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Automotive Technologie in Bavaria +e-Car

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... encountering the future.

Bayern Innovativ GmbH Gewerbemuseumsplatz 2 90403 Nuremberg Phone +49 911 - 20671 - 0 [email protected] Germany Fax +49 911 - 20671 - 792 www.bayern-innovativ.de

Today ''s knowledge for tomorrow s innovations 3

Dr. Bernd Martens

AUDI AG Board Member for Procurement

Gateway to innovations

Innovation is what powers our econ- cars internationally than in its home omy. We at Audi know that it is country. By 2016, we will have 14 fac- imperative to promote it – passion- tories operating around the world. ately, every day, at every workplace. That will generate growth here, too: We in the Procurement division see Last year, we created 3,000 new jobs ourselves as the gateway to innova- in Germany alone – most of them in tions from the mid-corporate sector. Bavaria. And many suppliers from Because there are many challenges Bavaria are involved in our process that we solve in partnership with our of delighting customers in other suppliers. This is a process where we countries. Procurement plays a key debate and shape; we show foresight role in it. For instance, we have fa- in involving our partners through miliar partners from back home in- innovation forums and concept com- volved in a wide variety of aspects of petitions – to our mutual advantage, our new plant in Mexico: the devel- with respect for each other‘s contri- opment of the plant, the Audi Q5 bution, and with the goal of offering vehicle project, and the creation of our customers that edge for which new sources for local content. We Audi is renowned. are exploring new horizons that will We are competing together – on a keep us focused on the future – worldwide scale. 2014 will be the first including at home in Bavaria, a hub year in which Audi will build more of innovation. 4

The vehicle of the future

The automotive industry is looking back on a history of unrivalled success. But which features will characterize the vehicle of the future? Carmakers and automotive suppliers will contribute significantly by coming up with more innovative developments. Bayern Innovativ GmbH offers tailored services to support them in managing their innovations. Bayern Innovativ showcases trends and developments around the vehicle of the future during a congress in the BMW Welt in Munich.

Personal mobility habits are changing. Megatrends such as globalisation, urbanisation, in- dividualisation, connectivity, new ecology and the demo- graphic development have a major impact on people’s mobility behaviour and on the products of the automotive industry. Change is driven above all by issues of customer-specific, technological, le- gal/political, ecological and economic relevance – challen- The driver of the future has outgrown the machinist of the past. Infotainment, assistance ges which car makers had to systems and a comfortable interior allow the driver to perform of number of tasks while driving face repeatedly in the past. What is new, however, is the cludes Prof. Lutz Fügener, a stuck in a traffic jam. Alluring speed with which these chan- renowned designer from the vehicle interiors become feel- ges are taking place. University of Pforzheim. In good spaces featuring a light his opinion, vehicle design and aspect, comfortable lighting, Individual – the customer new mobility concepts can jointless design, transparent, The needs and expectations assure that cars will continue coloured or decorative sur- of customers are the major to appeal to young target faces and natural materials. motors of innovation. They groups, even though the lat- The focus is on properties such ultimately decide whether a ter’s affinity for cars is in fact as value, genuineness, quality product is discontinued on the declining. and sustainability with a view to market or not. The wish to be Dr. Karlheinz Steinmüller, usage concepts such as car mobile is just one of many cri- Scientific Director of Z_punkt sharing as well as ruggedness. teria that influence the decisi- GmbH, goes even further. He on to buy a vehicle. This is is convinced that the multimo- Mobile and flexible because vehicles have always bile people of the future will Individual lifestyles and flex- been used to represent diffe- not consider travel time as ible working environments are rent lifestyles, too. „A car is a wasted time, but rather as qua- two factors that contribute to statement and each time we lity time that can be used in the change affecting traffic buy a car, we are making a many ways. Advanced functio- demand. People are looking decision as to how we are nalities, infotainment and for intelligent solutions to being perceived by others – a comfortable vehicle interiors make them mobile and flex- bit more agile, a bit better-off allow the driving time to be ible. Young adults in particular or a bit more sensible,“ con- spent productively, even while are causing a shift in the 5

mobility behaviour: „Metro- mobile“ travellers use and combine different means of transport to suit different pur- poses, relying on increasingly complex mobility services. „The future is multimodal,“ says Dr. Steinmüller. He is certain that the boundary between public and individual traffic is becoming blurred. User friendliness has top prio- rity in the networked smart mobility solutions of the future. Information technology is Drivers are increasingly valuing the individual design of the interior the key. It enables the joint Bayer MaterialScience has developed an integrated design concept to this end use of common means of transportation – from bus and suppliers are taking somewhat "Swipe and Zoom" underground to electric ve- unusually approaches when de- Efficient electrics and electronics hicles. Mobile smart devices veloping innovative components. are basic requirements for one of provide the right information Leoni-Bordnetz-Systeme GmbH, the most important trends in the in the right place at the right for instance, are using bionics to automotive industry today: auto- time. investigate new approaches to mated driving. The consumer Prof. Markus Lienkamp, head develop on-board systems. „A goods and entertainment indu- of the vehicle engineering de- vehicle equipped with multiple stry is providing important sti- partment at Technische Uni- assistance systems can basically mulus in this context: „Swipe“ versität München, is convin- be compared to a living being,“ and „zoom“, for instance, are far ced that the years from 2020 says Dr. Wolfgang Langhoff, more than just gestures. „The and 2025 will see a massive Vice President of R&D Global of driver’s function in the car of the transition towards electric Leoni Bordnetz-Systeme GmbH. future is no longer that of a ma- vehicles. The vehicle expert „Both have to coordinate huge chinist as in the past,“ explains believes that this change will volumes of information and Guido Meier Arendt, Ergono- not be driven by more strin- power transmission paths with mics Expert of Continental AG. gent governmental regulati- utmost efficiency; data transfer The car is adapting to his chan- ons, but rather by rising mobi- must be as robust and fault-tole- ged expectations and require- lity costs for users. „Laws to rant as possible to keep up over- ments. Electronic systems give reduce carbon emissions will all system operation in the him the freedom to perform lose importance, whereas event of malfunctions or „in- various tasks while driving. mobility offers including elec- juries“. And they must include Being one of the largest automo- tric vehicles will be on the ups- an appropriate number of re- tive suppliers worldwide, Conti- wing.“ dundancies to ensure vital func- nental AG is pursuing a clear-cut tions“. agenda to implement driving Technology as the driver Today, electrics and electronics functions that are party, highly The progress made in technolo- are the major enablers of inno- and fully automated. Continental gies, design and mobility con- vation. The annual growth rate develops and produces systems cepts regularly delivers answers in this sector is six percent with for automated driving functions to megatrends and assures that software, semiconductors, dis- and for adequate control func- cars will continue to be attractive plays and drive control systems tions. Systems for driver model- for different customer groups leading the list with growth ling, touch-sensitive surfaces, worldwide. Some OEMs and rates of around eight percent. new strategies of attraction and 6

in small batches, to integrate loped in all industries have to numerous simple components be designed in line with into a few highly complex sustainability aspects. BMWi parts and to work without emphasizes ecological aspects tools,“ explains Jim Kor, Pre- both in the development of sident of Kor Ecologic from the drive and the selection of Canada. His company aims to materials. „Driving with zero

Additive manufacturing is about ready produce a vehicle that is near- emissions is not enough,“ for series production. KOR aims to ly completely 3D printed: points out Benoit Jacob, head of produce a vehicle that is nearly entirely 3D printed: URBEE2 URBEE2. Combing parts in BMWi Design of BMW AG. one single component drasti- "Our i-models therefore inte- gesture control as well as dro- cally reduces assembly require- grate particularly many renewa- wsiness detection are crucial ments. Production steps be- ble and recycled materials. in this context. come redundant, allowing Some fabrics are made from the The BrainDriver project run by complex objects to be fabrica- fibres of PET bottles. the Berlin-based AutoNOMOS ted in a single production GmbH is a visionary experi- step. Decentralised manufac- Vision of networked living ment in human-machine inter- turing structures create more Jens Redmer, Business Devel- face (HMI) technology. A dri- flexibility, increased efficiency opment Manager with Google, ver equipped with EEG sen- and minimum inventories. is certain: „The future is now.“ sors is steering the car by This also applies to spare parts In fact, there is an abundance thinking control commands which can be manufactured as of technological options to such as „brake“ or „drive left“. needed on 3D printers direct- network our life in various These commands generate ty- ly from the software near the areas using intelligent techno- pical brainwave patterns which site of usage. Another advan- logies and state-of-the-art IT are interpreted by a computer. tage of additive manufacturing and communication technolo- „It will be some time, howe- is the fact that different parts gies to improve the quality of ver, until automatically driven can be manufacture on one living of people and the quali- cars are actually roadworthy. machine. „Ultimately, additive ty of industrial locations. But robotic experts anticipate manufacturing opens up a free- „Smart Cities“ are making use that by 2030 at the latest the dom of design unparalleled so of new digital options to crea- traffic will have been fully far. Good design enables create a comfortable urban envi- adapted to autonomous ve- ting more lightweight and ronment for citizens. The in- hicles,“ predicts Patrick Vogel, robust parts with complex formation and communication CEO of AutoNOMOS. geometries,“ Jim Kor explains. technology assumes a key role Bionics serves as the model in connecting vehicles, house- Printed cars here as well. holds, companies and other The vehicle of the future will facilities to the corresponding not only be influenced by Committed to sustainability high-performance networks. innovative vehicle enginee- Sustainability, which has its „Smart Grids“ are one exam- ring, but also by production origins in the green move- ple – intelligent power grids innovations. Additive manu- ments of the 80ies, is today that combine the use, genera- facturing, for instance, a pro- seen as a responsibility of tion and consumption of elec- totype technology until now, society and is also a part of tricity based on demand and is on the threshold of mass automotive future viability. consumption in an efficient production. „The major bene- This mega trend has been and intelligent way. Traffic fits of additive manufacturing accelerated considerably by solutions are enabled by net- lie in the possibilities to the soaring oil price and the working vehicles with each customize products and com- carbon discussion. In order to other and with the traffic ponents, to manufacture parts be marketable, products deve- infrastructure. Real-time traf- eeomn. nte 2 per- 20 Another development. arespent onthe necessary series remaining the 60 percent, 20 Of percent buyers. car with tance volumes because they lack accep- sufficient in produced be never can which or car serial a into it intoinnovations thatnever make investmentsallpercent goof 40 being actually sold offered today. innovations Around six in one neglect only with marketing,innovation also and preferences customer developments and ket suppliers know too little about future mar- and manufacturers because unsuccessful, quently fre- are Innovations engineers. based on the ideas and dreams of still are innovations car today's ofmajoritythe thatshows ever, Wyman consulting agency, how- Astudy conducted by the Oliver Solutions for the future in- living. of quality to the crease and flexible more life it make everyday facilitate to promises future the of life networked the whole, the On car station. electric charging free a find to or emissions reduce jams, traffic prevent accidents, to about warn instance, for help, data fic automotive industry The symposium "Das Automobil der Zukunft" (car of t ih alrd evcs o close to services tailored with customersInnovativitssupports Bayernvaluechain.the levels of all at science and industry from stakeholders together bringing rious industries and technologies, va- from partners cooperation tive selectively connects potential For this purpose, Bayern companies. Innova- medium-sized and of innovationssmall-particularlyin development dynamic the boost to aims Innovativ Bayern solutions. mobility future developing for requirements the describes tiv, Klaffke,ofCEO Bayern Innova- automotive sector,“ Prof. Werner the like future’ the of ‘city and energy mobility, of topics mega the spans that approach worked net- comparable a requires stry indu-other„No Gfk.periences motiveGermany, Consumer Ex- FranksaysHärtl, HeadAuto-of research mustface these newchallenges,“ Market approaches. new for calls age digital „The fitable. pro- actually are innovations in investments of percent 20 only that means This product. the distinguish not pro- do but visions statutory fulfill that merely innovations into go cent he future) on 7 and 8 July 2014 brings together dec sectors. sectors. these from decision-makers the with cooperation in innovations new promoting 2014allow July 8 and 7 on future) the of (car Zukunft“ der Automobil „Das symposium the as such forms Plat- potential.significant future with and areas focal five – mobility material health, energy, digitalisation, on centre tivities ac- The organisations. partnernetwork 80 and institutes arch from 40,000 companies and rese- professionals 80,000 some prise Innovativ GmbH presently com- channels. distribution The networks and of Bayern chains technologies,supply in gaps existing www.bayern-innovativ.de [email protected] E-Mail: +49 911 20671- 5216 Fax: +49 911 20671- 216 Phone: D-90403 Nuremberg Gewerbemuseumsplatz 2 GmbH Innovation und Wissenstransfer für Bayern Innovativ Gesellschaft Author: ision-makers from all sectors of the rjc Manager Project GmbH Bayern Innovativ Reinz-Zettler Jennifer

Pictures: Bayern Innovativ, Bayer, Continental, KOR 7 8

Emotion, dynamism and high-tech – The new Audi TT

• Audi TT and Audi TTS celebrated world premiere at Geneva Motor Show • Compact sports car impresses with its design and driving dynamics • Member of the Board of Management for Technical Development, Prof. Dr. Ulrich Hackenberg: “Offering drivers a technology experience that is even more compelling” The third generation of the compact sports car is again captivating, with its emotional design and dynamic qualities. The new Coupé is characterized by the use of innovative technologies in its engine and in its control and display concept, including the Audi virtual cockpit.

“The Audi TT is the epitome of an authentic design icon and a top- performance driving machine,” explains Prof. Dr. Ulrich Hacken- berg, Member of the Board of Management of AUDI AG for Technical Development. “With the new generation, we are making this technology even easier for the driver to experience – just as they would expect from a real sports car.

Body Lightweight construction is one of Audi‘s greatest areas of expertise. The second-generation Audi TT already featured an Audi Space Audi TT Coupé Frame (ASF) body made from aluminum and steel. For the new sills and roof frame are made of just 1,230 kg (2,711.69 lb). This TT, Audi has systematically taken extruded aluminum profiles that makes it around 50 kg (110.23 lb) this composite construction princi- are integrated into the structure lighter than its predecessor. The ple even further, in line with the using cast aluminum nodes. This low overall weight is further proof idea: the right amount of the right structural principle creates a very of Audi‘s expertise in lightweight material in the right place for opti- rigid and safe bodyshell. The construction. It impacts positively mal functions. The Coupé‘s under- aluminum side sections and roof especially on acceleration, handling body structure has optimized axle complete the structure. The hood, and fuel consumption. loads and is made of modern, high- doors and trunk lid are also made of strength and ultra-high-strength this light metal. All in all, the Audi Interior steel alloys. In the sections of the engineers have, for the second time Clearly structured volumes with passenger cell that are subject to in a row, succeeded in significantly a taut surface and light, almost the most structural stress, form- reducing the unladen weight of the floating lines – the interior is the hardened steel panels, which are Audi TT. At the first model change embodiment of the new Audi both ultra-high- strength and light in 2006, up to 90 kg (198.42 lb) TT‘s pure sports car character. are used – these constitute 17 per- were saved, and the 2.0 TFSI en- As with the exterior, horizontal

Audi TT Audi cent of the body‘s weight. The side gine variant of the new TT weighs lines and surfaces emphasize the Audi TT 9

the spokes. It also has a driver airbag that takes up 40 percent less space without compromising safety, and hence emphasizes the sense of visual lightness. Count- less details demonstrate the high standards which Audi places on interior design and craftsman- ship. They include the newly designed, split gear lever, the very precisely engaging MMI rotary pushbutton and the finely finished loudspeaker covers with light guides in the optional Bang Audi TT – interior & Olufsen sound system. As a 2+2 seater, the new Audi TT is a width of the interior. The center air vents. The 3D-designed toggle sports car that is highly suitable tunnel console, which supports switches activate the hazard for everyday use. The trunk has a the calves when driving fast warning lights, Audi drive select capacity of 305 liters (10.77 cubic through bends, and the door and the assistance functions. The ft), which is 13 liters (0.46 cubic panels have similar flowing shapes. standard sports seats in the new ft) more than before, and can be The rule was once again: “less Audi TT have integrated head extended by folding the rear seat is more.” Clear, purist lines restraints and are positioned backrests forward. underscore both the lightness lower than in the predecessor and the uncompromising sporti- model. Compared with the seats Controls and displays ness of the Audi TT‘s interior. in the predecessor model, they The operating concept for the Two other ingenious design and are more than five kilograms new TTS has been revised from technically innovative tricks ena- (11.02 lb) lighter. As an option – and the ground up – in line with the bled the designers to create an as standard in the TTS – there consistent sports car character, all instrument panel that is impres- are newly developed S sport the elements focus on the driver. sively slender: The instrument seats with highly contoured and There are two variants of the cluster and the MMI screen have pneumatically adjustable side sec- multifunction steering wheel been combined to form a central, tions that are exceptionally com- available. Drivers selecting the digital unit – the so-called Audi fortable and provide excellent top version can activate almost all virtual cockpit. In addition, the support. functions from the steering controls for the air conditioning The new multifunction steering wheel without taking their eyes system are positioned directly in wheel has a flattened rim, and off the road. The second control the air vents. Seen from above, aluminum-look clasps encompass unit is the likewise newly devel- the instrument panel resembles the wing of an aircraft; the round air vents – a classic TT feature – are reminiscent of jet engines with their turbine-like design. The vents also contain all the controls for the standard air conditioning system and the optional automatic air conditioning system (standard in the TTS). The controls for seat heating, temperature, direction, air distribution and air flow strength are located at their center; the setting selec- ted is shown on small displays in the automatic air conditioning system. The horizontal control Audi TT – cross section MMI panel panel is located under the central 10 Audi TT

Engine (All consumption and output figures are provisional) Audi offers the new TT and TTS with three different four- cylinder engines with turbocharg- ing and direct injection. Their power output ranges from 135 kW (184 hp) to 228 kW (310 hp). The two TFSI gasoline engines and the TDI combine athletic power with trailblazing efficiency. The start-stop system is a standard feature. For the launch Audi TT - interior: Audi virtual cockpit of the TT, the 2.0 TDI will be available with manual shift and oped MMI terminal on the con- area, too. For the first time in the front-wheel drive. It delivers 135 sole of the center tunnel. Two Audi TT, natural voice controls kW (184 hp) and torque of 380 toggle switches activate the navi- are used that enable simple com- Nm (280.27 lb-ft). The new gation/map, telephone, radio and mands – such as “Take me to sports car can thus accelerate media menus. There are two but- Munich” or “I want to talk to from 0 to 100 km/h (62.14 mph) tons on both sides of the central Sabine” – to control the vehicle in 7.2 seconds and reaches a top rotary pushbutton, supplemented systems without having to take speed of 235 km/h (146.02 mph). by a main menu and a back but- your hands off the steering Standard fuel consumption is a ton. The driver can easily enter wheel. Instead of the conven- mere 4.2 liters per 100 km (56.00 destinations using the touchpad tional analog displays, the new TT US mpg), which translates into on the top of the rotary pushbut- has the Audi virtual cockpit on CO2 emissions of 110 g/km ton (from the Connectivity pack- board – this fully digital instru- (177.03 g/mile), a new record low age upwards) – the MMI touch ment cluster sets new standards level in the sports car world. The recognizes your personal hand- with its dynamic animations and 2.0 TDI features two balancer writing. It is also possible to precise graphics. Drivers can shafts in the crankcase, adjustable scroll through lists or zoom in on choose between two display camshafts and a common rail maps. The menu structure of the modes: In the classic view, the injection system delivering maxi- MMI resembles that of a smart- speedometer and rev counter are mum pressure of 2,000 bar. The phone, including the free-text in the foreground; in “infotain- Audi TT 2.0 TDI meets the search. All important functions ment” mode the virtual instru- Euro 6 standard and, thanks to its can be accessed directly. One ments are smaller. The space that high efficiency, bears the “ultra” special highlight is the MMI becomes free as a result provides label. The 2.0 TFSI is available direct search. This enables you to ample room for other functions, in two versions – a 169 kW (230 start writing immediately when such as the navigation map. In hp) version for the TT and a 228 navigating, without having to use the Audi TTS there is a third, kW (310 hp) version for the a set form. In most cases, input- sporty mode. Here, the centrally TTS. In both versions it unites ting four letters is enough for positioned rev counter dominates various ultramodern technologies you to see relevant destinations the display. With a resolution of – the additional indirect injection throughout Europe. The two 1,440 x 540 pixels, the 12.3” supplementing the direct injec- side buttons activate context- TFT screen boasts brilliantly tion of the FSI, the Audi valvelift dependent functions (right but- sharp images. At work in the system (AVS) to adjust the valve ton) and options (left button). background is a Tegra 30 graphic stroke on the exhaust side and The operating logic is easy to processor from market leader thermal management, which uses understand and conveys a com- Nvidia‘s Tegra 3 series. At the a rotary valve module and an pletely novel “joy of use.” Along- lower edge of the Audi virtual exhaust manifold integrated into side the operations possible cockpit, the displays for outside the cylinder head. In the Audi using the control panel, the Audi temperature, time and mileage TT, the 2.0 TFSI delivers torque TT offers a further possibility: are permanently visible. Warning of 370 Nm (272.90 lb-ft) from the voice control system. Audi is or information symbols may also 1,600 to 4,300 rpm. It accelerates also breaking new ground in this appear there. the Coupé – which has a six- Audi TT 11

speed manual transmission and cally within fractions of a second. type precisely allows for efficien- front-wheel drive – from 0 to 100 The intelligence of quattro drive cy-optimized all-wheel-drive km/h (62.14 mph) in 6.0 seconds, – in other words, the software control – which can even result and on up to an electronically that determines precisely the in the temporary shutdown of governed top speed of 250 km/h possible torque distribution bet- the quattro drive system. In this (155.34 mph). On the version ween the front and rear axles – is operating state, the intelligent with six-speed S tronic and a completely new development software carefully monitors the quattro all-wheel drive, the key especially for the TT. The inno- driving situation and activates the figures are as follows: the sprint vative control philosophy contin- all-wheel drive before torque is from 0 to 100 km/h (62.14 mph) uously senses the ambient condi- once again required at all four takes 5.3 seconds; top speed is tions, driving status and the dri- wheels. In this way, quattro drive 250 km/h (155.34 mph); fuel con- ver‘s wishes. This means that the provides optimum efficiency sumption of 6.8 liters per 100 km ideal distribution of torque is cal- along with a level of traction and

(34.59 US mpg) and CO2 emis- culated and the TT‘s dynamic dynamic handling that is typically sions of 159 g per km (255.89 g/mile). drive characteristics enhanced in quattro. The dual-clutch transmission shifts every situation. By networking through the six gears without any quattro drive with Audi drive se- Chassis noticeable interruption in trac- lect, the driver of the new Audi TT The chassis also reflects the tion, and in manual model it can can adjust the all-wheel-drive technological expertise behind be controlled by paddles on the properties to suit his or her in- the new Audi TT. The front sus- steering wheel. In the “efficiency” dividual requirements. In “auto” pension is based on a McPherson mode of Audi drive select, the S mode, this produces optimum system; aluminum components tronic selects freewheel as soon traction and balanced driving reduce the weight of the un- as the driver takes his or her foot dynamics. In “dynamic” mode, sprung chassis masses. The four- off the gas pedal. The Audi TTS torque is distributed to the rear link rear suspension can process is a peak performer. It covers the axle earlier and to a higher de- the longitudinal and transverse standard sprint in 4.7 seconds; its gree, which means that driving forces separately. One particular top speed is electronically gov- dynamics are enhanced further, highlight is the new third genera- erned at 250 km/h (155.34 mph). especially on surfaces with low tion of the adaptive damper con- The 2.0 TFSI produces 380 Nm friction coefficients. Alongside op- trol system, Audi magnetic ride. (280.27 lb- ft) of torque at an timizing the driving dynamics, Compared with the previous ver- engine speed of between 1,800 the advances made to quattro drive sion, it has been improved in and 5,700 rpm. Controllable flaps also focused on the subject of terms of characteristic spread, in the exhaust system modulate efficiency. In the drive select control dynamics and precision as the sporty sound and make it “efficiency” mode the torque dis- well as user friendliness. Audi even richer. A manual transmis- tribution is adjusted to optimize magnetic ride can be adjusted to sion is standard. The S tronic the level of efficiency. Determin- three settings (comfort – auto – option includes launch control, ing driving conditions and driver dynamic) via Audi drive select which regulates maximum acceleration from a standstill. quattro drive In the new Audi TT, quattro permanent all-wheel drive delivers additional stability, traction and driving fun. It has been con- sistently advanced and optimized especially for the new TT. Its electro-hydraulically controlled multi-plate clutch is mounted on the rear axle. The special pump design reduces weight by around 1.5 kg (3.31 lb) compared with the previous model. The distribution of drive torque between Audi TT Coupé – materials in body structure the axles is controlled electroni- 12 Audi TT

version, have a diameter of up to 338 mm (13.31 in). The new electromechanical parking brake that the driver actuates by pressing a button is integrated into the rear braking system. The TTS uses newly developed aluminum fixed-caliper brakes to slow the front wheels; these are five kilograms (11.02 lb) lighter than on the predecessor model – another example of Audi‘s expertise in lightweight construction. The electronic stabilization control (ESC), which can be switched Audi TT Coupé 2.0 TDI off either partly or completely, perfectly complements the car‘s and, at the press of a button, eith- The body is lowered by 10 mm sporty handling. When driving er makes the compact sports car (0.39 inch) on the TTS, with the through bends, torque vectoring hug the road more tightly or lets S line sport package and with the takes effect. If required, the drive it glide smoothly across the road adaptive damper control system, torque is distributed from the irrespective of which mode the Audi magnetic ride. The dynamic inside front wheel to the outside driver selects. Magnetic ride driving system known as Audi front wheel (front-wheel drive) technology delivers ultra-swift drive select is an option for the or, on quattro models, to the rear wheel-selective control of the new Audi TT, but standard on wheels, too. Thanks to the diffe- damper forces, which means that the TTS. It controls the engine rence in propulsive forces, the car in all driving situations there is characteristics and the steering turns very easily into the curve, optimum contact between wheel assistance. The driver can choose which is helpful for the driver. In and road. In this way, the new between comfort, auto, dynamic, this way, bends can be navigated Audi TT‘s superb driving dynam- efficiency and individual modes. with great precision and neutrally. ics are further optimized, and In addition, Audi drive select This significantly boosts the body control also ensures good influences several optional TT‘s dynamism and stability. comfort behavior. The system is modules – the S tronic, quattro Sport mode supports particularly unique in this market segment. drive, the Audi magnetic ride sporty driving, facilitating steer- Audi magnetic ride is standard on system, which at the press of a ing and control when drifting. the Audi TTS and is available as button makes the compact sports The way that all components an option for all other TT ver- car hug the road even more interact and harmonize enhances sions. Another highlight is the closely, and the engine sound. In agile handling and consequently standard progressive steering – efficiency mode, Audi drive se- the driving pleasure that an Audi its rack is designed such that the lect influences the air condition- TT offers – just as you would ratio becomes more direct as the ing and the start-stop system expect of a sports car. steering is turned. In this way, accordingly. There are 11 differ- the new TT can be steered agile- ent wheel versions available. ly and precisely with little move- The TT 2.0 TFSI and the 2.0 ment of the steering wheel in TDI come as standard with 17” downtown traffic and on winding forged wheels in five-spoke country roads. The electro- design, each of which weighs mechanically driven and thus highly only 8.7 kg (19.18 lb), and with Contact: efficient progressive steering size 225/50 tires. On request, Christoph Lungwitz adapts its assistance to speed and Audi can supply other wheel AUDI AG forms the basis for the optional designs with diameters of 17”, I/GP-P3 assistance systems – Audi active 18” or 19”, and tires up to 245/35 D-85045 Ingolstadt Phone: +49-841-89-33827 lane assist and park assist. With R19. quattro GmbH also offers Mobil: +49-151-54331109 its elaborate chassis design and wheels with a diameter of up to Fax: +49-841-89-32817 firm setup, the new Audi TT 20”. The front discs are venti- E-mail: [email protected] www.audi.com handles superbly in all situations. lated and, depending on engine Magazines Future Technologies in Bavaria

Hans-Bunte-Str. 5 · 80992 München · Phone: +49 89 23 55 57-3 · Fax: +49 89 23 55 57-47 E-mail: [email protected] · www.media-mind.info 14 Innovative energy management for electrical systems to come

The Auto-Kabel Group encompasses about 2,300 staff worldwide. We develop and manufacture solutions for automotive energy management and distribution, as well as safety technologies for electrical systems and functional mechatronics. Our story of success portrays a reliable partner and specialist for holistic automotive system solutions. The constant formation of the Group, also beyond Euro- pean borders, attests the high innovative expertise of our staff. To boldly question the status quo SBK3.0 (left), SBK2.0 (right) and constantly search for new technical approaches is the incen- gression and optimization poten- with the increasing expectations tive to innovation and progress. tials have to be found and rea- regarding comfort and reliability.

With this philosophy the Auto- lized. Demanding CO2 limits for Particularly the electrical systems Kabel Group creates innovations vehicle fleets pose a challenge to of modern vehicles have to be and individual solutions for its OEMs and their supplier indus- optimized further in order to customers in eight countries around try that has to be tackled. meet quality demands of the the world. Efficiency is the ubi- The advancing electrification of society as well as increasing tech- quitous catchword. Further pro- future vehicles goes hand in hand nical demands for more and more electrical loads and higher energy consumption. In the last couple of years flexibility and active energy management have become necessities growing evermore important with the advancing development of electrical systems, and these necessities are still becoming more crucial. Established technical standards like the pyrotechnical separation unit SBK (3rd generation) have to be adapted to the technical ad- vancement of electrical systems, e.g. the conversion to 48 V DC. Furthermore a transfer into func- Auto-Kabel Group with headquarters in Hausen im Wiesental, Germany

Energy management tionally new scopes with flexible Energy management 15

Development of mean CO2 emissions of vehicle fleets and roadmap (passenger cars up to aprx. 3,5 t gross vehicle weight, based on ICC11b) possible fields of application is necessity for decentralized complexity of the electrical sys- required. enery distribution to optimize tem are two significant factors in The necessity for flexible solu- weight and efficiency each new vehicle generation. tions with increased functionalities Today‘s systems react according in due consideration of higher active energy management to to ambient conditions and are demands for e.g. functional safety increase efficiency thus unable to cover all imaginable becomes obvious. Keeping an fault models (e.g. detection of eye on the demands of future exponential increase of short-circuit and subsequent se- electrical systems, the electrifica- vehicle‘s energy demand at paration). tion of safeguarding functions is simultaneously tightened The answer is to combine and also obligatory. emission limits integrate various control and Amongst others, today‘s and safeguarding systems into one future vehicle generations pose Today, safeguarding and control- single unit. The electronic safety these challenges: ling functions are distributed to battery clamp (eSBK) is a central, various individual components, semiconductor-based and bidi- Safeguarding the electrical which consequently increases the rectional solution featuring a very system in emergency situations number of devices that have to low transition resistance (< 100 µΩ). be integrated into limited instal- Present safeguards (pyrotechnical leak current corrosion especially lation space. The immediate separation units, relays, melting when vehicle is immobile (sta- effect is the need for more instal- fuses etc.) become obsolete when tistically up to 90% of lifetime) lation space. Weight and high replaced by an eSBK as it resu- mes the function of these components. According to valid developing standards, the specifications of ISO 26262 (ASIL B) are met. The electronic switch (eSBK) enables controlled, reversible separation of the starter-generator line and miscellaneous high current loads when needed. Sepa- ration takes place within a milli- second, and the separation time is eSBK (visualization) customizable if needed. The 16 Energy management

Exemplary wiring scheme of eSBK

eSBK allows to easily and quick- signal of eSBK complies with the tive supplier looking back on a ly de-energize power lines that AK-LV 16 specification. The long history of innovative devel- are not in permanent use, and to current standard of airbag control opment we are pleased to carry activate them when needed. For units is applied without altera- on actively contributing to the example, the starter line would tion, and furthermore an activa- automotive future. only be energized at vehicle start- tion via LIN or CAN is possible. up and remains preventively sep- Safety-related parts of the elec- arated from the voltage supply trical system that feed e.g. warn- while driving. Safety aspects in ing lights, car phone etc. remain event of a crash are thus perfect- energized and are not affected by ly met. There is no mechanical eSBK‘s separation functions. wear and tear as in relays, and the Additionally, eSBK provides ways eSBK uses as little installation to integrate further functions like space and weight as possible. switching off and controlling A permanently energized electri- various systems (e.g. signal sepa- cal system (cables and wires, ration, controlled charging of contact parts, loads) is continu- capacitances etc.) and decreases ously affected by leak current the requirements to install de- Author: corrosion and electromigration. centralized safeguarding concepts Sohejl Rafati The eSBK is able to separate the (Energy Backbone and Intelli- Dipl.-Ing. / connected electrical system when gent Fuse Boxes). Graduate Engineer the vehicle is at standstill, which Diverse patented technologies Product & Program statistically mounts up to 90% of have been considered during Management its lifetime, not only to minimize development of eSBK to achieve the corrosion issue during stand- an optimum between functionali- stills, but to eliminate it completely. ty and also cost efficiency. Auto-Kabel Management GmbH The jump start function either at eSBK is a landmark of a new era, the battery or at an individual going hand in hand with issues Erkelenzerstr. 44 D-41179 Mönchengladbach-Rheindahlen contact has been observed during like the 48 V DC electrical Phone: +49 2161 30870 667 development and is sustained. system which is to find its way Fax: +49 2161 30870 612 E-Mail: [email protected] As for airbags and pyrotechnical into passenger vehicles in the www.autokabel.com separation units, the triggering years to come. So as an automo- YOUR KEY TO BAVARIA

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NH\WHFKBHQJB$LQGG 18

The future will be lighter: New materials in door systems

Lightweight design and efficiency remain the automotive industry's top concerns due to the ambitious global CO2 targets. Automotive supplier Brose received the "Automotive Innovations Award 2013" in the car body and exterior category last year for its lightweight solutions and the comfort and safety features for doors and liftgates. The award is presented each year by the Center of Automotive Management in conjunction with auditing firm Pricewaterhouse- Coopers AG. The judges were particularly impressed by the innovations in lightweight door systems. The international supplier has been setting new benchmarks in this field for many decades. Brose's engineers focus particularly on future-oriented materials that help design each generation to be even lighter and more functional at no additional cost. The mechatronic specialist managed to cut the weight of its door systems by some 30 percent within the last ten years. And the future will be even lighter.

Modular door system design Brose is considered the inventor of the modular door with wet/dry side separation, laying the foun- dation for the functional lightweight design of vehicle doors. All essential functions are combined on a module carrier to form a pre-tested and ready-to-fit unit including window regulator, lock, wiring harness, door trim, loudspeakers, seals, sunblind, control electronics and crash sensors. In view of the increasing pressure Brose broke new ground in high-volume production with its door system made of long on prices and the multitude of glass fiber reinforced polypropylene, combining light material and improved function options available for new models, integration. Today, this variant is standard the modular design plays a sig- state of the art. Featuring a wall cables. Consequently, the num- nificant role in the automobile thickness of just 1.8 mm, they ber of components can be re- industry. In the vehicle door, provide significant weight bene- duced and further weight and stringent mechanical require- fits compared to steel: almost 4 kg cost savings achieved. ments have to be reconciled with of weight can be saved in a increasing functionality and the vehicle. New generation cuts weight necessary reduction in weight. In addition to the lighter basic by another 40 percent Thanks to the use of new mate- material, functional elements With its latest door system gener- rials and technologies, Brose have been integrated in the plas- ation, the supplier goes one step meets all these requirements. tic carrier such as window regula- further: an intelligent blend of Highly-integrated plastic door tor rails, inner door handle, spea- materials enables additional weight

Door Systems systems have meanwhile become ker frame or fixing elements for reductions while maintaining the Door Systems 19

required strength. The carrier press-molded into shape while the plate consists of glass fabric re- functional elements of glass fiber inforced polypropylene (thermo- reinforced polypropylene are in- plastic composite) combined with jection-molded. Thus, the cycle functional elements made of long time is similar to that of a compo- glass fiber reinforced plastic. As a nent only consisting of injection- result, the aggregate carrier comes molded long glass fiber reinforced with a wall thickness of just 0.5 mm materials. and weighs only 580 grams. This means another 40 percent saving A glance at the future in weight compared to lightweight According to Brose, carbon fiber solutions made of long glass fiber reinforced plastics (CFRP) offer Brose's CFRP door structure delivers maximum functional integration, reinforced polypropylene. great potential for the future. thereby reducing the number or compo- Crash tests have demonstrated The material is extremely light nents and hence costs. OEMs only need that the material is as safe as stand- while retaining its strength: a to mount and screw the outer door panel, which considerably reduces ard door systems. Providing composite material that provides assembly time plenty of design potential for substantial weight savings with- high-precision shaping of the wall out sacrificing safety and com- assembly time for the OEMs. thickness, fiber orientation and fort. The mechatronic specialist Another benefit: if the wet side layer structure, additional strength- demonstrates its vision of the of the door needs to be accessed relevant functions can be trans- future use of CFRP by present- or small parking dents repaired, ferred to the module: where more ing a lightweight door concept the outer door panel can easily strength is required, the material that is a perfect combination of be dismounted or even replaced, if can be reinforced or the fiber design, material and manufac- necessary. Brose expects to be sup- orientation adjusted, in all other turing technology. The CFRP plying these CFRP door systems places the carrier plate remains prototype saves almost 4 kilo- for high-volume production from ultra-thin. Thus, it is possible to grams of weight per door com- 2020. dispense with reinforcement pared to aluminum and as much sheets used in standard systems as 11 kilograms compared to against stress caused by door sag, steel. In addition, this door con- Author wind forces and torsion in the cept provides new possibilities Michael Thienel door inner panel. Adjusting the for the vehicle assembly process: Advanced Development fiber orientation ensures improved thanks to maximum functional Door Systems strain-to-failure and hence safety. integration, the number of com- The manufacturing process still ponents and costs can be re- comprises only a single step: the duced. The outer door panel only pre-punched, heated mat of glass needs to be mounted and screwed fabric reinforced polypropylene is on, thereby substantially reducing

Brose Fahrzeugteile GmbH & Co. Kommanditgesellschaft, Coburg

Ketschendorfer Straße 38-50 96450 Coburg Tel: 09561/21-1957 Fax: 09561/21-1704 www.brose.com

Contact [email protected]

Sales 2013 4,7 billion euros

Customers Some 80 automobile brands Compared to standard plastic door systems, the carrier plate made of glass fabric rein- and more than 30 suppliers forced polypropylene saves some 350 grams of weight and as much as 1.2 kilograms compared to standard steel doors while maintaining crash safety and high functional Workforce 2013 integration Approximately 22.000 20 Quality Assurance throughContinuous Integration – What We Can Learn from Other Industries.

The rapidly growing networking within automobiles and to their environment, as well as the quickly increasing range of available vehicle functions are placing growing demands on the reliability of the individual car components and their software. For instance, a simple car radio used to be enough, but today a wide range of control devices, audio sources, controls and transmission routes are involved in enabling listening pleasure. With expanding comfort, the complexity of the electrical/electronic architecture increases and is also associated with a greater risk of software errors. The sooner an error is detected during the development process, the lower are the time requirements and the costs of the reme- dy. This is also true for the soft- Fig. 1: Continuous Integration circle ware development. Errors that initially come up in experimental thus enable the rapid localization already faced these challenges for runs in the vehicle could often and elimination in the code. The quite some time. Whiteblue already be detected, and even scope of testing grows along with Consulting has years of experi- avoided, at a much earlier phase the software to secure the newly ence in this area and advises and of integration on the module or implemented functions, and to supports well-known clients on component level. ensure the exclusion of regres- this topic. Continuous integration, as shown sions, i.e. the recurrence of already In a concrete project with about in Fig. 1, is a process in which a fixed bugs. A final process docu- one million lines of code and smallest possible, self- contained ments the input configuration, more than 5,000 component tests development step is released by the creation process, and test it takes an individual employee the developer (Check-in) and is results for the developed soft- several hours to perform this scope afterwards automatically created ware version, and then releases of testing, including the code and merged (Build) into the soft- the software (Publish). changes on the development ware modules. Concurrent and In this connection we can learn computer. The introduction of consecutive tests reveal any from other industries, such as Continuous Integration structu-

Whiteblue Consulting GmbH GmbH Consulting Whiteblue errors immediately (Test) and Telecommunications, which has res the procedure and sets the Whiteblue Consulting GmbH 21

stage for detecting and fixing often a manual and very individu- implemented, even in the increas- mistakes early. The provision of al process mastered by only a few ingly complex software projects the new source code by a devel- members of a project due to its in the automotive industry with oper automatically deletes the complexity and the usually inade- its expanding supplier networks. compilation of the software on a quate documentation. The auto- build server. If this is successful, mation of all the steps for creat- then the highly parallelized coming a package of installable soft- ponent tests are executed. This ware components leads to the gives the developer feedback on reproducibility of the processes the success of the changes within and thus avoids errors. 15 minutes. At night, the compu- In the above-mentioned project, tation capacity of the software the setup packages of the various development system is used for software components are usually execution of long-running appli- created in the early evening. Authors: cation testing. Protection is pro- When all the components have Dirk Kypers vided through a comprehensive been successfully built, they are suite of component tests. The automatically installed on a hard- results are processed, presented ware regression system. Then a centrally and distributed to the series of reference tests are car- relevant locations. In this way, ried out and the results are availa- errors can found within minutes ble to developers and the inte- after a Check-in, and the neces- gration team the next morning. Thorsten Wacker sary measures can be taken by This way we get a first impres- the development team. Jenkins, a sion of the quality of the nightly scalable and extensible open- builds and can determine source Continuous Integration whether further manual integra- server, is used to automate the tion tests are appropriate. software development. With The described process of Con- more than 600 plug-ins already tinuous Integration used in our built in, Jenkins offers meaning- telecommunication project has Whiteblue Consulting GmbH ful reporting. The results of the proven its utility by achieving a Emmy-Noether-Str. 4 software development are pro- significant reduction in the time 80992 Munich Tel.: +49 89 622338-0 cessed and presented through the requirements for software pro- Fax: +49 89 622338-50 embedded web server. tection and a clear increase in E-mail: [email protected] At that point the challenge is to quality. Our experience with this www.whiteblue.com create installable setups. This is process could be effectively 22 Network of Automotive Excellence:

The cross-sector network NoAE is a free, open initiative for the mobility sectors and their cooperation partners. The starting point was ten years ago with the automobile and supplier industries. From there, an international and cross-company expert network developed. The objective is the exchange of ideas on strategic organizational and technological questions and challenges for the company within and beyond the sectors. NoAE was founded in 2002 Mr. Alois Brandt, AUDI AG opened the kick-off conference www.future-city-factory.de by well-known personalities of the Image: © AUDI AG automotive sector and with the collaboration of the European Com- Joint Initiative from the Audi planners at the kick-off conference mission. factory and NoAE of the FutureCityFactory in order to The new initiative: With the initiative “FutureCity discuss opportunities for industrial FutureCityFactory Factory”, the Audi factory and the manufacturing in an urban context. Jointly master urban challenges Network of Automotive Excellen- The basis for this was the keynote Cities, science and busíness in the ce bring together cities, science and speeches on the specific challenges, dialogue business in order to discuss facing the sectors in the future. This opportunities, challenges and ideas was implemented in five market- for the design of urban manufac- places. turing of the future. Marketplaces as the basis for Kick-off at the end of April 2014 joint projects at AUDI in Ingolstadt Five marketplaces formed the discus- At the end of April, 140 representa- sion platform at the kick-off and also tives from the economic and science welcome cities, companies and science sectors met with city and transport to join the cooperation in future:

By 2050, over 70% of the world‘s population will be living in cities. Marketplace Employees A majority of the economic power will be concentrated on a few hundred cen- Cities and companies are in the same ters in the world. The city of the future boat: The one would like attractive jobs presents new challenges to the infra- for their citizens; the other is searching structure of industrial manufacturing, for qualified employees. Simultaneously trade and services – challenges, which the demands on employees at work, in can only be overcome with interdisci- the workplace and in the working envi- plinary cooperation. ronment have increased. Network of Automotive Excellence Automotive of Network Network of Automotive Excellence 23

A sixth marketplace was reserved for the representatives of communities: Under the key heading Marketplace Mobility ”City of the Future”, represen- Advanced urbanization means that the tatives from cities, in particular in population density in cities and agglom- Bavaria, Baden-Württemberg, erations will continue to increase. People North Rhine Westphalia and want to be mobile all the time, reliably, securely and more and more resource- Austria (Graz and Vienna), ex- friendly. changed ideas.

The ultimate goal was and is, to create suggestions for implementation using concrete tasks but Marketplace Internet also on the basis of ideas.

The marketplace ‚Internet‘ places the focus on one of the most powerful developments in the coming years for industry, politics and society. The (R)Evolution to Industry 4.0.

Marketplace Future Planning

Factories and the city belong together. The planning tasks of the future will be focused more than ever on synchronizing the interests of cities and companies.

Mr.Ralf Winterstein,Mahle,makes his evaluations at the marketplace ‚Energy‘. Image:© AUDI AG Marketplace Energy The initiators, the Audi factory and The marketplace ‚Energy‘ encompasses NoAE, welcome cities, science and all topics and challenges, which must be business to a continued coopera- observed by communities, companies and providers within the scope of new tion. The first subsequent dates energy concepts. have already taken place.

Contact: ewf institute NoAE

Dipl.-Kfm. H. Köpplinger

Becker-Gundahl-Strasse 19 D 81479 Munich – Germany Phone: +49 (89) 7489-9669 Mobile: +49 (170) 52 77 666 E-mail: [email protected] www.noae.com

Additional information in the internet

Platform for Future City Factory www.future-city-factory.de

Social Networks https://www.xing.com/de/communi- Ms. Monika Thomas,Wolfsburg, evaluating project ideas at the marketplace ties/groups/future-city-factory-64df- “City of the Future”Image: © AUDI AG 1005233 24 Good Design is in our Nature

Creative concepts, an intelligent made of high-strength aluminium implementation, validation, evalua- start with 2.000 E and depend on tion and optimization are elements of size as well as complexity. Our tools the product development cycles. In are designed for pieces with a part between are performance interfaces size up to 600mm and an injection with their typical loss of informa- weight up to 700g. tion, communication problems and a Applicable are all thermoplastics higher control effort located. At acad which are available on the market. all project accomplishments originate The 400 most important ones are from a single source. always on stock. The manufacturing For more than 12 years design as well F.S. Fehrer Automotive GmbH: Daimler of prototypes is performed on rapid as prototyping work closely inter- W222 S-Class centre arm rest SA rear moulding systems. This method linked and create all the sub-processes based on 3D-CAD data makes it that are a key for the efficient and possible to produce prototypes quick competent project realization. and easy even in the planning phase. Due to this service offer prototype parts, Due to the segmented structure, all designs and concepts can be supplied tools can be rapidly changed to meet with a higher level of maturity. the customer‘s needs.

acad engineering – Exemplary projects of acad proto- driven by evolution typing: You want to ensure a competitive Dräxlmaier Group:BMW control unit bracket Dräxlmaier Group: advantage over the business com- BMW control unit bracket petition in the automotive sector Exemplary projects of acad with unconventional solutions? engineering: Alfmeier Präzision AG: acad engineering will provide com- F.S. Fehrer Automotive GmbH: Pneumatic control housing petent advice and supports com- Daimler W222 S-Class centre plex projects targeted to a success- arm rest SA rear F.S. Fehrer Automotive GmbH: ful completion. Thanks to our 22 Opel Zafira centre arm rest years of experience we are special- csi entwicklungstechnik GmbH: ists in the development of interior Porsche Cayenne E2 centre arm components such as armrests, head rest rests, cup holders and seat compo- Author: nents for the automotive industry MEKRA Lang GmbH & Co. KG: Dipl.-Ing. Alexander in the premium segment. Our MAN Neoman urban bus front Kalusche customers include the OEMs, tier-1 mirror CEO and tier-2 from the automotive field. Every single development acad prototyping – step is assured systematically due “driven by improvement” to a development in 5 phases. acad prototyping manufactures plas- You decide after the completion tic prototype parts in an express acad group and the analysis of every single injection moulding process. Fabrikstraße 1a D-91560 Heilsbronn (Mfr) phase when and how to proceed, For quantities up to 1000 pieces the Phone: +49 (0) 9872 5298 which means minimizing your delivery within 15 working days is E-mail: [email protected] www.acad-group.de investment and development risk. possible. The prices for the tools Express Injection Express Special e-Car 26 The Audi Sport quattro laserlight concept car

• Dynamic coupe has powerful plug-in hybrid drive • Prof. Dr. Ulrich Hackenberg, Member of the Board of AUDI AG,Technical Development: “This show car embodies our engineering competence and shows cutting-edge electronic features such as high-performance laser-light headlights.”

The Audi Sport quattro laserlight concept is reminiscent of the classic Sport quattro of 1983 while pointing towards the future – with the latest of the brand's technologies in plug-in hybrid drives user control and display interfaces and lighting technology.

“The new show car demonstrates technical ‚Vorsprung‘ on many levels,” says Prof. Dr. Ulrich Hackenberg. “On-board this car we have e-tron technology with 515 kW of power and 2.5 l/100 km (94.09 US mpg) fuel economy; laser headlights that leave all previous systems in the dark with its higher performance as well as new display and operating systems with cutting-edge electronic performance. We are showing the future of Audi here.” The coupe, a new evolutionary stage of the Sport quattro concept, painted in Audi Sport quattro laserlight concept – front view the color Plasma Red, combines the power of the historic Sport technologies. Two low-profile trap- LED high beam lights. In this quattro with emotional elegance. ezoidal elements are visible within future technology, Audi is once Its body is tautly set over its large the headlights – the outer one again demonstrating its leadership wheels. The overhangs are short, generates the low beam light role in automotive lighting tech- and the car's proportions show a using LEDs and an aperture mask, nology with a system that will also sporty balance. With a wheelbase while the inner element produces be used on the race track in the of 2,784 mm (109.61 in), it is 4,602 mm laser light for high-beam function- 2014 R18 e-tron quattro. The (181.18 in) long. At a width of ality. The powerful laser diodes angular, swept-back C pillars of 1,964 mm (77.32 in), the two-door are significantly smaller than LED the Audi Sport quattro laserlight model is very wide, and it is just diodes; they are only a few mi- concept car and the blisters above 1,386 mm (54.57 in) tall, which is crons in diameter. Illuminating the fenders are other design ele- exceptionally low. In the dual the road for a distance of nearly ments reminiscent of the classic headlights, a typical quattro fea- 500 meters (1,640 ft), the laser Sport quattro. The broad shoul- ture, Audi is demonstrating the high- beam light has approximate- ders of the body were reinter- future of lighting technology by ly twice the lighting range and preted and intensively sculpted to

Audi Sport Audi laserlight quattro concept combining LED and laser light three times the luminosity of convey even greater dynamism. Audi Sport quattro laserlight concept 27

ters of the air nozzles also shows media data.

New solutions: displays and controls The interior of the Audi Sport quattro laserlight concept focuses very much on the driver. Even the multifunction sport steering wheel points the way towards future sporty production solutions. It has two buttons which the driver can use to control the hybrid drive, a red start- stop button, a button for the Audi drive Audi Sport quattro laserlight concept – rear view select vehicle handling system and a „View“ button to control Throughout the car, sharp con- look of the Audi Sport quattro the Audi virtual cockpit. All key tours frame muscular surfaces – laserlight concept. The sill exten- information is shown on the large the interplay between convex and sions are made of CFRP, the door Audi TFT display in high-reso- concave curvatures defines the handles electrically extend from lution, three-dimensional gra- athletic character of the coupe. the door when they detect the phics; a cutting-edge Tegra 30 The hexagonal single-frame grille approach of a hand. The center processor from Audi partner also offers an outlook on future locking wheels have a five twin- Nvidia processes the graphics. design of the sporty production spoke design. The driver can switch between models. The lower section is different modes. For example, in nearly vertical, while the upper Lightweight design the MMI mode the dominant follows the contour of the hood; made visible: the interior display elements include the the screen insert is a typical solu- In its generously cut interior, the navigation map and media lists, tion from car racing. The low elegant sporty styling of the show while in the Classic view the grille emphasizes the show car's car is continued with dark gray speedometer appears in the fore- width. Two large, vertical blades colors and clean lines. The interior ground. Nearly all functions of divide each of the large air inlets; design and material selections the Audi Sport quattro laserlight their form is repeated in the demonstrate the Audi philosophy concept can be controlled from creases of the hood. The splitter, of lightweight design. The slender the further developed MMI ter- which is made of carbon fiber instrument panel is reminiscent of minal that is mounted on the reinforced polymer (CFRP), is the wing of a sailplane. The sup- center console over the tunnel. shifted far to the front, as on a porting structure of the interior is Its large rotary pushbutton, race car. The combination of a a carbon shell that also serves as a which also serves as a touchpad, swept-back glass cabin and broad storage compartment in the doors. can be pushed in four directions, shoulders defines the proportions A line of trim beneath the wind- and it is surrounded on three at the rear. Another defining ele- shield wraps around the driver and sides by four buttons – for the ment at the rear of the show car is front passenger and integrates main menu, submenus, options the CFRP diffuser, which extends functions such as the inside door and a back function. The new upward significantly. Its upper handles. The folding race car shell user interface has a menu struc- section is honeycombed, while its seats with their high lateral sup- ture whose intuitive layout is lower section houses two large, ports and integrated head re- similar to that of a smart phone. oval tailpipes. The tail lights, straints, together with the two rear All frequently used functions can which are backed by a black seats, provide space for four per- be accessed lightning fast. For CFRP panel, are rectangular in sons. The climate controls are most inputs, just a few steps are form – another quattro reference. integrated in the air nozzles; a needed thanks to a new free text The luggage space, which is rein- single element is used to control search feature; generally just four forced by a large cross bar stiffen- the intensity, temperature and characters suffice for a navigation er, offers 300 liters (10.59 cu ft) of volume of the air stream. In addi- address. The driver can quickly cargo capacity. Precise design tion to showing climate control scroll through lists or zoom the details round out the dynamic settings, the slim display at the cen- map image using multitouch 28 Audi Sport quattro laserlight concept

for different levels of regenera- tive braking. In Sport mode, the operating strategy configures the drive system for maximum power. When the V8 and electric motor are boosting, the Audi Sport quattro laserlight concept accelerates from a standstill to 100 km/h (62.14 mph) in 3.7 seconds and can reach a top speed of 305 km/h (189.52 mph).

Body and chassis A lightweight design strategy also plays a major role in the car's dynamic performance. A combination of ultra high-strength Audi Sport quattro laserlight concept – Audi virtual cockpit steel sheet and structural elements of cast aluminum is used in gestures on the touchpad. Voice energy from a lithium-ion battery at the occupant cell. The doors and control functionality has also been the rear, which stores 14.1 kWh of fenders are made of aluminum, intensively further developed. energy – enough for up to 50 km and the roof, engine hood and (31.07 miles) of all-electric driv- rear hatch are made of CFRP. Powerful and highly ing. An Audi wallbox that is This results in an unladen weight efficient: the drive system used for charging provides for of just 1,850 kilograms (4,078.55 lb), The plug-in hybrid drive gives optimal energy transfer. An intel- including the large battery pack. the Audi Sport quattro laserlight ligent management system con- The front suspension is com- concept fascinating dynamic per- trols the interplay of engine and prised of five links per wheel, while formance. Its system output is motor on demand. The driver can the rear suspension is based on 515 kW (700 hp), and its system switch between three different the self-tracking trapezoidal link torque is 800 Nm (590.05 lb-ft). modes. In EV mode, just the principle of Audi, which guaran- Power flows via a modified eight- electric motor operates; its high tees dynamic performance and speed tiptronic to the quattro torque propels the show car with stability. Stiff tuning of the drivetrain, which features a sport plenty of power – even outside of springs and shock absorbers make differential at the rear axle. The the city. The active accelerator the Audi Sport quattro laserlight show car's combined fuel con- pedal indicates the transition to concept hold tightly to the road, sumption, based on the applicable Hybrid mode to the driver – by a while Audi drive select makes the fuel economy standard, is just 2.5 li- change in pedal resistance; this is driving experience even more ters of fuel per 100 km (94.09 US done so that the driver can inten- multifaceted. The dynamic steer-

mpg) – which equates to CO2 tionally influence the mode selec- ing system varies the steering ratio emissions of 59 g/km (94.95 tion. The Hybrid mode aims at as a function of driving speed. The g/mile). The combustion engine optimal fuel-savings in the inter- brake calipers grip large, carbon is a four-liter V8 with biturbo play between the TFSI and the fiber-ceramic brake discs, and the charging; it produces 412 kW electric motor, and environmental tire size is 285/30 R 21. (560 hp) of power and 700 Nm and route data are utilized here. (516.29 lb-ft) of torque. The driver can choose the Hold The cylinder on demand (COD) and Charge modes in the MMI system, which deactivates four to influence the operating strat- cylinders under part load and a egy, e.g. if the driver wants to Contact: start-stop system make the so- ensure that sufficient electrical Josef Schloßmacher norous eight-cylinder engine very energy is available for the final AUDI AG efficient. Located between the kilometers to the destination. I/GP-P 4.0 TFSI and the transmission is The Audi drive select dynamic D-85045 Ingolstadt Phone: +49-841-89-33869 a disc- shaped electric motor that vehicle handling system offers Fax: +49-841-89-90786 produces 110 kW and 400 Nm even more control options – indi- [email protected] www.audi.com (295.02 lb-ft). It draws its drive vidual driving profiles are set up eCarTec Munich 2014 6. Internationale Leitmesse für Elektro- & Hybrid-Mobilität

21. - 23. Oktober 2014 Messe München, Eingang Ost

Connecting Mobility Markets!

Verleihung des

www.ecartec.de 30

New materials used in electric vehicles require the adaptation of joining and cutting processes

The automotive industry is Laser cutting in and the burr-free cut edges. Chal- increasingly focusing on the battery production – lenges for this process arise mainly electrification of power trains. flexible trimming because the material properties of While vehicles that run purely of electrode foils the individual components of the on electric power have not been As part of the BMBF-funded electrode foil are different: the widely produced by car manufac- research projects ProLIZ and coating evaporates at a much lower turers, mass production of hybrid ExZellTUM, the automated pro- energy input than the metallic vehicles is already very popular. duction of lithium-ion cells is substrate. As a result, the metal A particular challenge of electric being inestigated at the iwb in a foil near the cut edge is decoated, vehicles is the automation of semi-industrial production line, which may cause short circuits production. This is coming not where electrode sheets must be within the battery cell. For a good only from the OEMs, but also cut automatically. The drawback of quality cut edge, suitable process from the need for equipment conventional methods, such as control is critical with respect to manufacturers and suppliers to shearing and stamping, is that tool the temporal and spatial energy develop new facilities and manu- wear results in a continuous input. The trend of increasing the facturing processes. In several decrease in the quality of the cut coating thickness and the specific projects over the last few years, edge. In addition, shearing and energy of a battery cell has led to the Institute for Machine Tools stamping are geometry-bound, more challenges in trimming the and Industrial Management (iwb) and thus inflexible. Remote laser electrode. More energy must be of the Technische Universitaet cutting (shown in Figure 1) is an used to cut this material, which Muenchen has developed new alternative method for cutting can lead to greater thermal damage processes and procedures with electrode films. It is a non-contact along the cut edge. At the same tailored solutions for electric and thus wear-free process that time, damage can occur during this mobility. Special attention has can be used in the manufacture of process, resulting in particulates, been paid to joining and cutting battery cells of various shapes and which may be deposited on the processes for both pure and sizes. The laser beam evaporates electrode surface. Therefore, the compound materials, which are the electrode material along the focus of this research is to quantify used for high-voltage batteries cut edge and enables a defined the influence of these effects on and electric drive systems. This ablation of the material. Particular- the quality characteristics of the article will present the individual ly advantageous are the high cut- finished cell, with the aim to maxi- production steps, challenges en- ting speed, the absence of wear, mize quality. countered, and innovative solutions for the production of lithium- ion high-voltage batteries. These include: trimming of electrode foils, connecting multiple cells in battery modules, pressure-tight welding of aluminum cooling plates, and joining of aluminum and thermoplastic glass-fiber reinforced plastics for the housing of the high-voltage Fig. 1: Laser cutting of electrode foils

New materials New battery. New materials 31

Welding of electric contacts Therefore, high electrical con- crash. These requirements can be for battery modules ductivities can be achieved de- fulfilled with FSW, whereas For use in electrified vehicles, spite the small area of the weld conventional welding technolo- multiple battery cells are connec- seam. The method was validated gies are only partially suitable. ted to each other, forming bat- with a battery module containing Welding with FSW is characte- tery modules. Due to the fact eight lithium-ion cells; the geo- rized by the absence of a melt that there are many cells in one metry of the weld seam was opti- pool, hot cracks, or pores, and module, the technology used for mized and successfully imple- therefore the connection is pres- joining the cells plays an impor- mented for welding the electrical sure tight. The ductility of the tant role in the production chain. contacts. Figure 2 shows the weld seam is equal to the ducti- The iwb is investigating joining finished battery module with the lity of the original material; there- technologies for lithium-ion cells electrically optimized weld seam fore more energy can be absor- that fulfill the requirements for geometry. bed in a crash compared to the use in electric and hybrid The welding time per contact case of conventional fusion wel- vehicles. Several technologies was as low as 0.9 seconds. Thus, ding. Maintaining a high ductility were screened regarding suitabi- manufacturing times less than also preserves the pressure lity for joining the electric one minute per module can easily tightness after a crash. Figure 3 contacts, and laser welding was be achieved. The technology of shows a cooling plate that was identified as the most suitable laser welding is an excellent so- joined by FSW with the DeltaN- process. Excellent electrical pro- lution for mass production of process (tool shoulder is statio- perties and a low connection electrical contacts with high con- nary). The cross section shows a resistance are achieved due to the ductivity. pore free and pressure tight weld material locking. seam. The use of laser scanning optics Friction Stir Welding has various advantages: the proof cooling plates Laser welding of cess is contact-free and the geo- for high voltage batteries thermoplastic fiber metry of the weld seam can be As part of the BMBF-funded reinforced plastics freely adapted. In order to pre- research project “eProduction”, with metals vent thermal damage of the cells the iwb is using Friction Stir Thermoplastic fiber reinforced during joining, the length, and Welding (FSW) as a novel tech- plastics have great potential for therefore the area, of the weld nology to join cooling systems use in the housing of high volt- seam have to be decreased. The for high voltage batteries. The age batteries because of the high- iwb developed a method to calcu- cooling concept for the project ly flexible design options and late an optimized geometry of consists of a 5 mm thick alu- their high specific stiffness. There- the weld seam using a genetic minum cooling plate underneath fore, they are well suited for algorithm coupled with a ther- the battery module. The cooling structural lightweight construc- mo-electric Finite Element Ana- plate has to withstand pressures tion of battery systems. The lysis in multiple simulation loops. up to 3 bar, as well as a vehicle polymer has to be joined to the aluminum in several places; tradi- tionally, technologies such as gluing, riveting and screwing are used for joining. These technologies have several disadvantages: they require a costly preparation and have long cycle times. As a result, they do not fulfill the automotive industry‘s production requirements. In order to overcome these issues, the iwb is focusing its research on laser welding of (fiber reinforced) polymers to aluminum, namely the processes of heat conduction welding and transmission wel- Fig. 2: Battery module with eight lithium-ion cells and electrically optimized weld seam ding (Figure 4). A bond, based on geometry a combination of an adhesive 32 New materials

Fig. 3: Cooling plate, joined by FSW with the DeltaN-process (a); cross section (b)

bond and a form fit, is created by used to deposit the energy on the tures (Figure 5) with regard to their melting the polymer and letting it opposite side of the metal. The heat eligibility for industrialization as well cool while pressing it against the is then conducted through the metal as their influence on bonding aluminum. Laser welding is especi- in order to melt the polymer at the strength in combination with diffe- ally suitable for the joining process, interface. Both processes require rent polymers; these polymers can because the energy can be applied in that the parts be clamped. However, be reinforced with short or endless a highly defined manner on the sur- this is usually done using masks or fibers. It has been shown that shear face of the workpiece. Laser trans- glass which is translucent for the strengths up to 42 MPa can be achie- mission welding can be described as specific wavelength of the laser. ved by laser welding. The strength follows: the laser beam is transmit- A prerequisite for a strong metal to itself depends on multiple factors, ted through the polymer and absor- polymer connection is that the such as the surface pre-treatment and bed in the interface between metal metallic surface is pretreated. Cur- the composition of the polymer. and polymer; the interface is con- rent research shows that higher secutively heated and the polymer strengths can be reached, compared Conclusion melts. For this process the polymer to conventional techniques, by using New challenges arise for produc- must be highly translucent for the laser irradiation for pre-treatment. tion engineering, especially cut- wavelength of the laser beam to be Using lasers has additional advant- ting and joining technologies, transmitted. Unfortunately, the ages like the absence of hazardous when using new materials and fibers in fiber reinforced plastics chemicals and the possibility to ge- material combinations in electri- impede the laser beam due to their nerate defined topographies on the fied vehicles. The iwb is there- absorption effects. Heat conduction surface, the height of which can fore developing flexible techno- welding on the other hand can be range from nanometers to several logies in various research projects used independently of the fiber frac- millimeters. The iwb is investigating in order to master these new tion volume, since the laser beam is the most promising surface struc- challenges.

Fig. 4: Laser transmission welding (a) and laser heat conduction welding (b) New materials 33

Fig. 5: Laser generated surface structures: Macroscopic structures (a); microscopic structures (b); nanoscale structures (c)

Acknowledgment Flexible trimming of electrode foils Welding of electric contacts for battery This publication is based on the Research projects ProLIZ und modules and Friction Stir Welding of research of the following projects. ExZellTUM, funded by the Federal cooling plates for high voltage batteries The authors owe great gratitude to Ministry of Education and Research Research project eProduction, the sponsors. (BMBF). funded by the Federal Ministry of Education and Research (BMBF).

Authors: Dipl.-Ing. Prof. Dr.-Ing. Contact: Alexander Fuchs Michael F. Zäh Dipl.-Ing. Alexander Fuchs

Institute for Machine Tools and Industrial Management (iwb) Technische Universität München Boltzmannstr. 15 D-85748 Garching Phone.: 089/289-15537 Further authors: Fax: 089/289-15555 M.Sc. André Heckert, Dipl.-Ing. Andreas Roth, Email: [email protected] Dipl.-Ing. Philipp Schmidt, M.Sc. Patrick Schmitz http://www.iwb.tum.de