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Strictly Confidential 22/10/2019 T h i s p r e s e n t a t i o n d e d i c a t e d t o t h e m e m o r y o f o u r f o u n d i n g p r e s i d e n t .Strictly Confidential 22/10/2019 V e h i c l e B o d y S t r u c t u r e a n d S a f e t y N I O f o u n d e d 1 1 / 2 0 1 4 . S t a r t o f d e v e l o p m e n t 0 7 / 2 0 1 5 E S 8 v e h i c l e d e l i v e r e d 0 6 / 2 0 1 8 E S 6 v e h i c l e d e l i v e r e d 0 6 / 2 0 1 9Overview NIO. More than a car company. User Experience. Nio Power. Nio House. Project Planning How we are so quick to Market. The NIO ES8 & ES6 : Agenda Product ES8 Overall Dimensions ES6 Overall Dimension. Roominess Scalable Platform. Attributes. Safety Body Structure And Concepts Joining Process. Pain Points Materials Development. Battery Swap. Battery Housing. Manufacturing Manufacturing Strategy and Challenges. Production Plant Brief. Stamping Process. Body Process Digital Development JoiningNIO is more than a car company Conceived and planned since 2012 and formally founded on November 25, 2014. NIO is a global company that designs, develops, and produces smart, high-performance, premium electric vehicles. Our aspiration is to shape a joyful lifestyle for our users through thoughtful design, amazing services, and cutting-edge technology.An Experience Beyond RefuelingPower Home Plug in and charge Power Swap Battery swap in minutes One Click for Power Worry-free power services powered by the internet Power Mobile Ten minutes of charging for 100km of rangeNIO Expressway Power Swap Network.NIO Cafe: Gallery: Joy Camp: A space for young people to explore, create and grow Living Room: The warm heart and a space to socialize, relax and think Library: A museum to share knowledge, relax and enjoy some alone time Lab: Bookable meeting rooms and workspace Forum: An inspiring space and a theater of thinking, dreams and collaborationThe NIO Office Environment is modelled the same as our NIO House concept. A warm and inviting open plan , relaxing atmosphere to encourage interactions and creative discussions. SAN FRANCISCO SHANGHAI LONDON SAN JOSE BEIJING NIO has over 7,000+ employees and world-class research and development, design, and manufacturing centers in Shanghai, Beijing, San Jose, Munich, London and seven other locations. Services Nationwide OXFORD Advanced Vehicle Concepts Computer Aided Engineering MUNICH Light Weight Engineering Advanced System Concepts Engineering HQ Manufacturing HQL1 L2 L3 President VP VE/VI VP MO VP FIN VP PUR VP .s Dir BIW Dir VI Dir Dir Mgr. Mgr. Mgr. Engineers Mgr. Mgr. Mgr. Engineers Dir Body Ass. Dir Stamping Dir Dir Engineers Mgr. Mgr. Mgr. Mgr. Mgr. Mgr. Engineers Lean decision making path. Quick Escalation and ResolutionBody SMT . Quick Escalation and Resolution SMT Leader Engineering Finance PQM Design Service Logistics EQ VI Manufacturing Mnf. Quality PM PurchasingHigh-Performance Electric SUV NIO ES8 Flagship SUVNIO ES6 High-Performance Long-Range Electric SUVNIO stands for Premium High performing EV attributes development in a born-electric platform easy of use spaciousness ride comfort quietness functionality design torsional stiffness mass weight distribution performances handling aerodynamic rangeFastest execution from zero to SOP 2015 2016 2017 2018 Program Gates Virtual loops Testing Builds 32 months from zero to first user delivery 32 months from 100 overall employees to 7000+ in 4 locations 1 3 5 6 7 VB TT NJ Pilot plan VB TT PP Mules PP MP HF plant 2 4 Mules design and Build LLP BIW / EXT Toolingtested around the world and please flags on - Europe - North America (Cali) - Australia - China south - China North Tested around the world Europe Vehicle Dynamics China Extreme weather Vehicle Dynamics AD Australia Extreme weather California ADThe NIO ES8 is a 7-Seater High Performance Electric SUV. Specifications Length: 5022mm (198 in) Width: 1962mm (77 in) Height: 1756mm (69 in) Wheelbase: 3010mm (118 in) Front Track : 1668mm (65.7 in) Rear Track: 1672mm (65.8 in) Seats: 7 (6 seat version available.) Curb weight: 2460Kg (5423 lb) Drag coefficient: 0.29 0-100km/h: 4.4s Max speed: 200km/h (124Mph) Dual motor intelligent E-AWD 240-240 Max power: 480Kw (650Ps) Peak torque: 840 N-m NEDC driving range: 355km 70kWh liquid cooled battery pack. (Swappable) Range when constantly run at 60km/h: 500km (310 Mi) Charging 0-100% on AC 7kW (hours): 10:00 Charging 0-100% on DC 90kW (mins): 00:47 Mobile charging 10 mins : 100km Battery Swap (mins) : 3 Springs : AirThe NIO ES6 is a 5-Seater High Performance Electric SUV. Specifications Length: 4850mm (191 in) Width: 1965mm (77 in) Height: 1758mm (69 in) Wheelbase: 2900mm (114 in) Front Track :1668mm (65.7 in) Rear Track: 1672mm (65.8 in) Seats: 5 Curb weight: 2345Kg (5159 lb) Drag coefficient: 0.28 0-100km/h: 4.7s 5.6s Max speed: 200km/h (124Mph) Dual motor intelligent E-AWD 160 -240 160 -160 Max power: 400Kw (544Ps)/ 320Kw ( 435Ps) Peak torque: 725 N-m / 610 N-m NEDC driving range: 430km 84kWh and 70kWh liquid cooled battery pack options. (Swappable) Range when constantly run at 60km/h: 510km (317 Mi) Charging 0-100% on AC 7kW (hours): 10:00 Charging 0-100% on DC 90kW (mins): 00:47 Mobile charging 10 mins : 100km Battery Swap (mins) : 3 Springs : Air or CoilRoominess ES8 Y2018 WB:3010 WB:2900 +110 FR-OH:922 FR-OH:926 -4 RR-OH:1089 RR-OH:1024 +65 OAL:5022 OAL:4850 +172 H30-1:319 H30-1:301.5 +17.5 H30-2:325 H30-2:325 0 L602:1864 L602:1800 +64 L605:522 L605:476 +46 L50-1:965 L50-1:888 +77 L113:625 L113:624 +1 H61-1:992 H61-1:1002 -10 H61-2:989 H61-2:960 +29 L99:899 L99:907 -8 ES6 Y2019T h e f i r s t a l l - a l u m i n u m b o d y s t r u c t u r e d e v e l o p e d a n d p r o d u c e d i n C h i n a W i t h a M o d u l a r a n d S c a l a b l e P l a t f o r m - Modular design - Great serviceability - Flexible platform strategy - Integrated design of key parts - High production efficiency flexible flexible flexible flexibleAir curtain Aero-dome Rear Lower diffuser lower bumper Fine-tuned fender Fine- tuned rocker Fine-tuned A pillar spoiler Underbody Aero-shield CFD Simulations Cases wind tunnel test hours 300 150 ES8 Aerodynamic 0,29 Outside Mirror Hood edge Rear fender Aero-blade Rear- deflector Skid plate A-pillar moldingSkid plate deflector Rear Lower diffuser lower bumper Fine-tuned fender Fine- tuned rocker Fine-tuned A pillar spoiler Aero-rim Underbody Aero-shield CFD Simulations Cases wind tunnel test hours 400 160 ES6 Aerodynamic 0,28 Outside Mirror Hood edge Rear fenderM u l t i p l e c l o s e d - R i n g s f o r t o r s i o n a l c o n t r o l d e s i g n s integration Ensuring great handling Improving the auto Torsion reinforcement ring of front end module Torsion reinforcement rings of front end structure Double torsion reinforcement rings of rear passenger compartment 2.0 2.1 2.2 2.3 2.4 2.5 150 200 250 300 350 400 450 LWI=M Body / (KT x A) BIW Weight Kg Competitor B Mass:362kg LWI:2.19 Competitor A Mass:288kg LWI:2.22 ES8: LWI Achieved :2.02 LWI High Stiffness & NVH targets for EV refinement BIW ( Measured ) 43.7 Hz 1 st global torsion 1 st Eigenfrequency body structure: 47.9 Hz 1 st global bending 2 nd Eigenfrequency body structure 25.5 Hz 1 st Eigenfrequency trimmed body structure: 29.6 Hz 2 nd Eigenfrequency trimmed body structure: 44.14 kNm/deg. static torsional stiffness 13.66 kN/mm static bending stiffness M body = 354Kg Stiffness Data ES8Torsion reinforcement ring of front end module Torsion reinforcement rings of front end structure Double torsion reinforcement rings of rear passenger compartment Stiffness Data ES6 High Stiffness & NVH targets for EV refinement BIW (Measured) 41.8 Hz 1 st global torsion 1 st Eigenfrequency body structure: 50.2 Hz 1 st global bending 2 nd Eigenfrequency body structure 30.6 Hz 1 st Eigenfrequency trimmed body structure: 32.7 Hz 2 nd Eigenfrequency trimmed body structure: 44.93 kNm/deg. static torsional stiffness 13.10 kN/mm static bending stiffness M body = 342KgStructural & Acoustic Composite Baffles Added in C / D ring (2.4kg) Reduced panel thickness (-7.0Kg) Weight reduction -4.6Kg Torsional Frequency same Bending frequency sameS a f e t yB e y o n d f i v e - s t a r s a f e t y s t a n d a r d 5 S t a r s C - N C A P O f f i c i a l P u b l i s h e d J u l y 2 0 1 9 P l a t f o r m d e v e l o p e d t o m e e t I n t e r n a t i o n a l S t a n d a r d c a s e s s u c h a s S i d e P o l e 7 5 d e g 3 2 k p h , R e a r I m p a c t F M V S S 3 0 1 8 0 k p h a n d R C A RES8 (NP1) Beyond 5 Stars. Storyline CHALLENGES C-NCAP 5 WORLDWIDE LOADCASES Starting from scratch Airbag roof mounted Unique Interior roominess EV HV protection TARGETS = 3 rd Row + Full Al BiW Swappable battery system SENSING High-performance 7-seater Electric SUV l o a d p a t h i m p a c t l o a d p a t hI n t e g r a l s i l l s e c t i o n T h e b i g g e s t i n t e g r a l c a s t i n g p a r t o f t h e w h o l e v e h i c l e T o r q u e b o x L o a d t r a n s m i s s i o nBody Structure. Concept Validation, Correlation Rail design in balance. Stable & progressive folding Validation rail + Casting drive shaftStable sub system. Progressive folding & sub frame in balance Validation CMS + rail + Sub frame Body Structure. Concept Validation, CorrelationF r o n t a l I m p a c t 6 4 k p h 4 0 % O f f s e t S t a b l e P a s s e n g e r C o m p a r t m e n t H V B a t t e r y f u l l y p r o t e c t e dO D B ( O f f s e t D e f o r m a b l e B a r r i e r ) Minimum deformation on footwell areaS t a b l e P a s s e n g e r C o m p a r t m e n t S O R B ( S m a l l O f f s e t R i g i d B a r r i e r ) 6 4 k p h 2 5 % O f f s e tS O R B ( S m a l l O f f s e t R i g i d B a r r i e r )S i d e i m p a c t p o l e t e s t a t 3 2 K M / h a n d a n a n g l e o f 7 5 d e g r e e s A i n t r u s i o n o f o n l y 1 2 0 m m , Side Pole Impact location not just aligned to Driver GoG but due care locationsR e a r c r a s h t e s t a t 8 0 k m / h ( 7 0 % o v e r l a p ) A d e f o r m a t i o n o f o n l y 4 2 5 m m , S a f e t y o f o c c u p a n t s s i t t i n g a t t h e t h i r d r o w a r e p r o t e c t e d .Stable structure + 3 row occupant well protected HV system integrity keptR C A R c r a s h t e s t E f f e c t i v e l y r e d u c i n g t h e a l l - No cooling damage. No BiW damage. No tailgate damageB o d y i n W h i t e D e s i g n a n d D e v e l o p m e n tES8 Major BIW Stampings 71 6xxx stampings ( 0.9 3.0mm / 118.2Kg) 8 5xxx stampings ( 1.2 2.5mm / 15Kg) 2 Steel stampings (SPFH590 U / 4.0mm/ 1.5Kg) ES8 Major BIW Castings 14 Castings (AlSi10MnMg /SF36-T6 / 90Kg ) ES8 Major BIW Extrusions 6 7xxx Extrusions ( Longitudinals, frt crash cans, rr crash box 14.6Kg) 12 6xxx Extrusions ( 72.4 Kg)ES6 Major BIW Stampings 7 7075 stampings ( 1.8 2.0mm / 7.86Kg) 70 6xxx stampings ( 0.9 3.0mm / 102.2Kg) 7 5xxx stampings ( 1.2 2.5mm / 10.4Kg) 2 Steel stampings (SPFH590 U / 4.0mm/ 1.8Kg) ES6 Major BIW Castings 21 Castings (AlSi10MnMg /DC-a /b/d-T6 / 100.1Kg ) ES6 Major BIW Extrusions 17 6082- T6 Extrusions ( 76.7 Kg) ES6 Major Composite GOR PP-GF40 ( 5.17 Kg) CFRP rear floor panel ( 5.58Kg)ES8 Closures Stampings 21 6xxx stampings ( 0.9 2.5mm / 26.5Kg) 9 5xxx stampings ( 0.85 1.5mm / 26.5Kg) 4 6082 Extrusions ( 2.5mm/ 3.4Kg) ES8 Closures (others) Tailgate SMC (10.9Kg) / PP + EPDM-T30 (3.9Kg) Supplier painted , GA assembly Fenders PP + EPDM-T30 (3.56Kg) Supplier painted , GA assembly GOR Mg. AM60B, Black Powder Coat (3.54Kg), GA assemblyES6 Closures Stampings 18 6xxx stampings ( 0.9 2.5mm / 25.9Kg) 9 5xxx stampings ( 0.85 1.5mm / 25.7Kg) 4 6082 Extrusions ( 2.0 - 2.5mm/ 3.2Kg) ES6 Closures (others) Tailgate SMC (2.5Kg) / PP + EPDM-T30 (3.55Kg) / PP-GF40 (8.41kg) Supplier painted , GA assembly Fenders PP + EPDM-T30 (3.76Kg) Supplier painted , GA assemblyMaterial Usage Comparison ES8 vs ES6 AL 6 Series Sheet 38% Steel 3% Magnesium 1% SMC 3% Fibre Reinforced 0% Thermoplastic 2% AL 5 Series Sheet 10% AL 7 series Extrusion 3% HP AL Casting 22% AL 6 Series Extrusion 18% ES8 BIW & CLOSURES AL 6 Series Sheet 33% Steel 5% AL 7 Series Sheet 2% SMC 0% Fibre Reinforced 5% Thermoplastic 2% AL 5 Series Sheet 10% AL 7 Series Extrusion 0% HP AL Casting 24% AL 6 Series Extrusion 19% ES6 BIW & CLOSURES ES8 Material Usage Rate ( Stampings) 52% Upper Body 48% Under Body 56% Closures 48% ES6 Material Usage Rate ( Stampings) 51% (FTI) Upper Body 46% Under Body 58% Closures 50%Joining technology innovate with lightweight 435 382 362 2T 324 2T 73 2T 58 3T ES8 ES6 1638 1547 1114 2T 1143 2T 520 3T 378 3T 4 4T 26 4T 5147 5560 6965 910 202839 202709 8 24 242 208 ES8 ES6 605 662 522 2T 604 2T 83 3T 58 3T 44 42 91 92 Structural Adhesive CMT FDS SPR RSW Laser Weld Blind Bolt Blind Rivet Weld Stud Weld Nut Clinch Nut 163 178 Clinch Stud 124 126 Rivet Nut 256 283 Rivet Stud 77 66Body Structure. Joining CAE Cross tension Lap Shear PeelingStrictly Con
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