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2004 FORD F-150STEEL BUMPER TECHNOLOGY
Rob FontichiaroMeridian Automotive Systems
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AGENDA
– Overview of Meridian Automotive Systems
– F-150 Front Bumper Design and Performance
– F-150 Rear Bumper Integrated Hitch Design and Performance
– Q/A
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Meridian Automotive SystemsCompany Overview
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Meridian Automotive SystemsCompany Profile
– Exterior Composites– Exterior Lighting– Interiors
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Front End and Rear End Modules
Stamped High Strength Steel Bumpers
Rollfromed Bumper Beams & Foam Energy Absorbers
Trailer Hitch SystemsPainted Plastic Fascias
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Meridian Automotive SystemsManufacturing Facilities
INDIANAAngolaGrabillHuntingtonRushvilleShelbyville
KANSASKansas City
LOUISIANAShreveport
MICHIGANCantonDearbornDetroitGrand Rapids (3)Ionia (2)
NEW YORKCanandaigua
NORTH CAROLINALenoirNewtonSalisbury
OHIOJackson
TEXASArlington
CANADABrantford, Ontario
MEXICOCelaya
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Ionia, Michigan Manufacturing and Test Facility
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Ionia, Michigan Manufacturing
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2004 FORD F-150FRONT BUMPER
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2004 Ford F-150 Front Bumper System
Front Bumper:Deep drawn SAE J1392 .075”gage
Chrome, A-gloss, or G-gloss Paint
Chrome blanks are flat polished prior to stamping
Removable tooling inserts for forming with and without foglamp holes
Added internal bracket structure to improve low speed impact performance
Molded and painted A-gloss TPO plastic upper fascia with plastic eggcrate structure
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2004 F-150 Front Bumper Structure
High Strength Steel 950 frame mounting bracket and corner hit brackets
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5mph Corner Barrier FEA
Allowable stroke: 93mm Actual stroke: 90mm
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2004 FORD F-150REAR BUMPER INTEGRATED HITCH
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2004 Ford F-150 Rear Bumpers
Styleside
Flareside
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Typical Non-Integrated Step Bumper and Receiver Hitch
5,000lb. Step Bumper:
65 lbs.
9,900lb. Receiver Hitch:
50 lbs.
Total Weight:
115 lbs.
Two redundant towing systems:
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Meridian Integrated Hitch Development History
Development work began in late 1997 for the Ford F-150, Expedition, Navigator, and Super Duty applications.
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U.S. Patent Number 6,139,044Filed June 5, 1998
Awarded October 31, 2000
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Meridian Integrated Hitch on 2004 Ford F-150
9,900lb. Tow Rating Integrated Hitch Bumper:
105 lbs. 50% take rate
10 lb. save on affected vehicles
Hitch brackets ship end item to final assembly plant.
Bumper Bars: High Strength SAE J1392 .075”
Brackets: High strength 950 steel.
Tubes: ASTM A500 -Grade B, 42,000psi yield strength
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2004 F-150 Rear Design Hurdles
Shackle Bracket Clearance
Leaf Spring Clearance
Spare Tire Clearance
Frame Horn Interface
D-pillar and Sheet Metal Clearance
Additional Issues:
•Assembly operations at 3 customer assembly plants
• Shipping rack requirements for 5k and 9900lb bumpers
• Common hitch structure on flareside and styleside
• Corner hit performance
• Up/Down and cross-car bumper adjustment (+/- 6mm)
• Winch access clearance
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F-150 Styleside and Flareside Integrated Hitch Bumpers
Styleside
Flareside
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Modular Hitch Design
Flareside
Styleside
Flange modified for flareside
Unique end brackets for flareside vs. styleside
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First Welder
Modular Hitch Section out of 1st Welder
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Second Welder
Finished Hitch out of 2nd Welder
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Final Bumper Assembly
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1.5mph Corner Hit FEA
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2.5mm Center Barrier FEA
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2.5mph Center Pendulum FEA
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Low Speed Impact Physical Testing
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Bench Durability Fatigue FEA
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Fatigue Testing in Ionia Test Lab
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Summary of Integrated Hitch Advantages
• Reduced piece cost
• Reduced weight
• Reduced assembly plant indirect labor costs (inventory, logistics, material handling)
• Bumper complexity at assembly plants can be eliminated by implementing In Line Vehicle Sequencing
• Reduced assembly plant direct labor costs
• Eliminated hitch rack fleet and transit costs to assembly plants
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Q/A and Follow-up
– Rob Fontichiaro• Engineering Program Management• (313) 253-3538• [email protected]
– David Holmes• Director of Sales• (313) 253-3503• [email protected]
