Company Profile

VE&D today • > 50 years of experience in “automotive engineering” • 4 sites (head quarters in Torino/Brescia + operative sites in Modena/ Chieti) + new company in Brazil (VEST) • >150 automotive technical specialists • 14 expert consultants • > 10 trainees/year

• CAD systems availability (U.G., Catia, Proe) • several ourselves developed dedicated softwares availability • Best in class commercial CAE systems availability • ISO9001:2015 Quality System • Research projects (funded and self funded):

MATERIALS/TECHNOLOGY CHASSIS SYSTEMS TRANSMISSION SYSTEMS ENGINES SYSTEMS HYBRID/ELECTRIC VEHICLES

• Main OEM customers: –FIAT GROUP, PIAGGIO, OERLIKON

• Main Parteners: –IAM/ Univ. Trento/ Univ. UNIMORE/ Univ. Brescia/ POLITO

Locations worldwide

VE&D Brescia

VE&D Torino

VE&D Modena

VE&D Santa maria Imbaro (CH)

VEST Engenharia Contagem (MG)

INNOVATION APPLIED RESEARCH PRODUCT DEVELOPMENT

•New architecture engine •DCT transmissions •New structural materials for chassis/body •Passenger/commercial hybrid vehicles •Kynetic Energy Recovery Systems for commercial vehicles •New material for engine structural components •Aerodynamics vehicle optimizations

TECNOLOGY

GATE APPLICATION

GATE

• Intelligent suspensions • Hybrid/powertrain systems • New material/technologies for weight/cost reduction

• DCT transmissions • New engines versions developments • EURO6 engines • AWD driveline • Electric urban vehicles

VE&D involvements

ORGANIZATION CHART 01.2016

OPERATIVE SITE BRESCIA

OPERATIVE SITE

TURIN

BUSINESS DEVELOPMENT

INFORMATION TECHNOLOGY

HUMAN RESOURCES

FINANCE

DEFENSE SYSTEM REFITTING

POWERTRAIN

PASSANGER CHASSIS/ VEHICLE

INDUSTRIAL CHASSIS/VEHICLE

QUALITY SYSTEM

PROTOTYPING

BENCH TESTING

RELIABILITY

ENGINEERING

VIRTUAL ANALYSIS

DEPARTMENT

CAPABILITY

DEPARTMENT

CAPABILITY

ENGINEERING

PROTOTYPING

TESTING

• Feasibility design: engine, sub-assembly, parts for vehicle integration

• Design and modelling of components for vibration and structural analysis

• Calculation (FEM,CFD)

• Balancing shaft analysis

• 2D drafting and preliminary design

• Assembly and interference check

• Complete layout

• Technical proposals and design modifications for release/ maintenance

ENGINE COMPETENCE AND PERFORMANCES

Main Results

On the same size range:

• Weight reduction: -16 / -20% ( Iron / Al )

• Power increasing: +15 / +20%

• Cost reduction: - 5%

Wide experience in calculation & design of complete projects :

• Diesel

• Gasoline

• Passenger and industrial

EMISSION REDUCTION Projects

from EURO 5 to EURO 6

Index

Wide experience in calculation & design of complete transmission projects :

• Longitudinal, transaxle and transversal transmission (3/4 axles)

• Single and dual clutch layout

• Power shift / Power split/ Hydrostatic configuration

TRANSMISSION EXPERIENCE AND PERFORMANCES

Main Results :

• Weight reduction: - 10%

• Over all length reduction: -7%

• Power capacity increasing: + 30%

• Cost reduction: -15%

• Feasibility design: assembly, , sub-assembly, parts for vehicle integration

• Design and modelling of components for vibration and structural analysis

• Calculation (FEM+ISO-DIN-AGMA)

• 2D drafting and preliminary design

• Assembly and interference check

• Technical proposals and design modifications for release/ mainteinance

SHIFTABILITY Implemention

Passenger shifter

SCALA

SAE

RUMOROSITA` DI AZIONAMENTO/TRILLI/ECC.

VALUTAZIONE SOGGETTIVA COMANDO CAMBIO ………

Molto buono EccellenteMediocre

Limite

accettabileAccettabile

1 2 3 4

Discreto Buono

Molto

scadente Scadente Povero

9 10

SOLUZIONI A CONFRONTO DESCRIZIONE SOLUZIONE TELAIO Km

5 6 7 8

B : C514 Step 2

A : C514 NP

Sol. C

C : VW Polo

NOTEDESCRIZIONE VALUTAZIONE Sol. A Sol. B

I N N E S T O

CARICO

entita` / durata 7,0 7,7 8,1

IMPUNTAMENTI / DOPPI SCATTI 6,5 7,1 7,8

CORSA 7,3 7,8 7,8

DIFFICOLTA` D`INSERIMENTO RM

manovra da folle a RM e da 1 a RM 6,5 6,5 7,7

INNESTO DA FOLLE A 1^ 6,7 7,1 7,5

RUVIDITA`

scarsa scorrevolezza d`azionamento 6,8 7,2 7,6

POSITIVITA`

Percezione dell`avvenuto innesto 6,7 8,0 8,3

GIOCO

sia in folle che a marcia innestata 6,6 7,1 7,3

GOMMOSITA`

Elast. in manovra ed in extracorsa 6,7 7,5 7,4

CARICO DI DISINNESTO 7,1 7,4 7,8

PASTOSITA`

frenatura di tipo viscoso 6,3 7,4 8,1

S E L E Z I O N E

CARICO 6,9 6,9 8,2

RUVIDITA`

scarsa scorrevolezza. di azionamento 7,0 6,8 7,0

CORSA 7,3 7,5 7,8

GIOCO 6,6 7,3 7,8

GOMMOSITA`

extracorsa 7,4 7,8 7,7

PRECISIONE

sensaz. di corretta esecuz. manovra 7,1 7,8 7,9

PASTOSITA`

frenatura di tipo viscoso nel ritorno in folle 6,1 7,4 7,9

VIBRAZ. LEVA

trasmis. vibrazioni motopropulsore

RUMOROSITA` DI FUNZIONAMENTO 7,2

7,5

7,6

7,8

7,9

7,9

7,4

6,6

R E T R O M A R C I A [ved.si anche 7-T2053]

E R G O N O M I A [ ved.si 7-T2207 ]

R U M. / V I B R A Z I O N I [ved.si 7-T2210]

SCUOTIM. LEVA

oscill. leva assoc. ai movim. mot.

INSERIMENTO INVOLONTARIO

RETROMARCIA

FUNZIONAMENTO/GIOCO

SIRINGA INIBIZIONE

AGIBIL.,PRENS.,RAGGIUNGIBILITA`

POMELLO

6,6

8,7

8,6

8,7

8,5

7,77,7 7,3

7,6

7,8

7,5

7,9

7,9

VALUTAZIONE DI SINTESI 6,5 7,5 8,0

industrial shifter

Index

Design, feasibility and development of engine and gearbox integration for commercial and passenger vehicles

Design, feasibility and development of all wheel drive transmissions

Design and development of vehicle suspensions

Fuel Conversion of commercial vehicles in Methane or LPG

POWERTRAIN & VEHICLE LAYOUT Feasibility

ARCHITECTURE COMPETENCES

1. Performing layout study of architecture for:

1. principal dimensions (track, wheelbase, ….)

2. suspensions geometry, attach point and wheel travel

3. steering geometry

4. steering angle/radius

5. wheigth distribution

6. tyres sizing

CHASSIS - SUSPENSION VEHICLE COMPETENCES

1. Execution layout study for suspension under the platform.

2. Performing pre-study of suspension system, for virtual verification and manufacturing feasibilty.

3. Execution of virtual analysis:

• kinematics

• handling

• structural (on system and component)

• measures

• vibration.

4. Design definitive study consistent with the virtual resolution.

5. Execution of mathematical models and drawing of approved components,

with:

tolerances,

tightening torques,

characteristic and performances,

attach point to the platform

final geometry of suspension

characteristic angles

spring sizing

Rear suspension twist axle

Front Mc Pherson suspension Rear Mc Pherson suspension

SUSPENSION COMPETENCES

Agricultural

axle

Rigid

axle

Suspension & vehicle

dynamics

1. Definition plant according to standard homologation

2. Checks dimensions caliper / disc with the suspension and wheel rims.

3. Execution study of layout for

• positioning the brake fluid reservoir

• positioning ABS / ASR / VDC

• route piping in the engine compartment

• route of pipes under the floor

• installation of handbrake lever

• route cables handbrake.

5. Performance studies for tube fittings and ropes hand brake to the platform and shelters event.

6. Virtual verification of fixing elements.

7. Executions of mathematical models and drawing.

CHASSIS - BRAKING SYSTEM COMPETENCES

1. Execution layout study for:

• positioning of the expansion tank

• positioning radiators

• course of the water pipes in the engine compartment

2. Check of virtual fluid dynamic flow, velocity and temperature of the air in the engine compartment.

3. Execution of definitive studies including fixings of tubes, of expansion tank and of the radiator.

4. Virtual verification of fixing elements.

5. Executions of mathematical models and drawing.

CHASSIS - COOLING SYSTEM OF ENGINE COMPETENCES

PROTOTYPING & TESTING

• Engine, transmission and vehicle prototyping.

• Assembly, inspection, validation and quality procedures.

• Technical reports according to ISO9001.

• Physical mock-up.

• Field test on the vehicle.

• Bench validation testing.

• Part Procurement

• Supply chain auditing and certification.

• Pre-series and series start-up.

VIBRATION DYNAMIC TEST

Using shaking tables and control systems, closed loop vibration tests are performed to verify the resistance to dynamic excitations.

Typical tests: - sine excitation (amplitude and frequency control)

- fixed frequency - time varying frequency (Oct/min) - Track and Dwell

- impulse tests: amplitude, pulse type (ISO, MIL-STD,...), and duration control - random: PSD user-defined, real time closed loop control - shaking table with or without slip-table (up to 40kN, 100g RMS)

Non-contact measurements: laser-Doppler vibrometer, laser telemeters

Typical application in Machine monitoring, Fault detection, Diagnostics, Prognostics

Climatic Test Chamber Temperature (Humidity) & Vibration Combined Environmental

Test Chamber (-70 +180°C)

Procedures

used in VE&D

- Design/Process FMEA

- FMEA II generazion

- SAE

- VDA volume 4

- AIAG

- MFA

- Customer Standard

VE&D Client

Experience and

Skills offers

- Senior Engineers

- Methodologist

- Technical Experts

Reliability

Activity

- FMEA

- MFA

- Problem Solving

- Maturity Level Assessment

Drawing

Analysis

SECTION 1 - Preventive Reliability SECTION 2 - Predictive Reliability

STATISTICAL

ESTIMATE OF

ATTENDED FAILURE

RELIABILITY

DEMOSTRATION

PLAN

Concept

Analysis

Failure

Analysis

RISK MATRIX

Reliability Data

and Failures

In alternative:

RISK MATRIIX

from D-FMEA

Follow Up

A new INTEGRATED approach to preventive and predictive reliability

FMEA : Method Phases

2a. Modular Analysis 3. Risk Analysis

•Description of the system

•Input data collection

•Block diagram

Relay box

Wiring

harness

Legend mechanical

electrical (power)

electrical (CAN)

….

out of scope

New Content

Carry Over

Out of scope

Retarder

(Telma)

Differential

Propeller shaft

(out)

Vehicle Control Module

(VCM)

Propeler shaft

(in)

Gearbox

Brackets (Left

and Right)

Wiring

harness

Elastic

Suspension

Frame

BatteryLever (4 torque

levels)

Retarder Control

Module (MCR)

Brake pedal

position sensor

Insulation

switch

ABS Control Unit

Insulation

button

Cruise Control

1. Preparation

4. Follow-up

Concept - Failure - Drawing

analysis RISK MATRIX

Type:

Subject:

Local End

user

Current Design

Controls

Detection

(Experimental

Test)

D

e

t

e

c

R

P

N

Recommended

Action(s)

S

e

v

Potential

Cause(s)

Mechanism(s)

of Failure

Drawing

Characteristic

and Design

Specification

C

l

a

s

s

Current

Design

Controls

Prevention

(Design

Criteria)

O

c

c

u

r

R

e

f

S

o

u

r

c

e

Item FunctionPotential

Failure Mode

Potential

Effect(s) of

Failure

2b. Correlation Matrix

TypeSubject

A B C D E F G H I J K L M N O P

FUNCTIONAL

BREAKDOWN

BASIC FUNCTION ELEMENTARY FUNCTION A B C D E F G H I J K L M N O P

1

2

3

4

CORRELATION MATRIX

………….

INT

ER

FA

CE

1

INT

ER

FA

CE

2

INTERFACE

EL

EM

EN

T 1

…………..

ELEMENTS NOT PHISIC INTERFACEItem (Element / Interface)

……..

EL

EM

EN

T 2

COST REDUCTION AND CONCEPT ANALYSIS ACTIVITY (WAR ROOM)

VE&D typical support to OEMs

1. TEAM ORGANISATION

2. PROPOSALS GENERATION

3. PROPOSALS MANAGEMENT

4. PROPOSALS VALIDATION

5. PROPOSALS IMPLEMENTATION

• BRAINSTORMING TEAM • ASSEMBLY LINE • BENCHMARKING

• FEASIBILITY • COSTS EVALUATION • MANUFACTURING EVALUATION • SERVICEABILITY EVALUATION

• PROTOTYPING • DESIGN RELEASE • COSTING

Main projects: FCA C635 transmission, Maserati QP/ Ghibli, Piaggio Porter, etc.

Weight & Cost Reduction Examples

w. Functional Implementation

CAST IRON ALUMINIUM

Index

PLASTIC

Index

Weight & Cost Reduction Examples

w. Functional (NVH) Implementation

METAL

VE&D SUPPORT AND NET ORGANIZATION

• SUPPORT TO SUPPLIER

-OEMs Metodologies application -Vehicle System KH transfer -Modeling &Calculation and DMU engineering activities

OEMs

VE&D SUPPLIERs

• SUPPORT TO OEMs

-OEMs Metodologies implementation -Vehicle System KH implementation -New product proposal -Modeling &Calculation & DMU engineering activities

RESEARCH AND DEVELOPMENT PROJECTS AT EUROPEAN LEVEL

EUROPEAN PROJECT FP7

Green Car Initiative

EVOLUTION (Pininfarina) G.A. 314744

hybrid components for urban electric vehicle, modular and lightweight: use of light alloys and composite materials

CONVENIENT (CRF) G.A. 312314

Development of efficient commercial vehicles: development and implementation of active aerodynamic system

About 5%

reduction fuel consumption

Variable thickness metal sheets Thickness

2,5mm Thickness

1,5mm

Seats frame

Thickness 2mm

Thickness

3,5mm

Thickness 2mm

Variable thickness tubes

1. POSSIBLE APPLICATIONS OF ALUMINUM FOAMS IN THE AUTOMOTIVE INDUSTRY

2. METHOD FOR CHARACTERIZATION AND DESIGN

3. REFERENCES

CONTENTS

30

Development of a Method for Characterization and Design of Aluminum

Foams