Lotus Engineering Seating Systems Overview …insidepenton.com/waw/GregoryPeterson-Lotus.pdfLotus Engineering Seating Systems Overview Ward’s Interior Conference May 22, 2013 2 lotuscars.com/engineering

5/21/2013

Lotus Engineering Seating Systems Overview

Ward’s Interior Conference

May 22, 2013

2

lotuscars.com/engineering

Presentation Topics

Ischial Tuberosities

(Sit Bones)

• Interior design philosophies

• Safety systems vs. weight

• Seat comfort vs. weight

• Current cars vs. Lotus projected 2020 interior system masses (some

surprises)

• Interior Mass Reduction Opportunities

• Summary Remarks

© Lotus Cars Limited3


Interior Design Philosophies

4


Holistic Approach to Interior Mass Reduction


(Sit Bones)

• Component integration/modularization

• Use interior components as stressed

members

• Use air to replace material

• Use electronics/electrical systems to

replace mechanical systems

7.6 kg

2012 C Class (passenger)

5


Component Integration/Modularization

• Console show surface is air distribution duct for rear seat occupants

• Molded in seat support system replaces

traditional seat risers and contributes to body structure

• Steering column module integrates primary instruments and pedals

6


Use Interior Components as Stressed Members


(Sit Bones)

• Synergistic approach helps to reduce mass in other systems

• Potential to reduce or eliminate

structural reinforcements

• Typically requires a systems approach

to provide cost offsets for more expensive materials

7


Integrated Seat Structure

Used on Audi 4000Q, VW Golf & Jetta and Ford Thunderbird (1980’s)

•Seat mounts to the strongest structures in the interior

•Reduces weight of traditional seat track mechanism

•Eliminates local floor reinforcements & mounting

fasteners

•Adds structure to body by “boxing” sill and tunnel

•Assists in transferring side impact loads

•Improves underbody aerodynamics

12.936 kg

(Adjuster & risers -

Power unit)

8


Applying Light Sport Aircraft Design Principles to Automotive Interiors

• 1,000 lb. maximum dry weight

• Complete interior weight is less than the weight of one automotive front seat –

includes:

• Instrument panel

• Seats

• Trim panels – front and rear

• Console/Armrest

• Floors – front & rear

• Carbon fiber based construction

Styling and CAD by ICON Aircraft

9


• IP Weight

• < 2.4 lbs.

• Weight normalized to mid-size car width: approximately 3 lbs.

• Material: Carbon Fiber w/Foam Core Sandwich

• 3 ply with 1c1 0.25 H60 reinforcement and 8 ply outer flanges

• Upper and lower core reinforcement H60

• Mounting bracket: 8 ply

Structural Instrument Panel & Air Ducts - LSA

• Opportunity for 3 lb. carbon fiber IP

• Integrates cross-car beam into “A”

surface

• Show surface is the support

structure

• Carbon fiber & CF foam core sandwich construction

• Potential for using air distribution

ducting as a structural component


10


Use Air to Replace Materials


(Sit Bones)

• Air injected plastics offer potential for reduced

weight

• Potential for reduced cost

• May need covering to achieve Class A

surface

• Active Noise Cancellation Using Audio System

• Provides attenuation in sub-200Hz region

• Potential for 10 kg to 20 kg mass reduction

• Requires higher capacity system than base

units for most vehicles

• Lightweight Cupholder

http://www.automoblog.net/2011/11/15/2013-ford-escape-innovations-tease-ahead-of-debut/

2013 Ford Escape Instrument Panel

Lotus Elise Cupholder

11


Use Electronics/Electrical Systems to Replace Mechanical Systems


(Sit Bones)

• Utilize a central touch screen as an actuator for key controls

• Integrate haptic features into screen

• Solenoid actuated transmission selector can save > 2.5 kg

• Solenoid actuated parking brake system can save > 3.0 kg compared to a foot

operated parking brake



Safety Systems vs. Weight

13


Safety Systems and Mass Reduction

• Interior safety systems are key toproviding a safe environment for

vehicle occupants

• Safety systems are a mature

technology

• Safety system mass is not a large

contributor to vehicle weight

• Potential to reduce air bag mass is low

• Risk/benefit ratio for potential massreduction is relatively high



Seat Comfort vs. Weight

15


Basic Seating Bio-Mechanics

• Increased torque creates stresses on thehuman body that can generate discomfort

and fatigue

• Creating a seated position that allows the

body to be in a balanced state helps to

reduce extraneous torques

• Minimizing extraneous torques is not

necessarily a mass intensive process

Correct Yoga postures utilize the principle of

minimizing external torques

16


Pelvis and Ischial Tuberosities


(Sit Bones)

• The body needs to be supported byits skeletal structure

• Minimal physiological differencesin the sit bones despite wide

variations in body size and weight

• Advantageous to use a seat insert that supports the ischial tuberosities to

rotate occupant pelvis forward

17


Anatomy of the Spine

Lordotic Curvature Kyphotic Curvature

• The lordotic spine shape (“S” curve)places the head near the centroid of

the spine

• The kyphotic spine shape (“C” curve)

creates an increased torque acting on

the spine

• An increased torque acting on the

spine creates stress that can cause discomfort

18


Lotus ProBax Technology - Implementation

ProBaxInsert

19


ProBax Technology – Seat Integration

ProBaxInsert

20


ProBax Technology – Improved Spatial Awareness

Typical Seat Lotus ProBax Seat

Moment Arm Acting on Spine Moment Arm Acting on Spine

Head CG Head CG

21


ProBax – Results from Lotus Elise

• Average reduction in distance from skull to head restraint - 18.9 %

• Effect is greater for taller drivers (up to 70% improvement)

• Improvement from posture change – no user adjustments required

• Simple - light-weight - cost-effective

Pre-06 MY Elise Seat ProBax Elise Seat

22


Media Seat Comfort Assessment

‘Forget your Maybachs and Rolls-Royce Phantoms.

The most comfortable car seat in the world could just be in

the little Lotus Elise’

Source: The Daily Telegraph

• Foam Thickness: < 1.5”

• Composite structure



Competitive Review of Production Seats

24


2020 Low Mass Driver Seat Summary BOM - Projection

•Mass reduction total: 6.33 kg (24%)

Driver's Seat Mass Reduction AnalysisVENZA BASELINE

(kg)

Ford Fiesta Seat Starting

Point (kg)

Starting Mass (kg) 26.92 18.47

Itemized Mass Deltas to baseline Low Development

Normalization to Venza

Best A2MAC1 Power Equipment (300C+Venza Lumbar) -- 0.00

Safety Equipment delta to From Fiesta - Venza -- -0.12

Azera Frame -- -3.64

Composite Seat Frame -- 0.00

Sizing Adjustment --

Back -- -1.52Cushion -- 0.66

Light weighting Content (Benchmark based)

300C Power equipment replacement (with Venza lumbar) -- 6.74

Remove springs (back and cushion) -- 0.00

Remove Foam volume (ergo foam replacement -- 0.00

-- 0.00

Remove Garnish and trim -- 0.00

--

Mass Results (kg) 26.92 20.59

Mass Reduction (kg) -6.33

Mass Reduction Percentage -24%

Please note that Toyota engineers were required to use legacy

geometry/hardware that limited their ability to reduce mass

25


2012 Car A Driver Seat (power)

22.839 kg vs. 2020 Projected 20.59 kg

Mass is within 11% of Lotus 2020 Projections

26


2020 Low Mass Passenger Seat Summary BOM - Projection


•Magnesium seat structure

•No springs, reduced foam mass and integrated trim & garnish

Passenger's Seat Mass Reduction AnalysisVENZA BASELINE

(kg)

Ford Fiesta Seat Starting

Point (kg)


Itemized Mass Deltas to baseline High Development


Safety Equipment delta to From Fiesta - Venza -- -0.12

Azera Frame replacement -- 0.00Composite Seat Frame -- -3.25

Longitudinal Rails from 300C (Fiesta is a hybrid rail/structure) -- 0.00

Sizing Adjustment --

Back -- -1.52Cushion -- 0.66

Light weighting Content (Benchmark based)

300C Power equipment replacement (with Venza lumbar) -- 0.00

Remove springs (back and cushion) -- -0.26

Remove Foam volume (ergo foam replacement -- -0.39Add Manual Seat Adjustment Bar --

Remove Garnish and trim -- -1.10

--


Mass Reduction (kg) -12.20

Mass Reduction Percentage -53%



27


2012 Car A (Class C) Driver Seat (manual)

21.684 kg

28


2011 Car B (Class C) Driver Seat (manual)

22.563 kg

29


Light Weight Front Seat Overview



30


2020 Rear Seat Projection vs 2012 C Class Sedan


•Production seat is 13% lighter than Lotus 2020 Projection

Rear Seat Mass Reduction AnalysisVENZA BASELINE

(kg)

Nissan Qashqai starting

point (kg)


Itemized Mass Deltas to baseline High Development

Normalized to Venza Volume 47.81 28.27


Remote Rear Cargo unlocking system -- 0.33

Back Frame normalized for center seatbelt (2-3)section -- 0.00

Add Venza Seatbelt Anchor 1.75

Modular seatback Laser welded roll formed

Mold seat lower into composite floor proposal -1.22

Utilize blow molded reinforced seatback frame (30% reduction) -3.70 --


Mass Reduction (kg) 38.57 -22.38

Mass Reduction Percentage -0.47

2012 C Class Production Rear Seat20.1 kg



• Normalize to Venza size: 20.1 kg x 10% = 22.1 kg

• Projected 2020 mass optimized rear sear: 25.43 kg

• Normalized C class rear seat is over 3 kg lighter than Lotus 2020 projections

Note: CUV rear seat vs. sedan rear seat

2020 Lotus Low Mass Seat



Lightweight Non-Automotive Seats

32


Light Sport Aircraft Seat Design

� ICON A5 LSA Seats

LSA maximum allowable dry weight: 1,000 lbs

Total interior weight: <One typical passenger car front seat

•Carbon fiber-foam core laminated shell

•<1.5” thick cushions

•<7 lbs. each

www.iconaircraft.com




Interior Mass Reduction Opportunities Summary

34


2020 Total Interior System Projections - Low Mass Model

Interior

Seats 97.9 kg 39% 55.2 kg 94%

Instrument Panel|Console|Insulation 43.4 kg 17% 25.8 kg 105%

Hard Trim 41.4 kg 17% 24.3 kg 105%

Controls 22.9 kg 9% 16.0 kg 108%

Safety 17.9 kg 7% 17.9 kg 100%

HVA/C and Ducting 13.7 kg 5% 11.3 kg 81%

Closure Trim 13.3 kg 5% 2.4 kg 75%

Total 250.6 kg 152.8 kg 96%

System

High

Development

Mass

High

Development

CostSub-System

% of

Interior

Venza

Baseline

mass


•Projected cost: 4% savings vs. baseline





Summary Remarks

36


Summary Remarks

• An holistic, total vehicle approach is required to maximize mass reduction

• The cost and mass of all systems must be assessed in terms of their

contribution to reducing the vehicle cost and mass rather than in isolation

• The cost for discrete sub-systems and components may need to increase

relative to historical targets to provide the least cost, total vehicle mass

reduction solution

• An holistic approach to interior system mass reduction has the potential to

reduce cost

CHINA

7th Floor, New Jinqiao Tower

No. 28 New Jinqiao Road, Pudong

Shanghai. PR CHINA 201206

Phone +86 (21) 5030 9990

[email protected]

MALAYSIA

Malaysia Sdn. Bhd. Lot G-5, Enterprise 3 Technology Park Malaysia

Lebuhraya Puchong-Sungai Besi

Bukit Jalil. 57000 Kuala Lumpur

Phone +60 (3) 8996 7172

[email protected]

Please reply to:

Job title:

Telephone:

Email:

Website: lotuscars.com/engineering

UNITED KINGDOM

Potash Lane

Hethel, Norwich

NR14 8EZ

Phone +44 (0) 1953 608423

[email protected]

USA

1254 N. Main Street

Ann Arbor

MI 48104

Phone +1 734 995 2544

[email protected]

Gregory E. Peterson

Senior Technical Specialist

586-698-1933

[email protected]

Documents

Lotus Engineering Seating Systems Overview …insidepenton.com/waw/GregoryPeterson-Lotus.pdfLotus Engineering Seating Systems Overview Ward’s Interior Conference May 22, 2013 2 lotuscars.com/engineering