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Geneva Motor Show 2015 Technology Trends Dr.-Ing. Karl Siebertz (VDI, SAE International) Ford Research & Advanced Engineering To be published in: FISITA Inside-track, April 2015 Why Geneva? Location: Geneva is surrounded by France, Italy and Germany, which provides a true international flavour. The show attracts manufacturers around the world. Timing: Geneva Motor Show is the most important European motor show in spring. Frankfurt and Paris Motor shows are in fall. The Geneva show is close to NAIAS, the Tokyo motor show (odd years ) and Auto Expo (even years). This offers good opportunities for product introductions on two continents. Size of the show: small, compared to Frankfurt and Paris. Show stands focus on innovations, concept cars and product introductions. General Observations in 2015 At first glance 2015 appeared to be a “quite show” with a lower amount of dramatic innovations, compared to previous years. However, looking into the details, this was not quite true. Manufacturers accelerated the conversion of concepts and technologies into real products. From the customer perspective this generates a larger variety of choices. For the industry this increases the pressure to bring technology to the market. Automotive is one of the most dynamic areas of engineering in these days. Content of this Report 1. Fuel Cell Electric Vehicles 2. Battery Electric Vehicles 3. Plug-in Hybrids 4. ICE and Transmission 5. Switching Gears 6. Lightweight 7. Connected Car and Infotainment 8. HMI and Displays 9. Active Safety and Driver Assistance 10. Steering and Suspension 11. Personalization 12. Roominess and Utilization of Space 13. Light Technologies 14. Heritage 15. X-Brand Platforms
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Fuel Cell Electric Vehicles
The first production FCEV’s are on the market now. Several manufacturers have concepts in place. The infrastructure is still an issue and prohibitive for the commercial success.
Figure 1: Toyota Mirai (left) and Hyundai ix35 Fuel Cell (right). •
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Toyota Mirai – on sale in Japan since December, launch in Europe by the end of the summer for 66000 € + VAT. 144kW max output, 3.1kW7l stack output density, 650V, two 700bar H2 tanks with 122 l total volume. Hyundai ix35 Fuel Cell – available in Europe since December 2014 for selected customers (lease and sales). 100kW max output, top speed 160km/h, 594km range, 144l tank capacity. Based on ix35. VW Golf Variant HyMotion – already shown in LA. Based on MQB (modular transverse matrix). 100kW, 500km range. Honda FCV Concept – already shown in Nov 2014. FCEV production announced for 2016. 100kW, 3100 W/L. PT packaged in engine compartment.
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Battery Electric Vehicles
Considerably low attention to BEV’s. Again, infrastructure is a substantial success factor, but this cannot be resolved by the car industry alone. Niche applications are on display and business models are introduced to foster the market penetration.
Figure 2: Audi A8 e-tron (left) and Nissan e-NV 200 (right; source Nissan).
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Audi R8 e-tron – 340kW, 920Nm, 0 -100km/h in 3.9 s, 450km range. In the press conference Prof. Hackenberg mentioned that he drove from Audi HQ to Geneva in the R8 e-tron. BMW 360° - ChargeNow grants the BMW i customer access to some 26,000 charging points in 21 countries around the globe. BMW i teamed up with a series of providers. Intermodal vehicle navigation combining different forms of transport to be extended at an international level. Projects in Germany, the USA and China are working on the reuse and recycling of the lithium-ion batteries. Nissan and Endesa - Nissan and Endesa, an Enel Group subsidiary, signed an agreement at the Geneva Motor Show that paves the way for a mass market vehicle-to-grid (V2G) system. Renault Zoe – New e-motor and extended range (240km).
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Plug-in Hybrids
PHEV’s combine the advantages of electric drives with the range, performance and independence of the conventional combustion engine. It appears to be a strategy of long term relevance.
Figure 3: VW Sport Coupe Concept GTE (left) and Volvo S60 D5e (right).
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VW Sport Coupe Concept GTE – the front E-motor integrated in 6-speed DSG, 40 kW; the rear electric motor 85 kW. System power 279 kW. AWD using an “electric prop-shaft”. In this case the front e-motor is a generator to feed the rear e-motor. Based on MQB. Volvo S60 D5e – 120 kW via combustion engine, 50 kW e-motor, 11.2 kWh battery, configuration as used in the V60 D6 Twin Engine (e-motor drives rear axis). M-B V Class PHEV Concept – gasoline engine 155kW, e-motor 90kW, 0-100 km/h in 6.1, top speed 206 km/h, NEDC fuel consumption of 3.0 l/100km. 13.5kWh battery, 50km range at speeds below 80 km/h. Hyundai 48V Hybrid Concept – 10% boost, Diesel engine, 109 g /km CO2. Hyundai Tucson PHEV Concept – Diesel Hybrid, DCT, e-motor at rear axle. 135 kW system output, 48g/km CO2. Others: Audi Prologue Concept, A8, Q7, Magna PHEV Concept, Mercedes Vclass PHEV Concept, 350 e, Seat 20V20 Concept, Suzuki iM4 Concept, Volvo XC 90, Ford Mondeo Hybrid.
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Internal Combustion Engine and Transmissions
Further improvements of the fuel efficiency and introductions of new Dual Clutch Transmissions (DCT). The downsizing trend of engines continues.
Figure 4: Jaguar Ingenium Diesel engine (source JLR; top left) Toyota 1.2l engine (source Toyota; top right) Ford GT with 3.5l EcoBoost engine (source Ford).
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Jaguar Ingenium Diesel– introduced in Paris in 2014. Meets Euro 6. Variable exhaust valve timing, low pressure exhaust gas recirculation, selective
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catalytic reduction, Al block, twin balancer shafts, acoustic sump cover, decoupled injectors, 2.0l, 180PS / 430 Nm. Kia 7 speed DCT: Developed in-house at Kia’s Namyang R&D centre, hollow double-gear input shaft minimises loss of torque, intro in cee’d, x-carline application announced, replacing the 6 speed torque converter automatic. 1.0l 3 cyl. “Kappa” engine: developed in-house, single scroll turbocharger with electric scavenging system, dual thermostat cooling, 200bar fuel injection, 120PS, 172 Nm. Toyota 1.2l 4cyl – direct injection, low inertia water cooled turbo, variable valve timing allows to switch between Otto and Atkinson cycle, 85kW, 185Nm, first application in Auris. Opel -1.0 ECOTEC with 55 kW/75 hp. All-aluminum one-liter, three-cylinder gasoline engine, available in the new Opel Karl. Ford GT – downsizing from 5.4l V8 supercharged to the 3.5l V6 EcoBoost. Ok, not really, since the power went up from 550PS to >600PS. Others: Smart with DCT, Skoda Superb with eight new EU6 compatible engines based on MQB platform.
5 Switching Gears Koenigsegg introduced a car without gearbox. Whilst other car makers keep raising the complexity of the gearbox, this super-hybrid just needs a hydraulic clutch.
Figure 5: Koenigsegg Regera (top left), powertrain data (source Koenigsegg; top right) and sketch to illustrate the propulsion concept (source Koenigsegg). Koenigsegg Regera - The patent pending Koenigsegg Direct Drive Transmission uses a hydraulic clutch, similar to a torque converter to engage the combustion engine at speeds higher than 50km/h. During full acceleration (dry conditions) the Regera stays at the tire slip limit from 0 – 270 km/h. 35km full electric range, 32 g/km CO2 emission, based on NEDC cycle. 410 km/h top speed. 1420kg dry weight and 1628 kg curb weight. Koenigsegg claims that the hybrid without gearbox is only 88 kg heavier than the same engine without electrification, but using a conventional DCT.
6 Lightweight Substantial use of CFRP in sports-cars. Successors tend to be lighter than previous models. First use of Aluminium for mid size cars.
Figure 6: Jaguar XE (left) and Audi R8 Space Frame (source Audi; right). •
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Jaguar XE – Jaguar introduced aluminum intensive manufacturing for the XE. 75% Al content of the body. 70% high grade, such as AC300 and AC600. Multi-material use in the b-pillar (Al, UHSS, hd-foam). Cd of 0.26. Audi A8 – 50kg weight reduction compared to previous model. Multimaterial space frame. Combination of Al and CFRP. Renault Espace – 250kg weight reduction, high Al content. Cd=0.3. Skoda Superb – 75kg lighter, Cd =0.275 Mazda MX5 - - 100 kg lighter
Figure 7: EDAG Cocoon concept.
EDAG Light Cocoon – EDAG used bionic shape optimization to identify the lowest weight geometry and then printed the parts using additive manufacturing. The cover is made of fabric, in cooperation with Jack Wolfskin. If required, this can be used as projection surface. Case study and scientific background: EDAG Cocoon
Figure 8: EDAG Cocoon concept (source EDAG). Bionics became popular in recent years. However, the scientific investigation of living organisms and their construction principles with respect to the mechanical strength is much older. In fact, it has some history in Germany. Wilhelm Roux investigated the human locomotor system (starting around 1878) and defined the principle of functional adaptation. Friedrich Pauwels took it further (starting around 1935), in cooperation with mechanical engineers from RWTH Aachen. A nice summary can be found in the lecture notes from Dieter Weichert. Werner Nachtigall can be seen as one of the pioneers in Bionics. He observed numerous principles (starting around 1969). Claus Mattheck established the first numerical methods to utilize bionics for shape optimization of components (starting around 1985). Lothar Harzheim refined the methods (starting around 1990), worked for Opel and applied the methods to automotive.
Figure 9: Additive manufacturing process and CAE (source EDAG). Bone remodeling and the growth of trees lead to ultimate lightweight constructions, far superior to everything which can be produced today. Within the limits of manufacturing, the basic principles of functional adaptation can be simulated in CAE and utilized to improve technical constructions. The EDAG Cocoon drives the idea of shape optimization to the next level, since it utilized additive
manufacturing methods, which take away several geometrical restrictions of the conventional design. The visual appearance of the concept car structure reminds to a biological system, not without reason. However, a few cool tricks of “mother nature” are still missing, e.g. the trabecular microstructure and the orthotropic material strength. There is a rapid development of Selective Laser Melting and Fuse Disposition Modeling. The fibre content is limited to 10% at the moment, but this might chance. Of course cycle times are far longer than what we are used to in current mass production. However, there might be a paradigm shift in the future, away from excessive tooling costs and short cycles towards low invest and longer cycles, at least for niche applications.
Figure 10: EDAG Cocoon concept (source EDAG). References Roux, Wilhelm: Der Kampf der Theile im Organismus. Ein Beitrag zur Vervollständigung der mechanischen Zweckmässigkeitslehre. W. Engelmann-Verlag, Leipzig, 1881. ( http://docnum.ustrasbg.fr/cdm/compoundobject/ collection/coll13/id/41242) Pauwels, Friedrich: Gesammelte Abhandlungen zur funktionellen Anatomie des Bewegungsapparates. Berlin, Heidelberg, New York, Springer-Verlag, 1965. Weichert, Dieter: Zur Mechanik des menschlichen Bewegungsapparates. Institut für Allgemeine Mechanik, RWTH Aachen 2006. http://www.iam.rwth-aachen.de/fileadmin/media/18/ Ringvorlesung_Biomechanik.pdf Nachtigall, Werner: Bionik, Grundlagen und Beispiele für Ingenieure und Naturwissenschaftler. Berlin, Heidelberg, New York, Springer, 2012. Mattheck, Claus: Design in der Natur: Der Baum als Lehrmeister. Rombach-Verlag, Freiburg, 1996. Harzheim, Lothar: Strukturoptimierung Grundlagen und Anwendungen. Wissenschaftlicher Verlag Harri Deutsch GmbH, Frankfurt, 2007. Barckmann, Johannes, et al.: EDAG Light Cocoon. EDAG Insights 1/15, 2015. http://www.edag.de/services/corporate-services/downloads-publikationen.html#insights_de
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Connected Car and Infotainment
Connectivity continues to be a trend. Modular systems, connectivity to various devices, cooperation with non-automotive partners and improved HMI are the topics.
Figure 11: VW Touran (source VW; left) and Qoros Could 2.0 app (source Qoros; right). •
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VW Touran – Range of five radio and radio navigation systems offered in this model, all with touchscreens (5-inch to 8-inch), part of the second generation of the modular infotainment matrix (MIB). DAB. Dynaudio sound system opt. AppConnect with CarPlay (Apple) and Android Auto (Google). Available with MirrorLink™. Jaguar XE – InControl offers access to smart phone apps, speech recognition, WIFI hotspot, remote control via smartphone, car localization in case of theft, contact to the Jag assistance in case of malfunction and emergency call. Meridian audio system as option. Qoros cloud – based on MS Azure, control via 8 inch touch screen or smartphone (Apple or Android). Version 2.0 starting March 15. Navigation, traffic info, connect to social network, car condition, maintenance check. GM – announced the x-carline offer of On-Star +4G in Europe. 1 year free of charge. Volvo – announced to extend the Volvo Cloud services with Ericsson. Focus on road safety. Audio with Bowers & Wilkins. Skoda Superb available with Canton audio system. Renault Kadjar and Espace available with R-Link 2 and Bose audio system. Ford – MyFord Mobile introduced at the Barcelona World Mobile Congress, exactly at the time of the Geneva Motor Show.
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HMI and Displays
(Low cost) Head Up Displays and electronic center displays enter the market.
Figure 12: Ford S-Max (source Ford; left) and BMW 2 Grand Tourer (right). • • • •
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Ford S-Max – (9/2014) Electronic Display, like the Ford Mondeo. Audi R8 – Electronic Display, similar to Audi CC. Configurable and context sensitive. Seat 20V20 with configurable electronic displays. BMW 2 series Grand Tourer – low cost HUD with plastic screen. A similar system is available in the Mazda CX3. Jaguar XE – Laser Head Up Display, high resolution projection on the windscreen. Examples of data are vehicle speed and navigation info. Voice recognition introduced, as part of their InControl HMI. Toyota Mirai, VW sport coupe concept, Mercedes - Maybach with electronic displays. Volvo XC90 and Renault Espace available with HUD. Several manufacturers offered touch screen displays for the second row (entertainment).
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Active Safety and Driver Assistance
Active Safety features continue to down cascade into volume models. Introduction of new low speed Driver Assistance, e.g. trailer parking and traffic jam assist.
Figure 13: Renault Kadjar (left) and Volvo XC90 (source Volvo; right). • •
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Renault Kadjar – Active Emergency Braking System, Lane Departure Warning, Blind Spot Warning, Easy Park Assist, Hill Start Assist, Traffic Sign Recognition. VW Touran – Automatic Post-Collision Braking System as standard, Adaptive Cruise Control ACC, Front Assist with City Emergency Braking, Traffic Jam Assist, Pre-Crash proactive occupant protection, Side Assist with Rear Traffic Alert and, for the first time in any MPV, Trailer Assist. Volvo XC90 – adaptive cruise control, traffic jam assist incl. steering up to 50km/h, lane keep assist, blind spot warning, Lane Change Merge Aid, Cross Traffic Alert, rear collision pre-safe, park assist, 360° Surround View. Mercedes CLA - ATTENTION ASSIST. Speed range 60 to 200 km/h, five-stage bar display to visualise the driver's current attention level. Magna MILA Plus Concept – low cost camera based system to track vehicle position and traffic. Opel Karl – Hill Start Assist, the Lane Departure Warning, City mode for steering and Park Assist.
10 Steering and Suspension Four wheel steering for sports cars. Air suspensions. Multilink constructions. Variable settings. EPAS for larger cars.
Figure 14: Audi Prologue Avant Concept (source Audi; left) and Mercedes-Benz GLE (right). • •
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Audi Prologue Avant Concept – four wheel steering. Air suspension. Light weight, multi-link. Audi R8 - variable adaptively controlled Audi magnetic ride shock absorbers. Electromechanical power steering system. Dynamic steering, whereby the steering ratio varies in accordance with the road speed and the settings in the Audi drive select dynamic handling system. Renault Espace – 4Control four wheel steering. Jaguar XE - Al suspension, double whishbone front, integral link rear. Electric Power Assisted Steering. Skoda Superb – Dynamic Chassis Control, Drive Mode Select. Mercedes C 350e – Air Suspension as standard. Mercedes Benz GLE – DYNAMIC SELECT feature to adjust the driving characteristics. Opel Corsa OPC - Frequency Selective Damping (FSD) technology by Koni enables the damping forces to adapt to the frequency of the car. Ford Focus RS - AWD system is based on twin electronically-controlled clutch packs. “torque vectoring” capability. Monitoring inputs from multiple vehicle sensors 100 times per second.
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Personalization
Adaptable vehicle settings for instrument cluster and suspension. High series with very luxurious flavour. Larger variety of choices. Ultra luxurious cars.
Figure 15: Mercedes-Benz Vision E (top left), Ford Multi-Contour-Seat (source Ford; top right), Renault Multi-Sense (bottom left), Lexus leather trims (bottom right). • • • • • • • •
Mercedes-Benz Vision E - business concept car, based on V-class with exclusive seats in the second row. Ford – Multi Contour Seat with 11 air cushions for static and dynamic seat comfort. Available in Mondeo and S-Max. Renault Espace – Multisense sytem to adjust car settings and ambiance. Presets for "Eco", "Comfort", "Neutral" and "Sport, own setting possible. Lexus – large variety of decoration parts and leather trims for the interior. Rolls-Royce Serenity – Ultra luxurious version with hand crafted interior in “kimono style”. Skoda Superb – Laurin & Klement special high series. Citroen DS – PSA tries to establish DS as an own premium brand. The Citroen DS was a very popular car in the 50s and created a strong brand image. Bentley EXP10 - first look at British interpretation of a pinnacle luxury, high performance two-seater sports car.
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Infinity Q60 Concept – InTuition system to store individual preferences for seat position, temperature, audio, navigation.
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Roominess and Utilization of Space
Besides sports cars, a number of very practical CUVs and family cars were on display. “Urban mobility light” starts with a compact vehicle.
Figure 16: Suzuki IM4 Concept (top left), Nissan Sway Concept (top right), Opel Karl (source Opel; bottom left), SsangYong Tivoli (bottom right).
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Suzuki IM4 Concept- length: 3.693 m, width: 1.709 m, height: 1.566 m, Wheelbase: 2.438 m, mild hybrid with integrated starter generator, 4WD. New platform. Nissan Sway Concept - compact hatchback. Length: 4.010m, width: 1.780m, height: 1.385m, wheelbase: 2.570m. No B-pillar, Al seat structure. GM Opel Karl – length: 3.675m, width: 1.698m, height: 1.476m, wheelbase: 2.385m, weight: 935kg. On Star available. SsangYong Tivoli – Compact SUV, 4,2m long. Already in production in Korea. VW Touran – flexible seat concept for 2nd row. Renault Kadjar – shares platform with the successful Nissan Qashqai.
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Light Technologies
Headlights continue to be used as one of the major design elements. LED and laser light are the upcoming technologies. Three dimensional effects are popular (front and rear).
Figure 17: Audi R8 lmx (source Audi; left) and Infiniti Q60 Concept (source Infinity; right). • •
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Audi R8 - LED headlights are standard. On demand Audi can supply the laser sport which doubles the range of the high beam to 600 m. Infinity Q60 Concept - intelligent LED lights, react to the steering, speed and elevation of the car and automatically adjust the beam around each bend to illuminate the road ahead. Inspired by the human eye the headlamp has very fine fiber optic-like lines branching out from the projector. When lit, these filaments of LED lights look like lines of the iris radiating from the pupil Mercedes Benz GLE - three-dimensionally designed all-LED headlamps Others: LED headlights seen at Suzuki im4 Concept, VW Sport Coupe Concept, Seat 20V20 Concept. Ford S-max with dynamic LED headlamps and Glare-Free Highbeam, Various 3D effect rear LED lights.
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Heritage
Emotions play an important role when it comes to the buying decision. Heritage and brand image are key factors and can last for decades.
Figure 18: Borgward Isabella (left) and Citroen DS 21 Pallas (right). •
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Borgward – Borgward used to be a famous brand in Germany in the 50s, with substantial export and premium reputation. Borgward went bancrupt in 1961. Foton now owns the rights to use the name Borgward. The grandson of the founder is in the exec board. Around 250M€ will be invested in Stuttgart to create a HQ (>200 employees). The first vehicle is announced for the Frankfurt motor show in fall. Borgward intends to sell cars in Germany in the premium segment. Citroen DS – La Déesse (the goddess). Introduced in Paris in 1955, this car was the spearhead of the French automotive engineering. PSA tries to build on this and declared DS to an own premium brand. Landrover Defender – ‘Defender Celebration Line’ re-creates in detail how the first Series I Land Rover was built at the Solihull manufacturing plant just after the Second World War. Others using heritage: Ford GT, Mazda MX5, Jeep Renegade, MercedesMaybach, Mercedes GT3, Skoda Superb, Volvo, Aston Martin Lagonda.
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X-Brand Platforms
Synergies are utilized to introduce a variety of models and fill every niche without creating new platforms. Complexity management becomes a major success factor.
Figure 19: Infinity QX 30 Concept (top left), Jeep Renegade (source Jeep; top right) and Bentley EXP 10 Concept (source Bentley). •
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Infinity QX 30 Concept – Infinity shares the MFA platform with Daimler. The QX30 is the Infinity counterpart of the Mercedes GLA. The 2.0l engines are shared as well. Jeep Renegade – This car does not look like a FIAT, but it shares the platform and powertrains with Fiat 500X. It is an AWD.
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VW Sport Coupe Concept – one more car build on the MQB. It is comparable large. Length: 4,870 m, wheelbase: 2,841 m. The powertrain is complex (2 electric motors + the ICE, AWD). Bentley EXP10 – very stylish, based on the Porsche MSB platform, introduced in Panamera.
