We Shape the Future of Mobility with Microelectronics Enabling Clean, Safe, Smart Cars

We shape the future of mobility With microelectronics enabling clean, safe, smart cars

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Let‘s talk about the future of mobility

Diesel crisis, blue badges, traffic bans, air pollution How can we avert the dangers that near- control, fewer emissions – the list is endless. silent electric motors pose to inattentive pedestrians? The challenges facing modern and sustainable mobility are enormous. Many recent articles show us the way to a better quality of life and a greater understan- Changes in the global markets and society ding of the technologies of the future. necessitate new technical developments and business models.

A world with emission-free mobility raises fundamental questions: Walter Fürst, Managing Director

What is the future for luxury class vehicles? Masthead:

What role will automated driving functions Publisher: media mind GmbH & Co. KG Hans-Bunte-Str. 5 play in future technological developments? 80992 Munich/Germany Phone: +49 (0) 89 23 55 57-3 What does remote laser welding mean for Telefax: +49 (0) 89 23 55 57-47 car body construction? E-mail: [email protected] www.media-mind.info How do we overcome challenges in the on- Managing director: Walter Fürst, Jürgen Bauernschmitt board value added chain? Design + DTP: Jürgen Bauernschmitt What can we expect from the emotional and Prepress: media mind, München powerful architecture of e-mobility? Responsible editor: Ilse Schallwegg Published annually: 1 x annually Can we meet the requirements of the auto- © 2018/2019 by media mind GmbH & Co. KG mobile industry in terms of costs, quality and No part of this magazine may be stored, copied or reliability? reproduced without the written consent of the editorial office Dear Readers,

For Audi, 2018 is the year of electric mo- architecture for our midsize and full-size bility. In the second half of the year, we electric cars over the coming decade. We will present our first electric car: the Audi are accepting no compromises, which is e-tron, an SUV that combines a range that why we are actively avoiding a multi-trac- is suitable for everyday use with a sporty tion strategy and instead using an architec- driving experience. We are committed to ture that is specially tailored for electric electrification, and we are pursuing a clear drive systems. This gives us considerable e-roadmap: The Audi e-tron is the first in freedom when it comes to technology and a long line of new electric models. By interior design. 2025, we will have over 20 electrified By 2025, we expect one-third of the cars models in our product range. More than we sell to be powered by electricity. In half of them will be fully electric, with the other words, our company is already in rest being plug-in hybrids. the middle of a huge transformation. We The Audi e-tron will roll off the produc- have redefined our core competencies and tion line in Brussels, followed one year we are establishing new expertise and train- later by the derivative Audi e-tron ing our employees for the future topics of Sportback. The batteries will be fitted electrification, digitalization and condi- directly in Brussels, while the e-motors tional automated driving. We have worked will come from our engine plant in Gyór with a wide range of Bavarian suppliers for in Hungary. In addition, we are already many years now. We greatly appreciate preparing our two main German plants for their technological innovations and the electrification, with Neckarsulm and “made in Bavaria” quality they deliver. Ingolstadt each set to produce two Audi Let‘s shape the future of mobility together! electric cars. Audi Sport will also release a Granturismo as an electric RS model – Dr. Bernd Martens manufactured at our factory in Heilbronn. Member of the We are working with Porsche on the Board of Management of design of the premium electrification AUDI AG, Procurement

Open for greater comfort

When cars drive autonomously in the future, it goes without saying they will have doors that open and close automatically. But this function will already be seen in more and more cars in the next few years, making vehicle access more comfortable and convenient than ever before. The mechatronics specialist Brose offers a complete system for this that encompasses everything from drives to a soft-close feature.

The car recognizes the driver, the door opens without human activa- tion and the side bolsters on the front seat lower to facilitate vehicle entry. This is how automotive supplier Brose presented the intelligent interaction between its door and seat functions at the International Motor Show 2017 in Frankfurt am Main. The central element of this new access experience is an electric drive that automatically opens and closes side doors. This function will be commonplace in the age of autonomous driving – and it can already provide useful services today in car sharing: if the user does not close the door properly when exiting, the vehicle must be able to do this itself before it drives off or after it has stopped. But first The compact side door drive by Brose can adapt to different customer and vehicle requirements. Series production starts in 2020. applications of the drive will offer greater comfort for entering and veloped this innovation until it was door can move freely. If the move- exiting vehicles – and enable car- series ready: the first production ment stops, the integrated currentless makers to set themselves apart ramp-up is scheduled for 2019; door check securely holds the door in from their competitors with this various uses in luxury vehicles and any position. function. mid-range cars are confirmed from 2025 on. The hinged car door opens Flexibility cuts costs Significantly enhanced and closes via remote control, smart- The Brose concept is unique comfort phone or gestures and can even be thanks to its compact and modular Brose introduced its side door drive operated on slopes and at an angle of design, which makes it possible to concept in 2015, building on its up to 15 degrees. flexibly adapt the side door drive expertise as a world market leader in Manual operation is still possible, but to different customer or vehicle systems for automatic opening and it is even more convenient: the elec- requirements. This not only short- closing of liftgates. The automotive tronics sense a manual movement ens development time, the use of

Side door drive supplier systematically further de- and disengage the drive so that the standard components also keeps Side door drive

coon” – the sum of lidar, radar and camera systems that OEMs use to prepare their vehicles for automated driving. Reliable environment monitoring is also essential when the computer takes control. There‘s just one catch: the area directly in front of the door is not recognized accurately enough. Brose presented a near-field radar sensor developed specifical- ly for this purpose. It is currently the only solution on the market that reliably recognizes even narrow obstacles with a monitoring angle of 180 degrees thanks to high-resolution technology. The family-owned company is the only automotive supplier to offer this sensor technology in its inte- The Brose door drive system comprises the (1) drive, (2) anti-trap and (3) collision grated mechatronic system. protection sensors, the (4) control unit and (5) open-by-wire latch with (6) power cinching unit. Intensive collaboration between vehicle manufacturers and system costs low. Brose‘s product uses Brose has expanded its expertise suppliers is still essential, how- existing door interfaces, so it can in the interaction of mechanical, ever: ultimately, only the interac- be offered as an option without electric and electronic systems tion between the sensor cocoon modifications to the vehicle body. and offers its door drive as a com- and the near-field sensors pro- The drive works directly at the plete system from a single source: vides comprehensive collision pro- door check strap. If the required this includes a power opening tection. space is not available there, the latch with soft-close feature and optional connection via Bowden the door control unit. Capacitive cables allows for flexible position- sensor strips on the hinge and ing of the unit in the door. latch side increase safety as contact-free anti-trap protection Authors and can also be used as switches. Rainer Weichel, This technology is based on Director Product Brose‘s proven liftgate systems Group Door Drives that have been in use for years. Brose Group

New sensor technology for collision protection There is currently still one con- Thomas Schindler, straint in comfort: the user must Vice President keep an eye on the opening Electronics movement and hold a button the Brose Group whole time, e.g. on a remote control. The reason for this – and at the same time the greatest technical challenge for the series readiness of doors that open fully Brose Fahrzeugteile GmbH & Co. Kommanditgesellschaft, Coburg automatically – is collision pro- Brose‘s power side door drive makes tection. Collisions with obstacles Max-Brose-Str. 1 vehicle access more comfortable and D-96450 Coburg convenient than ever before. Reliable such as posts or other motorists Phone: 09561/21-0 [email protected] collision protection is essential if doors must be ruled out. A module for www.brose.com open automatically. this is the so-called “sensor co- The new Audi A8: future of the luxury class · New design language and a pioneering touch operating concept · Piloted driving functions to be rolled out in production Audi A8 versions from 2018

In its fourth generation, the flagship model again provides the benchmark for Vorsprung durch Technik – with a new design language, an innovative touchscreen operating concept and a systematically electrified drive. The Audi A8 is also the first production automobile in the world to have been developed for highly automated driving. From this year on, Audi will gradually be taking piloted driving functions such as parking pilot, garage pilot and traffic jam pilot into production.

Doyen of style: the exterior design The Audi A8 is stylistically de- fining – it signals the dawning of a new design era for the entire brand. The front end with the wide, upright Singleframe grille and the fluid, muscular body sym- bolize sporty elegance, sophisti- cation and progressive status. The new A8 delivers on the promise made by the Audi prologue design study. The luxury sedan possesses a powerful presence – whether in the 5.17 meter (17.0 ft) Audi A8 - Front view standard version or the A8 L, which has a 13 centimeter (5.1 in) the upright front end combined Fingertip response: longer wheelbase. with the gently inclined rear cre- the controls The Audi brand is renowned ate visual tension. The flagship The luxury sedan‘s interior de- worldwide for sports appeal, model proclaims its identity both liberately adopts a reductive lightweight construction and day and night, drawing on both design; the interior architecture quattro permanent all-wheel drive the striking HD Matrix LED is clear and with a strictly hori- – and the design of the new A8 headlights with Audi laser zontal orientation. Audi carries conveys these values. The balan- lighting, and the LED light strip its high quality standards into the ced proportions emphasize all combined with OLED technolo- digital age with a radically new four wheels in equal measure. gy rear lights. These produce operating concept. It does away Muscular shapes above the wheel unique light animations as the with the familiar rotary push- arches give visual expression to driver approaches and leaves the button and touchpad of the pre-

The new Audi A8 Audi new The the quattro drive. Viewed side-on, car. decessor model. The instrument The new Audi A8

physical barrier separates the two carriageways. The system is activated using the AI button on the center console. Because traffic jam pilot is capable of handling the full driving task – acceleration, steering and braking – when certain conditions are met, drivers can take their hands off the steering wheel until the car requires manual driver control again. This takeover request occurs before the system nears the limits of its capabilities. From a technical perspective the Audi A8 - Cockpit with MMI touch response traffic jam pilot is revolutionary. panel is kept largely clear of but- services that draw on the swarm During piloted driving, a central tons and switches. At its center is intelligence of the Audi fleet. driver assistance controller a 10.1-inch touchscreen display The extensively optimized navi- (zFAS) now permanently com- which, when off, blends almost gation is another new feature: It putes an image of the surround- invisibly into the high-gloss black is self-learning, based on the route ings by merging the sensor data. surround thanks to its black-panel just driven. This provides the As well as the radar sensors, a look. driver with intelligent search sug- front camera and the ultrasonic The user interface appears as gestions. The map also incorpo- sensors, Audi is the first car soon as the car is opened. The rates highly detailed 3D models manufacturer also to use a laser driver controls the Infotainment of major European cities. scanner. The introduction of the system with fingertip control on Audi AI traffic jam pilot means the large display. They can use a World premiere: the statutory framework will second touchscreen display on the pilot-driving Audi A8 need to be clarified in each indi- the center tunnel console to The new A8 is the first produc- vidual market, along with the access the air conditioning and tion automobile to have been country-specific definition of the comfort functions as well as make developed specially for Level 3 application and testing of the text inputs. When the driver automated driving. The Audi AI system. The brand‘s high quality activates a function in the upper traffic jam pilot takes charge of standards are equally applicable or lower display, they hear and driving in slow-moving traffic at in the realm of highly automated feel a click by way of confirmati- up to 60 km/h (37.3 mph) on driving. In addition, a range of on. The glass-look operating freeways and highways where a approval procedures and their buttons respond in the same way. The combination of acoustic and tactile feedback along with the use of common touch gestures such as swiping make the new MMI touch response especially safe, intuitive and quick to use. The A8 can also engage in intelligent conversation. The driver can activate an array of functions in the automobile using a new, natural form of voice control. Information on destinations and media is either available on board or is delivered from the cloud at LTE speed. The extensive Audi connect range also includes traffic sign recognition and hazard Audi A8 - Sensor areas for environment observation information – innovative car-to-X The new Audi A8

corresponding timescales will need to be observed worldwide. Audi will therefore be adopting a step-by-step approach to the introduction of the traffic jam pilot in production models. The Audi AI remote parking pilot and the Audi AI remote garage pilot autonomously steer the A8 into and out of a parking space or a garage, while the maneuver is monitored by the driver. The driver need not be sitting in the car. They start the Audi A8 - Belt alternator starter appropriate system from their smartphone using the new rear wheels, complementing the Audi now for the first time fits it as myAudi app. To monitor the park- quattro permanent all-wheel drive the primary electrical system in all ing maneuver, they hold the Audi that is now standard in the new A8. model versions of the A8. In con- AI button pressed to watch a live The second new technology, Audi junction with the advanced air sus- display from the car‘s 360 degree AI active suspension, is a fully pension for the A8, the innovative cameras on their device. active suspension system. Depend- suspension concept delivers an New dimension: ing on the driver‘s wishes and the utterly new driving experience. the suspension driving situation, it is capable of rais- With a whole package of innova- ing or lowering each wheel sepa- Mild hybrid: the drives tions, the suspension revisits the rately with electric actuators. This The new A8 is available with two very limits of what is physically flexibility imparts the driving char- extensively reengineered V6 tur- possible. One such innovation is acteristic with huge latitude – rang- bo engines since market launch in dynamic all-wheel steering, which ing from the smooth ride comfort November 2017. Both engines combines direct, sporty steering of a classic luxury sedan to the operate in conjunction with a belt with unshakable stability. The steer- dynamism of a sports car. In com- alternator starter (BAS), which is ing ratio for the front wheels bination with pre sense 360°, the the nerve center of the 48-volt varies as a function of speed; the car is raised with lighting speed if electrical system. This mild rear wheels are turned in or against there is an impending lateral colli- hybrid technology (MHEV, mild the direction of steering depending sion, reducing the potential conse- hybrid electric vehicle) enables on the speed range. The car‘s quences of the accident for all the car to coast with the engine handling becomes even more occupants. switched off, and to restart dynamic and precise with the sport This highly innovative suspension smoothly. It also has an extended differential. This actively distri- system obtains the energy it requires start/stop function and an energy butes the drive torque between the from a 48-volt electrical system. recovery output of up to 12 kW. The combined effect of these measures is to bring down the fuel consumption of the already efficient engines even further – by as much as 0.7 liters (0.2 US gal) per 100 kilometers (62.1 mi) in real driving conditions.

Contact: Christoph Lungwitz AUDI AG I/GP-P3 D-85045 Ingolstadt Tel.: +49-841-89-33827 Fax: +49-841-89-90786 [email protected] Audi A8 - AI active suspension www.audi.com Multisensor calibration for sensor data fusion

Automated driving functions are of enormous importance for the future technological development of the automotive industry towards driverless vehicles. Without a doubt, a highly accurate environmental model of the vehicle‘s surroundings is one of the central themes. This requires knowledge of the exact positions and viewing directions of all installed sensors on the vehicle. This is an area where ESG is working on innovative solutions.

The extensive range of driver processing the sensor data of all assistance functions and the sensors. development towards highly Sensor positions and orientations automated driving already place for the vehicle are determined high technical demands on the based on the fact that sensors sensors and algorithms installed undergo different movements in modern vehicles. when cornering, depending on A prerequisite for ensuring the their positioning on an automo- correct operation of a system bile. In this case, a movement is with many different sensors is composed of a linear component the exact determination of the and a rotational component. This position and orientation of these is reflected in the following fig- sensors to the vehicle (i.e. their ure: When the car drives around extrinsic calibration). a curve, it is clear that the relative For each vehicle, a calibration movement of the displayed process must be carried out once camera differs from that of the per sensor simply because of reference point in the car. manufacturing tolerances. Furthermore, it is assumed that However, environmental influ- Calibration (OC), which uses the the position and orientation of ences, ageing effects and acci- method of visual motion estima- the sensor to the vehicle is rigid, dent damage change the align- tion (i.e. reconstruction of the or does not change much. Taking ment of the sensors, requiring camera movement based on the into account these assumptions continuous readjustment even video stream). From the recon- and information about the move- with minor changes. structed camera trajectory and a ment of the car and sensor, it is Depending on the calibration simplified vehicle model, it is possible to determine the positi- method, a “target” (i.e. an object possible to determine the view- on of the sensor to the car. known to the system) and there- ing direction of the camera. The The method described above is fore possibly also a visit to the calibration is performed per based on the availability of infor- workshop is required to perform camera, the calibration results of mation about the vehicle, as well the calibration. the other sensors are not taken as sensor movement. The former ESG has been working on cali- into account. This process was can be obtained from the auto- bration procedures that work expanded to include additional mobile‘s odometry data, for without targets while the vehicle sensor types for multi-sensor example. The latter is deter- is on the road in normal driving calibration, which determine the mined, depending on the sensor situations since 2010. alignment and position of all sen- used, with the aid of a variety of A solution for purely camera- sors simultaneously during a cali- algorithms. Some examples of

Optical Algorithms Optical based systems is the Online bration process by fusing and these are Visual Simultaneous Optical Algorithms

Localization and Mapping the system. The results obtained In summary, the multi-sensor (VSLAM) for cameras or Iter- have shown that this method can calibration system is an exciting ative Closest Point (ICP) for be used to obtain precise values application from many different LIDAR (Light Detection and for the sensor orientation, but fields of research for addressing Ranging). In order to increase the specific position does not the problem of calibrating a large the robustness of the system, the exceed the accuracy of values number of sensors on a vehicle. resulting equation is stretched for from a CAD model (production Such a solution promises many a variety of movements and the inaccuracies). However, accurate- potential applications and bene- sensor positions that represent ly determining the rotation of fits, such as recognizing the need the best consensus across all the sensors is more important for for recalibration or cost savings measurement data are selected. a precise environmental model in production and after-sales. Since, as mentioned above, a because small inaccuracies can large number of sensors are used cause very large errors. for automated driving, the system One problem that the tests have of equations can be extended not shown is the use of odometry as only in the time dimension, but a means for measuring the move- the different sensors - multiple ment of the car, as this merely Author: cameras, LIDARs, etc. - can also provides two-dimensional infor- Thomas Scherübl be linked to a get better result for mation and therefore cannot Senior Software the position of all sensors on the accurately determine all the Engineer, vehicle. degrees of freedom of the overall Development Advanced The approach described above vehicle system. For this reason, Driver Assistance / and the motion estimation algo- the integration of an additional Embedded Software rithms were implemented and motion estimation sensor, such as then verified, taking into account an Intertial Measurement Unit additional practical problems. For (IMU), significantly improves ESG ELEKTRONIKSYSTEM- UND verification purposes, a city trip results. This is currently the sub- LOGISTIK-GMBH including sensor data was gene- ject of internal further develop- Livry-Gargan-Straße 6 rated in a virtual simulation envi- ments of the calibration proce- 82256 Fürstenfeldbruck/Germany [email protected] ronment and then processed by dure. Highly flexible remote laser beam welding for the car body production of the future Innovations in photonics as an enabler for highly adaptable production systems

The general trend towards indi- project is to achieve a technologi- vidualized products is also evident cal breakthrough in automotive in the automotive industry with a engineering which, on the one strong increase in vehicle deriv- hand, makes the process chains in atives. In this context, the steadi- car body construction more fle- ly expanding use of electric drive xible and, on the other hand, ena- concepts is exacerbating the bles internal quality assurance in situation, with the variety of vari- remote laser beam welding. ants and thus the complexity of Finally, the functional principle production increasing significant- and the advantages of a highly ly. In contrast, rigid production flexible production cell are shown Fig. 2: Concept for making process chains structures can only cover a limi- by means of a demonstrator (see in body construction more flexible ted number of variants. For this Figure 1 left). reason, the Institute for Machine tomography (OCT sensor unit) Tools and Industrial Management Technology substitution forms the focus of the project, (iwb) at the Technical University in the field of with work packages shown in of Munich is researching together joining technology Figure 2. This enables for the with partners from industry to The desired flexibility of the first time an integrated and con- make car body production more process chains will be achieved tinuous process monitoring. flexible. The RoKtoLas project by replacing conventional resis- The information obtained by the consortium covers wide parts of tance spot welding with remote sensor unit concerning compo- the value chain - from sensor laser beam welding of individual nent positioning, measured in manufacturer to an automobile body parts. The sensor unit advance of the process zone, en- OEM. The aim of the research based on optical coherence ables the use of a robot-based clamping technology. Compared to fixture-based systems, this system can significantly reduce the accessibility requirements. For the first time, a component design optimized for laser beam welding can be used, which offers new possibilities for efficient lightweight construction. This allows the full potential of remote laser beam welding to be exploited and the implementa- Fig. 1: Planned functional demonstrator in the context of RoKtoLas and measuring tion of highly flexible production principle of optical coherence tomography

Photonic systems. Photonic

Universal sensor concept seen, illustrates the high process lished for a considerable time in for quality assurance dynamics and the influence of medical technology, is increa- The use of laser beam welding the escaping metal vapor on the singly finding its way into indu- processes in car body construc- observability of process irregu- strial production. Until now, such tion requires a reliable and repro- larities. sensors have been used only on duceable assessment of the weld A direct measurement of the fixed optics for one-dimensional seam quality. A comprehensive parameters within the process measurements. The transition to quality assurance is necessary to zone is a much more robust remote laser material processing qualify laser beam welding for approach for evaluating the pro- enables a comprehensive obser- this application. In addition, process result. So far, there are no vation of the interaction zone as cess monitoring as a measure for suitable methods for direct well as of the pre- and post-pro- maintaining and tracking the observation of the interaction cessing zone and thus an inte- seam quality is increasingly be- zone, with the exception of com- grated quality assurance. coming a basic requirement for plex X-ray procedures. The use the use of laser beam welding in of optical coherence tomography, Robot-based clamping the automotive industry. with the functional principle technology However, direct process observa- shown in Fig. 1 on the right, ena- Today, mainly workpiece-specific tion during laser beam welding is bles the processes within the clamping devices are used to currently only feasible to a very vapor capillary to be observed accurately position and align the limited extent. Optical images of directly. The method is based on individual sheet metal parts with the process zone are confined, the interferometer principle and the desired tolerance for the pro- for example, to the surface of the allows both high space- and time- duction of car bodies. Due to component. The characteristic resolved distance measurements. their solid construction, these processes during laser beam For example, it is possible to devices can reliably hold the welding within the capillary are determine the welding depth components in position during therefore not visible. Likewise, a during laser deep penetration the joining process. However, reliable evaluation of the image welding in real time. since they are usually individually data for quality assurance pur- In the context of the RoKtoLas adapted to a specific assembly, poses cannot be reproduced. Sta- research project, an OCT mea- they allow hardly any changes to tements on the quality of the surement system for the use in 3D the component geometry, the welds are usually derived from a scanner optics is investigated. component position or the pro- comparison with reference welds. The measuring beam can be cess sequence without significant In this way, larger deviations positioned in any position within changes to the assembly. If, for from the collected data of a stable the working area of the scanner example, the position of a com- process can be detected and cate- system via an additional deflec- ponent has to be changed due to gorized into high and low quality tion unit. It is thus possible not design modifications, it is often parts. However, since no absolute only to measure the welding necessary to transfer the compo- statements can be made about depth, but also to observe the nent to a subsequent fixture or the seam quality, indirect obser- front and rear area of the process even to a new fixture. This is not vation technologies such as zone. With the sensor, edges in only associated with high costs, camera systems are susceptible to the joining zone can be found but also with considerable interpretation errors. This and used for seam tracking or the restrictions in the planning of applies in particular to remote surface of the weld seam in the process steps. This means that laser beam welding, since the trailing zone can be analyzed (see any change, for example by a- dynamic mechanisms in the pro- Figure 4). The measuring dapting the joining sequence, cess zone and their influence on method, which has been estab- integrating new vehicle deriva- the seam quality are hardly tives or changing models, not detectable. This is due to the only leads to remarkable adjust- large working distance of the ments of the devices, but also of processing optics and to inter- the entire production process. ferences, such as metal vapor For this reason, robot-based, fix- escaping from the process zone. ture-free concepts for compo- The high-speed image of a nent positioning are currently remote laser beam welding pro- being researched. These aim to cess shown in Figure 3, in which Fig. 3: Process dynamics in remote laser replace rigid joining devices with beam welding a clear spatter formation can be flexible grippers on industrial Photonic

cation, Science, Research and Tech- nology (BMBF) under the funding code 13N14555 and supervised by the VDI Technology Centre (VDI TZ). We thank the BMBF and the VDI TZ for their support and the good and trusting cooperation.

Fig. 4: Measurement of the seam topology for quality assurance robots. In addition to cooper- component accessibility and thus ating robots, complex optical and improves the load-bearing design mechanical sensor systems are of components. usually used. The aim is always In addition, fixture-free joining to ensure that changes in compo- can be made possible by adapting nent geometry or in the process and optimizing the component sequence do not require hard- design. For this purpose, a robot- Authors: ware changes, but only software based gripper system for the posi- adaptations to the robot and grip- tioning of components is de- Christian Stadter per system. signed and developed. Based on Research Associate Previous research approaches the data of the optical measuring christian.stadter@ have focused on the integration system, the clamping situation can iwb.mw.tum.de +49 89 289 15560 of external sensors and on eval- be evaluated and adjusted with uation methods for component active grippers. The robot-based positioning. However, all ap- system offers a wide range of con- proaches lack an intelligent coup- trol variables. Machine learning ling of the gripper systems with processes are used to adapt the the joining process data and their clamping situation or the welding Maximilian integration into a highly flexible process so that the newly created Schmöller overall system. The extensive degrees of freedom can be used data of the sensor system enable efficiently. An intelligent positio- Research Associate maximilian.schmoel- this intelligent coupling so that ning facilitates the control of [email protected] changes in the joining process component tolerances and increas- +49 89 289 15492 can be flexibly handled at any es the process stability. time. For example, individual Finally, the new sensor concept component deviations that influ- enables a comprehensive and con- ence the dimensional accuracy of sistent process data generation on the assembly can be corrected. the basis of which integrated pro- Prof. Dr.-Ing. Overall, a wider range of compo- cess monitoring in remote laser Michael F. Zäh nents can be reliably processed. beam welding can take place for Head of Institute the first time. This enables a more michael.zaeh@iwb. demand-oriented design as well as mw.tum.de Highly flexible intelligent +49 89 289 15502 production systems an overall process-accompanying n summary, the joining processes quality assurance and represents commonly used in car body con- the prerequisite for the construc- struction require the use of rigid tion of highly flexible production clamping devices and thus lead to plants in the sense of a networked Technical University of Munich considerable restrictions in both production. Department of Mechanical component design and in produc- Engineering tion processes. Contrary to this, Acknowledgements Institute for Machine Tools and remote laser beam welding places The project is supported with funds Industrial Management (iwb) significantly lower demands on from the Federal Ministry for Edu- www.iwb.mw.tum.de/en Special e-Car Preface

Germany is undoubtedly an Automotive Euro 5 and Euro 6. Theses measures already and Mobility Country and this should con- work: several cities report about reducing tinue. Wie are currently confronted with emission rates. enormous challenges to keep the air clean It`s now necessary not to slacken. So the in our cities. The decision of the Bundes- federal government has chosen 5 Lead verwaltungsgericht concerning car-banning cities, in which one will test innovative accelerated the dynamics in this topic and measures to reduce nitrogen oxide exceed- showed that all measures to reduce the ing the measures of the on demand pro- nitrogen oxide have to be adequate. gram. So the question is: how do we manage to This could be a temporarily free public bring together more mobility with reduced transport a sophisticated traffic guiding and emissions and do without car-banning and environmental zones for trucks. the so called „blue plaque“. This is our intelligent package of measures The German federal government reacted to improve the air and life quality in our very quickly and sustainably and offered one cities and to combine more mobility with billion Euro with 11 support programs for reduced emissions. I am convinced, that if the retrofitting of Diesel-busses, and for the all - the federal level, the Länder level and electrification and digitalization of local traf- the cities, are pulling together the fic systems. „Emissionswende“ will be successful. With the on demand program „Clean Air 2017 - 2020“ and the implementation of a pilot point which assists the applicants with their access to the support programs, this process will be strongly promoted. Additionally the federal government com- Siegfried Balleis mitted the car manufacturers to refit 5,3 Sonderbeauftragter der Bundesregierung für das Mio. Diesel-cars of the emission category Sofortprogramm „Saubere Luft“ European Metropolitan Region of Nuremberg: strength in the automotive industry – e-mobility as a strategic driver of innovation

Automobile suppliers form the industrial backbone of the European metropolitan region of Nuremberg (EMN).With around 88,000 employees and job growth of over ten per cent within the last six years, they represent a key industry. The EMN‘s corporate landscape is shaped mostly by medium-sized businesses. However, it is also home to global market leaders from various sectors. Its particular strengths lie in electrical and mechanical drive technology and mechatronic system solutions.

It is therefore not without reason that the EMN‘s plans for development focus on the “automotive” technology-oriented field of expertise and the “intelligent mobility” action field. Key areas include: automated driving, environmental compatibility, intelligent networks, age-appropriate mobility and hybrid drive systems including e-mobility.

Efficient and electric mobility is gaining more and more importance and it seems only a question of time before it permanently replaces the classic combustion engine. With its mix of varied suppliers, the EMN is perfectly The world‘s first hybrid drive, which works with a voltage of 48V, was developed by Conti in Nuremberg and continues to be mass produced there. positioned to advance and dec- Image: Continental isively shape this and other issues. tion that significantly reduces fuel together with Renault and region- One example is provided by Conti- consumption and exhaust emis- al partners such as the Fraunhofer Temic microelectronic GmbH in sions. The 48-volt variant is an al- Institute for Integrated Systems Nuremberg, where around 2,500 ternative to the considerably more and Device Technology (IISB) employees work on all aspects of complex 300 to 400 volt technol- and the Bayerisches Laser- electrification. The world‘s first ogy that has previously been the zentrum (both based in Erlan- 48-volt hybrid drive has been standard in hybrid vehicles. Since gen). mass produced there since Octo- 2013, the engineers at Continen- ber 2016. The technology used is tal in Nuremberg have been Other companies and brands such

Metropolitan Region Metropolitan of Region Nuremberg a particularly cost-efficient solu- developing this hybrid drive as Siemens, Baumüller, Brose, Metropolitan Region of Nuremberg

Semikron, Schaeffler, MAN and ABM Greiffenberger also stand for considerable global expertise in the field of electric and hybrid drive technology.

The region‘s other strengths include the provision of components and solutions for electronics, cables, wiring systems, and storage and charging systems. Examples of companies and brands in these sectors include Bosch, Leoni, Komax, FCI Connectors, ZF, Delphi, Diehl, Schlenk, Scherdel, E-T-A, ABL The "Ladeverbund Franken+" combines the services of around 50 local municipal Sursum, TÜV Süd and TÜV utilities for a regionwide uniform and user-friendly charging infrastructure. Rheinland. There are currently around 200 charging stations available. Quelle: N-ERGIE The Nuremberg metropolitan area is home to several research sity of Applied Sciences Würz- Ostbayerische Technische Hoch- institutes and university depart- burg-Schweinfurt (i.a. load man- schule Amberg-Weiden (integra- ments specialising in electromo- agement with electromobility and ted systems and real-time soft- bility. Examples include the above- innovative charging technology) ware for electromobility) and the mentioned Fraunhofer IISB provide future-oriented solutions, Technologietransferzentrum Auto- (developing power electronics, as do the Institute for Power motive of the Hochschule Co- designing and implementing stor- Electronic Systems (ELSYS) at burg (TAC). age systems and test centres for the Technische Hochschule electric vehicles), the Fraunhofer Nürnberg Georg Simon Ohm Since 2013, the Nuremberg Institute for Integrated Circuits (network integration of electric Chamber of Commerce and In- IIS (e.g. information and commu- vehicles i.a.), Automobiltechni- dustry for Central Franconia has nication technology for battery kum Bayern in Hof (measure- provided the CCI Innovation & management, energy management and testing technology), the User Club e-mobility (http://emo- ment, connection to smart grids, non-destructive material testing), Fraunhofer Institute for Silicate Research ISC (material development for fast, high-performance and secure energy storage) and the Fraunhofer UMSICHT In- stitute Branch Sulzbach-Rosen- berg (centre for energy storage). Institutions such as the E|Drive Center at the Friedrich-Alexan- der Universität Erlangen-Nürn- berg (production-related design, production technology and application development for electric drives), the Bayerische Polymer- Institut in three Universities based in Bayreuth, Fürth and Würzburg (development of fibre- reinforced composites such as CFRP) and the Technologie- The electric engines from the Baumüller Group in Nuremberg are now also used in Transfer-Zentrum-Elektromobi- battery-powered FRAMO trucks. The 18-ton electric truck has a range of 250 - 270 km lität (TTZ-EMO) at the Univer- and can carry a cargo load of 9.5 tons. Quelle: Baumüller Metropolitan Region of Nuremberg

Authors: Dr.-Ing. Robert Schmidt

Netherlands@Schaeffler: The Schaeffler bio-hybrid combines benefits such as stability and weather protection with the energy consumption and space utilisation of a pedelec. Photo: Schaeffler bility-nordbayern.de) in cooperati- gion Nürnberg e.V. (project Dr. rer. nat. on with the chambers of commer- “CODIFeY”), Center for Trans- Ronald Künneth ce and industry based in Coburg, portation and Logistics Neuer Bayreuth, Regensburg and Würz- Adler e.V. (CNA), European Cen- burg-Schweinfurt to create oppor- ter for Power Electronics e.V. tunities for regional providers, (ECPE) and in Bayreuth the users and developers to cooperate Automobilnetzwerk ofraCar- and promote the exchange of kno- Automobilnetzwerk e.V. Fürth- Nuremberg Chamber of Commerce and Industry (CCI) wledge. Examples of other regio- based solid GmbH combines the Innovation & Environmental Affairs nal clusters and networks advan- electronic mobility activities of Division cing the issue of electronic mobili- regional energy providers, for Ulmenstraße 52 ty include Nuremberg-based Bay- example in the “Ladeverbund 90443 Nuremberg, Germany ern Innovativ GmbH, and the Franken+” project, a charging net- e-mail: [email protected] competence initiatives EnergieRe- work in and around Franconia. www.ihk-nuernberg.de Audi e-tron Sportback concept – Architecture of e-mobility · From 2019 on in series: a second e-Audi · Emotional and strong: Audi Coupé style · Enlightening: Seeing the e-tron lights communicating

Design study and technology demonstrator, electric car and power pack in the guise of a coupé: The study of a four-door Gran Turismo contains a powerful 320 kW electric drive. The formal idi- om of the coupé with Lux Silver paint finish combines classic Audi elements with an array of trendsetting details: an electrifying architecture, tailored consistently to the technology and the package of the electric drive.

The Audi e-tron Sportback represents an important milepost for Audi along the road to electric mobility. Rupert Stadler, Chairman of the Board of Mana- gement of AUDI AG, confirmed: “Our Audi e-tron will be starting out in 2018 – the first electric car in its competitive field that is fit for everyday use. With a range of over 500 kilometers (310.7 miles) and the special electric driving experience, we will make this sporty SUV the Audi e-tron Sportback concept - Front view must-have product of the next decade. Following close on its center console and in the door duce an excellent light yield. heels, in 2019, comes the produc- trims supply information and Minuscule Digital Matrix projec- tion version of the Audi e-tron interact with the on-board tors literally make their mark on Sportback – an emotional coupé systems. Horizontal surfaces on the road ahead, turning light into version that is thrillingly identi- the dashboard and the seemingly a versatile, dynamic channel of fiable as an electric car at the very floating center console convey a communication with the sur- first glance.” sense of open perspectives for roundings. In its consciously light-colored the occupants of the four indi- The brand with the four rings interior the Audi e-tron Sport- vidual seats. was the first in the world to back concept offers a blend of The concept car‘s lighting tech- adopt full LED headlights, and functional clarity and reductive nology is an innovation that is gave Matrix LED technology, controls as a formal principle. Ex- visible by both day and night. laser lighting and OLED technol- pansive touch-sensitive screens Digitally controlled Matrix LED ogy a significant push towards

Audi e-tron Sportback concept Sportback e-tron Audi below the central display, on the units at the front and rear pro- their breakthrough. The tech- Audi e-tron Sportback concept

tion Audi models with all-electric drive: One electric motor on the front axle and two on the rear power all four wheels, trans- forming the high-performance coupé into a quattro in typical Audi style. 320 kilowatts of power – which can even reach 370 kW in the boost mode – provide a fitting level of propul- sion, with the sprint from 0 to 100 km/h (62.1 mph) a done deal in just 4.5 seconds. With the battery‘s energy content of 95 kilo- Audi e-tron Sportback concept - Cockpit watt-hours, its range is in excess of 500 kilometers (310.7 miles) nology study now premieres a area light fields each comprising (NEDC). whole host of complex functions an arrangement of around 250 As previously on the e-tron that steer vision and interaction LEDs. They offer a vast array of quattro concept, the technology with the surroundings in a new direction. Narrow light strips on both sides below the front lid – the daytime running lights – become the eyes on the face of the study. Thanks to a combination of LEDs and a micromirror-studded surface plus complex control technology, a large number of animated movements and signatures are possible. When the e-tron Sportback Audi e-tron Sportback concept - Design sketch interior starts and also when the doors are opened, the system uses possibilities for creating engaging study‘s liquid-cooled lithium-ion switchable segments to generate graphics or specific communicative battery is positioned between the dynamic visual welcome signals. signs, even while on the move. axles below the passenger com- Below the daytime running For its drive, the e-tron Sport- partment. This installation posi- lights, to the left and right of the back uses a configuration that will tion provides for a low center of Singleframe, there are two large- also be adopted in future produc- gravity and a balanced axle load distribution of 52:48 (front/rear). And that gives the sporty SUV outstanding driving dynamics and driving safety compared with other vehicles in the segment. The Combined Charging System with two connectors enables charging with alternating current (AC) and direct current (DC). The study vehicle‘s front end displays the familiar octagonal Singleframe with an overtly wide, horizontal cut – the greatly reduced amount of air required by the electric motor means the large opening can be omitted here. The sculptural surface painted in Audi e-tron Sportback concept - Drivetrain the body color has a structured Audi e-tron Sportback concept

pattern emblazoned with the four-rings logo – just like the grille of the classic Singleframe. The edges of the central surface are drawn back, allowing air to flow through at the top. The air inlet is bracketed again by an octagonal, black-painted frame that structures almost the entire width of the front end. Between the front lid extending low down, the front apron and the wheel arches, it combines with the light units to give this Audi an unmistakable face. The Audi designers also adopt a new tack for the air flow through Audi e-tron Sportback concept - Rear view the front lid. Above its front section, which dips deeply at the Sportback into the brand‘s DNA. tually eliminated, as is the front, a bridge running parallel Large 23-inch wheels in a techni- obstruction to the diagonal for- with the nose connects the two cal 6-spoke design highlight the ward view. The camera images wheel arches and also doubles up confident presence of the im- are shown on separate displays in as an air deflector. This gives the posingly dimensioned coupé. An the doors. Audi is showing this front end a much more dynamic exterior length of 4.90 meters technology as a concrete fore- character than the hefty forward (16.1 ft), a width of 1.98 meters taste of the production version. structure of a car with a com- (6.5 ft) and a height of 1.53 At the 2015 Frankfurt Motor bustion engine installed at the meters (5.0 ft) with a wheelbase Show Audi unveiled the Audi e- front. of 2.93 meters (9.6 ft) position tron quattro concept – the fore- The four wheel arches with the e-tron Sportback in the C runner of the brand‘s first all- pointedly horizontal top edges segment, close to the Audi A7. electric-drive production auto- extend well out from the cabin. Small cameras replace the ex- mobile. As a radically reconfigur- They shape the conspicuous terior mirrors. This technology ed SUV it offers a range of up quattro architecture – not just by offers other advantages besides to 500 kilometers (310.7 miles) providing visual evidence of a improved air flow and reduced with the spaciousness and com- wide track and dynamic potential, wind noise. The blind spot of the fort of a typical full-size automo- but also by binding the e-tron physical exterior mirror is vir- bile from Audi. It has the road performance of a high-performance sports car – the Audi e- tron quattro sprints from 0 to 100 km/h (62.1 mph) in only 4.6 seconds. The production version of this pioneering electric SUV will appear on the market in 2018. The Audi e-tron Sportback concept car will be followed by its production version in 2019.

Contact:: Josef Schloßmacher AUDI AG I/GP-P D-85045 Ingolstadt Tel.: +49-841-89-33869 Fax: +49-841-89-90786 [email protected] Audi e-tron Sportback concept - Electric Drivetrain www.audi.com Electrical steel: Strong magnetic fields due to sharp tools

Researchers optimize cutting process for steel sheets used in electric motors

In an electric drive, magnetic fields have to be created in order to transform electric energy into kinetic energy. The magnetic properties of the motor's main components, referred to as electrical steel sheets, are the decisive factor in the efficiency of the electric motor. Scientists at the Technical University of Munich (TUM) have investigated the way these steel sheets are processed and have concluded that using blunt cutting tools deteriorates the magnetic properties of the steel sheets significantly.

Current criticism of electromobility usually focuses on long battery charging times and inade- quate range. Researchers are working to increase the efficiency of electric drives in order to reduce the energy requirements of electric vehicles. This involves a large number of individual components, in particular electrical steel sheets: These sheets are important since the magnetic fields that move the motor using attractive and repulsive forces are generated within them.

Depending on the motor's Hannes Alois Weiss, research associate at the Chair of Metal Forming and Casting, at the design, a variety of different punching machine. (Photo: Andreas Heddergott / TUM) holes have to be cut in the steel sheets, for example to make Power consumption rises The scientists found out that the room for copper coils built into by as much as 400 percent sharpness of the cutting tools the motor. Each steel sheet is Researchers from the TUM Chair used has a very significant impact "stamped" individually in a press, of Metal Forming and Casting have on the magnetic properties of the using the same principle as a hole investigated this process in detail in steel sheets. The effect can be punch. Special cutting tools are their workshop. "We wanted to compared to a pair of scissors used to ensure that the specified examine how manufacturing the which dulls over time: More geometries are created in the electrical steel sheets by blanking energy is needed to cut paper steel sheets. Finally, the steel influences their magnetic prop- with the scissors. Regarding sheets are put together in order erties," explained project director blanking, worn cutting edges

Magnetic fields Magnetic to form the desired shape. Hannes Weiss. result in higher tension in the Magnetic fields

Information on the project: Project work was conducted under the first part of the research project FOR1897 on low-loss electrical steel sheets for energy- efficient drives, "Verlustarme Elektrobleche für energieeffiz- iente Antriebe". The project was supported by the German Re- search Foundation (Deutsche For- schungsgemeinschaft or DFG) - 218259799.

Publications: Weiss, H. A. et al.: Loss reduction due to blanking parameter opti- Individual electric sheets are assembled into a compact package. The picture shows a mization for different non-grain rotor laminated core. (Photo: Andreas Heddergott / TUM) oriented electrical steel grades. Electric Machines and Drives steel sheets themselves – the Major energy savings Conference (IEMDC), 2017 material is bent and thus subject Processing electrical steel sheets IEEE International, 2017 to increased mechanical stress. is not only an important issue in The resulting stress has a major the context of electric motors. Weiss, H. A. et al.: Influence of impact on magnetic properties. The sheets are also used in trans- shear cutting parameters on the "In some cases as much as four formers, for example in mobile electromagnetic properties of times the amount of electricity is phone chargers and computer non-oriented electrical steel needed to achieve the same power supplies. The researchers sheets. Journal of Magnetism and degree of magnetization," Weiss also want to focus on the pro- Magnetic Materials Volume 421, explains. cessing methods in this context 2016, 250-259 as well. Weiss: "If we think of Another factor also has a major the enormous number of trans- influence, the distance between the formers in use, then even a small cutting edges, referred to as the increase in efficiency can save a cutting clearance. Once again, the large amount of energy." process can be illustrated using the example of scissors: When the screw which holds the scissor blades together loosens, the distance between the blades becomes too large and the paper frays when cut. "Sharp cutting edges and a very small cutting clearance are opti- mum in achieving the best magnetic properties and thus a high level of efficiency."

Weiss and his team have formu- lated recommendations for the production process. However, economic factors also have to be taken into account, the engineer Contact: explains: “When the cutting Hannes Alois Weiss, M. Sc. tools and their maintenance incur Technical University of Munich Hannes Alois Weiss, research associate Chair of Metal Forming and Casting additional costs, the final price of at the Chair of Metal Forming and the electric drives produced rises Casting, at the punching machine. Telephone: +49 (0)89 / 289 - 13998 E-Mail: [email protected] as well.” Photo: Andreas Heddergott / TUM Audi Aicon concept car – autonomous on course for the future

With the four-door design vision Audi Aicon, the brand with the four rings is presenting a autonomous Audi of the future – with no steering wheel or pedals. As a design concept, the four-door 2+2 boldly leaps ahead to show the exterior and interior design of the next decades. The technology demonstrator combines innovations relating to the drivetrain, suspension, digitalization and sustainability in a visionary manner. The Aicon, too, is designed for purely electric operation and should be able to cover distances between 700 and 800 kilometers (435.0 - 497.1 mi) on a single charge.

Design study, technology demonstrator, mobility concept: The Audi Aicon exploits every possibility offered by an autonomous luxury sedan of the future with unprecedented consistency. As a design study, the four-door 2+2 boldly leaps ahead to show the exterior and interior design of the next decades. The technology demonstrator combines innovations relating to the drivetrain, suspension, digitalization and sustainability in a visionary manner. And as a mobility concept, the Audi Aicon - Front view Audi Aicon shows the world of tomorrow, in which the advan- peek at a prestigious automobile as the significantly convex side tages of door-to-door individual of tomorrow that stirs the desires windows create a bright expanse transportation are combined with of demanding customers. of space for the travelers. A the luxurious ambiance of a first- distinct edge runs as a hard line class airline cabin. A cabin with no Pure presence – the exterior along the side window surfaces of steering wheel or pedals that can The Audi Aicon looks spectacular the Aicon back to the D-pillar – a thus offer all the comforts of from any angle. Its sheer size – an first in automotive design. This modern communications elec- exterior length of 5,444 milli- line emphasizes the car‘s length tronics and perfect ergonomics – meters (17.9 ft), a width of 2,100 and effectively reduces the appar- simply first-class. millimeters (6.9 ft) and a height of ent volume of the cabin relative to One look is all it takes: In contrast 1,506 millimeters (4.9 ft) – places the overall body. The darkened to a robot taxi, which is reduced it in the automotive top tier, the side sills rise subtly toward the to pure functionality, the autono- D segment. The wheelbase meas- rear, making it seem like the car is mous Audi Aicon concept vehicle ures 3,470 millimeters (11.4 ft). ducking. pulls out all the stops. Its presence That‘s 240 millimeters (9.4 in) The designers reduced the front is impossible to ignore, and its more than with the long version and rear ends to a minimum of exterior hints at the spacious of the new Audi A8. lines and focused on large, uninter- comfort afforded the passengers The central element of the ex- rupted surfaces. As with the Audi and the upscale technical aspira- terior is the cabin. Large glass sur- e-tron Sportback concept, the Aicon

ConceptAicon Audi Car tions. The Audi Aicon is a sneak faces at the front and rear as well front features the inverted hex- Concept Car Audi Aicon

spaciousness, and the lack of a steering wheel and a classic dashboard creates a sense of openness and expanse. The interior appears to be particularly wide when the two individual front seats are slid all the way back. The Audi Aicon is a 2+2-seater. An upholstered, two-seat bench is integrated into the rear panel. The two front seats are designed for maximum comfort and optimal

Audi Aicon - Design sketch lateral light fields spaciousness. Passengers can slide them up to 500 millimeters (19.7 agonal Singleframe, a typical feature bottom up when the car accelera- in) back and forth between the for- of the upcoming generation of tes and in the opposite direction ward and rear positions. The seats electric cars from Audi. The sharp- during braking. Their speed in- don‘t slide on rails, but rather on a ly inclined silhouette of the entire creases or decreases in sync with platform covered in high-pile car- front end evokes a sense of forging that of the car. pet that can be moved longitudinal- ahead – this, too, is a typical sports Future cars will expand their ly, and on which the passengers‘ car body line. sphere of communication to the feet also rest. The platform height surroundings. The Audi Aicon is variable, so that it can also be Emotion and information – uses projector modules to illumi- used as an ottoman for your legs. the LED lighting technology nate the road and surroundings in The pitch of the seat cushions and Conventional headlights and high resolution and project sig- backrests can be steplessly adjusted lighting units are absent from nals onto the ground. This ena- for a comfortable working or res- both the front and rear of this bles it to communicate warnings ting position. car. Instead there are fully digital and vehicle information to pass- The individual seats can also be display surfaces comprising hun- ers-by with no direct line of sight swiveled by up to 15 degrees. Turn- dreds of triangular pixel seg- to the car. ing the seats outward makes it even ments. They are three-dimen- easier for the passengers to get in. sional recreations of the Audi AI Space, form, function – Turning them inward makes it symbol. the interior easier for the passengers to talk and Grouped around the Singleframe The Audi Aicon features opposed interact. If the passengers turn are large light fields, in which – doors that open to the front and around, the head restraints fold as at the rear – more than 600 3D rear. There is no B-pillar. The en- back like a collar and become an pixels are arranged in space. The tire breadth of the interior is thus arm rest. large surfaces and high pixel exposed to the passengers as they The architecture of the seats is the count enable versatile graphics, get in the car. In the interior, the automotive reinterpretation of a animations and information lines of the decorative surfaces and classic piece of furniture, the lounge visualizations in any color. The functional elements are markedly chair. The seat cushion and Audi Aicon is thus no longer horizontal. Becoming lighter from backrest are visually separated from bound to a daytime running bottom to top, the interior rein- one another. Two outer shells sup- lights look, but rather can adapt forces the impression of unique port the light-colored, pillow-like to the driving situation and even its passengers. The customiza- tion is boundless. The Audi Aicon supports its surroundings intelligently and uses animations on its display surfaces to warn pedestrians or cyclists of dangerous situations. Driving modes such as platooning, urban driving or driving at a walking pace can be visualized. Horizon- Audi Aicon - Design sketch interior tal stripes of light move from the Concept Car Audi Aicon

upholstery elements with a square- the empathetic electronic vehicle looking. The passenger locks his quilted surface. The side bolsters assistant, recognizes the passen- onto a control element in the of the backrest are subtly angled ger by his phone and activates all area of the front main display to to provide sufficient support in of his personal settings. There select it and performs fine adjust- curves. are custom settings for the air ments using his hand or voice. There is also plenty of space in conditioning and seating posi- The full range of services offered the Audi Aicon long-distance tion, interior light color and the by modern communications elec- vehicle for luggage, of course. layout of the infotainment sys- tronics are available at all times in Thanks to the space-saving tem. The navigation system the Audi Aicon. Travelers can design of the electric drive, there awaits entry of a destination, and relax and watch a film or surf the is a storage compartment at both all accessible channels of commu- web. Video conferences are an- the front and the rear of the nication are ready for use, other option, as is interaction on vehicle with a combined capacity connected via the fastest available social media. Depending on the of roughly 660 liters (23.3 cu ft). standard. seating position, the passengers The Aicon also offers numerous New are the variably positionable can use the large front display as storage options in the passenger control interfaces in the encircl- the output surface or a virtual compartment. ing door rail. Depending on the head-up image displayed above it Accommodating – operation position of the seats, which can in the windshield. and communication be shifted by up to 50 centime- The glass roof panels can block The oft-cited paradigm change in ters (19.7 in), ergonomically per- out the sunlight, if desired. Their the automotive world – it shows fectly positioned touch and dis- transparency level changes upon in the Audi Aicon. One glance is play elements are available in the application of an electric voltage. all it takes to realize that all of digitized wrap-around. Your hand Integrated OLED lighting ele- the controls and displays are mis- instinctively finds its way to the ments allow for precise mood sing. Steering wheel, pedals, touch-sensitive control panels. lighting or the even illumination groups of buttons and instru- Passengers can set the most of the interior when getting in or ments – nothing. Instead just important settings by tapping out of the car, for instance. wide, uninterrupted surfaces. with their fingers without having The Audi Aicon opens up a new The passengers are enveloped by to sit up in their seats or leaning world of mobility to its passen- the gently curved armrest along forward. Operation is also inter- gers. Freed from the tasks of the doors, which rises slightly active. The PIA system is often driving, they can choose how to from back to front. Instead of a one step ahead of the passenger spend their time in the car. dashboard in front of them, there and offers services before they Working, communicating or sim- is a generous shelf and the cen- actively chose them. ply just relaxing and even nap- tral display below the windshield. There are multiple input modes ping: Anything is possible while The interior quickly comes to available for engaging with the the car autonomously and safely life once passengers enter. Illu- car. Besides the haptic-manual finds its way. minated lines of LEDs set color- layer, there are also voice control ful accents in the area of the and eye tracking, in which sen- Optimized for the long haul – doors. The front display lights up sors in the front end of the inte- drivetrain and suspension with a welcome message. PIA, rior track where the passenger is The very shape of the Audi Aicon reveals that it is a car from another world, an automobile of the future. The technology used in the concept vehicle has also been systematically designed for this world. It presumes a transportation infrastructure in which autonomously driving automobiles are a given on every street. Road users are connected to one another and their surroundings. The drive and the total vehicle have also been optimally adapted to this new world of mobility. A Audi Aicon - Interior highly efficient electric drive Concept Car Audi Aicon

The axle and drive units in the Audi Aicon are symmetrical, i.e. identical at the front and rear. Mechanical components, such as the steering shaft or steering hydraulics, have been eliminated. The car is therefore equipped with a complete all-wheel steering system without compromis- ing the available space and thus the passenger compartment. A positive effect for the practical qualities of the Audi Aicon: Despite its long wheelbase of nearly 3.47 meters (11.4 ft), the Audi Aicon - Drivetrain and seating concept car is extremely agile due to its two steerable axles – the turning provides for the dynamics of the pull up to a charging station on radius of only 8.50 meters (27.9 Audi Aicon. A total of four elec- its own and charge its battery ft) is below that of a small car tric motors are located in the area without any human assistance. thus making the Audi Aicon suit- of the front and rear axles. The As a true quattro, the Audi Aicon able for city center driving. energy storage units are integrat- offers ample performance and The Audi Aicon is an all-around- ed into the area below the floor. even autonomously always reach- er well prepared for its primary These are solid body batteries with es its destination safely regard- task: to offer a maximum of com- considerably more energy capacity less of the weather or road sur- fort, communications technology than lithium-ion batteries. face. The suspension is designed and freedom for its occupants The four electric motors produce for maximum comfort. Pneu- during a long journey. It com- a total of 260 kW and 550 matic spring and damper units bines the scopes for autonomous Newtonmeters (405.7 lb-ft). Each smooth out any road surface driving in an urban environment drives one wheel, enabling elec- irregularities. And electric actu- and on the highway with an tronically controlled, variable ators at all four wheels actively unprecedented range for an elec- quattro all-wheel drive. Maxi- counteract any body lean, tric drive. The Aicon will be mum acceleration played a less whether when cornering, accele- followed by further multitalented important role in the specifica- rating or braking. As a fully active Audi models, each with their tion than maximum efficiency suspension system, it also opti- own specialized discipline, ensur- and thus also range. This opera- mizes the qualities of the adaptive ing that the vehicle range of the ting strategy is also pursued by air suspension. The Audi Aicon brand with the four rings remains the powertrain and electric brake literally glides over even large as diverse as it is fascinating. units, which use recuperation to potholes. recover energy. Targeted light- The Aicon brakes primarily by weight construction of the multi- way of recuperation and in so material body and optimized doing recharges the batteries. aerodynamics also help the Audi The development engineers have Aicon to achieve ranges between relocated the disk brakes from 700 and 800 kilometers (435.0 - the wheels to a position close to 497.1 mi) on a single charge. the drivetrain. This improves the Even charging has been reduced aerodynamics at the wheels as to a minimum. Thanks to a high- there is no longer any need for voltage system with 800 volts, air cooling at the wheels, which is Contact: the Aicon‘s battery unit can be always associated with turbu- Josef Schloßmacher charged to 80 percent of capacity lence. Another secondary effect AUDI AG in less than 30 minutes. The car is the reduction of the unsprung I/GP-P is also equipped with a unit of masses, which the Aicon‘s pas- D-85045 Ingolstadt Tel.: +49-841-89-33869 inductive, i.e. wireless, charging. sengers perceive as a particularly Fax: +49-841-89-90786 The Aicon manages both with- sensitive damping response to [email protected] out a driver. In an AI Zone, it can road surface irregularities. www.audi.com Industry 4.0 and Intellectual Property Law

The catchword “Industry 4.0” are realized, completely or in acter of inventor provided for in stands for the revolutionary digi- part, using a computer program. patent law and his/her perfor- talization and networking of work- Revelant for the grant of Europe- mance of mental acts are to be ing and production processes. an patents in this field are the applied at all to automated devel- The use of computer-controlled EPO‘s Guidelines for Examina- opment results. Largely resolved production units in the form of tion, Part C II. In each individu- is the question of whether data robots and the utilization of al case it must be determined sequences generated by a paten- machine-generated data (artificial whether the subject-matter claim- ted process are capable of being intelligence) requires fundamen- ed is a computer program “as protected. In this regard, the tal innovations in the fields of such”, which according to Section Federal Court of Justice (BGH) automatization and production, 1, Sub-section 3, No. 3 PatG clarified in its “Rezeptortyrosinki- which are particularly relevant for (German Patent Act) and Art. 52 nase II” decision that patent pro- automotive technology. New de- (2)(c) EPC is not regarded as tection for such process products velopments, such as digital navi- patentable invention, or whether is only possible if the process gation and information systems, it fulfills the patentability require- provides them with specific driverless cars, electromobility, ment of technical character by objective technical properties, so and smart devices in automobiles technical effects that are present that, by their nature, they are call for suitable legal and organ- during implementation. If this is suitable of being protected by a izational protection concepts. not the case, there only remains product patent. Mere informa- the copyright law which protects tion is thus not patentable. New challenges for Patent its owner against the copying of Offices and Applicants his/her work but not against Standard essential patents In the field of patent law, the pri- third-party use of its content. If The increasing digitalization of mary focus lies on questions of the first hurdle of the require- products and services requires the patentability of new software- ment of technical nature has been development of globally valid based inventions and develop- cleared, the decisive factor for standard norms to facilitate the ments through artificial intelli- patentability is that it relates to a international exchange of goods gence. In many cases, interdisci- technical problem that is solved and services as well as the coop- plinary combinations of computer by technical means. This will eration in the scientific and tech- science and natural sciences will often be the case in the realm of nological sectors. This applies, in be involved, which make special industry 4. Here, however, both a particular, to the field of net- demands on the expertise of careful formulation of the patent worked products (smart devices, examiners and patent attorneys claims and an optimized applica- intelligent products for the home regarding prior art search and for- tion strategy already at the draf- and automobiles) that are con- mulation of patent claims. ting stage of the application will nected to the internet and other An increasing number of patent play a key role. devices. Corresponding standards applications relates to computer- It remains to be clarified who will are defined by international stand- implemented inventions. These be entitled to the ownership and ardization organizations. These are inventions involving a compu- right of use of computer-gene- standards often relate to tech- ter, a computer network or an- rated data. In this connection, the nologies that are protected by

Intellectual Property Law other programmable device, that question arises whether the char- patent, i.e. so-called standard Intellectual Property Law

essential patents (SEPs). Manu- tection which, under the current tive has already been provided for facturers of intelligent products system of territorially limited IP (Directive (EU) 2016/943 of the that utilize SEPs thus require rights, is difficult to guarantee. In European Parliament and of the licenses for the relevant stand- particular, this applies to cross- Council of 8 June 2016 on the ardized technologies. Under cur- border infringement where some protection of undisclosed know- rent legislation, SEP owners are process steps of a patented pro- how and business information obliged to grant licenses to cess are performed in Germany (trade secrets) against their unlaw- potential users of the standard at and some abroad. These proces- ful acquisition, use and disclo- fair, reasonable and non-discrimi- ses may be production, working sure). The Directive is to be imple- natory (FRAND) conditions for or controlling processes connect- mented into national law in 2018 patented technologies covered by ed to computer-controlled trans- and ensures a uniform protection the standard. According to the mitting and receiving units, such of trade secrets that, compared to decisive European Court of Jus- as autonomous motor vehicles, present national unfair competi- tice judgment in Huawei v. ZTE, that are distributed over several tion legislation, sets higher stand- the holder of a standard essential countries. In such case constella- ards regarding the measures to be patent may only seek an injunc- tions, a domestic patent infringe- taken to protect the confiden- tion against the infringement of ment will only be ruled if the par- tiality of trade secrets. Therefore, an SEP if prior to bringing that tial acts taken abroad can be attrib- special caution must be taken, action, the proprietor has, first, uted to the party acting in Ger- especially with respect to de- alerted the alleged infringer of many. The implementation of the centrally stored data that are pro- the infringement complained planned unitary patent system cessed across companies. about by designating that patent with a unitary patent valid in all and specifying the way in which it participating member states of the Conclusion has been infringed, and, secondly, EU and with the Unified Patent The application of current after the alleged infringer has Court (UPC), expected in 2019, intellectual property law in the expressed its willingness to con- promises a solution for these digital context presents a partic- clude a licensing agreement on cases. The UPC is an interna- ular challenge and requires the FRAND terms, presented to that tional court which will hear cases further development of legal and infringer a specific, written offer regarding infringement and revo- organisational protection con- for a licence on such terms. For cation proceedings both of uni- cepts. Therefore, the progressing lack of uniform legal regulations tary patents and regular European harmonization of European law and in view of divergent case law, patents. It is intended to set up in this field is highly welcome. there remains considerable uncer- local divisions in all participating tainty regarding the evaluation member states so that, for exam- and enforcement of standard ple, it will be possible to bring an essential patents. Thus, the inten- action before the local division in tion of the European Commis- Munich or Düsseldorf against sion to establish a harmonised infringements throughout Eu- framework for the licensing and rope. Thus, costly parallel actions enforcement of standard essential in several countries will no longer patents is to be welcomed. In this be needed. In the case of a cross- regard, reference is made to the border infringement, the ques- Communication from the Com- tion of attribution of liability for Author: mission to the European Parlia- acts partially taken in Germany Dr. Johann Pitz ment, the Council and the Euro- and partially abroad does not arise Rechtsanwalt pean Economic and Social Com- provided the individual process Patentstreitigkeiten und Patentverlet- mittee of November 29, 2017 steps are taken in the territory zungsprozesse (https://ec.europa.eu/docsroom/do of the participating EU member cuments/26583). states.

Transnational patent European-wide protection of Vossius & Partner protection know-how Siebertstraße 3 The cooperation of networked With respect to know-how, too, 81675 München Phone +49 89 41304-0 production and processing units harmonized protection for the Fax +49 89 41304-430 located in different countries territory of the European Union E-mail: [email protected] www.vossiusandpartner.com requires crossborder patent pro- on the basis of a new EU Direc- Artificial sounds for traffic safety

Acoustic Vehicle Alert System: TUM researchers design sounds for electric cars

The almost complete silence of the motors used in electric cars may pose a hazard to inattentive pedestrians. As a result, starting in summer 2019 all new electric and hybrid vehicles will have to be equipped with an acoustic warning system. Psychoacousticians at the Technical University of Munich (TUM) are developing the corresponding sounds.

It's supposed to sound similar to a vehicle – but not exactly the same as a diesel or gasoline-powered vehicle. The specifications for an Acoustic Vehicle Alert System warning sound that electric and hybrid vehicles will have to emit starting in the summer of 2019 are fairly general. Although playing a musical piece is not allowed, the nature of the sound with which individual approaching vehicles will warn pedestrians is being left up to manufacturers. One example of how the signal should sound can be found on the Internet page of the United Na- tions Economic Commission for Prof. Hugo Fastl in his Sound-Laboratory.(Photo: Uli Benz / TUM) Europe (UNECE) http://www.unece.org/fileadmin/ Hugo Fastl, Professor at the TUM or a Porsche – and that's supposed DAM/for_PR_Silent_car__AVAS_ Chair for Human-Machine Com- be the case with e-cars as well." sound.mp3: The listener is imme- munication, researches the basics of Frequency range, timbre diately reminded of a spaceship taking sounds design for electric cars and roughness off or an effect from a science fiction made by a variety of manufacturers. How exactly is a sound like that series. In Europe the warning sounds And although the sounds are still developed? "First we have a basic are required for e-vehicles travelling being kept secret, Fastl can reveal sound to which we assign a pitch," at speeds of 20 kilometers per hour one thing: Each company wants its says Fastl. Here the researchers or less. The sound created by the own branding, a sound which is work with medium-range fre- tires on the road surface is considered characteristic of the car in question. quencies: "Very low frequencies adequate for vehicles travelling at "After all, right now a BMW also are difficult to produce," says

Artificial sounds Artificial higher speeds. sounds different from a Mercedes Fastl. "This would require very Artificial sounds

large speakers on the car." On the for use as ingredients, based on a tram; the interior sounds are tai- other hand, elderly people can no algorithms we developed our- lored to the right target group just longer perceive frequencies that selves." The sound machine as the external sounds are. "An- are too high. Pitch can also indi- resembles a mixing board in a yone who drives a 7 Series BMW cate how fast the car is driving, sound studio. Its controls are used will want to have peace and for example with the sound rising to create a synthetic sound which quiet," Fastl points out. "On the in pitch as the automobile acce- is then processed and adapted other hand Porsche drivers will lerates. according to the results of lis- want to be able to hear their tening tests conducted with investment at work." Another sound property is tim- human subjects. bre. "It's like in music: You can And presumably pedestrians and play the first notes of a Mozart In addition to frequency range those living and working close to symphony on a smartphone in and timbre there are several other streets don't want to be over- such a way that everyone recog- particularly important properties whelmed by traffic noise. "For 20 nizes the melody," says Fastl. "But when it comes to automotive years the objective has always it doesn't sound so great. When sound design, for example rough- been to make cars quieter," says the same notes are played by a ness. Roughness is determined by Fastl. "Now things are in part too chamber orchestra with ten musi- the speed of changes in a sound's quiet and we have to get louder cians, it sounds much better. And volume. Particular roughness is again." Nevertheless, Fastl advises a full orchestra with 50 people can created when the volume changes against doing away with all the play the music to sound just the something like 50 to 70 times per advantages of the low-noise elec- way the composer intended it to second. "Roughness in a sound is tric vehicle: "More and more cars sound." Nevertheless, Fastl and perceived as especially sporty," with automatic pedestrian detec- his team don't work with an Fastl explains. "A Ferrari without tion will be coming onto the mar- orchestra, they generate the tim- roughness would be very hard to ket. We recommend that the bre of the sounds on the com- sell." e-vehicle only transmit sounds puter. when a pedestrian is in the vicinity." Loud, but not too loud Here they use a sound "construc- Special interior sounds are being Contact: tion kit" which they conceived designed for e-vehicles as well, Prof. Dr.-Ing. Hugo Fastl and programmed themselves to even though there are no appli- Chair for Human-Machine Communication develop target group-specific cable regulations. The actual sounds. "It's a computer that can sound created by an electric Phone: +49 (0)89 289 28541 [email protected] generate a wide range of sounds motor could remind the driver of aCar – The electric „all-rounder“

An electric car for Africa, custom-designed for the needs of the population there, that strengthens rural structures and helps drive the economy: Scientists at the Technical University of Munich (TUM) and partners have been working intensively towards this goal for four years. The aCar is designed for passenger and cargo transportation and is also interesting for the European automotive market.

Mobility is a part of our everyday lives: We transport large loads, commute to work, fly to a faraway country on vacation. However, access to a vehicle of any kind is hardly a given for many people in Africa. For farmers who live far from urban centers, this means that they have no direct access to medical care, education or to political processes. They are dependent on transport contrac- tors who bring their products to the next city for sale in order to make a living. As a result many people are leaving rural areas in search of better living conditions in the city. The new aCar prototype. (Photo: Florian Lehmann / TUM) "With the aCar we have developed a mobility concept that can developing countries" in 2013. train. "An electric drive is not solve these problems," explains The objective was to conceive a only greener, but is also the bet- Prof. Markus Lienkamp, head of vehicle that precisely meets the ter solution in technical terms, the TUM Chair of Automotive requirements of the rural popula- since it is low-maintenance and Technology. "The aCar is an off- tion in sub-Saharan countries. can apply its full torque directly road capable vehicle that is af- The project is supported by the to accelerating from a stop," says fordable for people there and is Bavarian Research Foundation. Martin äoltés, who shares leader- capable of transporting heavy ship of the project with Sascha loads. The modular structure also The concept: One vehicle, Koberstaedt at the Chair of Auto- allows other uses for example for a variety of demands motive Technology. water treatment." Together with Four-wheel drive is a must for the "Bayern Innovativ" campaign, the roads of Africa, the majority The vehicle is primarily intended the TUM launched the project of which are not paved. The team for transporting passengers and

Electric car Electric "aCar mobility - Rural mobility in also decided on an electric power cargo, with a total load capacity of Electric car

also meets all the demands placed on it on location, they shipped the vehicle to Ghana, where they tested the technology and concept under local conditions in July 2017.

The aCar passed all the tests with flying colors. "It spent six weeks in a container on its way there, we unloaded it, switched it on and it functioned perfectly all the way to the last day of testing," says Sascha Koberstaedt. The team also asked locals to drive the car; they were thrilled by the "Solar The new aCar prototype. (Photo: Florian Lehmann / TUM) car". Another important point was testing the impact of the high- one ton. The battery offers a location, the price for the basic er temperatures and air humidity variety of other possible applica- vehicle in Africa is to be kept on the electric systems. "We tions, either as an energy source under 10,000 Euros on a long- gathered a lot of data which we or as a drive for high-consumption term basis. "Cast nodes and sim- now have to evaluate," says applications, for example as a ple bolted construction enable Koberstaedt. "But we can already winch. A number of various simple manufacturing processes say that the aCar fulfills all the superstructures have been de- with very low investment costs," necessary requirements and has signed for the cargo bed which says Prof. Wolfram Volk, head of even exceeded our expectations." can be used on a modular basis. the Chair of Metal Forming and Additional modules can turn the Casting. New prototype: vehicle for example into a mobile Modern design, physician's office or a water treat- First prototype:Technology optimized technology ment station. testing and user studies In September, the new prototype The scientists produced the first of the aCar was presented at the The 20 kWh battery capacity prototype in May 2016 and con- International Motor Show in gives the vehicle an electric range ducted initial tests in Germany. Frankfurt. The car is characte- of 80 kilometers. The battery can However, to make sure the aCar rized by an unembellished, clear be loaded from an ordinary 220 volt household wall socket within 7 hours. Solar modules mounted on the roof of the aCar gather energy throughout the day. Optional solar collector sheets can be unrolled to significantly increase the amount of solar energy produced for self-contained battery charging.

“Of course we'll have to import high-tech components such as the battery and the electric motors in the beginning," says Martin Sˇoltés. In future, as many of the aCar's components as possible are to be manufactured on location, in order to strengthen local econ- omies. In order to make the auto- aCar, assembly of the prototype at R & R Fahrzeugtechnik. mobile affordable for people on Photo: Andreas Heddergott / TUM Electric car

About the project: The project "aCar mobility - Rural mobility in developing countries", supported by the Bavarian Research Foundation, involves the TUM Chairs of Automotive Technology, Metal Forming and Casting, Indu- strial Design as well as Strategy and Organization. The Rosenheim Uni- versity of Applied Sciences (Hoch- schule Rosenheim) and the Univer- sity of Bayreuth are scientific partners in the project. In addition, seven The aCar team,the aCar and guests at the IAA in Frankfurt.Photo:Andreas Heddergott / TUM industry partners are participating in the project: African Health & and modern design. "The chal- suited for use in Africa, but also for Agricultural Foundation, DRÄXL- lenge was to develop an appeal- anyone looking for a no-emission MAIER Group, Hirschvogel Auto- ing, functional and high-quality transport solution. Thus for exam- motive Group, McKinsey & Com- vehicle, while at the same time ple it could be used in urban opera- pany Inc., Otto SPANNER GmbH maintaining simple production tion for transport purposes, in and Schnupp GmbH & Co. methods and low manufacturing costs," explains Prof. Fritz Frenk- ler, head of the TUM Chair of Industrial Design. "Reducing everything to the essentials result- ed in a modern and thus long- lasting design." The aCar has also undergone considerable further technical developments. The team was working among other things on optimizing weight, on electrical systems and software, acoustics and ergonomic seating and visi- bility. Solar modules are installed on the roof of the vehicle. Model factory in Germany Credit: Florian Lehmann / TUM for the first vehicles To make sure the idea of the aCar maintaining urban parks and gar- Hydraulik KG. The concept of the becomes more than just an idea and dens and in agricultural settings vehicle was developed together with actually makes it to series produc- such as alpine meadows and scientific partners in Nigeria, Ghana, tion, Sascha Koberstaedt and Mar- vineyards. Compared to its compe- Kenya and Tanzania, the Federal tin äoltés have founded the com- tition, the purely electric aCar is University of Technology, Owerri pany "Evum Motors GmbH". The significantly more cost-efficient (FUTO) Nigeria, the Kwame Nkru- first vehicles are to be manufac- and uses the most modern battery mah University of Science and tured in a model factory in Europe. and power train technology. Technology (KNUST) Ghana, the "We'll have to master all the tech- Dedan Kimathi University of Tech- nical procedures before the car can aCar Technical Data: nology (DeKUT) Kenya and the St. be made in Africa. Then we can Power output: 2 x 8 kilowatts; Elec- Augustine University of Tanzania train people from Africa who can tric drive range: 80 kilometers; EU (SAUT) Tanzania. in turn pass on their knowledge vehicle classification: L7e; Voltage Contact: there." level: 48 volts; Battery capacity: 20 Dipl.-Ing. Sascha Koberstaedt kWh; Top speed: 60 km/h; Tare Technical University Munich The aCar is an electric four-wheel weight: 800 kg; Load capacity: 1000 Chair of Automotive Technology drive utility vehicle. These specifi- kg; Length: 3.7 m; Width: 1.5 m; [email protected] cations make it not only excellently Height: 2.1 m; Seating capacity: 2 Phone: +49 (89) 289 - 15875 VOSSIUS & PARTNER

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