Although the first regulation regarding mandatory fitment of airbags was introduced in the USA in the mid-1970s (but never actually adopted), it was only in 1980 that the world’s first airbag system was installed in a production model – the Mercedes-Benz S-Class. Since that time, airbags have undergone technological advancements to increase levels of protection for the front passengers.
Initially, the focus was in frontal collisions and much development was on the two airbags at the front. Then airbags were added to the sides, either at the seats, in the doors or deploying like curtains over the window openings.
The importance of providing protection at the sides cannot be understated. Studies in Germany show that side impact collisions are among the most dangerous type of road traffic accidents, accounting for nearly 700 deaths per year and nearly a third of all occupant fatalities.
Side airbag installed externally
To enhance the existing side airbag systems installed in many cars, ZF has developed a new pre-crash safety system (still in prototype stage) which uses an external side airbag deployed milliseconds before a collision. It provides an additional lateral crumple zone, which can help save lives and reduce occupant injury severity by up to 40%.
To make this possible, ZF has networked the airbags to the vehicle’s sensor systems and developed algorithms that are capable of determining if a crash is imminent and decide whether or not to deploy the airbag.
ZF is currently the only company to provide the full spectrum of integrated vehicle safety technology – from sensor systems, algorithms, and control units to active and passive actuators. “Our deep understanding of the entire ’see. think. act.’ process enables us to conceptualize and realize integrated vehicle safety solutions such as the new pre-crash safety system,” explained Uwe Class, Head of the Safe Mobility Systems department within ZF’s Advanced Engineering team.
Recognition to deployment – in the blink of an eye
The biggest challenge in the development of this system was reliably recognizing an unavoidable collision and deploying the external side airbag before the collision takes place. The system has approximately 150 milliseconds to make the decision to deploy the airbag and fill it – roughly the amount of time it takes a person to blink.
The vehicle’s sensors first have to identify a potential impact quickly and accurately. This is possible with connected cameras, radar and lidar. Algorithms within the system software decide whether or not a collision is unavoidable and the deployment of the airbag is both possible and beneficial. If these decisions are all affirmative, the system ignites the inflators to fill the airbag.
The airbag, which has a capacity of between 280 and 400 litres (5 to 8 times the volume of a driver airbag) depending on the vehicle, then expands upwards from the side sill to form an additional crumple zone in the door area between the A and C pillars.
In a side impact collision, the occupants on the side of the impact are at particular risk of serious injuries in the chest area if the passenger cabin is severely deformed. The ZF pre-crash safety system can reduce the penetration of the intruding vehicle by up to 30%, helping to significantly reduce the occupants’ risk of injury.
Depending on which segment of the car market you look at, manual transmissions are diminishing in popularity and some carmakers have even stopped offering them. The two giant markets of North America and China see more vehicles with automatic transmissions being sold each year but in Europe and other regions, there is still healthy demand for what is also referred to as the ‘stick shift’.
Until the 1980s, when electronics started to be used to manage automatic transmissions, they were seen as being a hindrance to performance. American drivers liked them as they worked fine with the big engines but on smaller engines, they took away the zip and worse, caused higher fuel consumption. So many motorists maintained the idea that if you wanted to have better fuel economy and you wanted to enjoy driving, stay away from an automatic.
Small number of innovations
The manual transmission has not evolved much since it is a simple unit. From the 1970s onwards, additional gears were added although five has been pretty much the norm for some time. There have been some innovations, a notable one being the TREMEC 7-speed transmission in the Chevrolet Corvette with its 1-4 ‘skip-shift’ strategy to improve fuel economy. Rev-matching technology, which first appeared in the Nissan 370Z, is another advancement that helped less skilled drivers enjoy shifting like a pro.
Although automatic transmissions have been the subject of much improvement and technological advancement, it appears that companies like Volkswagen have not stopped trying to make manual transmissions better. The numbers must still make commercial sense for the engineers to get money to work on them.
New gearbox can reduce CO2 emissions, raise efficiency
Recently, the carmaker announced its new MQ281 state-of-the-art manual gearbox which has better operating efficiency and is claimed to reduce carbon dioxide emissions by up to 5 gms per kilometre. The new Passat is the first model to be equipped with the MQ281, and this will be followed by almost all models of the Volkswagen Group.
Latest Passat will be the first to have the new 6-speed manual transmission option in some markets.
The trend towards vehicles from the SUV segment with large-diameter wheels places high demands on the gearbox. “With the MQ281, we have developed a highly efficient manual gearbox that reliably meets these demands – and is soon to be introduced into a number of vehicle classes in the volume segment,” explained Helmut Gobbels, Head of Manual Gearbox and Four-Wheel Drive Development at Volkswagen.
The MQ281 has a torque spectrum of 200 to 340 Nm, which means it completely or partially supersedes the current Volkswagen gearbox designs with the internal designations MQ250 and MQ350 respectively.
It is based on a 2.5 shaft concept and boasts a high gear spread of maximum 7.89. On the one hand, this guarantees good driving off performance – even for heavy vehicles with large wheels – and facilitates, on the other hand, ‘downspeeding’, which is (fuel-saving) driving in high gears with low engine speed.
New MQ281 manual transmission will be used in many models in the Volkswagen Group in coming years.
New oil conduction system
Development of the new gearbox focussed primarily on improving efficiency. “Here we employed virtual development methods,” said Gobbels. “This enabled us to design a completely new oil conduction system. Using a variety of oil conduction measures, we are able to achieve a uniform and optimum lubrication of gear wheels and bearings, reducing the amount of lifetime oil required to just 1.5 litres.” To further reduce friction, a bearing concept adapted to the gearbox was developed. The design used friction-minimised bearings with low-contact seals.
Material use and its distribution for the gearbox housing was also optimised. With the aid of a further virtual development tool, a strength-optimised housing structure could be designed. The new housing supports the noise requirements of today (avoidance of undesired secondary noises) and therefore ensures improved driving comfort through less audible and noticeable vibrations in the vehicle.
The Volkswagen Group, with its huge production volumes, is one of the few carmakers that can afford to make its own transmissions, rather than source them from specialists like ZF or Aisin Seiki. It will be produced at two locations – Barcelona in Spain and Cordoba in Argentina.
The only time Volkswagen model officially sold in Malaysia with a manual transmission was the Polo GTI in 2008.
Don’t expect it in Malaysia
It’s unlikely that we’ll get officially-imported Volkswagen models with the new manual transmission in Malaysia. In fact, since the carmaker got into marketing activities about 15 years ago, only one model has been offered with a manual transmission and that was a Polo GTI 1.8. As most other companies have concluded, there is just insufficient demand for manual transmissions in this market. One company importing a small hatchback from Thailand had to stop doing so when the factory said that the volume taken was so low that the price would be higher than for the automatic variant.
As the era of the electric car dawns and more such cars will be on the roads, safety issues are beginning to get increasing attention. The fact that cars with only electric motors run almost silently may be good for the environment but can be a danger to pedestrians. It’s already bad enough that there are pedestrians who are walk around with earphones blocking out ambient noises that they do not realise a car is approaching them. With electric cars, even pedestrians who can hear may not know a car is coming up behind them.
For the past few years, safety authorities in some countries have begun to introduce new regulations that require electric vehicles to ‘make noise’ as a safety measure. The U.S. Department of Transportation’s National Highway Traffic Safety Administration (NHTSA), for example, added such a requirement for all new hybrid and electric light-duty vehicles sold in the USA. The new federal safety standard is intended to help pedestrians who are blind, have low vision, and other pedestrians detect the presence, direction and location of these vehicles when they are traveling at low speeds.
Special acoustic chambers are used to conduct tests on noise generated by vehicles.
Under the new rule, to come into effect in September this year, all hybrid and electric light vehicles with 4 wheels and a gross vehicle weight rating of 10,000 pounds (4,545 kgs) or less will be required to make audible noise when traveling in reverse or forward at speeds up to 30 km/h. At higher speeds, the sound alert is not required because other factors, such as tyre and wind noise, provide adequate audible warning to pedestrians.
New EU directive to make noise
Since the beginning of July 2019, a new EU directive has made it mandatory to install a warning sound generator in electric cars in Europe. This stipulates that initially in newly certificated hybrid, electric and fuel cell vehicles – also trucks and buses – an Acoustic Vehicle Alerting System (AVAS) must be installed for the protection of other road users.
The warning is mandatory up to a speed of 20 km/h and the Directive formulates the parameters for how an AVAS warning may and may not sound in great detail. This applies for example to the minimum and maximum sound volume, and to certain sound components.
How manufacturers are meeting the requirement
It is subject to these and many other regulations that the sound experts of the acoustic test facility at the Mercedes-Benz Technology Centre in Germany are working on giving a ‘voice’ to the electrified Mercedes-Benz models. Special microphones in the exterior sound testing facilities are used to develop an individually configured e-sound for each electric model.
Simulations, measurements, evaluations and detailed improvements continue until the result is perfect. During the subsequent test drives, there is a particularly sensitive passenger on board – the artificial head. This registers the tiniest noises, and comes impressively close to human hearing.
The Mercedes-Benz AVAS sound differs only slightly for the EU, Japan and China. There are other requirements for the USA, for example concerning the sound volume. Furthermore, the stationary vehicle must already generate a sound when a gear is engaged, becoming louder up to 30 km/h. Switching off the AVAS by the customer is prohibited in almost all countries.
Besides range anxiety – the concern of whether you can reach a recharging point in time when your vehicle’s battery pack is low – those contemplating buying an electrically-powered vehicle (EV) also worry about the cost of replacing the battery pack. This issue has never before been in motorists’ minds as the battery has been used mainly for starting the engine. And though its life is just a year or a few years, the cost is not particularly high.
With hybrids and EVs, the battery packs are crucial items (more so with EVs) as they are constantly needed to power the electric motor. Over the past 20 years, battery pack technology has advanced rapidly and more energy can be stored to extend the range. However, the cost has not fallen to the level similar to that of the small batteries that have been in use for decades. Admittedly, the technology is far different and the battery packs for EVs are extremely advanced.
The first owner of an EV probably doesn’t feel the financial impact of having to replace a battery pack unless it’s damaged (and even then, insurance may cover the cost). Understanding that there was a discouraging factor in the cost of replacement – which can be RM4,000 upwards – most companies started to offer separate warranties for the battery pack of up to the first 8 years, in the event it was defective. Such warranties are still offered although the incidence of defects is not high as quality has improved.
Why can’t battery packs last forever?
Still, the fact that the battery pack has a limited lifespan and needs to be replaced at some point in the vehicle’s life. The reason for the deterioration is like that in humans. Stress makes cells age faster; something that geneticists have long since demonstrated for the human body is also true for EV battery cells. The older the batteries get, the lower their performance and capacity, and the shorter the range of the vehicle.
This obviously has implications on resale values. The second owner of the vehicle would want to factor this cost in, or as an incentive, the first owner changes it before offering it for sale so as to improve the resale value.
To help batteries last longer, Bosch is developing new cloud services that supplement the individual vehicles’ battery-management systems. “Bosch is connecting electric-vehicle batteries with the cloud. Its data-based services mean we can substantially improve batteries’ performance and extend their service life,” said Dr. Markus Heyn, Member of the Board of Management of Robert Bosch GmbH.
Smart software functions in the cloud continually analyze the battery status and take appropriate action to prevent or slow down cell aging. These measures can reduce the wear and tear on the battery, the most expensive component of an electric vehicle, by as much as 20%. Real-time data gathered from the vehicle and its surroundings plays a key role here. The cloud services utilize this data to optimize every single recharging process and to provide drivers with tailored driving tips on how to conserve battery power via the dash display.
Didi Chuxing, a globally leading mobility platform based in China, is working with Bosch to introduce Battery in the Cloud across DiDi’s electric vehicle fleet. The aim is to optimize battery performance, thus benefiting both drivers and fleet operators within DiDi’s ecosystem.
Precise real-time analysis
According to the experts, the average service life of today’s lithium-ion batteries is 8 – 10 years or between 500 and 1,000 charge cycles. Battery makers usually guarantee mileage of between 100,000 and 160,000 kms. However, rapid battery charging, high numbers of charge cycles, an ‘aggressive’ driving style, and extremely high or low ambient temperatures are all sources of stress for batteries, which makes them age faster.
Bosch’s cloud-based services are designed to recognize – and counter – these stress triggers. All battery-relevant data – eg current ambient temperature and charging habits – is first transmitted in real-time to the cloud, where machine-learning algorithms evaluate the data. With these services, Bosch is not only offering a window into the battery’s current status at all times, but enabling a reliable forecast of a battery’s remaining service life and performance to be made for the first time.
Previously, it was not possible to make any accurate forecast of how quickly an electric-vehicle battery would wear out. “Powerful batteries with long service lives will make electromobility more viable,” said Heyn.
Another feature of the smart software functions is their use of the swarm principle: the algorithms used for analysis evaluate data gathered from an entire fleet, not just from individual vehicles. Swarm intelligence is the key to identifying more of the stress factors for vehicle batteries, and to identifying them more quickly.
Various parts of a battery pack in the all-electric Mercedes-Benz EQC
Protecting cells against aging
The new insights gained into a battery’s current status enable Bosch to also actively protect it against aging. To give one example: fully-charged batteries age more quickly at particularly high or low ambient temperatures. The cloud services thus ensure that batteries are not charged to 100% when conditions are too hot or too cold. By reducing the battery charge by only a few percentage points, the battery is protected against inadvertent wear and tear.
Data in the cloud will also help improve battery maintenance and repair. As soon as a battery fault or defect is identified, for example, the driver or fleet operator can be notified. This increases the chances that a battery can be repaired before it becomes irrevocably damaged or stops working altogether.
Finally, the cloud services also optimize the recharging process itself. The recharging process – which, by the way, is one of the biggest obstacles to creating a mass market for electromobility – harbours the danger that the battery cells permanently lose some of their performance and capacity. Smart software in the cloud can calculate an individual charge curve for each recharging process, regardless of whether it takes place at home or elsewhere. This means the battery is recharged to the optimum level, helping conserve the cells.
Whereas existing apps with charge timers merely allow drivers to time the recharging process so that it is carried out when demand for electricity is low, the Bosch solution goes much further, offering a specially developed recharging process as part of the company’s new battery services. They optimize both fast and slow charging and control electricity and voltage levels during the recharging process, thus prolonging battery life.
AIWAYS, a Shanghai-based personal mobility provider, is poised to embark on what is believed to be the longest point-to-point drive of a prototype electric vehicle ever attempted. Its U5 battery-electric SUV will carry out a 14,231-km drive from Xi’an in China to Europe starting next week.
The initiative is part of the comprehensive test and development programme for the first vehicle of its kind to be launched by a Chinese brand in Europe when it arrives in April 2020. The route chosen is from the start of the Silk Road and has historical significance as a hub for trading, cultural exchange and communication between China and Europe.
Extreme testing to meet demands of customers
AIWAYS is subjecting the U5 to extreme conditions which will be encountered along the journey to ensure it delivers the real-world performance, reliability and range demanded by European consumers. The engineering team will also explore how simple and easy it is to live with the U5, driving and recharging as they pass through different countries where temperatures, road conditions and available charging infrastructures differ considerably.
The U5 is a mid-size SUV built on the company’s innovative aluminium-steel More Adaptable Structure (MAS) platform. It is claimed to have a range of 460 kms on a fully-charged battery pack. Its price is expected to be in the region of €25,000 (equivalent to about RM116,000).
To be built at a new production plant in Jiangxi Province, the U5 is the first of a range of electrically-powered family SUVs. AIWAYS plans to introduce one new model to its range each year. Initial production output is planned at 150,000 units a year with a second phase of expansion planned to bring capacity to 300,000 units.
AIWAYS is a Sino-German company which has the involvement of Roland Gumpert, a former Audi engineer who led the team that campaigned the Audi Quattro in the World Rally Championship in the 1980s.
One of the prototypes being prepared for the journey to Europe which starts next week.
They’re arch-rivals in the global marketplace but when it comes to collaborating, it’s a different matter. Given how expensive R&D costs are, carmakers often decide to work with selected partners or even form consortiums so that the costs can be shared. Each one may bring certain areas of expertise to the collaboration as well, reducing duplication and cost.
Daimler AG and BMW Group have recently announced their cooperation on automated driving as a long-term strategic move. This will focus on joint development of next-generation technologies for driver assistance systems, automated driving on highways and automated parking (all to SAE Level 4).
In addition, further talks are planned to extend the cooperation to higher levels of automation in urban areas and city centres. This underscores the long-term and lasting nature of the undertaking, which will extend to encompass a scalable platform for automated driving. The non-exclusive cooperation is also open to other carmakers and technology partners, with results being made available to under license if they want to use the technologies.
Swift market launch
A key aim of the cooperation is the swift market launch of the technology, expected to feature in passenger car systems for private customers from 2024. The two companies will each implement the technologies in their respective products independently.
The cooperation will see more than 1,200 specialists working together, often in mixed teams based at locations of both companies. Efforts will focus on developing a scalable architecture for driver assistance systems, including sensors, as well as a joint data centre for data storage, administration and processing, and the development of functions and software.
Along with Aptiv, Audi, Baidu, Continental, Fiat Chrysler, HERE, Infineon, Intel and Volkswagen, the BMW Group and Daimler have published a white paper entitled ‘Safety First for Automated Driving’. As well as covering all relevant safety methods for Level 3/4 SAE automated driving, the paper introduces a traceability system, which extends from the primary goal – being safer than the average driver – right down to the individual safety objectives of the various components.
Current development by both companies
Daimler AG has been working on series development projects not only for specific Level 3 vehicles but also for Levels 4 and 5. Long a leader in active safety systems, it programmed its systems largely in-house right from the very beginning.This year will see the launch in San Jose, California, of its first pilot programme, with Bosch, on self-driving vehicles (Levels 4/5) in urban environments.
This will be the next milestone within the existing cooperation between both partners and the cooperation will continue as planned. Early in the next decade, Daimler will bring to the market not only highly automated (Level 3) vehicles but also fully automated (Level 4/5) vehicles. It is the only carmaker in the world to be so well-positioned to apply autonomous driving in every relevant context, from passenger cars and vans to buses and trucks, and is therefore relying on scalable solutions to deliver automated driving.
The BMW Group has developed technology with unique scalability from Level 2 – 4 that both enables a high level of flexibility and ensures it will be viable in the future. Around the world, more than 70 test vehicles are testing the latest technology, collecting data in order to improve machine learning with artificial intelligence through simulations. The generation of technologies that is currently under development will go into production as Level 3 automation in 2021 in the BMW iNEXT where it will also be Level 4-enabled for pilot projects.
Sunshine does good and bad things for mankind. It provides light to see better for about half the day and it helps to dry clothes. However, it can cause skin cancer and in certain conditions, even start fires. Sunshine also contains energy which can be converted into electricity and at least one study suggests that solar power can be the world’s largest source of electricity by 2050.
Unfortunately, capturing sunshine to convert it in amounts large enough for practical usage has required technologies that have taken a while to develop. In fact, research began as far back as the 1930s but it is only in the past decade that R&D has accelerated and advanced technologies have been developed which are also commercially viable.
Technological advances needed
While sunshine alone can’t power a car (the technology would need to be very, very advanced), it can be used for the battery packs in electrified vehicles. Currently, the battery packs are recharged by drawing electricity from public or household electrical supply stations or by regeneration in the car’s powertrain. Solar power can supplement this and has the potential of improving cruising range and fuel efficiency of hybrid vehicles.
In fact, Toyota has already been using the approach since 2010 in the Prius to provide power for the climate control system. In 2017, it went further by enlarging the solar panel on the roof to provide electricity for the battery pack. Later this month, NEDO (a national R&D organization in Japan), Sharp Corporation, and Toyota Motor Corporation will carry out public road trials to assess the effectiveness this approach with Sharp’s modularized high-efficiency solar battery cells.
Thin-film solar battery cells
These solar battery cells are in a thin film about 0.03 mm in thickness. This makes it possible to efficiently install the film to fit the curves of parts with limited space. The battery cells will be installed on the roof, bonnet, rear hatch door and other areas of a Toyota Prius.
The idea is, of course, to maximise the area of coverage to capture as much sunshine as possible. By enhancing the solar battery panel’s efficiency and expanding its onboard area, Toyota was able to achieve a rated power generation output of around 860 W, which is approximately 4.8-times higher in comparison with the Prius Prime’s solar charging system.
In addition to substantially boosting its power generation output, the testcar will employ a system that charges the driving battery while the vehicle is parked and also while it’s being driven, a development that is expected to lead to considerable improvements in electric-powered cruising range and fuel efficiency.
