Q2, 2008 RicaRdo QuaRteRly Review EnginEEring a tactical advantage Applying the latest in automotive technology Hybrid future to develop next-generation defence vehicles Downsizing becomes real H-Power Hyundai’s new heavy-duty engine Interview Igor Kulgan, GAZ Group powertrain T:210 mm T:297 mm T:297 Introducing HPC on Microsoft. Great Performance. Better Efficiency. HPC users can take efficiency even further with Microsoft. The reason? Significant productivity gains through streamlined workflow and reduced idle time. It all adds up to easy cluster management, enhanced collaboration and common client and cluster development tools. contents Ricardo Quarterly Review Q2, 2008 06 18 28 24 news features 04 Industry news 06 Defence vehicle engineering Next-generation hybrids take shape; VW’s 89 g/km Golf; The role of the military has changed dramatically since diesels gear up for the US market; battery-electric vehicles 2000, requiring vehicle engineering solutions with far more back on the agenda; Fiat has lowest CO2 in Europe flexibility, versatility and more effective use of resources. Anthony Smith explains how Ricardo is leveraging its 28 Ricardo news extensive automotive expertise to create the next generation Battery systems development facility to open in Detroit; AFS of defence vehicles Trinity Extreme HybridTM celebrates Earth Day in Washington; City of London award for Ricardo; new WAVE8 launches 13 Tactical advantage North American truckmaker Navistar Inc has teamed up with questions and answers Ricardo on a key strategic project for the US armed forces – the Future Tactical Truck System. Jeremy Burne tells the story 18 Igor Kulgan, head of powertrain, GAZ Group of how the two organisations developed this ultra-advanced In charge of a vast network of vertically-integrated factories hybrid concept and its sophisticated on-board systems against conceived in the Soviet era, Igor Kulgan needs to bring GAZ a tight timetable Group into the 21st century. Co-developing a heavy duty truck engine with Ricardo is a strong start, as Tony Lewin finds out 24 Hyundai H engine Developed in conjunction with Ricardo, Hyundai’s new 10-litre 21 Delphi on biofuels bus and truck engine breaks new boundaries in the design of Engineers from Delphi’s fuel injection division give their follow- heavy duty diesels. Jesse Crosse speaks to the men behind the up to our report on biofuels in the last issue of RQ, spelling out successful programme the major challenges presented by the variability, instability and incompatibility of many biodiesel types Head office: Conceived and produced for Ricardo by: Ricardo plc, Shoreham-by-Sea, TwoTone Media Ltd West Sussex, BN43 5FG, Editor: Tony Lewin United Kingdom Contributors: Tel: +44 (0)1273 455611 Mark Roberts, Anthony Smith, Ricardo contacts and locations: Jesse Crosse, Jeremy Burne www.ricardo.com/contacts TwoTone Media Ltd contacts: RQ subscriptions: www.ricardo.com/rq Anthony Smith: [email protected] Sales enquiries: [email protected] Tony Lewin: [email protected] industry news Next-generation hybrids take shape he recent Geneva motor show T and its hybrid concepts with significantly downsized engines provided a strong indication of the likely shape of production models expected in the next two to three years. Saab’s 9-X BioHybrid, a four-seat coupe concept based on GM’s lower- medium architecture, has what the company describes as a rightsized 1.4 litre turbo engine giving 200 hp on E85 – an engineering concept based on the Nm delivered by the diesel-electric fuel. The four-cylinder unit is linked to large X5 SUV. Powered by a two-litre combination, the X5 reaches 100 km/h in an electric motor (of unspecified power) four-cylinder twin-turbo diesel engine 8.9 seconds and emits just 172 g/km CO2. and a lithium-ion battery. GM claims instead of the usual six-cylinder diesel Volkswagen’s take on the diesel CO2 emissions of 105 g/km on E85 and or gasoline V8, the mild hybrid solution hybrid sees a Golf potentially capable of 117 g/km on conventional gasoline. drives all four wheels via a new eight- delivering less than 90 g/km CO2 – the BMW showed the latest thinking speed transmission developed by ZF. current TDI BlueMotion is rated at 119. in its Efficient Dynamics programme The 20 hp electric motor-generator The TDI Hybrid Concept centres around is flange-mounted onto the gearbox, a three-cylinder, 1.2 litre common-rail while the alternator is integrated into the TDI, developing 75 hp, and linked to a 27 crankcase. Lithium-ion batteries in the hp electric motor, which also replaces trunk store regenerated brake energy, the starter and alternator. The battery with power supplemented by roof- is a 220 volt, 45 kg nickel metal hydride mounted photovoltaic cells. Unusually, unit, and drive is via VW’s new seven- this power is also used to pre-heat the speed dual dry clutch transmission. diesel fuel and transmission fluid; this, The Golf is able to run in pure EV says BMW, shortens the less efficient mode in town and always starts off warm-up phase considerably. under battery power. The TDI Hybrid Thanks to the total 224 hp and 610 is likely to inspire a future production vehicle, says VW: later this year, the Saab BioHybrid (top) current Golf will be replaced by a sixth- has downsized 1.4 litre gasoline hybrid generation version. while Golf TDI hybrid In an apparent reversal of policy, promises 89g/km Europe’s second-biggest carmaker, PSA CO2 and BMW x5 Peugeot Citroen, is to focus its diesel concept (left) 172 hybrid development on larger, premium vehicles rather than the big-selling lower medium vehicles originally targeted. “As our project remains an expensive solution, we are going to apply it to expensive cars, and the volumes will be more limited,” PSA’s director of R&D, Pascal Henault, told the French financial daily Les Echos. Further hybrid surprises at the Geneva show were a diesel hybrid concept chassis from Korea’s Ssangyong and a plug-in gasoline hybrid from BYD of China. Plastic for hot exhaust EcoBoost beats hybrid, says Ford Peugeot Citroën’s fuel cell van Audi’s seven-speed DCT Anvisgroup and VW have Vehicles with Ford’s EcoBoost PSA and Intelligent Energy have Audi models will offer a new developed the first thermoplastic turbo GDI technology will provide co-developed a fuel cell electric seven-speed in-line dual clutch component for the hot end of the greater real-world efficiency delivery van based on the transmission suitable for use exhaust system. VW’s Golf now benefits and quicker payback, Peugeot Partner. The 10 kW fuel with its quattro four wheel drive features a composite catalyst says Andreas R Schamel, chief cell provides a range of 100 km system. The concentric clutches bracket capable of operating in an engineer for research and on each of its interchangeable are oil-protected and torque News in brief environment of 175 degrees C. advanced engineering. compressed hydrogen cylinders. capacity is 550 Nm. 4 RICARdo QUARteRLY Review • Q2, 2008 RicaRdo Electric vehicles back QuaRteRly on the agenda Review series of announcements by major Bank examined the Project Better Place The task of RQ is to highlight the latest thinking automakers, systems suppliers, business model and declared that a pure in automotive engineering and technology A worldwide – both within Ricardo and among battery providers and infrastructure electric car should not cost any more other leading companies. By presenting groups point towards a significant than a diesel or gasoline powered car, an up-to-date mix of news, profiles and resurgence of interest in pure electric and that in most countries – even the US interviews with top business leaders we paint vehicles and plug-in hybrids. – its operating costs would be lower. an interesting and exciting picture of R&D activity at a world-class automotive engineering Perhaps the most significant At the Geneva show Norway’s Th!nk services provider. development is the momentum being launched its new battery powered small It is a formula that has certainly been a hit with built up by Renault-Nissan (which has car, boasting a range of 200 km on a the worldwide automotive community: in the a commitment to production electric single charge, and showed the larger seven years since RQ was launched we have had to increase our print run to 14,000 copies vehicles by 2010) and US-based Th!nk Ox electric platform designed to keep pace with the demand to read about infrastructure entrepreneur Project to accommodate a variety of different Ricardo and its activities. Better Place. The two organisations have bodies. Earlier, at the Tokyo show, Client confidentiality is of the utmost announced electric car schemes in Israel Subaru had surprised commentators importance to Ricardo, which means that we can only report on a small fraction of the and Denmark, beginning in 2011, and with a similar range claim for its G4e work carried out by the company. So we are at April’s New York auto show Nissan electric concept. especially grateful to those Ricardo customers unveiled its Denki Cube, a battery- Smart’s electric Fortwo is already who have kindly agreed to co-operate with RQ powered version of the Cube design undergoing field trials with approved and allow their programmes to be highlighted in print: without such help from customers fashionable in Japan. customers in London, and Mitsubishi it would not be possible to present such a Analysts from Deutsche plans to market its lithium-ion fascinating insight into the way vehicles are battery i-MiEV minicar conceived and developed. in the UK in 2009 (left). Europe, and GM’s Chevrolet is making At the opposite great efforts to publicise its progress in end of the price the development of the Volt electric car.