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VMA - vehicle assembly and manufacturing The Energy Cost of Making an Automobile
Presentation in 2015 FGS (Weizmann Inst.) Guided Reading Course
Energy and SustainabilityYehonatan Ben Zvi
History
Karl Benz, the German mechanical engineer who designed and in 1885 built the world's first practical automobile.
Henry Ford in 1913 installs the first moving assembly line. His innovation reduced the time it took to build a car from more than 12 hours to two hours and 30 minutes
Life cycle of vehicle
1. Material production
2. Product assembly – VMA
3. Product use
4. Maintenance and repair
5. End of life “Though less understood, the burdens for part manufacturing andvehicle assembly, henceforth denoted as the VMA stage, appearto be the largest in magnitude” Sullivan et al. 2012
VMAMaterial Processing
Parts Production
Vehicle Assembly
Argonne National Laboratory, 2012
Raw materials
Assembly line
Body Chassis
Next step
• Most small vehicles such as small SUV’s and sedans use a unibody (or monocoque) construction.
Vehicle main materials
• Steel 54%• Iron 10%• Plastic 10%• Rubber 7%• Aluminum 6.4%• Glass 2.8%• Copper 1.7%• Lead 0.8%• Others 7% (sealants, fluids)
Sullivan et al. 2012
Activities in the VMA
Metal FormingStampingExtruding
CastingMachining
Forging
Polymer FormingInjection Molding
Compression Molding
HVAC & LightWelding
Compressed air
Painting
Sullivan, A. Burnham, and M. Wang., 2010
Material transformation Assembly Operations
Material Transformation Data
Casting Aluminum 55 MJ/kg Iron 32 MJ/kgForging 45 MJ/kgInjection Molding 25 MJ/kgCompression Molding 13 MJ/kgStamping 5 MJ/kgExtruding 7 MJ/kg
Material Transformation (MT)Vehicle weight – 1532 kg
Iron (10%) 153 kg
Casting (85%) 32MJ/kg Forging (15%) 45.1MJ/kg
130 kg made by casting 4160MJ 23 kg made by forging 1031MJ/kg
5191 MJ
Energy required for MT
• Steel (54%) 4871MJ• Iron (10%) 5195 MJ• Aluminum (6.4%) 4262 MJ• Plastic (10%) 2124 MJ• Rubber (7%) 1947 MJ• Glass (2.8%) 800MJ• Copper (1.7%) 393 MJ• Lead (0.9%) 441 MJ
20000 MJ
Assembly Operations
Machining 982 MJ
Vehicle painting 4,167MJ
Welding 920 MJ
HVAC & lighting 3,335 MJ
Total Energy Cost for VMA
Material Transformation 20000 MJ
Assembly Operations 14500 MJ
34500 MJ
Hu et al. 1995 30600 MJSullivan et al. 1998 39000 MJBurnham et al. 2010 33924MJ
Raw Materials Production
During the VMA stage, production-ready materials in the form of ingots, billets, sheet stock, pellets, rods, etc., are delivered to factories where parts are fabricated and ultimately assembled into a vehicle.
How much energy does it take (on average) to produce 1 kilogram of the raw materials?
Iron (from iron ore): 20-25MJSteel (from iron): 20-50MJAluminum (from bauxite): 227-342MJ 83400MJ
http://www.lowtechmagazine.com/what-is-the-embodied-energy-of-materials.html
Future of the Car Industry
Top 5 Advanced Car Technologies by 2020
• Autonomous Vehicle
• Biometric Vehicle Access
• Active Window Displays
• Active Health Monitoring
• Reconfigurable Body PanelsForbs,Jan 19, 2015
The Move to Aluminum
Aluminum
Mass reduction
ACCELERATION BRAKING HANDLING DRIVING COMFORT
The first production vehicle to move to an Al frame was the Audi A8 in 1994.
Today’s Car Aluminum Content
car body- bonnets & doors- front structure- bumper beams
26kg
chassis & suspension- wheels- suspension arms- steering system
37kg
drivetrain- engine block & cylinder head- transmission housings- radiators
69kg
Total aluminum content = 132kg
Aluminum vs. Steel
Material properties
Density:
– Aluminum 2,700 kg/m3
– Steel 7,750 kg/m3
Weight reduction is seldom achieved since it is necessary to increase the average thickness of aluminum compared to steel to achieve the same part characteristics
EUROPEAN ALUMINIUM ASSOCIATION, Aluminum in cars, 2012.
In total Aluminum structure is much more expensive than conventional Steel design
Energy cost
Raw materials:
Aluminum is 7 times more expensive than steel
Conversion cost:
Aluminum is 8 times more expensive than steel
• A model for calculating the energy burdens of the part manufacturing and
vehicle assembly (VMA) stage of the vehicle life cycle.
• This model based on a process-level approach, accounting for all significant
materials by their transformation processes and assembly line operation
activities.
• When the model is applied to a well-characterized conventional vehicle, the
estimated cumulative energy consumption is 34.5 gigajoules/vehicle.
• Regardless of the construction technique, steel is still the predominant
material used in automotive frames.
Thank you!!
References1. Sullivan et al., 2012 Part Manufacturing and Vehicle Assembly Model Journal of Industrial
Ecology2. Sullivan et al., 1998a, Automotive Life Cycle Assessment: Overview, Metrics, and Examples.3. Sullivan, J. L. and Hu, J., 1995, Life Cycle Energy Analysis for Vehicles.4. EUROPEAN ALUMINIUM ASSOCIATION, Aluminum in cars, 20125. Sullivan, A. Burnham, and M. Wang., 2010 Energy-Consumption and Carbon-Emission
Analysis of Vehicle and Component Manufacturing, Argonne National Laboratory