R56 Introduction: Bodyshell: Notes

The R56 is a logical further development of the R50. However, the bodyshell has been completely redeveloped in regard to vehicle structure.

The outstanding crash behavior can be attributed to the specific use of high-strength steels and, in part, aluminum components (in the door area).

Although the vehicle has short overhangs and deformation zones, crash loads are well transferred. This is due to intelligent load paths. The front end features crash cans on the front axle carrier in addition to the bumper carrier and the crash boxes.

This creates a second load path which together with the engine mountings allows energy to be shunted into the floor structure. The bulkhead with appropriate cross members and the so-called ski ramps in the front area of the floor assembly stabilize the footwell.

Together with sturdy seat cross-members, the side frame and the rear carrier structure produce a rigid passenger cell. The doors with extrusion molded aluminum profiles in the shoulder area and the door diagonal reinforcers constitute, together with the A-pillar and B-pillar, the deformation zone in a side-on crash.

The solid passenger cell is a prerequisite for putting the restraint systems to the best possible use. In the R56, in addition to front airbags for the driver and front passenger, side airbags (pelvis-thorax airbags) in the front seats, belt force limiters and belt tensioners for the driver and front passenger, head-level airbags (curtain) for all seats and a steering column unit with crash elements ensure that occupants are restrained in a great variety of collision situations.

In a frontal, side or rear-end collision, in particular in the event of a rollover, the front seats with integrated pelvis-thorax side airbags offer a high degree of safety for the occupants.

In accidents at low speeds, the crash boxes prevent damage to expensive components such as the body, lights and cooling system. Energy is dissipated by the deformation of the crash boxes.

The R56 has to pass the 5-star Euro NCAP test. For this, the following developments were implemented:

• highly stressable carrier structures
• extremely rigid passenger cell
• compatible design of the front end structure
• highly-efficient restraint-systems.