R&D Archives

Run-flat tyres – an example of technology transfer from motorsports

Run-flat tyres, though seemingly a recent development, have been around since the 1930s although they were not as commercialized like today. From the 1980s onwards, most of the major manufacturers developed tyres that could continue to be used even when the air pressure was lost due to a puncture. This capability was initially required for military vehicles as well as vehicles carrying important people that might be attacked.

Eventually, run-flat tyres entered the market and appealed to carmakers because they not only provided extra safety and convenience but also gave the possibility of leaving out the spare tyre and saving some weight. Of course, due to the technology they have, they are more expensive than normal tyres but are an acceptable extra cost for premium luxury models.

Keeping rallycars running
At Pirelli, development of run-flat tyres began in the 1990s, mainly to provide tyres for rally drivers to continue even with a puncture, rather than being stranded by the side of the road. New technology was tried and tested in rallies by teams associated with the tiremaker. These had a reinforced structure that mad the tyres stronger and able to still run for several minutes after air was lost. In competition, those few minutes made a big difference.

As another example of technology from competition being transferred to road-going cars, Pirelli was able to use the same technology from its first run-flat tyres to offer motorists in 2001. However, as comfort was not a priority when the tyres were used on rallycars, the early run-flat tyres were hard and ride comfort was not so good initially.

*Providing tyres that could keep rallycars running even with punctures helped Pirelli to develop run-flat technology.*

Improvement in comfort for road use
Nevertheless, Pirelli carried out R&D into new materials and processes to improve comfort and also other aspects such as grip and handling. Thanks to new technology in the tyre’s structure as well as advances in the materials used, the way that the tyres absorb bumps in the road has been refined over time, to the point that they can now offer the same levels of comfort as standard tyres. To use run-flat tyres, engineers have to tune the suspension of the cars accordingly.

The key advantage of having a run-flat tyre is that the driver does not have to stop and change to the spare tyre when a puncture occurs. It is possible to continue for some distance, at least to a tyre shop where the puncture can be fixed or the tyre replaced. However, there are speed limitations (around 80 km/h) and the tyre is intended for emergency use and not long-term use.

Pirelli’s Self Supporting system (blue areas) is incorporated in the sidewalls for specific reinforcement which allows a deflated tyre to support lateral and transverse loads of the vehicle even in the absence of air pressure.

Original fitment by many carmakers
Over the last 20 years, Pirelli’s engineers have developed more than 1,000 different types of tyre featuring run-flat technology of different sizes and seasonal applications. To date, the company has supplied more than 70 million run-flat tyres, mostly as original fitment on models by BMW, Mini, Mercedes-Benz, Alfa Romeo, Audi and others.

Good for EVs
Run-flat tyres are also of interest to manufacturers of electric vehicles, which still need tyres to run on. Being able to leave out the spare tyre or even not have to carry a repair kit can mean less weight on board and that can help in adding to the cruising range. Additionally, the space that is usually allocated for a spare tyre can be utilized for the battery pack.

2021 Mercedes-Benz EQA — *Run-flat tyres are also good for electrically-powered cars which need to be as light as possible, so not having the weight of a spare wheel helps.*

Run-Flat technology will therefore also play an important role in electric vehicles as well as autonomous vehicles, the latter by helping the vehicle remain under control even in an emergency situation.

Some of the Pirelli run-flat tyres include Pirelli Elect and PNCS noise-cancelling technology. The former is dedicated to electric vehicles and is focussed on low rolling resistance, reduced tyre noise, immediate grip, and a structure that can support the weight of a battery-powered vehicle. PNCS is focussed on reducing perceived tyre noise inside the cabin, thanks to the use of special sound-deadening material on the inside of the tyre.

So long as motor vehicles run on wheels, tyres will be needed and run-flat technology will remain an important element. Pirelli continues to improve its run-flat tyre range as new technologies become available and affordable, with a view of future requirements by the industry and motorists.

All-electric Porsche Macan begins real-world testing, launch in 2023

After the Taycan, the next all-electric sportscar from Porsche will be the Macan. Developed with the usual secrecy, prototypes have been running around the proving grounds of the Porsche Development Centre and the next step is to take them into the outside world for road-testing.

Real-world testing on public roads and in a real-life environment are important stages in the development of a new model. In the case of the electric Macan, due to be launched in 2023, the testing will cover at least 3 million kms worldwide in varying conditions. This will add on to the experience gained from countless previous test kilometres – driven in a virtual space.

Digital development preserves resources
Digital development and testing not only saves time and costs but also preserves resources, so it enhances sustainability. Instead of real vehicles, the engineers use digital prototypes – computational models that replicate the properties, systems and power units of a vehicle to a high degree of accuracy.

There are 20 digital prototypes for the purpose of simulation in a number of development categories, such as aerodynamics, energy management, operation and acoustics. “We regularly collate the data from the various departments and use it to build up a complete, virtual vehicle that is as detailed as possible,” explained Andreas Huber, manager for digital prototypes at Porsche. This allows previously undiscovered design conflicts to be swiftly identified and resolved.

The aerodynamics specialists are among the first engineers to work with a digital prototype. “We started with a flow-around model when the project first started about 4 years ago,” explained Thomas Wiegand, Director of aerodynamics development.

Low aerodynamic drag is fundamental to the all-electric Macan with a view to ensuring a long range. Even minor flow enhancements can make a huge difference. The engineers are currently using simulations to fine-tune details such as the cooling air ducts. The calculations not only take into account different arrangements of the components, but they also reflect real-life temperature differences.

*Advanced and powerful simulation software allows almost all aspects of a new model to be viewed and tested before physical prototypes are built, saving time and money.*

Virtual testing
New methods now allow very precise simulation of both aerodynamics and thermodynamics. “The digital world is indispensable to the development of the all-electric Macan,” said Wiegand. ”The electric drive system – from the battery through to the motor – requires a completely separate cooling and temperature control concept, one that is very different from that of a conventionally powered vehicle.”

While a temperature window of 90 to 120 degrees is the target for combustion engines, the electric motor, powertrain electronics and high-voltage battery require a range of between 20 and 70 degrees, depending on the component. The critical scenarios don’t occur on the road but can occur during fast high-power charging at high outside temperatures. However, the Porsche developers are able to precisely calculate and digitally optimise position, flow and temperature.

Virtual prototypes can be combined with real-world scenarios at an early stage. The best example here is the development of a completely new display and operating concept for the next generation of Macan. Using what is known as a seat box to recreate the driver’s environment, the display and operating concept can be brought to life in an early development phase in conjunction with the digital prototype.

“Simulation allows us to assess displays, operating procedures and the changing influences during a journey from the driver’s point of view,” explained Fabian Klausmann of the Driver Experience development department. “Here, the ‘test drivers’ are not just the specialists themselves but also non-experts. This allows all interaction between driver and vehicle to be studied down to the last detail, enabling selective optimisation even before the first physical cockpit has been built.”

To be the sportiest model in the segment
The first physical prototypes of the electric Macan were built using data obtained from the simulations – in some cases elaborately by hand or using special tools. These are then regularly adapted based on the virtual refinement process. By the same token, the findings from road testing are fed directly into digital development.

“Endurance testing on closed-off testing facilities and public roads in real-life conditions is still indispensable to ensure that the vehicle structure, operational stability and reliability of hardware, software and all functions meet our high quality standards,” said Member of the Executive Board Michael Steiner.

*Prototype of all-electric Macan being tested at Porsche’s test track. Some cars, with camouflage over their bodies, are now being tested on public roads in different parts of the world.*

The demanding test programme for the electric Macan, carried out under the extremes of climatic and topographical conditions, includes disciplines such as the charging and conditioning of the high-voltage battery, which has to meet very rigorous standards.

“Like the Taycan, the all-electric Macan, with its 800-volt architecture, will offer typical Porsche E-Performance,” promised Steiner, citing development goals such as long-distance range, high-performance fast charging and reproducible best-in-class performance figures.

Combustion engine will still be offered
While Europe is accelerating into the era of pure electromobility with all-electric vehicles, Porsche understands that the pace of change will vary considerably across the world. In some regions, there will still be demand for vehicles with conventional combustion engines. Therefore, the next Macan will continue to have a variant with a combustion engine for markets which want it.

Entry-level Porsche Taycan available from March, priced from RM605,000

Italdesign and Williams Advanced Engineering offer complete range of services to design and develop high-performance EVs

*Visit www.bhpetrol.com.my for more information.*

Henry Ford believed in his company owning and managing every aspect of making cars – including even owning the plantations of rubber trees that provided rubber for his cars. But as the years went by, specialisation began and while carmakers focussed on designing and manufacturing cars, some activities were also farmed out to other companies. Design, for instance, was sometimes done by external consultants more specialised in the work, notable Italian studios like Pininfarina, Ghia and ItalDesign being among them.

In the 21^st century, as the whole idea of making cars changes with the transition to electric vehicles, there are many newcomers (especially in China) who want to get into the game. Some of these have experience in other types of manufacturing, eg batteries or mobilephones, but no experience in engineering cars. For them to gain that experience as the global players did will take too long; today’s companies do not have the luxury of time to learn themselves as the market is so competitive.

So the answer has been to commission companies that specialise in certain areas. In fact, Chinese companies have been doing this, not just for design but also for powertrains. There are top-notch engineering consultancies in Europe like Lotus Engineering that can develop a car on par with any experienced manufacturer – and even the established ones sometimes ask Lotus to help.

Manufacturers sometimes ask experienced design studios to propose designs for future models. This was the EMAS hybrid concept for Proton by Italdesign Giugiaro which was displayed at the 2010 Geneva Motorshow.

So there’s a growing business in offering a full range of services to develop cars and Italdesign has formed a partnership with Williams Advanced Engineering (WAE) to provide such services to those who want to produce and sell high-performance EVs. WAE is the technology and engineering business that was established by Williams F1. It takes technology originally developed for Formula One cars and adapts it for commercial applications.

Combining a state-of-the-art composite electric vehicle rolling chassis from WAE with turn-key vehicle development services from Italdesign, the joint venture will enable both newcomers and customers to benefit from the expertise of two global leaders in EV engineering and vehicle design, supporting them in the creation of a range of upper premium EVs from high performance GTs, crossover and sedans.

The foundation of this new venture is WAE’s innovative EV architecture – a new rolling chassis which distils WAE’s expertise in electrification, light-weighting, innovative chassis structures and vehicle and system integration into one advanced architecture known as ‘EVX’.

Differentiating itself from other EV platforms currently in the market, EVX integrates the battery pack casing with elements more commonly perceived as part of the body structure. Front and rear chassis structures mount to the carbonfibre composite case and crash loads can be transferred via internal reinforcements to the integral side sills.

The resulting higher profiled cross section achieves much of the torsional stiffness needed to deliver the full potential of the platform. These two design philosophies reduce reliance on the upper structure, which then gives greater design freedom for a variety of ‘top hats’.

Starting from WAE rolling chassis, Italdesign’s Engineering Team then complete the vehicle architecture adding safety systems, structures, and UX devices to constitute the modular platform that will be the base to build-up several different high-performances vehicles.

The innovative modular platform is ready for customisation by the Italdesign styling team who will shape the final vehicle to match the brand’s requirements in terms of marketing positioning, design direction etc. As well as being a structural component of EVX, the platform can accommodate wheelbases from 2900 mm to 3100 mm, with customers able to choose rear-wheel drive and 4-wheel drive layouts.

Combining recycled composite materials with aluminium, EVX is lightweight and sets new standards for static and torsional stiffness. With class-leading performance and mass targets, EVX will provide the perfect basis for tomorrow’s electric vehicles, supporting a flexible range of powertrain options with outstanding aerodynamics and safety performance.

Majoring on high performance, reduced time to market, flexibility and affordability at low-to-medium volumes, the new platform is capable of supporting production runs up to 10,000 units, up to 500 of which could be manufactured by Italdesign at its facilities in Italy.

WAE was the original supplier of batteries to all participants of the FIA Formula E World Championship cars in 2014, a relationship that has been revived for the 2022-23 season. WAE also supplies battery systems to ETCR and Extreme-E and has considerable experience in high-performance electrified road car programmes stretching back more than a decade.

“We are delighted to join forces with Italdesign on this exciting and timely joint collaboration” said Paul McNamara, Technical Director at WAE. “Demand for high performance electric vehicles is continuing to show considerable growth but to date, there has not been a complete EV production solution. This unique relationship brings together state-of-the-art EV rolling chassis technology with one of the world’s leaders in vehicle body engineering.”

Production-ready Nissan GT-R50 by ItalDesign makes debut on track

Renault’s E-TECH powertrain began as a prototype made from LEGO parts

The development of Renault’s E-TECH powertrains drew on the company’s experience in Formula 1 and also contributing has been a LEGO model. Yes, those little plastic blocks that can be attached together to form cars which have entertained children for over 70 years. The development story actually began at the end of the last decade. It was a time when Renault was stepping up its electrification program and advancing hybrid technology was an important step towards developing electric vehicles (EVs).

Nicolas Fremau, a member of the hybrid powertrain team, saw that using the LEGO parts – which includes gear wheels, could form a drivetrain. He built a working model from the parts and then demonstrated it to Ahmed Ketfi-Cherif, Renault’s Mechatronics Synthesis Architect and his team. Immediately, the engineers realised that if it could work in the LEGO prototype, it could surely also work as a working powertrain for a car.

*Ahmed Ketfi-Cherif (left), Renault’s Mechatronics Synthesis Architect, was involved in the E-TECH’s development which began with a prototype made from LEGO parts.*

Smooth operation a priority
Ahmed, who works as a control specialist, needed to ensure that transitions between driving modes were possible with a simple ‘dog clutch’. Normally used in competition cars, the dog clutch system – which replaces both a sprocket and synchronising ring in a clutchless configuration – is a gearbox boasting superior efficiency due to the reduced number of components.

This particular type of ‘flat’ version works well over time and is more reliable than other types of dog clutch. However, the team needed to find a solution to make the system smoother, as the components are less likely to fit together than in alternative setups such as a ‘roof’ dog clutch. Furthermore, unlike racing car drivers, customers who bought cars from a showroom for daily use also expected quality and smoothness.

“We’re used to using dog clutches in Formula One, for a racing engine. But it was something completely new for a ‘general public’ engine. We had to make this simple object usable by customers,” explained Ketfi-Cherif, who understood that a smooth and refined drive of much higher importance than winning lap times.

Adding a high-voltage starter generator
The team quickly came up with the solution to ensure enhanced smoothness by adding a second electric motor, called a High-voltage Starter Generator (HSG). “Its role is to replace the synchronisers of a traditional gearbox to facilitate the clutch and therefore the gear change. By working in conjunction with the electric motor, it allows very precise regulation of the speed of rotation of the gearbox for smooth gear changes,” he explained.

From this, the original LEGO model concept was updated and tested on the road. They discovered the HSG brought other benefits with immediate torque contribution smoothing acceleration at low speeds, avoiding any break in torque delivery when changing gears.

This also meant the system could operate as a series hybrid for enhanced comfort and flexibility, without the need for an excess of stored energy or a charging socket. According to Ketfi-Cherif, the possibilities for use in the range were multiplied, with both E-TECH hybrid and E-TECH plug-in hybrid powertrains now possible.

At the end of these tests, the E-TECH development teams were reassured that what had worked in the LEGO concept and in simulation also worked ‘extremely well’ in real life. A ‘toy’ had become an engineering reality, allowing up to 80% of urban driving to be done on just electricity, and having the extra boost in power or range with the petrol engine assisting when needed.

2021 Renault 5 Prototype

Toyota to use motorsports to develop hydrogen-fueled engine (w/VIDEO)

Motorsports have long been used for the testing and development of many new technologies which have eventually been used for everyday cars. Engineers who work with racing teams have to do so under challenging conditions that also require speed due to competition, and this provides fertile ground for developing new solutions to improve performance.

Toyota Motor Corporation (TMC) will also be taking this approach in developing a hydrogen-fuelled engine. Actually, the engine already exists and It has been installed in a racing car based on Toyota’s Corolla Sport. This car will enter races under the ORC ROOKIE Racing banner, starting with the Super Taikyu Series 2021 Powered by Hankook Round 3 NAPAC Fuji Super TEC 24 Hours Race in May.

*The hydrogen-fuelled racing car undergoing tests.*

By refining its under-development hydrogen engine in the harsh environment of motorsports, Toyota aims to contribute to the realization of a sustainable and prosperous mobility society, ultimately enabling a carbon-neutral mobility society.

Toyota has long engaged in the innovation of engine technology, and in fact, the company has not only successful developed fuel cells (FCs) which use hydrogen that chemically reacts with oxygen in the air to produce electricity, but it has also used those fuel cells to power the electric motor in the Mirai, Toyota’s first commercialised fuel cell electric vehicle (FCEV). Except for the combustion of minute amounts of engine oil during driving, which is also the case with petrol engines, hydrogen engines emit zero CO₂ when in use.

For the hydrogen engine, the fuel delivery systems for FCEVs have been modified from those used with petrol engines. Combustion in hydrogen engines occurs at a faster rate than in petrol engines, resulting in a characteristic of good responsiveness. While having excellent environmental performance, hydrogen engines also have the potential to relay the fun of driving, including through sounds and vibrations.

Plans are for the hydrogen-engined racing car to be fueled during races using hydrogen produced at the Fukushima Hydrogen Energy Research Field. While aiming to expand the hydrogen infrastructure in Japan by promoting hydrogen use, Toyota intends to continue advancing efforts for economic recovery and revitalization of the Tohoku region together with all parties concerned.

Even in safety, Toyota intends to apply the technologies and know-how that it has accumulated through the development of fuel cell vehicles and the commercialization of the Mirai. To ensure safety related to the use of hydrogen and high voltage, the countermeasures cultivated during the development of electrified vehicles such as FCEVs and HEVs were implemented. These measures are based on the basic approach of ensuring that hydrogen does not leak and, in the unlikely event that any leaks should occur, ensuring their immediate detection and stoppage.

Toyota Mirai 1st Generation — *Mirai – Toyota’s first commercialised fuel-cell electric vehicle runs on hydrogen. Two generations have been produced since it first went on sale in 2014.*

Toward achieving carbon neutrality, Toyota has been strengthening its efforts, such as by aiming to promote the use of hydrogen through the popularization of FCEVs and numerous other fuel-cell-powered products. Toyota has been taking various initiatives toward the creation of a hydrogen society, such as selling the Mirai and SORA FCEV bus, selling FC systems to FC product companies, as well as allowing royalty-free use of its FCEV-related patent licenses.

Toyota has developed a product that packages individual FC system-related products of second generation Mirai with enhanced performance, such as the FC stack, as well as components that handle air supply, hydrogen supply, cooling, and power control, into a single compact module.

Toyota Mirai FCEV fleet in Germany clocks total of over 5 million kms

Headlights on Future Ford vehicles will be able to predict conditions ahead for greater effectiveness (w/VIDEO)

The built-in headlights in every car today have been around for about 100 years and over the decades, the lighting systems have evolved to make the illumination stronger, giving a better view of the road or ground ahead. From making headlights more powerful, the engineers have also been making them operate ‘intelligently so that optimum illumination is achieved with changing conditions.

Driving in the dark can be stressful, especially on unfamiliar, winding roads. Ford is therefore working on a new technology to increase comfort and safety when driving after sunset. The company has already done pioneering work in the camera-based recognition of traffic signs and lane markings to optimize headlights in order to better illuminate streets in the dark, especially at intersections.

Now, engineers from Ford Research and Advanced Engineering Europe are testing technology that uses real-time location data to effectively show the car the way to go. The predictive ‘smart’ headlight system directs beams into upcoming corners – even before drivers may have seen them, illuminating hazards and other road-users more quickly and effectively.

How it works
The prototype advanced lighting system uses GPS location data, advanced technologies and highly accurate street geometry information to accurately identify turns in the road ahead. An algorithm calculates the trajectory and speed of the vehicle to proactively adjust the direction of its headlights, providing optimal light coverage of bends, junctions – and even hazards lurking around the corner.

If the vehicle encounters a stretch of road where location data is not available, the system will work alongside camera and steering‑based dynamic headlight-bending technologies to continue to intelligently light the road until the location data improves.

Researchers have made extensive use of ‘digital twin’ simulation that recreates the physical world in a virtual environment. The simulator accurately calculates how light falls and reflects in the real world, enabling researchers to better visualise and optimise the technology for drivers. The Ford researchers used a simulation that reproduces the real world in a virtual environment. The simulation environment calculates the correct reflection of the headlights as in the real world, so that the researchers can visualize the lighting technology realistically and optimize it in terms of traffic safety.

“The predictive lighting technology we are now developing could one day make driving in the dark so easy that the driver basically just has to follow his headlights,” said Michael Koherr, Lighting Research Engineer, Ford of Europe. “This new map and location-based system is the next step in our search for how we can make driving at night as easy as it is during the day.”

Road Edge Detection – available today
The advanced lighting technology will complement another new technology that Ford has developed which can be especially useful on rural roads at night – Road Edge Detection. Roads in rural areas can be tricky as they may not only lack proper lane markings but also give way to open land, muddy ditches and sheer drops.

Ford’s new technology can help make rural driving easier as Road Edge Detection scans the road ahead and can gently steer the vehicle back on track when needed. Designed for use at speeds of 70 – 110 km/h, Road Edge Detection relies on a camera located below the rearview mirror to monitor road edges 50 metres in front of the vehicle and 7 metres to the side.

How it works
Where a paved road becomes a soft side, gravel hard shoulder or grass, the system provides gentle steering support as required to prevent the vehicle from drifting off the carriageway. The system features an advanced algorithm that determines when there are clear structural changes from the road to the area beside the road. It can also provide steering support on marked roads when the lane marking is obscured or hidden by snow, leaves or rain.

If the driver is still close to the edge following initial steering support, the system vibrates the steering wheel, to prompt the driver to steer. At night, the system uses the illumination from the headlights and functions as effectively as during the day.

While predictive lighting technology is still under development, Road Edge Detection is already available in Europe on certain models and will be offered in more models in future the way advanced safety systems like Pre-Collision Assist and Automatic Emergency Braking have been progressively included in almost all models.

To experience Ford’s safety technologies, ask any authorised Ford dealer for a test-drive. To locate a dealership in Malaysia, visit www.sdacford.com.my.

New Ford Ranger Raptor X Special Edition Redefines The Pick-Up Truck

Yamaha offers newly developed 350 kW/476 ps electric motor for hyper-EV models (w/VIDEO)

Yamaha Motor has completed development of an electric motor which it claims reaches the industry’s highest class in output density. This unit, which can be used in hyper-EV models to provide exceptionally high performance, is available for ordering for commissioned prototype development from this month. This would be useful for companies which are not established car companies with technical and financial resources for R&D but require a well engineered powertrain.

Maximum output up to 350 kW/476 ps
Since 2020, Yamaha Motor has been accepting commissions for developing prototype electric motors (35 – 200 kW/48 ps – 272 ps) for automobiles and other mobility applications. However, the company has also newly developed a unit boasting a maximum output in the 350 kW/476 ps class (operating voltage of 800V) intended for installation and use in hyper-EVs and other high-output applications.

The main feature of this newly developed electric motor is its compact construction that treats the mechanical and electrical components as a single entity, integrating the gear and inverter into one unit. It was also developed in anticipation of installation and use of multiple units on a single vehicle.

Broad scope of prototype development
Regarding commissioned prototype development, Yamaha will leverage its production technology and know-how in the casting, machining and assembly fields that give the company the flexibility to adapt to the needs of motorcycles and its numerous other products, its prototyping equipment and facilities and more in order to develop prototype motors tailoring to the specific requirements of clients in a short period.

Involved in high-performance Toyota engines
To many, Yamaha may be well known for its motorcycles although it has business units involved in various power units. It also has long experience in high-performance engines and helped Toyota develop and built the DOHC 6-cylinder engine in the 2000GT in 1967. The company was also involved in the development and manufacture of various Toyota twincam engines, among them to 2T-G and 4A-GE used n models like the Corolla Levin/AE86 and MR2. The V10 in the Lexus LFA was also developed with assistance from Yamaha.

*1.6-litre Toyota 4A-GE engine used in the Corolla Levin AE86 (above) and V10 engine in the Lexus LFA (below) were developed with Yamaha’s expertise.*

Ford too commissioned the Japanese company to make a 3-litre DOHC V6 for its Taurus SHO model and it is known that the 4.4-litre V8 in the Volvo S80 and XC90 was developed with expertise from Yamaha too.

FEATURE – The German engine that was born on a Japanese bullet-train

Re:Move project creates zero emissions motorised sled for last-mile deliveries (w/VIDEO)

Back in the early 1980s, Honda launched a small hatchback called the City (the original one, not the popular model sold today) and an ‘accessory’ which owners could get with it was a Motocompo motorbike. This was a tiny two-wheel weighing about 45 kgs, and it was designed to fit into the boot of the City with its handlebar and footpegs folded to form a rectangular package.

That Honda came out with such an idea was hardly surprising since the company was the world leader in motorcycles and had all sorts of two-wheelers and other type of motorised vehicles. While the car is just another model in Honda’s history, the Motocompo is fondly remembered and has a certain cult status to it in some countries.

The idea of carrying a motorcycle in the car was to provide mobility for ‘the last mile’ in a journey. The driver could park the car at a fringe carpark at the edge of the city and then ride the motorcycle in, an approach which would be ideal for places with traffic-restricted zones like London and Singapore.

Now Polestar is also revisiting such a concept of mobility using a simple 3-wheeler with a project named Re:Move. The group behind the project saw the need to reimagine last-mile deliveries and how goods are transported within cities as the world looks to reduce reliance on combustion engines. Re:Move strives to become a catalyst for change, inspiring new thinking around electric mobility.

Viable and functional reality
Designer Konstantin Grcic designed Re:Move to be a dynamic, three-wheeled urban ‘sled’, though it is not intended to be carried in a car but could be in a van. A team of e-mobility innovators and material engineers collaborated remotely to make his vision a viable and functional reality. Compact and mobile enough for most bike lanes, but big enough to handle a 275-kg payload, Re:Move defines a new vehicle category. Built with fully recyclable and low carbon aluminium, it will handle deliveries in a cleaner, quieter and kinder way.

“Weight is critical for e-mobility performance, and aluminium offers light weight, high strength and recyclability,” said Jonas Bjuhr, MD of Hydro in Sweden. “As we now see reductions of emissions in the use phase of cars, the next big task for car manufacturers will be to reduce emissions in the production of the vehicles”.

To overcome the complex engineering challenges of realizing his design, Grcic worked with the Hydro engineering team, Polestar’s design engineering lead at the company’s UK R&D facility. A working version of Re:Move will be unveiled sometime during the fourth quarter of this year but the story behind its development thus far will be presented at the SXSW (South by South West) Conference & Festival in Texas next week.

Also involved in the Re:Move project is CAKE, a Swedish company specialising in electric motorcycles. They provide their expertise in drivetrain and battery technology with a view that such a project, involving peak competence, truly accelerates the journey towards zero emissions.

Beginning of a journey
“This is only the beginning,” declared Thomas Ingenlath, CEO of Polestar which is owned by Volvo Cars and recognised as a vehicle manufacturer in its own right. “The electric drivetrain is only the first step; then we have to look at the whole supply chain and what materials we design with. This is so much more exciting than the last 20 years when designers were just making things pretty.”

Commenting on the design of the Re:Move, Grcic said: “The horizontal platform and the vertical shield is something you don’t see in vehicle design. This is how you’d build a table or a shelf. I think the simplicity and directness… the pragmatism… is nice. Good design has always been sustainable, because it’s lasting. Things that have a long lifecycle are sustainable.”

“The Re:Move project is an amazing example of what you can achieve when you bring together the right collaborators and they get behind a good, clear idea. There is just a real energy and sense of purpose in play. The engineering and material challenges are actually quite complex but at every turn, solutions have been found. Konstantin has responded to that and the design of Re:Move has rapidly evolved, becoming more compelling and dynamic,” said Nick Compton, contributing editor of Wallpaper (a British design publication), which commissioned the project.

Ninebot GoKart Pro Lamborghini Edition

Final real-world testing of next-generation Mercedes-AMG SL now underway

On this day of March 12 in 1952, Daimler-Benz AG sent out preliminary technical information and a picture of the new Mercedes-Benz 300 SL sportscar undergoing testing on a public road. It was the first public appearance of the new racing sportscar and drew a great deal of interest.

Exactly 69 years later, Mercedes-AMG has sent out another press release – electronically this time rather than by postal mail – of a SL undergoing testing. This is the eighth generation of the model line and while the SL300 of the 1950s was tested along an autobahn which permitted very high speeds, the testing of this 21^st century successor takes place away from public eyes at a closed course in Sweden.

The testing follows extensive development work on the Roadster, configured as a 2+2-seater, which took place in digital form. However, a certain amount of real-world development driving with prototypes is still essential. For instance, the final tuning of the fully variable all-wheel drive system 4MATIC+, which will now be offered for the first time in the SL as well, is being undertaken in snowy regions.

The redesigned fabric roof has also to be tested and prove itself able to meet the brand’s demanding conditions in the climate near the Arctic Circle. The handling dynamics of this iconic Roadster will also be undergoing final refinement, but this will be done on the north loop of the Nurburgring circuit (amongst other places). It is there, on the most challenging racing circuit in the world, the specialists from Mercedes-AMG will make sure the new SL, due for launch later this year, confirms its sporting roots.

Different variants of the Roadster will progressively be available, branded exclusively under the Mercedes-AMG name.

On March 12, 1952 (a Wednesday), Daimler-Benz revealed the 300 SL (W 194) for the first time. The media was able to see it on a stretch of autobahn near Stuttgart. Only a few weeks later, the brand began its participation in international motorsport with that sportscar. In 5 races the car entered, it had 4 victories. Responding to calls for a production version of the highly successful racing, Mercedes-Benz launched the 300 SL Coupe in 1954 in New York, and the SL line began.

Increased track testing for Mercedes-AMG Project ONE prototype

Porsche Taycan Cross Turismo in final stages of development, market launch by mid-2021

*Visit www.bhpetrol.com.my to know more about promotions at BHPetromart.*

With the Taycan – Porsche’s first production all-electric sportscar – successfully launched and progressively entering various markets, including Malaysia, the carmaker is now busy following up with final development work of the Taycan Cross Turismo. Prototypes have already covered more than 998,361 testing kilometres, a distance that equals almost 25 times around the planet (measured at the equator).

“When developing the Cross Turismo, we were of course able to build on our experience with the Taycan sports saloon. The biggest challenge was combining the requirements of sportiness with off-road capabilities,” explained Vice-President Model Line, Stefan Weckbach. “The Cross Turismo has to be capable of high performance on the racetrack and must also be able to handle mud and gravel.”

25 times around the planet
The latter conditions were simulated on the Endurance Testing Ground at the Development Centre in Germany. The conditions at this facility include a ‘Safari’ track that mimics terrain in Africa. Having completed a total of 998,361 testing kilometres, the Cross Turismo prototypes have circumnavigated the globe almost 25 times (measured at the equator).

The extensive Porsche testing programme has also taken place on racetracks such as the Nurburgring Nordschleife and the Grand Prix track in Hockenheim (both in Germany) as well as on testing grounds worldwide. The Cross Turismo has also been tested off the beaten track in the south of France and in the Pyrenees region.

‘Swiss army knife on wheels’
“The result is impressive. However, the Cross Turismo is not a hardcore off-road vehicle, but specialises in unpaved and dirt roads. It’s like a type of ‘Swiss army knife on up to 21-inch wheels’,” added Weckbach.

The new derivative, which features all the strengths of the Taycan sportscar, will have a chassis with all-wheel drive and height-adjustable air suspension. There is also significantly more headroom for the passengers in the rear and a large load capacity under the tailgate. The package and space conditions have been optimised down to the very last detail.

2021 Porsche Taycan Cross Turismo — *The mock-up – a faithful, physical representation of the interior – and the package function model alone took 650 design, electronic and coordination hours and 1,500 workshop hours to complete.*

Same test programme as other sportscars
At Porsche, electric cars have to undergo the same rigorous testing programme as all its other sportscars with combustion engines. In addition to displaying superior performance, this always includes proving unrestricted everyday usability in all climatic conditions. Particularly demanding tasks such as charging the battery, or controlling the temperatures of the powertrain and interior under extreme temperatures, are additional aspects that are tested in the battery-powered electric models.

Other development goals typical for Porsche include racetrack performance, the ability to perform repeated acceleration runs at full throttle, and a range suitable for everyday use. Extensive testing is also carried out in the laboratory and on test rigs, and includes development and validation of the aerodynamic design. The Cross Turismo braved the storm in the wind tunnel for around 325 hours, part of the 1,500 hours spent there during its development process.

The new rear bicycle carrier designed by Porsche for this model also underwent its own rigorous testing programme with rough road tracks and driving dynamics tests. It sets new benchmarks when to comes to handling, ergonomics, driving safety and stability. Several e-bikes can be transported on its generously spaced wide rails.

The Taycan Cross Turismo combines Porsche E-Performance with enhanced suitability for everyday use. It will go on sale in Europe in mid-2021. To date, more than 20,000 Taycans have been delivered worldwide.

2020 Porsche Taycan — *The Taycan was launched in Malaysia last September by Sime Darby Auto Performance.*

Click to know more about the Taycan and other Porsche models in Malaysia

Porsche Taycan does 165 km/h inside a building – a new Guinness World Record (w/VIDEO)

Piston.my

R&D

Run-flat tyres – an example of technology transfer from motorsports

All-electric Porsche Macan begins real-world testing, launch in 2023

Italdesign and Williams Advanced Engineering offer complete range of services to design and develop high-performance EVs

Renault’s E-TECH powertrain began as a prototype made from LEGO parts

Toyota to use motorsports to develop hydrogen-fueled engine (w/VIDEO)

Headlights on Future Ford vehicles will be able to predict conditions ahead for greater effectiveness (w/VIDEO)

Yamaha offers newly developed 350 kW/476 ps electric motor for hyper-EV models (w/VIDEO)

Re:Move project creates zero emissions motorised sled for last-mile deliveries (w/VIDEO)

Final real-world testing of next-generation Mercedes-AMG SL now underway

Porsche Taycan Cross Turismo in final stages of development, market launch by mid-2021

Lima Pengeluar Kereta Terbesar Eropah Catat Penurunan Keuntungan pada Separuh Pertama 2024

Significant Profit Decline Among Major European Car Manufacturers for the First Half of 2024

DRB-HICOM And Geely Sign Agreement On Development of Automotive Hi-Tech Valley (AHTV)

More Advanced Honda SENSING Systems With Enhanced Capabilities Being Developed

Ford Headlight Tech Helps Keep Drivers’ Eyes on the Road

50th anniversary of the Pininfarina Wind Tunnel which has shaped car designs by air

Hyundai Motor Group and Michelin to collaborate on EV tyre innovations

Hyundai Motor Group starts pilot autonomous car-hailing service with IONIQ 5 in Seoul

Using brainwaves to change the colour of your car!

The Honda VTEC Story

Archive

GAC Aion ES: Fully Electric Sedan Launched For RM106,800

Bermaz Motor Unveils the All-New Mazda CX-60 SUV at KLIMS 2024

BMW 2 Series Gran Coupé to Launch in March 2025, Featuring Enhanced Performance and Advanced Digital Integration

Malaysia Targets 20% EV Sales by 2030 Amid Growing Adoption and Infrastructure Expansion

Chery Aims to Introduce Solid-State Batteries by 2026

Follow us on Facebook

Follow us on YouTube

The Piston Show