vehicles worldwide will increase from 800 million today to 2 billion in the year 2050 [a]. Global demand for energy will increase by 60 % between now and the year 2030. It is estimated that global fossil fuel reserves will last between 40 and 50 years.

a) Goeudevert, D.: Die Automobilindustrie ist nicht innovativ. VDI-Nachrichten, Ausgabe 24.3.2006. D“sseldorf, 2006

This statistic shows the number of passenger cars and commercial vehicles in use worldwide from 2006 to 2012. In 2012, around 833 million passenger cars and 310 million commercial vehicles were registered worldwide.

http://www.statista.com/statistics/281134/number-of-vehicles-in-use-worldwide/


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.

http://www.theautochannel.com/news/2007/12/26/074045.html

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.


http://www.thecarcareclinic.net/index.php/services-3


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

Chassis structures can be separated from the body, as in industrial vehicles and some commercial and off-road vehicles, or they can be integrated, as found in unitized bodies. In this case, auxiliary structures are sometimes applied, to better distribute local loads to the body, supporting suspension mechanisms, engine or power train, transmission and final drive. Chassis structures in these three cases are also called, respectively, frames, underbodies and subframes.

G. Genta and L. Morello, The Automotive Chassis, Volume 1: Components Design, 351 Mechanical Engineering Series, 2009


Note: Today, automakers only manufacture about 30 % of each car themselves. The remaining 70 % of the components are purchased from suppliers.

Temel Kavramlar

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.

http://www.forocoches.com/foro/showthread.php?t=3781364

2004 5 series

http://www.forocoches.com/foro/showthread.php?t=3781364

2013-SL-Class_body_in_white

B“t“n taşıtlar kendilerini ve “zerlerindeki y“k“ taşıyan bir gövdeye sahiptir. Kullanım amaçlarına göre farklı olmakla birlikte taşıtların gövdeleri genel olarak iki ana kısımdan oluşur. 1. Şasi 2. Karoseri

https://www.google.com.tr/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&ved=0CAcQjRw&url=http%3A%2F%2Fmontada.haraj.com.sa%2F8241%2F&ei=tvnkVN_7GIjUOcnUgKAH&psig=AFQjCNG2eUDDgpdD2i0uPaQ6QMP6eT89qw&ust=1424378657220238

Figure : The different panels of the vehicle structure

A typical BiW consists of about 300 – 400 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).

Mohammed A. Omar, The Automotive Body Manufacturing Systems and Processes, © 2011 John Wiley & Sons Ltd. ISBN: 978-0-470-97633-3

A-pillar: A-direği / s“tunu, A-dikmesi. Quarter panel: Arka kelebek panel, çamurluk panel

Stamped pieces: Preslenmiş parçalar

…

OKUMA PARÇASI: Şasi ve karoseri, otomobilin gövdesini oluşturur. Şasi çerçevesi Şasi çatkısı , aracın b“t“n parçalarını “zerinde taşıyan, motora, karoseriye ve g“ç aktarma organlarına desteklik eden bir temeldir. Karoseri ise aracın kaporta ya da gövde diye tabir edilen sac aksamıdır. G“n“m“z araçlarında en genel anlamda iki t“r şasi çerçevesi bulunmaktadır. Bunlar ayrı şasi çerçevesi ve birleşik şasi çerçevesidir. Eğer şasi çerçevesi sonradan karoseriye cıvatalarla tutturulacak şekilde yapılmışsa ayrı şasi çerçevesi olarak isimlendirilir. Şasi çerçevesi oldukça katı ve sağlam bir yapıya sahip olmalıdır. G“n“m“z otomobillerinde pek kullanılmamaktadır. Daha çok ağır ticari araçlarda kullanılır. Birleşik şasi çerçevesinde ise; şasi çatkısında parçalar kaynakla tutturulmuştur. Bazı birleştirme yerlerinde kuvvetlendirmeler yapılmak zorundadır. Onun için birleşik karoseri-şasilerin çeşitli böl“mlerinde birbirini kuvvetlendiren, t“m gövdeyi birlikte destekleyen bir yapı özeliği vardır.

Chassis

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

• 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

«INTRODUCTION TO AUTOMOBILE» Sunumu, SAEINDIA.

• 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.

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.


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 unibody (or monocoque)

Binek otomobilleri eskiden şasili olarak yapılırlardı. Ancak g“n“m“zde takviye edilmiş karoseri yekpare gövde ile birlikte yapılmaktadırlar. Kendi kendini taşıyan karoseri şasisiz taşıyıcı gövde ve h“cre tip karoseri), tabanı kuvvetlendirilmiş bir yapıdadır. Saç gövde gerekli takviyelerle ve şekil mukavemeti yardımı ile dayanıklı hale getirilmektedir

Kaynak: Şase ve Karoseri Sunumu, TÜVTURK, 08/0 / 006.

Ağır kamyonlar ve y“k taşıyan taşıtlar şasilidir ve “zerinde s“r“c“ kabini ile y“kleme yapılan kasası vardır.


http://fleetowner.com/photo_galleries/photos-ford-commercial-vehicle

Karoserinin görevi: Taşıta şekil veren, fonksiyonları yerine getirmesi için ana hacim sağlayan kısmıdır. Kaynak: Şase ve Karoseri Sunumu, TÜVTURK, 08/0 / 006.

Made of steel, aluminum, fiberglass, plastic, or composite materials

Forms the outside of the vehicle

Serves as an attractive covering for the chassis


Automobile Body Parts


Kaynak: Toyota

Şasi, Çerçeve ve Gövde - Karoser/i

Şasinin görevi: İnsan v“cudundaki iskelet gibi ana taşıyıcılık görevini yerine getirir. Taşıtın birçok elemanını “zerinde taşır.



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.) [13]


Merdiven Tipi Şasi (Paralel Kollu Şasi): Kamyon ve otob“slerde yaygın olarak kullanılan şasi tipidir. Paralel iki kol ve bu iki kola bağlanmış kuşaklardan oluşur. Kollar genelde U, kare, dikdörtgen ve daire kesitli olarak preste yapılırlar. Kuşaklar ve “st yapı, kaynak, perçin ve cıvata ile şasi kollarına bağlanır.

• 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


Kaynak: Şase ve Karoseri Sunumu, TÜVTURK, 08/03/2006.

Paralel Kollu Şasi (Merdiven Tipi Şasi)

Kaynak: VW, Otomobil Teknolojisinin Temelleri


Çapraz Kollu (X Tipi) Şasi: Oldukça hafif bir yapısı vardır. Daha çok kamyonetlerde tercih edilir.


Tek Kollu (Platform) Şasi: Ortada tek bir kol ve buna bağlanmış kuşaklar, bazen de taban sacı ile bir b“t“n olarak yapılırlar. Otomobillerde tercih edilir.


Çatal Kollu Şasi: Taşıt motorunun bağlanmasına ve destek oluşturmasına elverişli bir şasi tipidir. Kamyonetlerde ve otomobillerde tercih edilir.

Gövde Tipleri Body Types

Vehicle Classification Vehicle Type

Body Style Power Train Suspension

Passenger Car 2D/3D/4D/5D UniBody Engine: 1.0-3.0L Trans: 5spd/Auto Driveline: FWD

Front: McPherson Rear: Multi-link

MPV 4D/5D UniBody Engine: > 2.0L Trans: Auto Driveline: FWD


SUV 5D Unibody or Body on Frame

Engine: 1.8-5.0 L Trans: Auto Driveline: FWD/RWD/AWD

Front: McPherson/SLA Rear: Multi-link/Solid Axle

Luxury Car 4D Unibody or Body on Frame

Engine: >2.5 L Trans: Auto Driveline: FWD/RWD

Front: SLA Rear: Multi-link

Sports Car 2D/3D Unibody Engine: >3.5 L Trans: 5Spd Driveline: RWD


Pickup Truck 2D/4D Body on Frame Engine: >2.5 L Trans: Auto Driveline: RWD/AWD

Front: SLA Rear: Solid Axle

Commercial Truck

2D Body on Frame Engine: >5 L Trans: Auto Driveline: RWD

Front: SLA Rear: Solid Axle

Fundamentals of Vehicle Design; Dr. Shirish P Patil & Dr. Kamarul Tawi

Lorenzo Morello, Lorenzo Rosti Rossini, Giuseppe Pia, Andrea Tonoli, The Automotive Body, Volume I: Components Design, e-ISBN 978-94-007-0513-5

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.


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 ).

emmesei.com

http://emmesei.com/car-parts/car-body-parts-best-way-to-renovate-cars-aftermarket-car-body-parts/attachment/car-body-parts-names/

Body Types


Automobiles are available in several body types, including: • sedan • hardtop • convertible • hatchback • station wagon • minivan • sport-utility vehicle

Sedan

Uses center body pillars, or B pillars, between the front and rear doors. A hardtop does not use B pillars.


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.

Convertible

Uses a vinyl or cloth top that can be raised and lowered


A convertible is

a car with a

removable or

retractable top.

Hatchback

The large rear door allows easy access when hauling items


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 full-height body all

the way to the rear;

the load-carrying

space created is

accessed via a rear

door or doors.

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 10.000

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.

Sport-Utility Vehicle

Provides the comfort of a passenger car, the interior space of a station wagon, and the durability of a truck


An MPV (multi-purpose vehicle) is

designed as large cars or small buses having off-road capability and easy loading of

goods. However, the idea for a car with a

multi-purpose application can be seen in

other classes, especially SUVs.

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

multi-purpose vehicle.

Most SUVs are four-wheel-

drive 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, full-

size, and large SUV.


Tam Taşıyıcı Karoseri:

G“n“m“zde binek otomobiller şasisiz olarak imal edilmektedirler. Gövde kendi kendini taşıyan bir formda dizayn edilmektedir. Genellikle karoseri gövdesi hücre tip dediğimiz gövdedir. Bilgisayarlar yardımı ile orijinal yapının ve istenilen bölge veya parçaların tek tek deformasyon ve gerilmeleri hesaplanabilir.


Hücre Tipi Karoseri: Taşıt gövdesi ayrı h“crelerden oluşur. Yolcu böl“m“ taşıtın ön ve arkasına göre korunmaya alınmıştır. Çarpışma anında ön ve arka h“creler daha elastik yapıldıkları için yolculara gelecek darbe minimuma indirilmiştir. Binek otomobillerde genellikle uygulanan bir gövde tipidir.


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 otob“slerde uygulaması vardır.



http://www.audi-technology-portal.de/en/body/aluminium-bodies/audi-spaceframe-en

Audi Space Frame When it introduced the first A8 in 1994, Audi had not only developed the radically new ASF design and put it into series production, it had also developed all of the steps required for its production. The launch was preceded by a development process lasting 12 years. Since this time Audi has built on its competitive edge step by step. The arc spans three generations of the A8 and also includes the A2 along with its legendary three-liter version, the A2 1.2 TDI. By the end of 2010 alone, the company had produced some 550,000 vehicles with the ASF body – far more than any other manufacturer in the world.

ASF olarak bilinen Audi Space Frame (Audi Uzay Kafesi), hafif gövde yapısı sayesinde daha fazla performans ve daha d“ş“k yakıt t“ketimi gibi avantajlar sunmaktadır.


Şasisiz Otobüs Gövdeleri: Otob“s imalinde şasisiz gövdeye örnek olarak gösterilen iki ana grup vardır. Bunlar: 1. Platform takviyeli otobüs gövdesi 2. Tam taşıyıcı otobüs gövdesi Her iki yapı tipide şasili tipe nazaran hafiftir. Taşıt ağırlığında azalma tam taşıyıcı otob“s gövdesinde daha fazladır. Ağırlık azalması şasinin çıkması ile %8 civarında 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.

http://www.fikssan.com/TR/yetkinliklerimiz1.aspx

Ek Okuma ve İnceleme Bölümü


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.

Fig. 1: Common body and chassis configurations.


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).

Farklı ifade biçimleri: Unitized body: Unibody (or monocoque) Body on frame: Body-over-frame

Unibody Construction

The frame is an integral part of the body


Body-over-Frame Construction

The body bolts to a thick steel frame Russell Krick, “Modern Automotive Technology” Sunumu, The Goodheart-Willcox Co.

Figure 1.1: Top left: (a) a uni - body design, top, right: (b) truck platform; and bottom right: (c) space - frame design

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 uni-body 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.


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 120...200 m. The flange widths are 10...18 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


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).

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.

M. Ravi Chandra1, S. Sreenivasulu2, Syed Altaf Hussain3; Modeling and Structural analysis of heavy vehicle chassis made of polymeric composite material by three different cross sections; International Journal of Modern Engineering Research (IJMER) Vol.2, Issue.4, July-Aug. 2012 pp-2594-2600 ISSN: 2249-6645

Ladder Chassis: Ladder chassis is considered to be one of the oldest forms of automotive chassis or automobile chassis that is still used by most of the SUVs till today. As its name connotes, ladder chassis resembles a shape of a ladder having two longitudinal rails inter linked by several lateral and cross braces. Monocoque Chassis: Monocoque Chassis is a one-piece structure that prescribes the overall shape of a vehicle. This type of automotive chassis is manufactured by welding floor pan and other pieces together. Since monocoque chassis is cost effective and suitable for robotized production, most of the vehicles today make use of steel plated monocoque chassis. Backbone Chassis: Backbone chassis has a rectangular tube like backbone, usually made up of glass fibre that is used for joining front and rear axle together. This type of automotive chassis or automobile chassis is strong and powerful enough to provide support smaller sports car. Backbone chassis is easy to make and cost effective.

KISA… KISA… KISA…

Chapter 9 Vehicle Construction, Thomson

(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 body-over-frame construction

(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.

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.



Figure 3: This top view of unibody construction shows how structural members are added to support the engine suspension and other mechanical systems.


Figure 4: Doors normally have strong steel beams under the door skin to protect people during side impact collisions.


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

Documents

MARMARA ÜNİVERSİTESİ TEKNOLOJİ FAKÜLTESİ · Chassis structures can be separated from the body, as in industrial vehicles and some commercial and off-road vehicles, or they