F2008-04-027
The Development of the A3 Cabriolet Body in White and Hang Ons
Author Wilhelm Lohmar, AUDI AG
Co-Author Susanne Welker Wilhelm Karmann GmbH
Objective of paper
Within the growth strategy of AUDI there is a necessity to cover market niches and to have entrance products which offer a AUDI life style product which helps bring new potential customers to the brand.
Considering this context, AUDI decided to develop a soft top Cabriolet on the basis of the A3 platform in February 2006 taking Karmann as a development partner with the objective of starting sales in spring 2008. Ingolstadt was chosen as the production site thus requiring an integration of the cabriolet production within the overall A3 production lines.
Itīs always been a challenging task to lay out geometrics and enforcements of a Cabriolet body in order to make up for a lacking roof structure. The A3 Cabriolet development has been even more challenging when one considers the stringent time table mentioned above and the boundary conditions due to the implementation of the Cabriolet production into the existing A3 production line. In addition, the package requirements of a full 4 seated car with max. priority on customer value, as represented by the trunk volume and its usability, in conjunction with a declinable rear seat did not simplify the task of the FEM analysts and project engineers. Within this frame of conditions, the structural performance aimed for of the body in white in conjunction with the hang ons were to deliver the base for the same passenger safety protection as the A3 base model as well as for the typical dynamic ride performance and comfort which a customer expects from an AUDI.
Hence, our paper will stress the following points: o The Cabriolet within the Audi growth strategy and model structure o The package of the A3 Cabrio o The Integration concept of the A3 Cabriolet into the A3 Production o AUDI/Karmann organizational structure and responsibilities o Developing the structural lay out on the basis of CAE. o Performance of base structure (cutting the roof) o The integrated enforcement structure BIW and hang ons o The material mix and applied bonding technologies. o Performance w.r.t. ENCAP, NVH, roof crush/roll over o Pedestrian protection . o Closing movie
Session: Body Design