Derivation of special equipment weights in early development phases of a luxury SUV

In the early development stages of a luxury SUV, accurate component and system weight estimates are critical to meeting performance, efficiency and regulatory compliance targets. Optional equipment, which includes customer-selected optional features, can significantly impact the vehicle's overall mass, weight distribution and associated subsystems. This use case outlines a methodology for estimating the mass of special equipment to support lightweighting strategies.

Goals

Provision of reliable mass estimates of special equipment at the beginning of the concept phase.
Enables mass budgeting and trade-off analysis for system integration.
Supporting lightweight construction principles by identifying effective options.
Facilitate early dialog with suppliers and systems engineering.

Methodology

The derivation of special equipment weights is based on a combination of a benchmarking database, simplified TGM models, supplier data and historical values from predecessor models.
The process comprises the following steps:

Identification of frequently selected optional extras.
Analysis of functionality and integration complexity (e.g. electronics, actuators, effects on the interior).
Estimate using simplified TGM equipment models or adjusted values from predecessors.
Use of a central weight management database.

Example: Mass estimates for special appliances

Special equipment	Description	Approx. mass [kg]
Rear-seat entertainment system	Two screens with control unit	10
Mulliner refrigerator	Refrigerator in the rear center console	20
Panorama glass roof	Large panoramic sunroof	25
4-seater configuration	Individual rear seats with comfort features	+18
Massage seats	Massage mechanism in the seats	10
Night vision assistant	Infrared camera system	5
High-end audio system	Naim for Bentley with amplifier/subwoofer	21
22-inch wheels	Larger alloy wheels	4
Carbon-ceramic brakes	Performance brake system	5
Tow bar	Electrically extendable towing system	28

Conclusion

Early mass estimates of special equipment support the strategic development of vehicle concepts and enable optimal layout, load path design and lightweight construction. Through continuous updating and validation, these estimates form the basis for accurate weight targets and efficient system integration in the development of luxury SUVs.