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INTERNATIONAL www.VehicleDynamicsInternational.com A new era of body control

Mercedes-BenzMerc has developed a comprehensive body control system,system which debuts in the GLE. We bring you the inside story

A master of feel Interview: Dave Coleman, vehicle dynamics Jost Capito International Awards manager at Mazda R&D North VDI joined VW R boss Jost Capito on The innovative , dynamicists and America, reveals his thoughts the T-Roc R test program to technologies that most impressed our on optimizing steering feel get his thoughts on dynamic setups judges this year MAY/JUNE 2019 WHAT’S NEW 01

4 -Benz body control technology The GLE model marks the introduction of Mercedes-Benz’s E- technology, which enhances both on-road manners and off-road ability Product & service profiles 42 BorgWarner What’s new? Features 44 SKF 46 Racelogic 48 RAPA 6 Mazda3 twist beam 18 Interview: Jost Capito 50 Altair The 2019 Mazda3 is the first model VDI joined R boss Jost from Mazda’s seventh generation of Capito on a chassis testing program, 52 Tenneco . A key dynamics feature is 06 to get his views on dynamics 54 BWI the return to a twist-beam rear 55 MVO 22 Intelligent speed assist 56 Dewetron 8 Bugatti’s innovation What does the proposed European 59 Dytran Bugatti’s Chiron has the world’s intelligent speed assist technology largest, most powerful automotive mean for the dynamics sector? 60 GeneSys . The next stage may be for 61 A&D the calipers to be 3D printed from 12 26 VDl Awards 2019 62 Kistler titanium… The technologies, teams, cars and innovations that most impressed our 10 BMW 1 Series expert jury this year The next-generation 1 Series has a surprise in store: its setup is going 36 Mazda’s steering secrets back to front Dave Coleman, dynamics manager at 20 Mazda R&D North America, shares his 12 Q&A: AP Racing expertise in steering feel Richard Joyce, head of engineering at AP Racing, discusses the 64 Dynamic legend: JK Wrangler advances and challenges in The Wrangler’s classic profile has reducing brake system weight changed little over the decades, but its dynamics have evolved Columns 24 “A lot of rivals have a ppoorr

14 John Heider basebase chassis and thetheyyyy trtryy Why the investments and timescales required in automotive and mask it with electronics. innovation are daunting With me the base chassis 16 Graham Johnson 64 has to be good with An incident close to home shows why oversteer is overrated everything switched off” Jost Capito, Volkswagen R

May/June 2019 • VehicleDynamicsInternational.com 02 ROLE CALL

Vehicle Dynamics International A note from the editor Abinger House, Church Street, Dorking, Surrey, RH4 1DF, UK editorial tel: +44 1306 743744 sales tel: +44 1306 741200 email: vehicledynamics@ Wise words ukimediaevents.com Annual subscription £90/US$120 published by UKi Media & Events, a division of There is such a lot of great insight in this issue of Vehicle Dynamics UKIP Media & Events Ltd International that I’m going to let its content speak for itself. For example, we have Dave Coleman, Mazda R&D North America’s vehicle EDITORIAL i Editor Adam Gavine dynamics manager, advising on the importance of steering feel and why Technical editor his team has developed a bespoke EPS system: “We almost wrap our whole Geoff Kingston Production editor company around the idea that 99% of drivers don’t know that they care Alex Bradley Chief sub editor Andrew Pickering about steering feel, but 100% of them actually do. People who drive Deputy production editor Nick Shepherd cars with good and bad steering feel will think that the one with good Senior sub editor Christine Velarde steering feel drives better, but they won’t be able to tell you why.” Sub editors Tara Craig, Alasdair Morton On page 36 Coleman shares his thoughts on why Mazda customers enjoy great steering feel. Contributors We also gain dynamics acumen from a huge name in motorsport who Guy Bird, Joshua Dowling, is becoming a big name in the automotive industry: Jost Capito, who has Kyle Fortune, Graham Heeps, John Heider, Andrew Noakes, recently been appointed boss of Volkswagen’s R division. Capito’s ethos is Marc Noordeloos to focus on getting the basics right before looking to technology. “A lot of rivals have a poor base chassis and they try to mask it with electronics. ADVERTISING With me the base chassis has to be good with the electronics off. Publication director Electronics are for safety, not for making a better chassis.” Christopher Richardson International sales Find out on page 18 what he looks for in a chassis design and how it Aboobaker Tayub should feel to drive. As someone who sees rock-hard suspensions on road cars as a little ridiculous, his phrase “stiff isn’t quick” is music to my ears. DESIGN AND PRODUCTION We also hear from Simon Kern, who was a key figure in developing Art director Craig Marshall Mercedes-Benz’s E-Active Body Control system. He extols the virtues of Design team increased processing speeds and swapping electromechanical controls for Andy Bass, Anna Davie, Louise Green, electrohydraulic systems to improve roll and pitch control, and achieve Patrick MacKenzie, James Sutcliffe, Nicola Turner, Julie Welby, Ben White excellent ride comfort. Exciting work, which debuts on the GLE (page 4). Further innovation is explored and recognized in the 2019 Vehicle Head of production and logistics Dynamics International Awards, the results of which are announced on Ian Donovan page 26. Without spoiling the surprises, here’s what our global judging Deputy production manager panel and the CEO of an OEM had to say about this year’s winners: Robyn Murrell “Passengers have the sensation of floating over bumps and hollows”; Production team Carole Doran, Frank Millard, “A complete modular solution designed to satisfy the requirements of George Spreckley vehicle manufacturers, developers, dynamicists and race engineers alike”; “Wow, there were some very impressive cars on the shortlist this CIRCULATION year”; “It’s incredible how such powerful supercars can be so easy to drive contact Adam Frost extremely fast, and be so easy to control if you want to play with some [email protected] slide! This is thanks to 4WD and perfect suspension settings…” CEO The 2019 awards have highlighted some truly impressive innovative Tony Robinson thinking and technology, and I can’t wait to see what the coming Managing director year brings. Graham Johnson

The views expressed in the articles and technical Adam Gavine papers are those of the authors and are not necessarily , editor endorsed by the publisher. While every care has been taken during production, the publisher does not accept any liability for errors that may have occurred. If you wish to cancel your subscription to this magazine please email [email protected]. For more information about our GDPR-compliant privacy policy, please visit www.ukimediaevents.com/ policies.php#privacy. You can also write to UKi Media Vehicle Dynamics International is brought to you by UKi Media & Events, Abinger House, Church Street, Dorking, RH4 1DF, UK to cancel your subscription or request a copy & Events, publisher of Engine Technology International, of our privacy policy. Automotive Testing Technology International, Automotive This publication is protected by copyright ©2019. Interiors World, Electric & Hybrid Vehicle Technology ISSN 1479-7747 (Print) ISSN 2397-6403 (Online) International, Tire Technology International and Professional Vehicle Dynamics International Motorsport World, and organizer of Automotive Testing Expo, Average net circulation per issue for the period Professional MotorSport World Expo, Global Automotive January 1, 2018, to December 31, 2018: 6,926 Printed by William Gibbons, Willenhall, Components and Suppliers Expo and Autonomous Vehicle West Midlands, WV13 3XT, UK. Technology Expo. Go to www.ukimediaevents.com to discover more.

VehicleDynamicsInternational.com • May/June 2019 04 WHAT’S NEW

was our first intention. Then we had these additional ideas for off-road use,” says the chassis engineer. Body control Employing a 48V onboard electrical system, the E-Active Body Control (developed by RAPA – see p48) not only allows active roll stabilization, but also acts on lifting and pitching on the body. In the Curve driving mode, the GLE is technology lifted by as much as 3° to counter the forces acting on the passengers inside. The unique features that help off-road driving include the ‘recovery mode’. A comprehensive body control system has been developed by Kern’s just been demonstrating Mercedes-Benz, for debut in the GLE model. Kyle Fortune finds with the sand scenario, as well as the ability to individually move each out more and tries out the system via the touchscreen inside, to enhance off-road ability in the “That’s me in the car,” says as 40 years ago. We’re familiar with the toughest situations. Kern admits Simon Kern, the man in charge of Road Surface Scan and Curve features ABOVE: E-Active that few owners are likely to ever get Body Control helps developing E-Active Body Control of the S-Class, but with E-Active Body themselves into such a scenario, but i make the GLE at Mercedes-Benz. We’re watching a Control there are some core differences. driving experience suggests that the on-road benefits are video of a GLE extract itself from axle- “With the S-class we compensate as comfortable on compelling, too. deep sand, the suspension bouncing the every roll hit with the multi-seeing rough road surfaces The objectives for E-Active Body car, each wheel operating independently camera we introduced scanning of the as on tarmac Control were full roll and pitch control to allow the GLE to drive itself free. road in front of the car,” explains Kern. for improved driving dynamics, all is nothing new “That helps the controller, because it combined with good ride comfort. Kern at Mercedes-Benz, with the company can act in advance [of a road issue]. It’s admits that key to the system’s success having explored such systems as long proactive. Developing all these features is the increased processing speed and

VehicleDynamicsInternational.com • May/June 2019 WHAT’S NEW 05

Tech Spec Vehicle name Width: 1,947mm Track: 1,661mm (F); 1,678mm (R) Length: 4924mm : 2,995mm Steering: Electrically supported rack-and-pinion Curb weight: 2,165kg “We knew we would have to do sometethihinng Brakes: Disc brakes all-around, internally ventilated at the electrical, becauusse thhee cecenntratral hydraulics front, electric , ABS, brake assist, ESP wouldn’t work anymore”

the mounts for the anti-roll bar in the ABOVE: With the passively suspended GLE. The E-Active GLE, the Airmatic is Body Control system adds around 50kg available for the (110 lb) to the vehicle’s overall weight. first time with Kern says, “With the S-Class we had the ADS Plus a central hydraulic system that always continuously needs the engine to be running. We variable damping system knew with the new hybrid models we would have to do something electrical, because the central hydraulics wouldn’t work anymore.” E-Active Body Control’s electric power also has the benefit of future-proofing the active suspension system for the increasingly electrified powertrains that Mercedes-Benz is adopting today. It allows the system to work with the adoption of electrohydraulic rather active force, and easily and quickly combustion engines, and eventually full than electromechanical controls. modulated, the electric motor powering BEV applications. In the GLE, E-Active “We have a lot of actuation through them can reach very high speeds Body Control uses the starter-alternator, the pump, and leveling with the air immediately to benefit vehicle control. with the 48V system controlled by an springs, with individually accessible Kern says the motor pump unit can energy management system. for compression and rebound,” run at speeds of up to 70,000rpm. Power In practice it all works fairly says Kern. Each damper has a usage is typically 150W, rising under convincingly, with the GLE’s ride continuously adjustable damping peak performance. The electrohydraulic impressively flat, although when the and hydraulic accumulator. system is also beneficial because it is ABOVE LEFT: Curve function leans to compensate for RAPA’s E-Active The dampers are all connected to self-lubricating, very low friction and Body Control bends it can feel a touch unnerving and their own motor pump unit for self cooling, and offers relatively easy system. See p48 unnatural. It’s not a cheap option individual control. Able to create packaging solutions. The unit is fitted to for more details either – for now at least.

May/June 2019 • VehicleDynamicsInternational.com RAPA MAKES INNOVATION COME ALIVE Developed in partnership with Daimler – motor pump unit for the new eABC suspension. Read the complete story on our website www.rapa.com

Complete Vehicle Dynamics Measurement

• Vehicle model development • Stability and traction control analysis • Chassis and suspension tuning • Real world driving data collection • Tire performance and • Road load to chassis dyno correlation www.aanddtech.com Discover Precision 48 PRODUCT PROFILE Intelligent SUV chassis RAPA has developed a unique motor pump unit for the E-Active Body Control chassis, as fitted to the trend-setting Mercedes-Benz GLE

1 2

After six years of development, lowered for driving on the highway and With regard to the electrical Rausch & Pausch GmbH (RAPA), raised for rough terrain. FIGURE 1: An components, RAPA decided to use based in Selb, Germany, has The motor pump unit consists of three individual eABC a permanent-magnet synchronous ii motor pump unit created a motor pump unit with main components: an internal gear machine. The machine includes a integrated control electronics for the hydraulic pump, a permanently excited FIGURE 2: An axle wet runner with crevice tube, which E-Active Body Control (eABC) in the new synchronous machine as an electric set for the eABC represented a big challenge for the Mercedes-Benz GLE SUV. motor, and a 48V control device, which development team, such as having eABC – a milestone technology in uses software from cooperation partner, to achieve both high efficiency and RAPA’s company history – is a further Silver Atena. pressure resistance under all operating development of its established ABC For the displacement principle to conditions, which are at least 150 bar. system. The traveled road surface is work, a four-quadrant-capable internal After numerous structural-mechanical recorded with the help of a stereoscopic gear machine with leakage compensation simulations, RAPA developed a now- camera, and a corresponding control has been specified, with a volumetric patented design for a crevice tube that algorithm is created that enables the efficiency of almost 100%. The high supports itself on the stator teeth vehicle’s passenger compartment to be efficiency is necessary to prevent when it is under pressure and kept level and horizontal in any given active cooling. automatically braces. driving situation. As well as the unit having four- The integrated electronic unit consists Four corner modules, which consist of quadrant capability and very high of a performance circuit board and a a motor pump unit and an active , volumetric efficiency, its specified signal circuit board. The electronics with the used as an displacement enables a compact design provide numerous parameter variables actuator. Roll and pitching movements and the best possibility for optimal for the motor pump unit on the CAN are compensated for by the system. The integration between the displacer and connection. As well as typical parameters can be changed, for example the electric motor. such as rotation speed, temperature,

VehicleDynamicsInternational.com •May/June 2019 PRODUCT PROFILE 49

3 input voltage and current consumption, For RAPA, the development of the two pressure sensors that are integrated motor pump unit, in view of the system’s into the hydraulic machine also provide complexity, was nothing less than the current operating pressure of the the greatest challenge in the almost two hydraulic connections for the motor 100-year history of the company. In pump unit on the CANbus. The power February 2019, Daimler presented RAPA electronics are of special significance to with a special award as Most Innovative the overall performance of the eABC, in Supplier of the Year 2018. particular due to the high system-based Since the company was founded in safety requirements (ASIL-Level C). 1920, Rausch & Pausch has become The integration requirements of the known for continuous development unit necessitated a highly integrated and innovative product solutions. In design for the whole motor pump 4 particular, its strategic vision in high- unit. For this reason, the hydraulic tech niches, as well as its reputation as displacement machine and the electrical The driving comfort that has been a flexible development service provider, machine are integrated, connected achieved, and additional features such FIGURE 3: A cross- makes the medium-sized company a as override mode or curve function, section of the eABC by a single shaft. Depending on the motor pump unit respected technology partner and a installation space requirements in the mean that this is a tangible and highly hidden champion in the automotive, vehicle, the various bracket designs beneficial improvement for customers. FIGURE 4: The new medical and industrial sectors. mean that the motor pump unit can be For Daimler, the systematic trend-setting installed either as an individual motor development of the fully active chassis Mercedes-Benz GLE READER INQUIRY SERVICE REF. 04 pump unit or as complete motor pump is one of the three most important To learn more from RAPA, visit unit axle set. innovations in the new-generation GLE. www.ukimediaevents.com/info/vdm

May/June 2019 • VehicleDynamicsInternational.com