ssp 520, la golf 2013 carrosserie et protection des … 520 - the golf 2013 body and...audi a3...
TRANSCRIPT
Training Service
520 Self-Study Program
The Golf 2013
Body and occupant protection
Design and function
2
When new development Golf, the main objective was to reduce vehicle weight while meeting increased demands on vehicle safety and
comfort.
Based on the modular platform for transverse engine (MQB) to build lightweight steel, the new Golf manages to achieve substantial weight gain of 23
kg in the body structure, but also reduce material costs and manufacturing time. Taking into account all organ groups Golf 2013, the weight gain of up
to 100 kg compared to the previous generation (depending on version).
This Self-Study Programme presents the new features of the Golf in 2013 for Body and occupant protection.
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This Self-Study Programme presents the design and
operation of recent technical innovations! Its content
is not updated.
For current instructions control, adjustment and repair, please
refer to the documentation of Customer Service.
Caution Note
At a glance
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Body structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
body assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Occupant protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Check your knowledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
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4
Introduction
The modular platform MQB transverse engine
The body of the Golf 2013 has been completely designed from scratch. The floor is based on the new modular platform strategy to transverse engine.
The modular platform strategy for transverse engine was developed by the research department and development of Volkswagen in Wolfsburg. This
modular transverse engine platform is the basis for future vehicle design projects within the Volkswagen Group.
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•
•
Back rail tunnel
transom seat
Bottom inside box
Floor Traverse
Sheet steel
High yield - <1000 MPa ultra-high tensile (hot formed)
•
> 1000 MPa
Thanks to the significant strengthening of the quality of materials used, particularly in the use of components with ultra-high strength (hot formed), the
weight of the new vehicle has been reduced by 18 kg compared to the previous platform . The floor of the Golf 2013 is characterized by a framework
structure made up of components with ultra-high strength, formed by the tunnel, the top and bottom rails of the floor, the bottom of inner body and the
rear cross member.
The transom seat with high elastic limit is an additional lateral support. The modular transverse engine platform is perfectly prepared for future
alternative propulsion systems such as electric powered or rechargeable hybrid.
For more information on the modular transverse engine platform, see Self-Study Programme 513 "The Golf 2013".
The modular platform is transverse engine crossover, which means that the differences wheelbase are provided by varying the length of the floor plate.
One tool performs five different lengths of floor panel (difference in length of 165 mm). •One tool performs five different lengths of floor panel (difference in length of 165 mm). •
The differences in width are carried out only with the bottom of inner body and leg strength turrets in the wheel arches.
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Škoda Superb
Passat, Touran, Tiguan
Škoda Octavia, Tiguan
Golf
Audi A3 2-door Seat Leon
(- 35 mm)
Bottom inside box
Apron
The Golf 2013 has a closed deck. The latter has been optimized by the
geometry of the profiles and to the rib surface thereof. Ribbed patterns
thus possible to improve the acoustic properties and rigidity. It was
therefore possible to reduce the thickness of plates and dispense with a
heavy sound-absorbing carpet. •heavy sound-absorbing carpet. •
•
The rigidity of the strut links in the front part of the vehicle is ensured
by the optimum shape of the profiles in the region of the water box.
ribbed patternsProfile form the plenum
chamber
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6
Introduction
rear cross
To meet all requirements of rigidity and collision, the cross under the rear floor between the wheel arches is also sheet ultra-high strength (hot
formed). •formed). •
At the junction between the floor and the rear floor rear cross this ultra-high strength (hot formed) is responsible for distributing the load during a side
collision. The technique tailored blanks obtained by rolling enables a customized distribution of sheet thicknesses between 0.95 mm and 1.70 mm mini
maxi and an appropriate positioning of deformation zones, and leads to weight gain 2.0 kg for single component.
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Thickness of sheet metal
0.95 mm
1.15 mm
1.25 mm
1.50mm
1.70mm
front spar
The front of the rails is designed as a C-section of 2.0 mm thick on the inner side with an outer closure member of the same quality, of 1.5 mm. The
junction zone of the side member with the underside of the front floor is also made in ultra-high tensile steel hot formed from 2.0 mm thick also. Under
the floor of the vehicle, from the junction zone to the rear cross member, the spar has two different thicknesses. This is a piece made of tailored blanks
obtained by rolling. The front portion has a thickness of 1.75 mm and the rear portion of 1.0 mm.
The forces applied to the beam in the joining area between the front of the vehicle and the passenger are distributed via the profiled floor cross upper
and lower in the middle of the vehicle by integrally tunnel also ultra-high tensile steel , and outwardly from the bottom of ultra-high tensile crate.
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1.75 mm
1.0 mm
C-profile closure piece
junction area
The implementation of the gearbox bearing in the spar has increased local rigidity while reducing weight. The height of the spar has been
increased by 25%.
Longeron U Golf
2009
C-spar of the MQB, Golf 2013
shaped sectional view for comparing the front
side members
Golf •Golf •
2013
Golf •Golf •
2009
Section AA
AT
AT
AT
ATs520_010
+ 25%
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8
Body Structure
On the Golf 2013, ultra-high strength to components (hot formed) are also used for the superstructure of the bodywork to ensure maximum safety and
the highest level of comfort, even as the rigidity requirements and collision are even higher and that the dimensions of the vehicle are more important.
The novelty lies in the concept of continuous low crate with reported amount of reinforcement B and A reinforcement amount inside. These two
components being made of ultra-high tensile steel (hot formed), the upper part of the pillar, in the top box, is provided with anticollision folds. These
folds are excess material designed to absorb the energy released in a side impact against the post.
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A pillar with reinforcement
Reinforcing amount B
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collision folds
Resistance of steel sheets
<160 MPa <220
MPa <420 MPa
<1000 MPa
Ultra-high strength (hot formed)> 1000 MPa
body assembly
Before body
front bumper with lock door
The lock holder is in polyamide reinforced glass fibers 40%.
It is available in two versions. It features screw holes in the area of the grille to enable the fixing of it for repairs. The support of the pedestrian
protection is riveted to the crossmember. The support of the ACC sensor (Adaptive Cruise Control - Cruise Control) is screwed onto the crossbar. •protection is riveted to the crossmember. The support of the ACC sensor (Adaptive Cruise Control - Cruise Control) is screwed onto the crossbar. •
If necessary, the lock holder can be deposited dry.
Door-lock
Traverse
guide piece
A molded foam
bumper front bumper
Grille Support for pedestrian protection
air guide part left
radiator support
Housing VAC carrier
Support lock door
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mechanical coding
radiator support
The components of the radiator are now snapped into the front using
new media. A mechanical coding to exclude any incorrect assembly of
radiator supports. •radiator supports. •
The radiator bearings are fitted with grooves corresponding
to the mechanical coding.
9
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Breaking point
(Dismantling)
Point of screwing
(mounting)
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body assembly
athermal windscreen
The Golf 2013 is available with an athermal windscreen optional. This
windshield is new in that it incorporates a thermal protection function
and defrost function, without any visible heating son. When the vehicle
is parked in the sun, the protective layer reflecting infrared allows a
reduction in temperature in the passenger up to 15 ° C compared to a
conventional windshield green glass, as 60% of solar heat does not
penetrate the passenger compartment. In cold weather, the extra
defrost function defog the passenger side windshield. The marking of
these windshields includes the additional indication IR-H
(InfrarotReflektierend-heizbar - reflecting infrared and icing).
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A layer for protection against infrared
The protective layer against infrared is a very thin silver layer applied on the outer face of the inner pane. The low penetration of heat inside the vehicle
reduces the load on the air conditioner and fuel consumption. In cooling mode, the air broadcast is less cold, increasing comfort.
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A layer for protection against infrared
acoustic PVB sheet 0.10 mm
PVB sheet of 0.33 mm
2,10 mm smooth ice
1.60 mm smooth ice
1
defrost function
When the silver layer is electrically activated, the thermal windshield
warms. In case of light frost and if the frost layer on the outside is not
too large, this heated windscreen visible without son can serve as an
aid to defrost.
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In case of larger gel and / or the layer of frost or snow
is thicker, ice or snow needs to be removed manually.
Design and function
The upper part of the windscreen contains surfaces without silver layer In addition, the lower part of the windshield has invisible copper son
and which are not de-iced. These surfaces are needed to run the rain
sensor, the multi-function camera and electronic toll receiver. This area
must be defrosted manually if necessary.
outside, that allow to defrost locked wiper blades from freezing in the
rest position.
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Copper son defrost wiper
ZDC fitting
ground strap from the body
A layer for protection against
infrared
ceramic
layer
Window for the multi camera
and the rain sensor
ZDC fitting
lower contact bar layer
protection against infrared
upper contact bar of the protective layer against infrared
communication window
to receiver
ETC
grounding cable
copper son
communication window •communication window •
for electronic toll receiver
1
12
body assembly
Sliding roof / pan tilt
The sliding / tilt sunroof panoramic glued to the body is an external
guide to roof system. •guide to roof system. •
•
This roof is an evolution of up roof, plus the sliding function over the
vehicle roof. The sliding / tilt sunroof pan has a manual sunblind. •vehicle roof. The sliding / tilt sunroof pan has a manual sunblind. •
•
It meets the legal requirements for safety pinch.
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Operation
up roof function
When opening, the roof pass through the first raised position.
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Sliding roof function
In the sliding roof function, the glass cover opens by sliding above the
pavilion. •pavilion. •
The deflector, which reports if the sliding roof, diverts the wind created
by the movement of the vehicle above the opened glass cover.
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1
Thermal insulation
The cover glass is tinted and thus contributes to the thermal
insulation. Thermal insulation is achieved through the following
reflection rate:
• Reflection 99% UV
• Reflecting 92% of the thermal radiation
• Reflecting 90% of the light radiation
Design
Glass cover
Roof mechanism sliding / tiltingDeflector
Front cover (material
plastic)
sliding roof
frame (material
plastic)
Roller blind
Frame slide guide
roof motor sliding engine cover
sliding roof / roller sunblind
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Flexible water flow
before
Rear water drain hose
3
14
body assembly
Doors
Front door
On the Golf 2013, the doors consist of an outer panel and an inner
panel. There is more than pre-assembled support plate. All the
components located within the door are mounted through a large
opening provided for this purpose. •opening provided for this purpose. •
This opening is closed with a cover of plastic material through which
the inner opening control cable door. •the inner opening control cable door. •
•
The power window motor is bolted to the outside of the inner door
panel and thus forms a unit with the icing-up mounted in the door. •panel and thus forms a unit with the icing-up mounted in the door. •
•
During assembly, the ice gate is latched in the power window by pins.
For removal, push on the fixing lugs through the assembly opening.
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inserted coins
•
upper door hinge
•
Limiter door opening
•
•
Engine power window
bottom sealHidden
mount opening
Pin fixing
oblong hole
Guide rail
Fixing the ice door
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1
patches
The exterior mirror has a new fixation in door support. Under the cache,
it is attached with two screws. The plug contact is directly on the door
calculator mounted inside the door.
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Hidden
The ice-guide seals are inserted and blocked with a clip in the angle
formed by the roof frame and the amount of ice deflector A.
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Mounting Clip
The seal of the amount B is bonded to the B-pillar in the region of the
side window only to vehicles two doors.
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5
16
body assembly
Limiter door opening
The comfort-optimized door opening limiter is an independent
component and is not integrated with the lower door hinge. To the first
stop, the door closes; beyond, the door can be opened continuously.
The stop limit switch is in the second notch.
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Side window
The rear quarter glass is mounted at the same time that the seal ice
guide and B. amount gasket •guide and B. amount gasket •
Its upper part is fixed in the door frame using two clips. The rail ice
guide is clipped at the top in the door frame and screwed to the inner
door panel by means of two screws.
clip
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Ice deflector
The ice deflector is bonded with perfect adhesion to the amount A. It
does not form part of the front doors.
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1
handholds
holding the handles are snapped factory in the holding brackets
screwed and blocked with a clip.
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The T10517 special tool is required to deposit the
handholds.
hatch
The tailgate is fixed to the body by simple hinges. It can be set through the through holes of large screws. The tailgate coverings are mounted together.
To remove them, you must first remove the coatings located on the frame of ice, then coating the tailgate.
The VW logo, which serves as unlocking element can contain a rearview camera according to the vehicle trim level. A discharge hose evacuates
towards the bottom of the tailgate water entering the unlocking element.
The rear spoiler is integrated into the outer sheet of the tailgate.
7
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rear spoiler
Coating
18
body assembly
Towbar
The 2013 Golf comes with a hitch ball with manual swivel. The device is In addition to the release handle in the rear door-lock coating, the
controlled by a trigger handle in the coating of the door-lock.
device also comprises an LED. This indicator lights green when thehitch ball is properly latched. When the ball is pivoted position or it is
not latched, the indicator flashes red.
•
When the 2013 Golf is fitted with a coupling device, it features the large pack radiator for the engine from 1.6 liters of displacement.
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fuel door module
The fuel door module comprises:
- the actuator
- The cuvette for the filler with the carrier plate of the tank flap
- The fuel filler flap
The tank flap is clipped on plaquesupport. To disassemble, simply slide
it forward.
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Support Plate tank
hatch
1
inside equipment
edge and center console table
Depending on the vehicle trim level, decorative covers on the dashboard can be provided or not with chrome inserts.
The center console is available in two versions. The basic version has open storage. •The center console is available in two versions. The basic version has open storage. •
The top version has a center armrest. Its compact design allows a wide adjustment range in length (100 mm) and height adjustment end, five
levels.
9
control unit heating / air
conditioner
parking brake
arm rest radio / navigation
system
central rear air diffuser
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s520_042
Diffusers
center console as standard
Glove compartment
s520_041
central computer with card readers
(optional)
20
inside equipment
seating
ergoActive seat
The Golf 2013 is for the first time with a ergoActive seat with extended
adjustment possibilities for the driver. This seat has adjustment
functions in height and seat heating, allows manual adjustment of the
depth and inclination of the seat and has a lumbar support 4-way power
positions more massage function. These exceptional ergonomics
features have already earned this seat to get in Germany the official
sign of approval (Aktion Gesunder Rücken - Action for a healthy back).
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Setting options
• Height of the headrest
• Recline
• Seat height
• Length adjustment
• Seat tilt
• seat extension
• Adjusting massage
• lumbar support
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2
fold down
The rear seat has a 60/40 split folding backrest which, added to the folding front passenger seat, makes the boot very functional bags for transporting
bulky items. The forward tilt of the backrest folded was significantly increased compared to the headquarters of the previous generation. The
height-adjustable load floor now has an almost flat load surface. From the Comfortline finish, the record has a series of loading hatch.
s520_027
•
Top tether
Isofix
•
loading hatch
rear seats
The weight of the rear seats has been reduced significantly thanks to
lightweight construction measures. The folded armrest contains
cupholders. These can accommodate sizes of bottles, cans and most
diverse cups. This flexibility is made possible by two separators.
1
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separators
2
Occupant protection
2
T h e n e t w o r k i n g o f a c t i v e s a f e t y
m e n t i n c l u d e s a i r b a g s a n d d r i v e r
r k n e e b a g .
i t h t h r e e - p o i n t b e l t s t o r e e l . T h e
b e l t r e m i n d e r i s s t a n d a r d f o r t h e d r i v e r
security systems
W i t h t h e i n t r o d u c t i o n o f t h e m o d u l a r t r a n s v e r s e e n g i n e p l a t f o r m , n u m e r o u s i n n o v a t i v e s a f e t y f e a t u r e s a r e e m e r g i n g .
s y s t e m s w i t h p a s s i v e s a f e t y s y s t e m s c r e a t e s n e w p r e v e n t i v e p r o t e c t i o n f u n c t i o n s .
T h e n u m e r o u s i n n o v a t i v e s a f e t y e q u i p m e n t o f t h e n e w G o l f o f f e r o p t i m a l p r o t e c t i o n f o r a l l o c c u p a n t s . S t a n d a r d e q u i p
a n d f r o n t p a s s e n g e r , h e a d a i r b a g s f o r b o t h r o w s o f s e a t s a n d s i d e a i r b a g s f o r t h e f r o n t s e a t s , a n d a n i n f l a t a b l e d r i v e
S i d e a i r b a g s a r e o p t i o n a l l y a v a i l a b l e f o r t h e r e a r s e a t s i n c o m b i n a t i o n w i t h b e l t t e n s i o n e r s . A l l s e a t s a r e e q u i p p e d w
s e r i e s o f b e l t t e n s i o n e r s f o r t h e f r o n t s e a t s a n d b e l t f o r c e l i m i t e r s f o r a l l s e a t s e n s u r e e f f e c t i v e p r o t e c t i o n . T h e s e a t
a n d f r o n t p a s s e n g e r . A l o o p b a c k i n d i c a t o r b e l t s f o r t h e r e a r s e a t s i s o p t i o n a l .
A i r b a g s y s t e m : S y s t e m o f b e l t s :
w i t h p r o a c t i v e
• d r i v e r ' s a i r b a g , a t a l e v e l
• A i r b a g f r o n t p a s s e n g e r , a t o n e l e v e l , b e d e a c t i v a t e d
• s i d e a i r b a g s a t t h e f r o n t
• s i d e a i r b a g s i n t h e r e a r , o p t i o n a l
• A i r b a g s h e a d
• i n f l a t a b l e d r i v e r k n e e b a g
• S e a t b e l t s t h r e e - p o i n t r e t r a c t o r f r o n t
• S e a t b e l t s t h r e e - p o i n t r e a r
• r e v e r s i b l e b e l t t e n s i o n e r s a t t h e f r o n t o f t h e v e h i c l e
p r o t e c t i o n s y s t e m f o r o c c u p a n t s , o p t i o n a l
• B e l t f o r c e l i m i t e r s a t t h e f r o n t
• T o p t e t h e r
A c c e l e r a t i o n s e n s o r , •A c c e l e r a t i o n s e n s o r , •
C r i g h t a m o u n t
A c c e l e r a t i o n s e n s o r ,
C a m o u n t l e f t
p r e s s u r e s e n s o r , d r i v e r ' s
d o o r
•
P r e s s u r e s e n s o r , •P r e s s u r e s e n s o r , •
f r o n t p a s s e n g e r d o o r
c r a s h s e n s o r f o r a i r b a g
b e f o r e
C a l c u l a t o r a i r b a g
J 2 3 4
s 5 2 0 _ 0 0 2
2
sensor concept for collision detection
When a severe frontal impact occurs, the crash sensor system must Operating phases
react within milliseconds to the air bag computer can initiate without
delay the triggering of restraint systems.
The concept of optimized crash sensors measure vehicle deceleration
and determines from this data if it is necessary to trigger the airbags or
belt tensioners.
• Analysis of low frequency deceleration signals
"perceptible"
• Measures midrange "audible" in less than or equal to 20 kHz range
(frequencies generated in the form of structure-borne noise during
the rapid deformation of the carriers of the front of the vehicle)
• Smart Linking the two signals in an algorithm to identify the nature
of the collision
For more information on the concept of optimized sensors, see Self-Study Programme •For more information on the concept of optimized sensors, see Self-Study Programme •
492 "The 2011 Jetta EU".
reversible belt tensioners
reversible belt tensioners consist of a pyrotechnic retractor and an
electric retractor and a calculator. The computers are integrated into
the CAN bus system.
When information indicating a collision is transmitted on the data bus
reversible electric belt tensioners are activated. Pyrotechnic
pretensioners are triggered by the airbag ECU.
The system has two different power levels:
1. Average strength = partial retraction in case of transverse and
longitudinal dynamic critical behavior
2. Important Force = complete retraction in case of very critical
transverse and longitudinal dynamic behavior
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3
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Occupant protection
Proactive protection system for occupants
The distinguishing feature of this optional system of protection proactive occupant lies in the connection of active and passive safety elements. It
relies on the use of sensor dynamics control systems such as ABS, ESP and the Front Assist system. They can detect critical situations for the
vehicle stability and with increased risk of accident.
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The proactive protection system for occupants can take the
following steps:
• Retraction of seat belts by an electric motor in order to immobilize
the driver and front passenger in their seats
• roof closing sliding / tilting pan and side window until they are no
longer qu'entrebâillées in case of understeer or oversteer
pronounced
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For more information on the proactive protection system of the occupants, •For more information on the proactive protection system of the occupants, •
see Self-Study Programme 449 "The Touareg 2011".
2
multiple collision avoidance braking
In almost a quarter of accidents, the first collision is followed by other
collisions. This is due to the fact that many drivers lose control of their
vehicles during the reaction time. An automatically triggered braking
can effectively prevent any subsequent accidents. •can effectively prevent any subsequent accidents. •
•
When a first collision was detected, the multiple collision avoidance
braking device triggers an automatic braking so as subjecting the
vehicle to a controlled deceleration. The driver can intervene at any
time and interrupt the multiple collision avoidance braking accelerating
or braking more heavily.
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For more information about the multiple collision avoidance braking, see Self-Study Programme 516 "The Golf 2013 -
Support Systems line."
Safety clip
The safety clip is a special fixing member which holds the door skin on
the door inner panel in a collision, and thus allowing the side air bag to
deploy freely. The safety clip is mounted on vehicles four doors. The
clip has a retention force of more than 1000 N. •clip has a retention force of more than 1000 N. •
•
The clip is not required on the vehicle two doors, because on the latter,
the amount B maintains the liner in place by mechanical connection
form.
s520_013
s520_060s520_059
5
26
Check your knowledge
What are the correct answers?
Among answers indicated, there may be one or more correct answers.
1. Which statement about the weight saving is accurate?
❒ a) The weight of the crude bodywork of the Golf 2013 is less than 23 kg to that of the body shell of •a) The weight of the crude bodywork of the Golf 2013 is less than 23 kg to that of the body shell of •
the 2009 Golf.
❒ b) The weight of the modular platform in transverse engine is lower than 23 kg to that of the body •b) The weight of the modular platform in transverse engine is lower than 23 kg to that of the body •
the 2009 Golf.
❒ c) The weight gain of the body shell can reach 100 kg compared to that of the 2009 Golf.
2. Which statement regarding the variation in width of the modular transverse engine platform •2. Which statement regarding the variation in width of the modular transverse engine platform •
is accurate?
❒ a) The change in width is achieved only with the outer rocker and turrets •a) The change in width is achieved only with the outer rocker and turrets •
strenght leg.
❒ b) The change in width is effected only with the bottom of inner body and turrets •b) The change in width is effected only with the bottom of inner body and turrets •
Strut in the wheel arches.
❒ c) The change in width is effected only using an individualized superstructure.
3. How is the vehicle before the basic rigidity ensured?
❒ a) Using a closed deck
❒ b) Using a separate strut bar
❒ c) Using a torsion ring closed on itself
❒ d) Using a selection of high tensile materials Hot formed in the front of the •d) Using a selection of high tensile materials Hot formed in the front of the •
vehicle
4. How is called the shape of the front spar of the modular transverse engine platform?
❒ a) Beam C
❒ b) Spar U
❒ c) Beam B
❒ d) spar O
2
5. How is the ice gate before the Golf 2013 fixed?
❒ a) The ice front door is screwed into the power window during assembly. For removal, •a) The ice front door is screwed into the power window during assembly. For removal, •
These screws must be removed through the assembly opening.
❒ b) The ice front door is riveted on the power window during assembly. For removal, •b) The ice front door is riveted on the power window during assembly. For removal, •
these rivets have to be removed through the mounting opening.
❒ c) The ice front door is snapped into the window regulator by pins during assembly. •c) The ice front door is snapped into the window regulator by pins during assembly. •
For removal, push on the fixing lugs through the assembly opening.
6. What is the peculiarity of the front doors of the Golf 2013 four-door version?
❒ a) A support plate is mounted in the front doors.
❒ b) The front doors have a safety clip which can absorb 1000 N.
❒ c) An airbag is first mounted in the door skin.
7. How many retractions reversible belt retractor of the Golf in 2013 he carried out?
❒ a) It performs three retractions: no belt, partial retraction and full retraction.
❒ b) It performs a partial retraction and a full retraction.
❒ c) It performs only pyrotechnic retractions.
Réponotses:
1.at);2.b);3.at),c);4.at);5.c);6.b);7.b)
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