Fueling Change Is the Electrical Revolution Upon Us?

Home , Denza, Electric motorsport, Joint venture, Wolfgang Bernhard, Zinoro

Magazine

On the safe side 3/2016

Fueling Change Is the electrical revolution upon us?

Market of the Future How China is becoming the pioneer of electric mobility Energy Sources Oil keeps the world turning – but for how much longer? Efficiency in Trucking Saving fuel in convoy – the effects of platooning, tested Editorial

Big Challenges Ahead Contents 3/2016

Electric mobility becomes a 8 reality Stefan Kölbl on energy for mobility

Dear Reader, Are we on the brink of an electric revolution? In this issue of DEKRA solutions, we will throw light on the interplay between energy and mobility. Upon hearing these two words, more than a few people will instantly think of electric drives, which are often lauded as a cure-all remedy for pressing environmental problems. One of electric mobility’s key benefits is of course the local elimination of emissions in urban areas. Several megacities intend to exclude all but electric vehicles from their centers. For this reason, the topic is gaining importance in the automotive industry. In addition to passenger transport, the emissions-free distribution of goods is another important task in built-up areas. 08 Batteries vs. Burners Cover Topic This, however, poses the question as to how we Retirement for the combustion engine? will quench our growing thirst for electricity. The When and where the electric drive will majority of our energy needs are fulfilled by classic assume the throne. Our mobility is on trial. power plants, using either fossil fuels or nuclear energy. The pros and cons of both have already 18 Interview been discussed at length. ‘Clean’ electricity is cam- Daimler Trucks Chief Dr. Wolfgang Bern paigned for by many, however wind turbines and hard discusses advances in electric heavy high-voltage pylons are often unwelcome. Due in goods transport. A 26-metric-ton electric part to this, electric mobility is becoming a driving truck by Mercedes Benz is coming soon. force in finding new energy concepts. DEKRA too is tackling these exciting developments. We have 20 Building Cars long worked to ensure safety both on the road and Spurred on by the smog in its megacities, in energy generation. Many more challenges will Chinese industry is grasping the present themselves in the future. We are ready. opportunity to supplant established car manufacturers with a new generation of Yours, electric cars.

Stefan Kölbl

Chairman of the Board 18 Interview with DEKRA e. V. and DEKRA SE Dr. Wolfgang Bernhard Digital

E-Paper Fancy reading DEKRA solutions on your tablet, Crude oil – and being able to click too valuable to burn? links and videos directly? 30 Not a problem, simply download for free. 26 Electrifying Motorsport 20 Whether it be the hybrid technology of Smog as a Formula 1, or the battery-powered racers of E-Paper also driving force for Formula E, alternative drives are spreading available at: electric mobility in modern motorsport. www.dekra- solutions.com 30 Black Gold Crude oil continues to define our standard of living like no other raw material. Taking stock of our number one energy source.

36 Private Energy Revolution Fully digitally-controlled smart homes are in. And now they’re even filling up our cars with energy. solutions online The DEKRA magazine 38 Slipstreaming to Save now has a homepage Platooning is the hot new word in chock full with updates economical goods transport. DEKRA put from DEKRA. It’s certified the potential of these mini convoys on trial. interesting! We look forward to your visit. Standards More information: www.dekra- 02 Editorial 16 solutions.com Battle of the 04 News systems in 42 Masthead numbers Icons

Video

Web Link

Phone Number

38 Email Platooning trucks on the Event test track

3 DEKRA solutions 3/2016 News

Eco-Odyssey

BRIEFLY NOTED THE FIRST ROUND-THE-WORLD FLIGHT by a solar speed of 78 km/h. Instigator of the 150 million powered aircraft took 500 days and finished on euro project Bertrand Piccard wanted to make July 26, 2016. ‘Solar Impulse’ stopped 16 times the world aware of the impending refocusing of on its journey to carry out vital repairs and the global economy towards energy efficiency to wait out adverse weather. Despite state-of- and renewable energy sources. Solar Impulse the-art solar technology with specially devel- certainly delivered, circling planet Earth with- oped batteries and 17,000 high-performance out using a drop of kerosene. Piccard also made solar cells on gigantic wings, the solar pow- the headlines in 1999, when he flew his balloon ered plane had to make do with 15 HP of power, ‘Breitling Orbiter 3’ around the world in only and trundled around the planet at an average 20 days.

NINE EYES,

POKÉMON SIX WHEELS STOP! The smartphone game ROBOTIC COURIERS ‘Pokémon Go’ has tak- are being tested by parcel en the world by storm, company Hermes Versand but also presents a high in Hamburg and Düssel- distraction risk. This can dorf. The circa 70 cm long be extremely dangerous carriage can – according on the road. There to manufacturer are reports of players Cable Cars Starship Technologies running into traffic, and AS ROAD TRAFFIC accounts for more than a – carry parcels up to even drivers playing third of Sweden’s CO emissions, the country’s 15 kg five kilometers at the wheel – not just 2 transport authorities began testing an electric at walking pace, using its nine illegal, but extremely risky. At 50 km/h, every highway system in June. The goal is the cameras to avoid obstacles. To avoid second of distraction permanent usage of the e-highway. This will anything happening to the packages inside, equates to 15 meters of play a large part in making Sweden’s transport they are secured with a safety lock, PIN code driving blind. sector fossil-fuel-free by 2030. and tracked using GPS signal.

4 DEKRA solutions 3/2016 News

“All methods of transport, excluding rockets, will turn to electrical energy” Tesla Founder Elon Musk THE DRIVING BRIEFLY NOTED TUNNEL

CHINA’S ROADS ARE BURSTING AT THE SEAMS. Respite is planned to come in the form of the traffic-independent electric TEB-1 bus. At 22 meters in length, eight meters in width and 4.5 meters in height, the vehicle will coast above Reddot Award the chaos of the traffic below at 64 km/h. It will DEKRA was awarded hold up to 300 passengers. The prototype of this the ‘Red Dot Award: innovative vehicle was tested on public roads Communication Design’ for the first time on 2. August in Quinhuangdao. for its annual report 2015. 7,838 companies Further information on this story: from 46 different http://en.tebtech.com.cn countries took part in the communications industry’s renowned design award. A Second Wind BATTERY RANGE IS OFTEN THE Each stop therefore provides has been certified by DEKRA, MAIN WEAKNESS of electric an additional portion of power, will be trialled by the Cologne buses in regular service. enough to guarantee the public transport authority An elegant solution for this seamless running of scheduled (KVB) on an electric bus line in problem is provided by Dutch services. Complete recharges late 2016. The experiment will company Heliox, based in Best of the batteries take place involve eight battery-powered near Eindhoven. The company overnight at the bus depot. articulated buses provided by specializes in rapid charging The charging system, which VDL Bus & Coach. technology for charging devices and DC/AC inverters. Core to their new solution is a charging mast with a contact hood that provides charging power of up to 240 kilowatts (kW). The charging station can Road Safety be installed at the ends of bus is a major subject for routes. Upon arrival at the sta- DEKRA. Helpful tips and tion, the roof-mounted charging extensive information connector automatically docks in four languages can with the mast’s contact hood. be found on the Road The charging process then Safety Portal, which is smartphone-optimized. takes between two and five minutes, depending on the Further info: battery’s level of charge. www.dekra- roadsafety.com/ en/homepage

5 DEKRA solutions 3/2016 News

BRIEFLY NOTED New research facilities and laboratories are currently being built at the Kleefse Waard industrial US Road Safety Report park in Arnhem in the Netherlands. “The Clean Incidents involving private passenger vehicles Mobility Center sees itself as a European hub are the leading cause of for innovation, in which various partners may death for young people share and further their knowledge and skills in the United States of together,” explains DEKRA ‘Products Europe’ America. DEKRA’s US Sector Head Vincent Roes, who is also the Road Safety Report foundation’s chairman. In addition to DEKRA, intends to help change the founders of the Clean Mobility Center this sad statistic. include consulting firm DNV GL and electric NEW INNOVATION mobility specialists Allego and EL-KW. Arnhem and Nimwegen University (HAN) is also involved FOR MOBILITY in the foundation. The Clean Mobility Center will be fitted with a Charging Plaza, where electric SUSTAINABLE MOBILITY requires fast and vehicles can recharge at digitally controlled efficient innovation. The key to this is the close charging points. One of the first projects is cooperation between business, research, ‘Project Trolley 2.0’, which focuses on electrify- science and politics. This is the goal pursued ing local public transport. The recharging of bus by a new foundation called the Clean Mobility batteries will take place using overhead trolley Center, which was established in April 2016. lines installed on certain sections of the bus line. Eric Labe is new Chief Regional Officer for DEKRA North America. “Our mission to create a safer world is key to our growth,” announced Labe upon his appoint- ment. DEKRA will use him in developing further synergies in Mexico, Canada and the USA to continue the success story.

60Degree water Perfect Pit Stops prevents legionella ONLY WHEN A TRUCK IS MOVING reliable quality across a uni- an audit, work processes, bacteria forming in pipes. does it earn any money. As form service portfolio. The equipment and employee These purveyors of a result, maintenance and service of this Bosch, ZF and skill is put to the test. sickness multiply when repair work must be profes- Knorr-Bremse joint venture has Alltrucks benefits both from little water is flowing through the pipes, e.g. sionally planned and quickly been certified by DEKRA Assur- the objective appraisal of its during holidays. DEKRA completed. Partners of the ance Services GmbH. Alltrucks processes and the credible recommends flushing Alltrucks workshop system workshops are springing up certification of quality pro- pipes and heating the support this aim by offering throughout Europe. During vided by DEKRA. boiler to 60 degrees.

6 DEKRA solutions 3/2016 PHOTOS: ALLTRUCKS, DAIMLER, DEKRA, DPA PICTURE ALLIANCE, HELIOX, HERMES, MAN, MAURITIUS/PHOTOJA, SCANIA, SOLAR IMPULSE/DESCLOUX/REZO.CH, ZF, 84% were professionals. visitors camein2014, show. Around 4million gest commercial vehicle at theIAA,Earth’s big- their newdevelopments countries demonstrate Exhibitors 2066 for mid-2017. Market launchisplanned starting at3metrictons. permitted weights vehicles withmaximum its portfoliotoinclude market, whilstextending ny enterthetransporter the Munich truck compa- the VWCrafter, willhelp The MANTGE,basedon MAN withaVan BRIEFLY NOTED by ideas by Driven from 45 from 45

Scania UnveilstheFuture Future Luxuries by nomeansthirsty itself. when compared with the current generation – new generation 5%less uses fuel onaverage, optimized aerodynamics anddrivetrains, the generation of trucks at this year’s With IAA. the systemsandintervenesin emergencies. omously pulluptobusstops.The drivermonitors pedestrians walkingintheroad. Itcanalsoauton- communicate withtrafficlights, aswellavoid nology withcameras,sensors and radar, itcan on theroad already. ThankstoCityPilottech- IN AMSTERDAM, cles inthe fleet and the distances travelled. siderable savings, depending onnumber of vehi reducing fuel consumption could result incon SCANIA On afleet level, the promised potential for will pull backthe curtains onits new Mercedes Benz’‘Future Bus’is 7 DEKRA solutions 3/2016 - - allows for further increases inoperating effi a communications system as standard, which accidents inwhich the vehicle rolls. increase driver andpassenger safety inserious trucks to feature side airbags, which greatly addition, the new generation will be the first cle-distance radar, are of course also fitted. In include emergency braking systems and vehi ciency. The newest safety standards, which guarantee safetywhilstdoingso. the driverliftingafinger. Camerasandsensors whilst alsoreversing intoloadingbayswithout within itslane,andfollowtrucksdrivingahead, assistant toprevent seriousaccidents, keep THE ZFINNOVATION TRUCK VISION ZERO The new Scania trucks willbeconnected to usesitsavoidance - - Energy for Mobility

Batteries versus Burners

Motorists and car enthusiasts are currently watching the most exciting motoring renaissance in recent memory unfold before them – the development away from classic powertrains to new, alternative drive systems. But are these new alternatives more environmentally friendly? And will we really wave goodbye to the combustion engine? Author Patrick Broich

8 DEKRA solutions 3/2016 Batteries versus Burners

9 DEKRA solutions 3/2016 Energy for Mobility

ive years have passed since the motoring standable, as combustion-engined cars of the time world celebrated the car’s 125th jubilee in rarely featured electric starter motors and there- F 2011. Experts are in agreement that it was fore required laborious cranking to start. Electric in 1886 that the automobile was born – the year vehicles’ attractiveness was more pronounced in in which Carl Benz’ motorcar first took to the urban areas, where the limited range proved less streets. Powered by a water cooled single-cylinder of an issue. four-stroke engine, its choice of drive seems very The same can be said today. The day-to-day familiar, save for the fact that modern mainstream shortcomings of most modern electric cars result cars now feature a four-cylinder system. For whilst from the one-two hit of limited battery capac- the car has changed fundamentally over the last ity and long recharging cycles. Even so-called 130 years, the underlying principles beneath the fast charging technology requires the car to be bonnet have remained remarkably constant. Now, plugged in for at least half an hour. Despite intense however, this fact may be set to change as we wit- research and development efforts, no marketable ness the dawning of a new era in mobility. More electricity storage system can yet rival the energy and more different battery-powered electric mod- density of chemical fuels. els are creeping into manufacturers’ portfolios, with some even offering hydrogen-powered run- Strict Regulations abouts! All around the world, experts are discuss- So why is everybody so hyped up about elec- ing whether classic petrol and diesel combustion tric vehicles? Well, the reasons are as diverse as engines will still have a place in the future. they are numerous. The jury is out as to whether But first, let’s clear up one common misconcep- our realization of the finite quality of global oil million tion: whilst the electric car is a novelty for the mod- reserves prompted this revival of the electric car. 1electric vehicles ern consumer, the concept itself is not new at all. One thing is for certain: it is nigh-on impossible – Volkswagen’s annual As far back as the early 19th century, there was a to predict when the end of the ‘oil age’ will come – production goal from 2025 similar battle of drive concepts, and electric cars there are simply too many external factors to con- even took an early lead. Ultimately, their reliance sider. Modern mobility technology is constantly on big, heavy lead-acid batteries proved their down- improving, yet global demand is increasing too. fall. The drawbacks were the same as those cited of Consider the Chinese car market, which will con- today’s battery powered cars: their limited ranges, tinue to grow with vigor for years to come. Despite coupled with long charging times rendered the cars this, fossil fuels won’t be exhausted any time soon, unfit for seamless day-to-day usage. Naturally, which goes some way to explain stagnant oil prices. efforts were made to address these shortcomings Localized emissions are another big issue. – battery exchange stations opened in New York, Whilst Germany is fortunate enough to not have as car historian Gijs Mom points out. The appeal to struggle with smog-polluted megacities, the of electric cars in the early 19th century is under- city of Stuttgart repeatedly demonstrates the

Electric Cars for the Museum of the Future

1900 1971 Lohner-Porsche Lunar Roving Vehicle (LRV) Semper Vivus Drive Electric Drive Electric, front Power 180 W motor per wheel wheel-hub motors Speed 13 km/h Speed 50 km/h Battery 36 V silver oxide & zinc Battery Lead Range 92 km Range 50 km

10 DEKRA solutions 3/2015 Bad Air Smog presents a daily challenge for residents of Los Angeles

issues posed by particulate matter pollution. The tric cars. The strict regulation of CO2 emissions is Baden-Württemberg capital has announced will- a major factor and looks set to stay; repealing emis- ingness to consider driving bans as a last resort sions legislature would unleash too much political to bring high pollution levels into check. Nitro- backlash. Europe’s 2021 goal of reducing the aver- gen oxide – produced both by industry and traf- age emissions of the continent’s car stock down to

fic – promotes the formation of ozone, which can 95g of CO2 per kilometer merely marks the begin- cause respiratory issues. ning. Even the USA – a country known for its love Air pollution alone won’t compel the automo- affair with throaty V8s – has introduced policies to bile industry to ramp up efforts to sell more elec- cap emissions at ‘acceptable’ levels. The year 2025

1997 2009 Toyota Prius I Smart Fortwo ED Drive Hybrid Drive Electric Power Petrol engine Power 65 kW (48 HP) 43 kW/58 HP, electric Speed 125 km/h motor 30 kW (40 HP) Battery Lithium ion Speed 160 km/h with 17.6 kWh Battery Nickel metal hydride Range 145 km TECHNICAL INFO – MANUFACTURER’S DATA TECHNICAL INFO – MANUFACTURER’S

11 DEKRA solutions 3/2015 Energy for Mobility

Free Parking and a Recharge Norway is the no. 1 country for electric car penetration for a reason

will see an emissions limit of 90g of CO2 per kilome- rent electricity mix, even electric cars would not be ter enforced. At last year’s UN Climate Conference regarded as environmentally friendly. According to in Paris, Germany joined the so-called Zero Emis- the World Energy Council, we continue to generate sion Vehicle Alliance, whose goal is to stop sales more than two thirds of our electricity from fos- of all vehicles with combustion engines by 2050. sil fuels. Should energy be generated from a mod- It’s a noble goal, yet its effectiveness in protect- ern, coal-burning steam power station, which typ- ing the environment is questionable. With the cur- ically boasts an efficiency level of under 50% and

2011 2012 Renault Twizy Tesla Model S Drive Electric Drive Electric Power 13 kW (18 HP) Power 225 kW (306 HP) Speed 80 km/h Speed 190 km/h Battery 6.1 kWh Li-ion Battery 60 kWh Li-ion Range 100 km Range 390 km

12 DEKRA solutions 3/2015 churn out masses of CO2, then the fact that elec- lanes, complimentary usage of public charging sta- tric motors are almost 100% efficient is of little tions and free parking. Of course, the hassle-free significance. Furthermore, there are dramatic dif- usage of bus lanes for flitting around the city will ferences in the electricity mix around the globe. only work for as long as electric cars remain in the Countries such as China and India are actively minority. Otherwise, congestion would begin form- increasing their reliability on coal, whilst Germa- ing on the special lanes, defeating their very pur- ny’s goal of abandoning its nuclear energy program pose. Approximately 9,000 charging bays service will force the country to depend on coal power for Norway’s population of 5.5 million, whilst Germa- many years. ny’s 81.8 million make do with 15,000. The sys- temic drawbacks of electric cars naturally pres- Support for Electric Mobility ent challenges for the Scandinavians too, yet it is Irrespective of this, development continues to prog- worth noting that their energy is 95% hydroelec- ress – after all, there is much to be done to ensure trically generated. the breakthrough of the electric car. Ranges must The battery-powered car isn’t the only electric be extended considerably, whilst charging times alternative that engineers are working on. Another need to be shortened dramatically. According to popular solution is the hydrogen fuel cell, which data from the German Federal Office of Economics sidesteps both the range and charging issues of and Export Control, there have been around 1,800 batteries. Cars can fill up with hydrogen in a mat- applications for the government’s 4,000 € subsidy, ter of minutes, in much the same way we are used “The car of provided to those purchasing an electric car up to to with conventional chemical fuels. However, the future will 60,000 € in value. In 2015, electric cars made up both the range of models and number of fuel sta- 0.3% of all new cars registered. There is work to be tions stocking hydrogen are limited. As of Janu- be electric, done to realize Germany’s target of having a mil- ary 2016, there were less than 40 hydrogen fuel and run free of lion electric cars on the road by 2020. pumps across Germany. Europe as a whole hosts emissions” Norway – Europe’s trailblazer in terms of elec- 95, the USA a mere 50. Japan offers just over 100 tric car penetration – has had great success with its such stations. The Japanese are very ambitious Dieter Zetsche, incentive measures, with almost 20% of the mar- when it comes to hydrogen. By 2030, they intend Chairman ket held by electric cars. The Scandinavian nation to bring that number up to 5,000 stations. Accord- Daimler AG taxes conventional cars far more vigorously. This ing to H2 mobility, 400 hydrogen fuel stations are means that the relief afforded by purchasing an scheduled to open in Germany by 2023. electric car is far more pronounced than in Ger- The fact of the matter is that battery-powered many. Volkswagen fans in Oslo can save up to cars are far less complex in their construction than 9,000 € by opting for the Electric Golf rather than those powered by hydrogen fuel cell. In addition its combustion-engined brother. There are several to the highly complicated fuel cell itself, a tank other benefits too, such as the right to drive in bus capable of withstanding high pressures is required.

2013 2013 BMW i3 Mercedes SLS AMG Drive Electric Coupé Electric Drive Power 125 kW (170 HP) Drive Electric, four synchronized Speed 150 km/h electromotors, all-wheel drive Battery 18.8 kWh Li-ion Power 552 kW (751 HP) Range 190 km Speed 250 km/h Range 250 km TECHNICAL INFO – MANUFACTURER’S DATA TECHNICAL INFO – MANUFACTURER’S

13 DEKRA solutions 3/2015 ing new technologies a reality. One can already say with a reasonable degree of certainty that the lithium ion batteries currently in use will not be the last battery technology we see. If we take claims by car manufacturers at face value, the effective ranges of electric vehicles could exceed 500 kilometers in the near future. The nationwide installation of electrolysis plants for the generation of hydrogen would go some way to ‘clean up’ Germany’s energy production. A lack of quickly chargeable batteries means we are currently unable to store excess energy, such as that generated by wind turbines during high winds. Hydrogen could provide an answer, as it can be produced immediately and stored in unlimited amounts. The long and short of it all is that electric cars are only environmentally friendly when the electricity that they use is generated in a sustainable manner. Bridging Technology In addition to battery and fuel cell powered vehicles, plug-in hybrids are another alternative in Clean Strategy eliminating traffic emissions in urban areas. On By the time of the Olympics in 2020, Tokyo balance, they do not perform too well; they are plans to have built a ‘Hydrogen Highway’ both heavy and complicated to build, requiring the installation of both a combustion engine and electric motor. Over longer distances, they consume Carbon fiber reinforced plastic is used for this pur- petrol or diesel too, just like conventional cars. pose. If scientists were to suddenly discover a bat- Most experts view them as nothing more than a tery technology with considerably higher energy bridging technology to aid manufacturers in their

density than the current lithium ion affairs, the compliance with CO2 limit regulations. fuel cell would be in for a difficult time. Who knows There are a great many more hurdles to over- what feats batteries of the future will be able to per- come, but the drive technology revolution is upon form – researchers are constantly working on mak- us and cannot be stopped. Environmental and eco-

2013 2013 Hyundai ix 35 FCEV VW E-UP Drive Hydrogen fuel cell Drive Electric Power 100 kW (136 HP) Power 60 kW (82 HP) Speed 160 km/h Speed 130 km/h Range 594 km Battery 18.7 kWh Li-ion Range 160 km

14 DEKRA solutions 3/2015 TECHNICAL INFO – MANUFACTURER’S DATA PHOTOS: GETTY IMAGES (2), MAURITIUS IMAGES, PORSCHE, NASA, IFCAR, DAIMLER AG (4), ILJA C. HENDEL/LAIF, RENAULT, TESLA, BMW, PICTURE ALLIANCE, HYUNDAI, VOLKSWAGEN, TOYOTA; ILLUSTRATION: MICHAEL STACH 2014 fall further thanks to economies of scale, andthe stricter CO tive drivetrains inorder to comply with the ever- turers must therefore develop cars with alterna to protect the health of their residents. Manufac cities, slowly choking onsmog, must do something tions to vehicles with combustion engines. Mega the year from which they willstop issuing registra nomic concerns have led many countries to name Range 500km Speed 160km/h 114 kW(155HP) Power Electricmotor: Drive Toyota Mirai Hydrogen fuelcell 2 limits of the future. Battery prices will “By 2025,atleast25percent ofourportfolio

will bebattery-powered cars” Rupert Stadler, Chairman,AudiAG 15 remarkable timefor the automobile. global market leadership. We are living inatruly electric cardevelopment, thus winning themselves not least, countries such asChina intend to lead and autonomous driving technologies. but Last market players by combining alternative drive thesensed opportunity to supplant established New players such as Tesla, Google and Apple have construction of new-factories mega for batteries. DEKRA solutions 3/2015 2014 Range 200km Battery 28kWhLi-ion Speed Power Drive Mercedes BClasse-Drive Electric 160 km/h 132 kW(179HP)

production in2017 which istobegin Tesla’s Gigafactory, Big Plans Energy forMobility

Fighting for their Future Revolution faces the modern motoring world. Will cars of the future be greener? Which powertrains will prevail? It all depends on a great number of factors – political included.

CO2 Emissions per Capita (in metric tons) Source: PBL Netherlands Enviromental Assessment Agency / 2014

17.3 16.5

12.4 9.3 10.1 9.4 7.6 7.4

2.5

Australia Brazil China Germany Japan Netherlands Russia S. Africa USA

Breakdown of Fuel Prices in Germany Source: ARD Exchange / August 2015 2.96% 0.18% 5.71%

46.77% Energy tax VW Golf 1.0 TSI – 115 HP – 20,675 € Crude oil price The three-cylinder engine of the combustion Golf 16% Value Added Tax is remarkably efficient, yet doesn’t hold a candle to Overhead contribution the efficiency of its fully-electric brother. Refinery costs Oil reserve fee

28.57%

46Electric Cars: Energy consumption+28166+3+1z using VW Golf as basis Source: Volkswagen / 2016

Golf 1.0 TSI (115 HP) e-Golf (115 HP)

9.7 9,675,000,000 kWh % 3,150,000,000 kWh 12.7 4.3 43lower 1.4 energy consumption Consumption (L) Petrol Fuel Value Consumption of 1 Million Vehicles Consumption of 1 Million Vehicles Equivalent Petrol Usage (L) Consumption in kWh average/100km 1 litre in kWh driving 25,000km/year driving 25,000km/year average/100 km average/100km Fighting for their Future Energy Sources Around the World Source: International Energy Agency / 2015

861+86.1% 63+77= 6.3% 7.7% Australia 642+64.2% 32132.1% +36= 3.6% Chile 676+67.6% 265+26.5% 60= 6.0% Turkey 611+61.1% 141+40+208=20.8% 14.1% 4.0% Germany 7.2% 5.4% 76.5% 72+765+109+54= 10.9% France 3.5% 8.3% 88.1% 881+35+1+83= 0.1% Netherlands

95.9% 2.2% 1.9% Norway 22+959+19= 0.4% 4.3% 86.2% 862+4+91+43= 9.1% Japan 681+68.1% 194+19.4% 66+58= 6.6% 5.8% USA Fossil fuels Nuclear power Hydro-power Wind/Solar/Geothermal

Electric Car Registrations (inc. Plug-in Hybrids) Source: Center of Automotive Management / 2015 188,000 VW e-Golf – 115 HP – 34,900 € The battery is currently still expensive, with a low 115,000 energy density. The high efficiency of the electric motor does compensate for this, with comparably 23,500 28,000 25,000 27,000 little energy required.

China Germany Great Britain Norway France USA

Optimistic Forecast – Germany Falling Prices of Batteries (Cost prices in Euro per kWh) Forecast: Roland Berger / 2016

160 130 120 110 95 80 2020: 140,000 New registrations 2030: 840,000 New registrations

worldwide electric car 2014 2016 2018 2020 2022 2025 100,000,000 registrations 2030 (forecast)

Electric Car and Hybrid Incentives around the globe Source: Goodimpact Magazine / 2016

Canada China France Germany Netherlands Japan Norway USA

Grant of up to Premium of Buyer’s premium of Up to Buyer’s premium of Buyer’s premiums up to Savings of up to Maximum 5,800 € 6,000 € 6,300 € 4,000 € 6,000 € 6,400 € 9,000 € tax saving of in buyer’s premium for cars depending on model 6,800 € Free charging of car No company car up to 60,000 € Various tax savings tax for electric cars Government assumes 5 years 50% of Electric cars may be exemption from additional costs involved in Exemption from various Permitted to drive

PHOTOS: VOLKSWAGEN; ILLUSTRATION: MICHAEL STACH ILLUSTRATION: PHOTOS: VOLKSWAGEN; registered immediately vehicle tax No vehicle tax buying electric car special taxes in bus lanes DR. WOLFGANG BERNHARD The 56 year old industrial engineer has been a Daimler AG board member since 2010. He has directed Daimler Trucks & Buses since 2013

“Coming on in Leaps and Bounds” Dr. Wolfgang Bernhard discusses advances in electric goods vehicles and the corporation’s dedication to drive this technology forward. Interview Michael Kern

Dr. Bernhard, you have never made a secret of ited performance. It has, however, come on in your skepticism regarding electric trucks. Yet leaps and bounds, and a market is developing. Mercedes Benz has now revealed exactly such a vehicle. What changed your mind? What has happened in terms of technology? Bernhard: We have been working intensively on Bernhard: As the première of our Urban eTruck this subject for years. For a long, long time, it demonstrates, the electric revolution has come to appeared that electric drives for trucks were out our segment too. Take the batteries, for instance – of the question; the possible applications were massive progress is being made in this area, and extremely limited. Battery technology was held between 1997 and 2025, costs are projected to sink back by high costs, long charging times and lim- by a factor of 2.5 when compared to 1997, whilst

18 DEKRA solutions 3/2016 PHOTOS: JACEK BILSKI, DAIMLER payload, meaning it iseffectively only reduced by ric ton. This more orless negates the reduction in weight of trucks with alternative drives byamet declared itself infavor of increasing the maximum bustion engine. The European Commission has grams more than acomparable truck with acom Bernhard: The Urban eTruck weighs 1,700 kilo diesel cousins? Can Mercedes’ electric truckcompetewiththeir System’ connector. way of the European standard ‘Combined Charging Connection of the truck to acharging station isby The truck can also recover energy whilst braking. rarevery that batteries are completely discharged. two to three hours. In practice, however, it willbe discharged batteries canbecharged to 100%within Bernhard: With a charging power of 100 kW, fully How are thesebatteries charged? securely mounted within the frame for crash safety. ters. We lithium use ionbattery modules, which are presented provides energy for around 200 kilome 26-metric-ton, three-axle solo truck that we recently Bernhard: The basic battery configuration of the eTruck? What istherangeofMercedes Benz’Urban in ourcities. cations. Electric trucks may beacommon sight soon they are enoughfor short-radius distribution appli nology aren’t quite sufficient for that currently, but Bernhard: The achievements made inbattery tech tance haulage? Does thesameapplytotrucksforlong-dis- but the electric truck too. That doesn’t just make the electric car feasible, performance willincrease bythe sameamount. ------19 compressor, similartothebrakesystem. driver’s cabin,withtheclimatecontrol systemrelying onanelectricallydriven tial capacity. Warmth from thepowertrain’s coolingcircuit isusedtoheatthe This shouldsufficefor3,000charge cyclesbefore degradingto80%oftheirini- three-module lithiumionbatterypack,whichhasatotalcapacityof212kWh. for 11,000Nmoftorquea atthewheel.Thebasicconfigurationconsistsof nominal voltageis400V, withamaximumoutputof2x125kW. Theseallow – amodifiedversionofthesolutionweoftenseeinelectricbuses.Theengines’ a low-floorportalaxlesolutionwithelectricmotorspositionednearthewheels vehicles. Insteadofaconventionaldieseldrivetrain,theUrbaneTruck relies on which intendstoopenthedoorarrivalofbattery-electricheavygoods emissions-free mobility”,andhasrecently revealed athree-axle 26tonnetruck Daimler Trucks describestheirelectricdriveas“theidealsolutionforlocal, The UrbaneTruck from Daimler IN DETAIL longitudinal beams situated betweenthe The batterypacksare Packed in DEKRA solutions 3/2016 typical application area of urban distribution. 12.8 trucks. Asaresult, the Urban eTruck has apayload of 700 kilograms when compared with conventional ers, allowing them to reliably perform their logistics. the near future that are economical for ourcustom in ourportfolio. Our goal isto offer electric trucks in part of ourstrategy, andwillbecome afirmfixture the beginning. The very electric truck is a concrete in the development of this emerging segmentfrom Bernhard: We are committed to being a driving force What isyourstrategy? mercial vehicles. right. The electric revolution has arrived for com too late andyou’ll lose the market. Now, the timeis too andyou’lltions –begin soon lose money, begin Bernhard: Timing isdecisive for all new innova This surely hasn’t happenedovernight? starting the dialogue. themselves for such eventualities. They are the ones gether from 2020.Our customers want to prepare with conventional powertrains from entering alto Paris, for example, isconsidering forbidding trucks enforcing stricter regulations onheavy goodstraffic. continue. Simultaneously, more andmore cities are in cities than ever before, andthat trend that to isset tinues to do so. Around the world, more people live in electric trucks has grown considerably, andcon the right place to do inthe so early 2020s.Interest serial production.begin Ibelieve that we willbein Bernhard: We will,of course, have to wait awhile to duction? can youenvisagetheUrbaneTruck enteringpro Is the demand for an electric truck here yet? When metric tons, which ismore than enoughfor its Interview ------

China’s Automotive Opportunity

There’s something in the air Chinese megacities are fighting tooth and nail to bring their air quality into line. Traffic restrictions and alternative powertrains should aid in improving quality of life. Simultaneously, China is establishing itself as the leading market for alternative drive technologies. Author Bernd Ostmann

20 DEKRA solutions 3/2016 A Heavy Burden Especially in the winter months, smog hangs over Beijing like lead

21 DEKRA solutions 3/2016 China’s Automotive Opportunity

mog alert in Beijing! Visibility isn’t enough lic charging stations. A congestion charge, akin to see the other side of the street, the peo- to that in place in London, has been in discus- S ple are wearing face masks (but coughing sion since 2009. Should it ever be implemented, nevertheless), and school is canceled. vehicles with alternative drive concepts would Such images should be a thing of the past, and be exempt. The financial incentives are sure to the Chinese government is trying to make it so. tempt those considering buying an alternative Heavy industry, for example, is to be relocated to car concept too. For example, depending on their other areas of the country. Road traffic – which range, electric cars are subsidized by the govern- is to blame for between 20 and 30 percent of the ment by up to 6,140 euros, without taking into air quality issues – must also be reduced. In 2020, account further subsidies provided by regional Beijing intends to introduce the strictest emis- 6 million and municipal authorities. These may total up sions regulations on the planet. ‘China 6’, as the Beijing wants to freeze to 17,000 euros. new regulations are known, should reduce the air the number of vehicles The measures are proving successful. Of the pollution generated by car emissions by between in the city at six million. approximately 650,000 electric and plug-in 15 and 20 percent. Simultaneously, the Beijing Source: Beijing City Administration hybrid cars sold worldwide in 2015, 180,000 vehicle stock is to be frozen at six million vehi- were in China. Looking at the first half of 2016, in cles. Additional measures to rein in the traffic which 170,000 such vehicles were sold in China, are in force even now, such as the requirement to it seems the country is on course to double sales forgo one’s car for one day every week. New car and consolidate its position as the world’s lead- registrations are issued using a lottery procedure, ing alternative drive market. In second place is with the chance of receiving a new car registration lying at around five percent. In addition to restricting the registration and Off the Pace usage of cars powered purely by combustion Daimler builds the Denza engines, vehicles with alternative drive concepts together with Chinese car are being promoted. Whoever buys a hybrid, elec- and battery manufacturer tric, or fuel cell powered vehicle will have their BYD. With 1301 registra- registration approved instantaneously, and may tions in 2015, it was only the 14th bestseller drive on any day of the week. Future benefits may include free parking or the usage of pub-

Big Seller The Qiu plug-in hybrid from BYD, of which 28,365 were sold in 2015 Big Plans The Chinese government is supporting the switch to alternate drive solutions and the development of infrastructure with 4.2 billion euros. By 2020, 4.8 million charging facilities are planned throughout China the USA, with 66,000 electric and plug-in hybrid sales rankings is the Qiu plug-in hybrid from vehicles sold. Norway is in third with 22,000. Ger- BYD, followed by a fully electric model by BAIC. many sits in sixth place with 10,481 alternative The Denza finds itself in 14th place, with 1301 drive registrations. units sold. This puts it far behind Tesla’s Model S, Despite their relative success, cars with alter- which found 3,000 buyers. Arguing that the native powertrains constitute a mere one percent Denza – Daimler and BYD’s joint-venture – is too of China’s new car market, in which 19 million expensive is a bogus argument in any case. After cars are sold every year. A drop in the ocean, but taxes, the Tesla Model S costs 120,000 euros in there are ambitious plans to make it more. By China (85,000 euros in Europe). 2020, five million electric vehicles are to be sold annually. The masterplan foresees 200,000 electric buses, 300,000 electric taxis and 200,000 % 331,090 logistics vehicles – for communal services, 20 Chinese Sales Beijing wants to reduce patient transport and the like – in addition to of Electric and air pollution by 20 Plug-in Hybrid 4.3 million new private and commercial vehicles. percent. To this end, China is investing heavily in infrastructure for Vehicles ‘China 6’, the ‘strictest Source: China Association of this. By 2020, 4.8 million charging stations are emissions standard Automobile Manufacturers (CAAM) planned. on the planet’ will be Plug-in Hybrids introduced. Electric Cars International cooperation Source: Beijing Environment Who is going to be supplying all this business? Administration There are currently 33 Chinese vehicle mod- 74,763 els with alternative powertrains, and ten built through joint ventures. These include the Denza 17,642 – a cooperation between Daimler and BYD – and 8,159 12,791 BMW’s cooperation with Brilliance, the Zinoro. The first model is based on the BMW X1 and is 2011 2012 2013 2014 2015 currently only available for lease. Leading the Private vehicles, commercial vehicles and buses

23 DEKRA solutions 3/2016 All Change, Please! By 2020, 300,000 electrically-powered taxis should be on the roads

So what is the reason? Is German engineering no longer ‘in’ in China? It seems more likely that the Germans are exercising caution in their Chi- nese electric vehicle business. The Chinese government has forced them into founding separate businesses as joint ventures with Chinese partners. In order for customers to qualify for subsidies, these businesses must develop their electric cars together. This results in a full transfer of the development know-how to the Chinese partner. The goals are obvious: China knows that the traditional automotive countries’ lead in the development combustion engines cannot Battery Production be overtaken. The situation is somewhat differ- No less than 57 ent when it comes to alternative drive concepts, companies are already producing batteries in especially electric motors. China has experience China. DEKRA carries on tap. After all, China’s streets are teeming with out product safety 200 million motorbikes and mopeds with electric testing for various drive. Furthermore, the ‘fourth battery catalogue’ manufacturers lists no less than 57 home-grown companies that

24 DEKRA solutions 3/2016 PHOTOS: PICTURE ALLIANCE (2), DAIMLER AG, NEWSPRESS, BLOOMBERG VIA GETTY IMAGES, DDP IMAGES, REUTERS, DEKRA combustion engine powered vehicles are inplace. tration restrictions anddriving bansfor solely only booming in the metropolises where regis such alternatives –electric cars andhybrids are incentives that are leading customers to opt for drive concepts inChina: it isn’t just the financial in the shortbutexplosive growth of alternative to year. One thing has already become apparent 2020, although these are to bereduced from year tive drive concepts have been guaranteed until a sure-fire success. The grant funds for alterna mously too. best electric car;they want it to drive autono 2020, they don’t merely want to build the world’s dealing with big goals, why notgoonefurther? By cars peryear by2020.Seeing asthey’re already produce between 250,000 and400,000 electric management director. Their declared goal: to train developer, the headdesigner andproduct manager for the i8,butalso the chief drive have notmerely signed BMW’s overall project shopping. serious some In Carsten Breitfeld, they to belittle issue, the Chinese company has done popular chat platform. Seeing asmoney seems net giant responsible for ‘WeChat’, China’s most the automotive sector stands the inter Chinese funding andabig plan. Behind this new player in a carorfactory, the company has considerable to compete too. Although they don’t yet have dollars. The start-up Future Mobility intends ment isrumored to bearound nine billionUS Chinese real estate company. The planned invest own factory inChina, incooperation with a China thus far –are planning onbuilding their Tesla –disappointed intheir performance in Newcomers versusestablishedplayers electricnese vehicle manufacturer. wants to invest 2.3 billionUSdollars into the Chi- prising that Korean electronics giant Samsung streets of Brussels andLondon. It’s hardly sur port, and fleets of electric BYD taxis are on the arebuses inactionat Amsterdam’s Schiphol Air at the endof 2016. Even now, 35of these electric producing electric inKomarom, buses Hungary, expansion isalready beginning. BYD willbegin thing that China isgoing to give uplightly. The pects of global market leadership is notsome manufacture batteries. This lead andthe pros- But even inChina, the electric carisfar from ------

25 the interplaybetweenairqualityandgrowing marketforelectricvehicles? er responsible for East Asia in its entirety based in Shanghai. How do you perceive Mr Zurkiewicz,youhavebeenlivinginAsiasince2002,andare theDEKRAmanag Three QuestionsFor... INTERVIEW more, we are keeping up with the increasing demand for wireless technologies technologies wireless for relating tothe‘connectedcar’and‘autonomousdrive’technological megatrends. demand increasing the with up keeping are we more, Further support. and training installation providing by network station charging a international markets. We are supporting a German automotive brand in developing connectors. These enable EV and components manufacturers cables to access both EV Chinese domestic and for standards of development leading been have we of EV powertrains. In partnership with the Chinese national certification body CQC, in Jiading Shanghai, where we will test both charging stations and key components laboratory major a up setting by activities our up scaling of process the in are we Now years. of number a for components (EV) vehicle electrical for services testing Yes, very much so, and in a variety of areas. In China, we have already been Is DEKRAinvolvedinthisdevelopment? providing are inEurope. arevehicles thereforesuch adopt to more incentives far The pronounced they than usage. electricity of planning precise require will Both standards. emissions lower with vehicles on impacts significant have also will Oil’ 6 ‘Beijing whilst 2020, by ed this, ‘China 6’ – China’s strictest environmental standard – is likely to be implement many electric vehicles must be registered by each branch or authority. In addition to how to as regulations tough include will Measures this. restrict further to trying are The desire to have one’s own car remains high in China. Conversely, the authorities five millionby2020seemsomewhatambitious.Are they realistic? The authorities’planstoincrease thenumberofelectricvehiclesonroad to in urban areas, whereas electric cars and plug-in hybrids are accepted immediately. to impossible already on engines nigh register combustion it conventional find with be modernized or relocated. Road traffic is also a key focus of these plans. Vehicles will facilities industrial and plants Topower cities. end, Chinese this major other all into ensuring that more than 90% of days remain smog-free. Similar plans exist in Here in Shanghai, the environmental protection regulators are putting all their efforts DEKRA www.dekra-certification.com More information: solutions 3/2016 DEKRA ChiefRegionalOfficerEastAsia

Stan Zurkiewicz, China’s AutomotiveOpportunity - - -

Electric Drives in Motorsport

26 DEKRA solutions 3/2016 Electrifying Racing Alternative powertrains are gaining ground in motorsport. Formula 1 cars and the endurance machines used in the WEC now rely on hybrid technology, whilst Formula E forgoes the combustion engine entirely. We got the inside track. Author Robert Dunker

27 DEKRA solutions 3/2016 Formula 1 Hybrid petrol 1.6 liter V6 turbo with recovery of brake and exhaust energy System power: 1,000 HP Top speed: 370 km/h 0–100: 2.5 secs

WEC Petrol 2 liter V4 turbo hybrid (Porsche) Petrol 2.4 liter V6 turbo hybrid (Toyota) Diesel 4 liter V6 turbo hybrid (Audi) System power: 1,000 HP Top speed: 340 km/h, 0–100: 2.2 secs

Turbine Engine Fuel Tank MGU-K Battery

Budgets and ntil now, Formula E could be regarded as a both drivers and team bosses alike; and the technol Team Sizes somewhat brief pleasure. After 25 minutes, ogy is astronomically expensive. There are, there U the drivers must return to the pits and swap fore, good omens for this successful, green and FORMULA 1 to their second cars – the first having run out of bat approachable racing series. Yet Formula E chief Ale tery. Within two years, batteries that can endure an jandro Agag – a former Spanish Member of Euro hour of racing are envisaged, making the vehicle pean Parliament and, since 2007, owner of a GP2 80 – 300 Million € change go the way of the monotonous whirr of the junior team – has announced diplomatically that “to electric motors that assailed our eardrums from the make Formula 1 our competitor would be the wrong first race in Peking in 2014 up until the start of last approach”. Yet this could well be the direction that season. Now, each new development to the power it takes, even if FIA Chief Jean Todt regards the bat train brings with it a more pleasing soundtrack, tery-powered racers as a ‘supplement’ to Formula 1, causing even motorsport purists such as Niki Lauda rather than a rival series. 200 – 1,300 People to tone down their often harsh criticism. The leg The old establishment continues to have many end was even cited as saying: “I’ve already seen reservations. Four-time Formula 1 champion Sebas WEC such high caliber racing, that the sound becomes tian Vettel believes the sustainability offensive in almost irrelevant.” Formula 1 has already gone too far – the shrunken, 20 – 150 Million € The third season of Formula E will commence six-cylinder engines now sound “like lawnmowers” in October, with races in Hong Kong and New York to his ears. Clunky acronyms such as ERS (Energy guaranteeing spectacular scenery. One of the cham Recovery System), MGU-K (Motor Generator Unit – 100 – 260 People pionship’s singularity is the ‘FanBoost’ – a system Kinetic) and MGU-H (Motor Generator Unit – Heat) by which fans can vote online to give their favorite have also led to Formula 1 being described as “far FORMULA E driver some extra pep. Voting takes place up until too complicated” this year. the sixth minute of the race, with the additional 100 kilojoules then ‘activated’ for the replacement car. Motorsport – Driving Innovation 5 – 6 Million € This initiative gets the audience more involved in Agag has cleverly positioned Formula E as a pio the happenings of the race. neering racing series. “For us, Formula E is a test 15 – 20 People The pioneering electric motorsport champion ing ground to trial systems in a tough environment,” ship is also benefiting from the faltering of Formula explains Paul McNamara, Head of Technology for 1; a sport in which viewer and spectator figures are Williams, who provide the high performance batter nosediving; regulations are constantly attacked by ies for all teams. “We were able to thoroughly test

28 DEKRA solutions 3/2016 Electric Drives in Motorsport

Formula E Electric powertrain with 272 HP, 28 kWh battery capacity, three-speed gearbox, rear- wheel drive, weight incl. driver: 888 kilograms, Top speed: 225 km/h, 0–100: 2.9 secs

and validate our cooling systems, charging times are also pursuing with our cars for road usage,” and module designs for applications in other proj- announces Head of Audi Motorsport Dr. Wolfgang ects outside of motorsport.” Ullrich. The effort undertaken by the brand with Motorsport and space entrepreneur Richard the four rings is enormous. Nothing of the previ- Branson believes Formula E may become FIA’s num- ous year’s car has survived the complete overhaul of ber one racing series in the not too distant future. the redesigned Audi R18: the flywheel energy stor- The entrepreneur himself is involved with the team age system of the hybrid drive has been replaced Virgin Racing. BMW provides the safety cars for the by a high-voltage battery, whilst both the four-liter event, and is even entertaining the idea of compet- V6 TDI engine and braking energy recovery system ing itself, having seemingly recognized the series’ have been overhauled. The car generates over 1,000 “The TDI tech ‘green’ credentials. It’s worth bearing in mind that HP of system power, something that can also be said we use in our BMW turned its back on Formula 1 back in 2009. for the Porsche 919 hybrid. As last season’s top dog, production Another example of top-tier motorsport adopting the Porsche has merely been refined for 2016. Toy- cars has alternative powertrains can be found in the long-dis- ota has followed in Audi’s footsteps, unveiling an benefited tance racing of the World Endurance Champion- entirely new car for the 2016 season, yet one that ship. However, whilst in Formula E there is an open is strongly inspired by the title-defending Porsche. considerably transfer of technology between teams, the WEC is a The Japanese brand will now rely on a six cylinder from its usage power struggle between Porsche, Audi and Toyota. biturbo engine with battery storage, rather than its in the WEC” Works teams have been showing off their techno- old V8 with supercapacitors. The Toyota collects logical might since the first 24 Hours of Le Mans energy during braking from both the front and rear Dr. Stefan Knirsch, back in 1923. axles. Porsche uses braking energy from the front Audi AG Board Member for Since the establishment of hybrid systems, the wheels, with a second hybrid system collecting heat Technical Development significance of the additional electric drive has from the exhaust. increased with each passing year. For the 2016 sea- Energy efficiency is the difference between win- son, competition has stepped up a notch, with the ning and losing in Formula E too. “The challenge is fuel consumption limit for Le Mans being drasti- to go as fast as possible whilst using as little energy cally reduced. The WEC is another testing ground as possible,” explains team owner Hans-Jürgen Abt. for systems that may make an appearance in series The crux? “If you use too much energy going fast, production. “The result is a racing car that is even but you may end up running out of juice. But drive

PHOTOS: GETTY IMAGES, FERRARI EMDIA, PICTURE ALLIANCE, PORSCHE, ALLIANCE, PICTURE EMDIA, FERRARI IMAGES, GETTY PHOTOS: OF MMDI GRAHAM MURDOCH IMAGES COURTESY HONDA, RENAULT, more frugal with its energy usage – a goal that we too slowly, and you’ll be left behind.”

29 DEKRA solutions 3/2016 Crude Oil Extraction – Status Check

Elixir of Life Crude oil is the most valuable substance on Earth. Without the black gold, civilization would be unrecognizable. We check how secure our oil supply really is in the midst of reports of dwindling reserves. Author Lars Lubienetzki

30 DEKRA solutions 3/2016

Changeover Workers commute by helicopter to their drilling platform

he wind is howling, and menacing waves heating fuel, and, far more importantly, the most sweep across the ocean below the drilling prevalent energy source for transport. No other T platform, several kilometers off the coast energy source comes close. of Brazil. The 200 meter tall semi-submersible, 1.68 In the early 19th century – the beginning of as such floating oil rigs are known, is fixed to the ‘oil age’ – private entrepreneurs fought over the sea floor with steel cables. Despite this, it Billion barrels the world’s oil deposits, and business was boom- sways in a concerning manner as the rain lashes is the estimated ing. At a certain point, however, the countries quantity of crude the rig workers’ faces. They’re grateful for their oil that can still be with the greatest oil deposits realized the value protective clothing on days like this. Many days extracted. of what they were sitting on. This led to the bal- are spent under the blistering sun, and even on Source: BP ance of power in energy markets shifting radi- these days they are required to wear their full protective gear. Every day, they extract several hundred thousand barrels of crude oil from the ocean floor far below, its sulphurous stench combining with the salty sea air. These men don’t mind. The curious blend stays in their nostrils long after returning to shore for a few days of recuperation. Work on an oil rig is back-breaking but indispensable – the human race is addicted to this sticky, stinking substance. Crude oil was first used around 12,000 years ago as cement for weapons and tools, and as paint for jewelery The Daily Grind and sculptures. It was later used as lamp fuel. High spirits prevail Its real potential was first discovered during the despite difficult work in industrial revolution. Nowadays it finds use as a the rig’s break room

32 DEKRA solutions 3/2016 Crude Oil Extraction – Status Check

cally within a short space of time. Transporting oil from faraway lands to the world’s industrial powerhouses remained almost exclusively the task of private corporations such as Esso, Shell and BP as recently as the 1970s. These corporations also managed its sale upon arrival. The brands are still around, and although their market power has been heavily eroded, they still enjoy substantial economic potential. The biggest oil corporations are now state-owned, with far less evocative names. Amongst them are Rosneft (Russia), Saudi Aramco (Saudi Ara- bia), NIOC (Iran), PdVSA (Venezuela), CNPC (China), Pemex (Mexico), and Sonatrach (Alge- ria). According to estimates (state-run corporations do not release any official figures), state- owned oil corporations control between 80 and 90 percent of global oil production. Estimated Reserves According to BP’s calculations, there are approximately 1.68 billion barrels of oil left in global deposits (1 barrel = 159 liters). This value Safety revised upward once again. Other technologi- has been repeatedly revised upward in recent Pins in the board mark cal advances will also make oil transport safer decades thanks to advances in technology. BP possible dangers on the and more efficient. “Avoiding corrosion to the estimates that the remaining crude oil depos- drilling platform facilities and pipelines incurs significant costs, its will suffice for at least another forty years, especially offshore,” explains BP Group Head of assuming energy demands remain stable at Technology David Eyton. “In order to identify current levels. A revolution in drive technology corrosion as early as possible, we use wireless could, however, lead to these estimates being sensors that keep us informed of the condition of the pipes.” Now, the rusting-through of pipelines is almost out of the question. IN DETAIL The success rate in the search for oil has Safety in Offshore Extraction also steadily improved. In the past, companies drilled eleven times on average in order to hit The largest, as yet untapped oil fields lie beneath the ocean floor. Offshore oil. Nowadays, that average has sunk to two extraction – the drilling for oil on the high sea – is an established concept. Oil test bores. Supercomputers and the ability to has been being extracted from the North Sea since the mid 1970s. DEKRA produce subterranean 3D imaging have helped subsidiary Optimus Seventh Generation works on a range of oil extraction considerably in ending the expensive lottery of projects in the North Sea with various companies, including BP. “There are a divining for new oil wells. Each borehole costs great many risks involved in offshore oil extraction,” says Optimus Seventh several million US dollars. Generation’s CEO Derek Smith, before continuing: “for example, there are The search for new sources of oil continues high pressures, extreme temperatures, the stability of the rig, and long dis- around the world at a rapid rate. The USA used tances (both to the shore and to the borehole itself) to deal with. We know to be constantly rated as one of the world’s most that the industry has technical solutions for all of these, and provides appro- powerful oil producers, but this position came priate safety mechanisms. We see our job as limiting human error to the low- under threat in the early 2000s as domestic pro- est possible level. We don’t intend to unsettle people, or make them think duction began to slow. Rising oil prices, how- that something bad will necessarily happen, but we do want each and every ever, suddenly made a new extraction method worker to recognize that something could happen.” viable. Fracking brought the Americans up to the top of their game again, whilst simulta-

33 DEKRA solutions 3/2016 Crude Oil Extraction – Status Check

the water table for years. Putting environmental concerns aside for a moment, even business experts are not convinced. They believe fracking is only viable when oil prices exceed 60 dollars. They currently lie at around 45 dollars. The Changing Face of Energy Crude oil continues to rule the world. But what comes after that? According to experts, transport will continue to be dominated by oil for another twenty years at least. Especially when it comes to long distances and heavy loads, the energy value of crude oil products cannot be beaten. Current technology cannot replace fossil fuel for aircraft and cargo ships. Experts forecast a battle between hybrid technology, batteries and fuel cells for supremacy amongst smaller vehicles with more modest require- ments in terms of range. “We believe that the hybrid vehicle concept is the most technologi- cally mature,” states BP’s Head of Fuel Research in Bochum Dr. Peter Sauermann. His reasons are clear: “A hybrid is the best option for a second car for urban driving. On short journeys, neously providing for heated debate amongst Steel Giants drivers will pretty much forget that their car experts. Fracking, or hydraulic fracturing, North Sea platforms are also has a petrol or diesel engine under the involves releasing oil from rock layers, some- firmly anchored into the bonnet.” Such plug-in hybrids – the batteries of thing achieved by introducing a chemical solu- sea floor which suffice for fully-electric short-radius jour- tion to force the oil from the strata. Environ- neys – only use the combustion engine on longer mental organizations criticize this method as journeys. “Instead of filling up with fuel three the substances used can pollute the earth and or four times every month, the hybrid owner

SERVICE What Does DEKRA Inspect?

DEKRA is a service provider for the energy sector, offering independent appraisals, measurements, facility and material inspections. These ensure compliance both with the law and other standards for added safety. Here are a few examples:

Explosion Prevention Safety Non-Destructive Audits Wind Farms An important subject Training Testing DEKRA energy audits DEKRA is authorized to issue at oil extraction DEKRA teams run At power plants, DEKRA are available to business type registrations and carries installations. DEKRA safety training courses tests safety-relevant parts across all areas, and out periodic checks in its specialists inspect for oil rig personnel. using inspection robots and allow efficiency to be authority as an approved the facilities. cameras. measured objectively. inspection agency.

34 DEKRA solutions 3/2016 Piled High The drill rods tower above the platform deck.

Checking it Twice by the Arbeitsgemeinschaft Energiebilanzen Engineers work through e. V. (Energy Balance Working Group). The their inspection lists report also noted that 14.1 percent of domestic meticulously energy is generated by nuclear plants. The Ger- man government has announced that no more nuclear power will be used after 2022. To cover the resulting shortfall, energy from renewable sources will be further increased above its current 30 percent share. Oil derivatives contribute a mere 0.8 percent of Germany’s energy budget. This is positive news, as the black gold is a bigger part of our lives than many of us would expect. Take a moment to look away from this page, and let your gaze wander: CD cases, the paint on the walls, the case of your computer or smartphone, the kitchen work surface, those comfortable stockings, your TV and that pain relief gel – all of these and more are made using will fill the tank maybe once every six months,” oil derivatives. I’m sure a great many more prod- adds Sauermann. ucts will come to mind, but without crude oil, However, electricity is predominantly gener- we’d have to forgo all of it. And that is why the ated by burning other fossil fuels, such as coal men on the drilling platform off the coast of for instance. Coal’s share of electricity pro- Brazil will continue working through all weath- duction in Germany was 42.2 percent in 2015. More information: ers to bring it out of the seabed. They work so Almost nine percent was provided by natural www.dekra- that we remain mobile, don’t freeze, and can

PHOTOS: BP, GETTY IMAGES PHOTOS: BP, gas. These are the findings of a report compiled insight.com generally enjoy life as we know it.

35 DEKRA solutions 3/2016 The Private Energy Revolution Give and Take Everybody wants their energy ‘green’ these days – ideally self-generated and ready to power their electric cars. The automobile industry has been listening. Author Karl-Gerhard Haas

1 BMW offers i Series customers a car port built by Solarwatt. The photovoltaically generated electricity is stored in a battery and trickled to the car overnight 2 The Powerwall, built by US electric car company Tesla, also functions as a battery for home-generated electricity 3 Mercedes Benz offers battery modules that save excess energy. Management is by way of the energy provider’s app

36 DEKRA solutions 3/2016 PHOTOS: BMW, DAIMLER, TESLA T old batteries retain between percent 70and80 of falls below the guaranteed lower limit. Yet these ger powerful enoughfor road usageastheir range after around ten years, their batteries are no lon are inherently flawed. This isbecause as it stands, ship, thanks to the fact that current electric cars Mobility House have a well-thought-out partner excess windorsolar energy until needed. ter Tesla, marketing its batteries which canstore adays, Lichtblick isbuddied upwith UStrendset longer attractive –the market had changed. Now ect, it becameapparent that the product was no ended somewhat acrimoniously; during the proj power, making it extremely efficient. motor that simultaneously generates heat and cars. Lichtblick’s co-generation plant a VW uses pany Lichtblick long before the dawn of electric was teaming upwith ‘green’ German power com means averse to working together –Volkswagen 3 However, the marriage of these two companies Stuttgart carcompany Daimler andMunich firm to that of cat and dog. Yet the two are by no tries may an unlikely sound partnership, akin he automobile and renewable energy indus ------their original capacity andare still far too goodto solar panels andabattery, meaning that whilst out now fillupon electricity from acar-port fitted with tion for its iSeriescars. The i3andi8models may is working with Dresden firm‘Solarwatt’solu on a - date. Meanwhile, Bavarian carmanufacturer BMW storing excess energy for private usageat alater ated energy backto the grid–experts recommend becoming less and less lucrative to sell self-gener Energy Storage’. The reason behind this is that it is ered family homes,under the name ‘Mercedes Benz products. vided with asource of discounted materials for its of their road usage, whilst Mobility House ispro ferently if they don’t endupinthe trash at the end ler isable to calculate the prices of its batteries dif a lucrative business model for all involved –Daim age units for commercial usage. This could prove theseposes old batteries asstationary energy stor be carelessly tossed away. Mobility House repur euros, depending onversion. the next adventure. Prices start at around 10,000 on the road, the solar cells are already charging for Daimler also offers new batteries solar-powfor ------Future Testing This is a view that road users will grow accustomed to in the future. Platooning describes the practise of digitally linking trucks together on highways, allowing them to safely drive in each others’ slipstreams to save fuel. DEKRA’s Automobil Test Center investigates the real benefits. Author Joachim Geiger Truck Platooning on Test

he biggest questions of the future often start front result in additional savings at the pump? with the smallest of things. A roll of tape, The DEKRA Automobil Test Center’s series of T for example. Thilo Nikolaus craftily makes a tests will investigate whether these assumptions square frame from four thin strips of tape on the hold any water, using DEKRA’s own equipment inside of his Mercedes Actros 1845’s windscreen. and testing circuit. As vehicles with the requisite The shape reflects that of the rear of the truck 15 digital coupling mechanism aren’t yet available, meters ahead of him. The 42 year old mechanic this test must rely on those four little strips of is a test driver at DEKRA Automobil Test Center tape on the windscreen. This solution allows the in the Brandenburg town of Klettwitz. Together DEKRA experts to replicate the digital coupling with his colleagues, Michael Hausdorf, Andreas during convoy driving with conventional vehicles. Bönisch and Jörg Müller, Nikolaus is engaged in a special mission on the DEKRA Test Oval. Testing with Tonnage On their roster are around 300 test drives The protagonists of this field test are typical 460 involving numerous articulated trucks, which HP large-cab long-distance haulage machines are to be driven behind one another at intervals from Volvo, Scania, Mercedes Benz and MAN. of 15, 20 or 25 meters. As vehicles equipped for The quartet are then mounted with four identi- this digital cooperation are not yet on the market, cal trailers from Schmitz Cargobull with sliding Thilo Nikolaus uses the tape frame on the win- tarpaulin sides. At the core of the test equipment dow as a tool to help maintain the intended dis- is the driving data recorder, which records param- tances between the trucks in the convoy. To use eters such as distance, driving time, speed, accel- it, he simply aligns the rear of the truck in front eration and consumption from the vehicles’ CAN with the square on his windscreen. If it remains The DEKRA bus data system. in the frame, the distance is correct. As distances Test Drivers The DEKRA test drivers’ day begins with a thor- change between the vehicles, the rear will either Hausdorf, Nikolaus ough pre-departure inspection. Following this, grow and overspill the frame, or shrink within it. and Bönisch (left to there are several warm-up laps on the DEKRA Test This form of convoy driving simulates ‘pla- right) discuss the Oval in order to bring the engines of the trucks up tooning’. The term describes a ‘platoon’ of several day’s schedule to their regular operating temperatures. After cal- trucks which are digitally connected and travel along the highway closely behind one another. Vehicle spacing of between six and ten meters has been achieved by truck manufacturers in their own testing. This method of convoy driving was first adopted at the end of the 1990s, under the scope of the EU joint project ‘Promote Chauf- feur’. Since then, technology has made massive advances in highly developed, partially automated systems. The most recent evidence of this is the European Platooning Challenge in April 2016. Several goods vehicle manufacturers sent convoys to the rally in the Dutch city of Rotterdam, demonstrating the effectiveness of the so-called ‘digital tow bar’. Platooning will do more than merely aid highway safety. It should also bring about considerable fuel savings. These savings are cited as amounting to between seven and ten percent. An important precedent to this project – the semi-autonomous truck – is already on the horizon. Man- ufacturers presume that platooning trucks will be production-ready in between five and eight years. Thanks to the speed of new development, these claims seem – dare we say it – realistic. The question remains, however, whether adjusting the gap between vehicles can elicit further consumption savings. Does each meter closer to the vehicle in

39 DEKRA solutions 3/2016 Doloreme ste ipsum Xerese perspiention rem poremquam voluptatur Xerum volorec torero

1 1

2 2

1 The taped square on the windscreen aids the driver in maintaining the correct distance to the articulated lorry ahead 2 The driving data recorder logs relevant parameters such as the distance driven, the time, and the fuel consumption ibrating the intended distance between the con- tooning. The crucial question is therefore what joined trucks, they return to the track together. percentage of fuel a truck can save by driving in Four laps are performed for each vehicle config- platoon formation rather than independently. uration. The program prescribes three rounds of The test laps are performed under predefined testing, each with different distances between the conditions. The stopwatch reads four minutes vehicles. First up is the solo driving phase, during and 24 seconds when the trucks pass the mea- which the drivers follow each other with a kilo- suring point as they exit the south curve. This meter in between the vehicles. Following this, the is the time that it takes to complete a lap of the vehicles form pairs for platooning around the cir- 5.8 kilometer test track at 80 km/h. One of the cuit, the following vehicle 15 meters behind the test drivers, Andreas Bönisch, describes the chal- lead vehicle. After four laps, the vehicles swap lenge for his team: “The test drive should be coor- positions. The lead vehicle slows and moves to the dinated and take place without any major correc- back, with the former following vehicle now tak- tions. It’s a test of consistency and uniformity.” To ing on the leadership. They remain in this constel- make it a touch more challenging, the lead driver lation for the next lap. This procedure is repeated has an additional task – maintaining a clean line twice to also test the efficiency of driving with in the middle lane of the test circuit. This is espe- intervals of 20 and 25 meters. Their finale for the cially important in the 800 meter long banked day is performed as a quartet, testing each of the corner. The trucks must be maneuvered through distances between vehicles. the corner with carefully dosed usage of the steer- Analysis of the data predominantly focuses ing wheel – as little as a single uncontrolled steer- on the fuel consumption of each vehicle in the ing movement is enough to send the lap outside various phases of testing. The solo journeys pro- of the required reference values. vide a reference figure, which is then compared The drivers in the platoon don’t get to see much with the vehicle’s performance as second, third More information: of each other during their laps. On the straights, and fourth position in the platoon. This compar- www.dekratechno- following trucks remain out of sight in the rear-

ison will display any economizing effects of pla- logycenter.de/en/ view mirrors, their cabs hidden behind one’s own PHOTOS: WOLFGANG GRUBE

40 DEKRA solutions 3/2016 Truck Platooning on Test

trailer. Only when they enter the banked corner do INTERVIEW they gain a glimpse of their colleagues’ vehicles. Three Questions For ... Slipstreaming throws up peculiarities in another area too. Initial analyses reveal that the aerodynamics of the lead vehicle play a secondary role in the performance of the following trucks. It is the trailer that provides the slipstream. Despite this, the driving resistance of the trucks in the platoon play a role in their own consumption. Dif- ferent cab designs can cause a minor pendulum effect in one direction or the other. Perfect Test Conditions Constant as a metronome, the quartet threads into the south curve. Upon passing the measuring point, the drivers confirm completion of the current lap and start a new recording for the next one. The twelve-liter six-cylinder diesel engines grum- Uwe Burckhardt, ble away, quietly and evenly. Upon the approach Deputy Chief of DEKRA Automobil Test Center to the north curve, a spectacular landmark draws into view – the grandstand of the neighboring What is the underlying idea behind the series of tests on the Test Oval? Lausitzring, behind which the rotors of a wind Platooning promises to offer transport companies the potential to considerably increase turbine turn languidly. Shortly afterwards, the both safety and fuel efficiency. If a truck can save between eight and twelve percent of track passes through a small wooded area. Unlike diesel, that’s going to be very interesting. The question was, therefore, whether we can on the highway, drivers don’t have to worry about confirm the presumed advantages of platooning, and whether there is a direct relationship close encounters with deer or boar – the DEKRA between fuel consumption and the size of the gap between the vehicles in the platoon. Test Oval is entirely surrounded by fencing and regularly patrolled by a huntsman to ensure no What are the safety implications for both driver and vehicle whilst platooning? wildlife ventures onto the track. In good conditions, the electronic system can bring the entire platoon safely to a complete Back to business, the consumption data for stop. In practice, however, good conditions cannot be guaranteed. Dry and wet surfaces two-vehicle platoons suggest that an interval provide different friction, a laden vehicle has a different braking distance to that of an empty of 15 meters results in savings of between eight one, and a good tire is better at decelerating on wet surfaces than an older one. Our braking tests have shown that these factors lead to different braking distances. This could be an argument for increasing the distances between vehicles in a platoon. Even at 20 or 25 meters, there are considerable fuel savings.

What kinks are there in the platooning concept that still need working out? The reliability of communication between vehicles is of ultimate importance for platooning’s success. If there are issues here, the safety of the platoon can no longer be fully guaranteed. The safety of wireless connections between vehicles (C2C) and infrastructure (C2I) is being investigated by our colleagues at DEKRA AT4Wireless in Spanish Malaga. Transport regulators must also introduce rules, such as to govern the maximum permitted number of vehicles in a platoon, and how a convoy may form and disband.

and twelve percent for the second vehicle. The lead vehicle profits from the cooperation – the data reveals that the configuration reduced consumption by between 0.5 and 2.5 percent. This may be due to the fact that the geometry of the platoon reduces drag on the rear of the lead vehi- Andreas Bönisch’s cle’s trailer. day begins by testing The data for vehicle combinations at greater the tire pressure intervals are also exciting. It reveals that the at the test circuit trucks don’t necessarily have to drive bumper-

41 DEKRA solutions 3/2016 Truck Platooning on Test

Never miss an issue! MASTHEAD Want to receive DEKRA solutions Publisher: DEKRA e. V. to your home free every month? Communication A fax or email is all it takes! and Marketing Publishing Coordinator: Stephan Heigl Editor-in-Chief: Bernd Ostmann (responsible according to press law) Editorial Staff: Carina Belluomo, Jana Bronsch, Andreas Techel, Georg Weinand Authors: Patrick Broich, Robert Dunker, Joachim Geiger, Slippery When Wet Braking tests on wet roads Karl-Gerhard Haas, Michael Kern, Lars Lubienetzki, Bernd to-bumper to economize on fuel. The consump- Ostmann Creative Director: tion data for intervals of 20 meters between Diddo Ramm trucks point towards savings of between 8.2 and Production Management: 11.8 percent, whilst the savings achieved at 25 Johann Girteit, Lukas Kramer meters also remain in the eight to 11.4 percent Layout: range. The reduction in efficiency at higher dis- Dennis Bock, Marten Mochel tances is therefore relatively small. An increase Photo Editing: in distance between vehicles simultaneously pro- Olaf Rößler, Sven Dannenberg Surname, Name Translation: vides dramatic increases in safety. Alex Evans “Even when digitally coupled, the distance Publishing Company: Company between vehicles plays an important role,” ETMservices, explains Uwe Burckhardt, Chief of the DEKRA ein Geschäftsbereich der Test Oval and responsible for the platooning EuroTransportMedia Verlags- Position project. One of the questions that the DEKRA und Veranstaltungs-GmbH experts must answer is how platooning vehicles Handwerkstraße 15 70565 Stuttgart Street address react to unfavorable conditions when emergency in Cooperation with braking. A possible example of this could be that Motor Presse Stuttgart City/Zip code the lead vehicle brakes on dry asphalt, shortly Corporate Media after entering a tunnel. The following vehicles, Leuschnerstraße 1 however, are still on the wet. Even when regulated 70174 Stuttgart Country by an electronic system, a small gap between vehi- Project Manager: cles could be used up very quickly. The effects Andreas Techel Email: Email of vehicle braking performance are tested by [email protected] DEKRA in the second part of the investigation. Internet: The roster calls for 160 brake tests on the ABS www.dekra-solutions.com Phone number for queries braking track’s variety of road surfaces. Many dif- Printed by: ferent situations are replicated during brake test- Dierichs Druck + Media GmbH & Co. KG, Kassel Complete and send the coupon ing – braking with both laden and empty trailers, by post to: Item No.: 84596 on both wet and dry surfaces, with new and old DEKRA/ETMservices, Handwerkstraße 15 Solutions 3.2016 tires. This task is yet another that the test driv- 70565 Stuttgart, Germany Cover Image: ers will master with confidence. Driving trainer by fax to: BlueBox Concept, Getty Images +49 711 784 9846 Andreas Bönisch is positively looking forward to Photo Credits: by email to: all the action. See individual stories [email protected]

42 DEKRA solutions 3/2016 DeteCtiNG tHe trutH ... Design: Streng + Christ Kommunikationsdesign, Cologne + Christ Design: Streng

... using the classic among the coating thickness measuring gauges

» Large measuring range (up to 5000 µm) on steel (Fe) and aluminum (nFe) » Ease-to-use thanks to practical style » No time-consuming calibration using measurement foils (zeroing only) » High operational safety and precision » High robustness and durability

» Quality “made in Germany” with 3-year-manufacturer’s warranty » Excellent customer service

Automation Dr. Nix GmbH & Co. KG · Robert-Perthel-Strasse 2 · 50739 Cologne · Germany

Phone +49 (0)221-917455-0 · Fax +49 (0)221-171221 · [email protected] · www.automation.de of supply included in scope certificate test Manufacturer’s

dekra-solution-1500 - ENGLISCH - final.indd 1 08.03.16 12:13 WIN VIP TICKETS TO THE AWARD CEREMONY Register today at www.dekra-award.de/de/gewinnen

Find out who is making the world a little safer. We have received numerous applications for the DEKRA Award. Excellent ideas, initiatives and processes can help to prevent accidents and make the world a little safer. The DEKRA Award 2016 is being presented on October 25th, 2016 to recognise top performance in the following categories: Safety on the road, safety at work and safety at home.

We are giving away ten VIP tickets for the evening event featuring invited guests. Register today to become part of the DEKRA Award 2016 ceremony!

Media co-operation:

DEKRA-Anzeige_215x280mm_Solutions-Award_RZ_EN_af.indd 1 25.08.16 16:23