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Porsche's New Panamera, in the Premium Grand Tour Class, Sports a Lightweight Torque Roll Restrictor made by ContiTech with Polyamide from BASF
Making a bee-line from the visual world to under the engine hood
With engine output of up to 500 HP, the Panamera represents Porsche's first four-door premium grand tour class model. High-performing vehicles like this place special demands on the engine mount. For this innovative car, Porsche has opted for an equally novel material solution. As the torque roll restrictor can be seen when the hood is up, ContiTech Vibration, in close collaboration with the Porsche design department, endowed the part with an attractively grained surface.
"The torque roll restrictor must be capable of absorbing high loads. As a visible component, though, it must also satisfy aesthetic requirements. ContiTech Vibration Control thus employs a special mold in manufacturing it to obtain an especially high-quality surface appearance," notes Stefan Wöhler, in charge of product development at ContiTech Vibration Control.
From the very start the component was developed in BASF's Ultramid® polyamide and more or less completely computer designed with the help of BASF's universal simulation package, ULTRASIM(TM) . "As materials specialist and development partner, BASF intensively supports its customers in this way with simulation technology that incorporates a number of novel features and has demonstrated its worth in actual use many times over," notes Bernhard Aumer, ULTRASIM expert for BASF's technical plastics.
In this case it was a matter of ensuring a specific functionality and loadability in a defined installation space. In just a few calculation runs, BASF put together a component concept on the direct basis of which ContiTech, the systems supplier in charge of the complete integrated elastomer bearing or composite component, was able to generate a manufacturable design. No backup prototype testing was needed and optimization work could be kept to a minimum, amounting, in vehicle development, to enormous savings in terms of time and money.
Compliance with the requisite specifications was confirmed in test rig trials at ContiTech Vibration Control and vehicle trials carried out at Porsche.
Installed longitudinally on two suspension points, the torque roll restrictor not only secures the vehicle engine but, as a visible part, must also fulfill high demands in terms of an aesthetically pleasing surface appearance. Just to satisfy this latter requirement, the injection mold at ContiTech Vibration Control was optimized to allow for a fine, matte surface grain. Made of Ultramid® A3WG7 CR, the novel plastic component replaces a metal part of comparable functionality. Employing BASF's ULTRASIM(TM) simulation package, it was possible to develop a design directly on the computer that could then be transformed into a production component without having to pass through a prototype phase. Photo: BASF
BASF is the world's leading chemical company: The Chemical Company. Its portfolio ranges from chemicals, plastics and performance products to agricultural products, fine chemicals as well as oil and gas. As a reliable partner BASF helps its customers in virtually all industries to be more successful. With its high-value products and intelligent solutions, BASF plays an important role in finding answers to global challenges such as climate protection, energy efficiency, nutrition and mobility. BASF posted sales of more than €62 billion in 2008 and had approximately 97,000 employees as of the end of the year. BASF shares are traded on the stock exchanges in Frankfurt (BAS), London (BFA) and Zurich (AN). Further information on BASF is available on the Internet at www.basf.com
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