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Automotive
Technologie
in Bavaria
+e-Car
GLOBAL PARTNER
VOSSIUS & PARTNER Special ideas require special protection. For over 50 years, VOSSIUS & PARTNER has been providing high-end FRQVXOWDQF\IRULQQRYDWLYHFRPSDQLHVLQDOO¿HOGVRISDWHQWWUDGHPDUN GHVLJQDQGFRS\ULJKWODZ9266,86 3$571(5ZRUNVLQ\RXULQWHUHVW competently, reliably, precisely and creatively. Legal areas.3DWHQWVWUDGHPDUNVDQGEUDQGVGHVLJQULJKWVFRS\ULJKWV NQRZKRZSURWHFWLRQGRPDLQVFRPSHWLWLRQODZDQWLFRXQWHUIHLWLQJ software and IT, law on employees’ inventions, licensing, food law, distribution agreements, franchise agreements, R & D agreements, media law, right of publicity, antitrust aspects in licensing, supplementary SURWHFWLRQFHUWL¿FDWHVSKDUPDFHXWLFDOODZ Technical areas. Mechanical & electrical engineering, IT, physics, chemistry, biotechnology, pharmacology, life sciences. Services. IP prosecution, IP litigation, IP searches, freedom to operate, contracts, annuities, arbitration, mediation, IP portfolio management, due diligence, strategic IP consulting, IP landscaping, IP valuation services. It is not without reason that VOSSIUS & PARTNER is among Europe’s PRVWUHQRZQHGODZ¿UPVLQWKH¿HOGRILQWHOOHFWXDOSURSHUW\ VOSSIUS & PARTNER · Patentanwälte Rechtsanwälte mbB · MÜNCHEN · DÜSSELDORF · BERLIN · BASEL 0DLQ2I¿FH 6LHEHUWVWUā0XQLFK*HUPDQ\ā7HO āLQIR#YRVVLXVDQGSDUWQHUFRPāZZZYRVVLXVDQGSDUWQHUFRP
Editorial
Mobility at the heart of society
No sector influences people's behavior as causally Mobility & health – is this a symbiosis of
and effectively as the automotive industry. increasing importance?
New test fields are opening up, bound for the Find out how collaborative work can help
mobility of the future. The development of the develop useful standards and correct solutions.
automobile is being driven forward in order to
maintain competitiveness.
Priority is given to autonomous and environ-
mentally friendly systems as well as the provision Walter Fürst, Managing Director
of an appropriate infrastructure.
Exciting questions that need answers:
Masthead:
What role do trucks play in the freight trans-
port of the future? Publisher: media mind GmbH & Co. KG
Hans-Bunte-Str. 5
80992 Munich/Germany
Is synthetic fuel an option on the way to a Phone: +49 (0) 89 23 55 57-3
clean internal combustion engine? Telefax: +49 (0) 89 23 55 57-47
E-mail:
mail@media-mind.info
What will sustainable, environmentally www.media-mind.info
friendly mobility solutions look like in the
Managing director: Walter Fürst, Jürgen Bauernschmitt
next few years?
Design + DTP: Jürgen Bauernschmitt
Can hydrogen technology be a long-term Prepress: media mind, München
strategy in the mobility field? Responsible editor: Ilse Schallwegg
Published annually: 1 x annually
What intelligent solutions in the field of
© 2019 by media mind GmbH & Co. KG
battery and charging technology are there No part of this magazine may be stored, copied or
for at home and on the go? reproduced without the written consent of the editorial office
Dear readers, if you read this magazine page by page, you will The product initiative is well under way. In 2019 gain some remarkable insight into the creativity alone, we launched 20 models. Many of these and capabilities of the automotive industry in were entirely new and had no direct predecessors. Germany‘s largest state. Even on a global scale, It is particularly important to note that by the end Bavaria is a region that sets an example to others of 2020, our line-up will boast five electric cars in the industry. AUDI AG as a company and, in and seven plug-in hybrids. When it comes to fuel- particular, I as the member of the Board of cell drive systems, Audi is even acting as a com- Management responsible for Procurement petence center for the entire Volkswagen Group, know full well just what benefits are on offer with the first vehicles due to enter series produc- thanks to the diversity that we have right on our tion at the dawn of the next decade. That means doorstep and throughout the entire value chain. that we will be adding to our range in this prom- We have a lot to defend as we negotiate a phase ising segment more rapidly and systematically of industrial development characterized by dis- than any of our competitors. Just six years from ruptive technologies and new competitors from now, a third of new Audi vehicles will be electric. all kinds of countries and industries. Audi has In preparation for this monumental accom- continued to refine its strategy so as to focus plishment, we have already added considerably more closely on offering the best solutions to to our expertise and given our employees fur- meet customer demands concerning premium ther training in electrification, digitalization and mobility. conditional automation. The pace of the trans- At the heart of this strategy are products that formation is building all the time. deliver distinct added value relative to the com- Many other companies in the industry across petition when it comes to electrification, digital- Bavaria are setting themselves similar assign- ly connected services and sustainability. Our ments. We need to work together to meet these Audi e-tron, for example, is manufactured on a challenges, partly for the future of our company, completely carbon-neutral production line, but also for the future of the entire state. After which is an environmental plus without parallel all, something that even critical voices in politics anywhere in the world on an industrial scale. and society in general should keep in mind at all Audi also offers its own eco-electricity solutions times is that the automotive industry accounts for customers as well as digital updates to key for 30% of industrial added value in Bavaria. vehicle functions such as drive system power components or lighting. That means real Dr. Bernd Martens Vorsprung durch Technik for people buying our Member of the Board of Management of AUDI AG technology. Procurement and IT
Founded by the Bavarian Ministry of Economic Af- Concerning service strength, three Occubot seat
fairs, Infrastructure, Transport and Technology, the test robots made by KUKA are available at ATB.
test laboratory is accredited according to EN 17025 Using a system for changing test dummies does not
and situated within the Automobilzulieferpark (= Au- only provide an automated programme process, but
tomotive Supplier´s Park) Pole Position at Hof-Gat- a continuous picture documentation as well. At the
tendorf. It performs tests and experiments in ac- same time the test loads are constantly observed
cordance with customerspecific test instructions and readjusted. The area of service strength com-
and requirements. As regards concepts, the tests prises as well four spring testing machines, versions
are supervised by competent staff. Engineering ser- „Schenck“ and „Reicherter Short and Long Stroke“.
vices and solutions to problems as well as construc-
tional adjustments are offered individually.
Automobiltechnikum Bayern GmbH
The Automobiltechnikum Bayern is your independent
competence center for environmental simulation, fatigue
testing, measuring methods and electrical engineering.
Contact
Automobiltechnikum Bayern GmbH
Ferdinand-Porsche-Straße 10
95028 Hof/Haidt
E-Mail info@atbayern.de
Phone + 49 (0) 9281 / 850 19 - 0
Fax + 49 (0) 9281 / 850 19 - 500
Vibrations / wideband noise / harrowing: Audi VR611.4 2004-07, DIN 50100, DIN EN 60068-2-6, DIN EN 60068-2-53 Climate tests: BMW PR303.5, VW PV
1200, VW PV 2005, DAG A166 620 0000, DAG 7.1.1, DAG 7.1.2, DAG 7.1.3, PSA D17 1058, GM 9540P, DIN EN 60068-2-1, DIN EN 60068-2-2, DIN EN 60068-
2-14, DIN EN 60068-2-30, DIN EN 60068-2-38, EN 60068-2-78, DIN EN ISO 9227, PV 2005-A, PSA-10-AF, P PV 4015, P PV PTL 8140
we test the best.
www.atbayern.de
The servo-hydraulic testsystem with a total of The 90 kN shaker is fitted with a Headexpander
8 hydro-pulse cylinders operates with loads of up measuring 150 cm x 150 cm. The frequency range
to 40 kN and mximum strokes of 400 mm. goes from 5 Hz to ca. 2000 Hz. Maximum accelera-
tion is achieved at ca. 15 g. In addition, the control
Two electric stroke cylinders with loads of up to 20 system enables tests in multisinus mode. A climate
kN and maximum strokes of up to 350 mm can also chamber of 15 m3 may be positioned over the sup-
be operated in connection with a climate chamber port plates.
of 1,5 m3. Tests with lower loads may be run by
using various pneumatic stroke cylinders.
The area environmental simulation disposes of 14
climate chambers with sizes ranging from 240 Author
litres to 30 m3, the latter being accessible by Peter Rüpplein
vehicles. Temperature ranges lie between -70 °C
and 180 °C, the relative humidity can be program- Executive Director
med continuously between 10 % and 97 %. Automobiltechnikum
Bayern GmbH
The two heating furnaces with a volume of up to
720 litres allow tests up to 300 °C. The salt spray E-Mail: pru@atbayern.de
fog chamber with a test volume of 2 m3 complies For further informations please
see our website
with all established test standards, also for conden-
www.atbayern.de
sation tests.
environmental simulation
electrodynamic shaker in action
The measuring laboratory contains a material fatigue testing
testing machine for tensile and pressure tests, measuring laboratory
several digital tracers by HBM with up to 8 measu- electrical engineering
ring channels per system, an infrared camera and a
digital light optical microscope with up to twohund-
redfold enlargement.
Furthermore, photogrammetric surveys are
offered, thereby using a system produced by AI-
CON.
Tensile and pressure tests: DIN EN ISO 13934-1, DIN EN ISO 527-1, DIN EN ISO 527-2, DIN EN ISO 527-3 Electrical engineering: LV 124 / VW 80000, LV 148
More standards: Audi VR 630.1, DAG A0010017499, VW PV 6732, VW TL 226, VW 50014, VW PV 1303, DIN 75 220, DIN 60068-2-5, EP 84.300.19, PR
080.3Ford DVM-0004-RG, Ford DVM-0035-ST, RSA D 171058, Volvo 1579605, Opel TM 422000
The New Audi
A1 Sportback –
ideal companion
for an urban lifestyle
In 2010, a brand-new Audi model line made its debut in the shape of the A1. And now the second
generation of the compact success model is rolling to the starting line. Its dynamic design charac-
terizes the new Audi A1 Sportback. It is the ideal companion in the urban environment and is also
very well-suited for longer journeys. With its full-size-worthy infotainment and driver assistance
systems, the A1 Sportback is firmly networked with the digital world. New trim lines provide
ample opportunity for customization.
Exterior design: Striking,
masculine with genes of the
sporty Ur-quattro
The A1 Sportback has grown sig-
nificantly in length—with an addi-
tional 56 millimeters (2.2 in), it
now measures 4.03 meters (13.2 ft).
At the same time, the width has
remained almost the same at 1.74
meters (5.7 ft). The new-genera-
tion model is only 1.41 meters
(4.6 ft) tall —including antenna, Audi A1 Sportback
the car is 1.43 meters (4.7 ft) tall.
The wide track and short over- flanks, from the window edge to The distinctive daytime running light
hangs provide for a taut, sporty the sill, slope upward toward the graphics of the optional full-LED
look. The wide, low-placed Single- rear in a wedge shape. The lights echo the dynamic wing shapes
frame grille and the implied side distinctively highlighted wheels from sailing, known as hydrofoils.
air inlets dominate the distinctive and the low shoulder line in be- The design of the trims for the main
front. Below the edge of the hood tween give the A1 Sportback a light functions also draws inspiration
are three flat slits – an homage to solid stance on the road. The low from sailing. The wing segments on
Audi A1 Sportback
the Sport quattro, the brand‘s ral- line between the fender edges the flanks create an impression of
ly icon from 1984. draws the visual focal point maximum width. A low-set, concen-
The new A1 Sportback also downward even further. trated look in conjunction with the
emphasizes a resemblance to the With S line equipment, Audi has small rhombus segments in the top
Audi Ur-quattro and Sport emphasized the sporty character section of the headlights provides a
quattro when viewed from the even more through numerous fea- sporty appearance.
side: The wide, flat sloping C- tures. These include larger air The dynamic segmentation motif
pillar seems to push the car for- inlets, additional sill trims, three flat also features in the rear lights to
ward even while standing still. slits located centrally beneath the reinforce the instant recogniza-
The roof contrast line, which is hood – the middle slit is larger than bility of the A1 light graphics. It is
available in two dark colors, ends the two outer ones. The larger rear encased in the striking 3D geom-
above the C-pillar. This gives the wing rounds off the sporty overall etry of the lens. The seamless
impression that the roof is flatter package. The top-of-the-line en- light pattern of the graphics in the
and the complete car is even gine is also recognizable with its dark constitutes a remarkable feature
lower-slung. All lines on the stricking twin tailpipes. of the two-part rear lights.
Audi A1 Sportback
taking into account the entire traf-
fic situation.
Additional highlights are the satellite
map view and the new 3D city
models, which offer a precise map
view of many urban centers. Up to
four map updates per year are auto-
matically downloaded and installed
free of charge – in addition, the
customer can also use the versatile
online services from Audi connect.
The Audi smartphone interface
ensures you are always well
connected on board the new A1
Sportback. It integrates iOS and
Audi A1 Sportback – Interior Android smartphones using Apple
CarPlay and Android Auto into
More space and comfort: the full-size class. The MMI an environment in the MMI pro-
the space concept radio comes as standard – it can be grammed specifically for them and
The new A1 Sportback is much operated via the multifunction offers two USB interfaces (1x
more spacious—making life much buttons on the steering wheel and USB-A, 1x USB-C with increa-
more comfortable for the driver, the display in the fully digital sed charging current). Another
front passenger and rear passen- instrument cluster. In the top option, the Audi phone box, in
gers. Despite the compact exterior configuration, MMI navigation this way ensures improved recep-
dimensions and the sporty roof line plus offers a 10.1-inch MMI tion quality with LTE support and
adults in the rear seats still enjoy touchscreen, which blends seam- charges the smartphone induc-
plenty of head and leg room. lessly into the black glass look tively via wireless charging
Luggage capacity has increased by area. As with a smartphone, all according to the Qi standard.
65 l (2.3 cu ft): Normal capacity is commands are via touch input. Music and acoustics aficionados
335 liters (11.8 cu ft); with the rear The latest generation of voice will be pleased to find a Digital
seats folded down, this increases to control further improves the dia- Audio Broadcasting tuner, the
1,090 liters (38.5 cu ft). Loading sill logue between driver and car. Audi sound system and the Bang &
height is a comfortably low 67 cen- In conjunction with Audi connect, Olufsen Premium Sound System.
timeters (2.2 ft). MMI navigation plus offers A1 The B&O system drives eleven
Sportback drivers functions such speakers with an output of 560
Fully digital: as hybrid route guidance – this watts. Its 3D effect uses the wind-
operation and display calculates the route in the cloud, shield as a reflecting surface.
The new Audi A1 Sportback is fit
for the digital future. Even the basic
version comes standard with an all-
digital instrument cluster with a
high-resolution, 10.25-inch display
and a multifunction steering wheel.
The optional Audi virtual cockpit
with an extended range of func-
tions presents comprehensive and
diverse information such as animat-
ed navigation maps and graphics of
some driver assistance systems in
the driver‘s direct field of vision.
Fully connected and always
up to date: Infotainment and
Audi connect
The Infotainment concept in the
Audi A1 Sportback – Dashboard
new A1 Sportback comes from
Audi A1 Sportback
form the backbone of the passen-
ger cell. The rigid body and exact
fits ensure sporty, precise driving
and prevent intrusive noise on
board. With a front area of 2.07
sq m (22.3 sq ft) and a drag coeffi-
cient of 0.31, the new A1 Sport-
back offers very little windage.
Plenty of scope for
customization
The new A1 Sportback is availa-
ble in a choice of ten colors. The
roof of the small compact model
can be optionally finished in a
contrasting color from the A-pil-
lar to the roof edge spoiler. The
Audi A1 Sportback – Sensors areas for environment observation exterior mirror housings, the side
front spoiler lips and the side sills
Safety first: the driver lights are switched on. The adapti- are also available in a contrasting
assistance systems ve cruise control also is radar-based. color.
The driver assistance systems for It keeps the Audi A1 Sportback at The “edition one” model, based
the Audi A1 Sportback also come the desired distance from the vehicle on the S line equipment line and
from the full-size class. They ahead. If the vehicle is equipped available from market launch, is
keep the small compact car at the with S tronic, the system covers a particularly distinctive. It impres-
right distance from the car ahead, speed range of 0 to 200 km/h (0 to sively showcases the design lan-
making it easier for drivers to 124.3 mph); with the manual trans- guage of the A1 with numerous
maintain the lane and help them mission, the range begins at 30 km/h contrasts. Large 18-inch wheels –
with parking. (18.6 mph). In stop-and-go traffic, in bronze, white or black depend-
The standard lane departure warning the A1 Sportback with S tronic ing on the exterior finish – set
helps the driver to keep the car in the transmission brakes to a standstill powerful accents. The Audi rings
lane from a speed of 65 km/h (40.4 and gets going again under certain in film on the side of the car are
mph). Also standard is the speed conditions automatically. also available in the rim color.
limiter, which reliably prevents the The new Audi A1 Sportback offers Borrowing from the legendary
A1 Sportback from exceeding a se- various systems to make parking Audi Sport quattro, the LED
lected maximum speed. easier. For the first time there is a headlights and LED rear lights are
Another standard feature is Audi reversing camera in addition to the dark-tinted. The Audi rings in the
pre sense front. The radar sensor parking system, rear. The front Singleframe and the model des-
recognizes critical situations ultrasonic sensors of the parking ignation at the rear are in black.
involving other vehicles, crossing system plus recognize objects in
pedestrians or cyclists ahead of front of the car and emit acoustic Freely combinable:
the vehicle, even when visibility is and visual warnings. The park assist the equipment lines
poor such as in fog. The system steers the A1 Sportback length- A new feature in the A1 Sport-
then gives an acoustic and visual ways and sideways into parking back is the modular lines structu-
signal to warn the driver. At the spaces. With the new version of re. This provides for a particularly
same time it prepares for a possi- the assistant, the A1 Sportback also high degree of flexibility. For the
ble full brake application and, if parks forward into perpendicular first time, customers can combine
necessary, initiates automatic parking spaces, maneuvering multi- exterior and interior lines how-
emergency braking in order to ple times if necessary. The system ever they like.
prevent an imminent collision or also exits parallel parking spaces. Depending on the equipment line-
reduce its impact. If necessary, the basic, advanced or S line – the
protective measures of the option- Light and particularly robust: attachments on the exterior are
al Audi pre sense basic are initiat- the body available in various configurations.
ed. The front seat belts are elec- The body of the new Audi A1 The black styling package sets
trically tensioned, the windows Sportback includes components additional accents. By offering the
are closed and the hazard warning made out of hot-formed steel that lines “Interior advanced,” “Interi-
Audi A1 Sportback
Sporty, poised tuning:
the suspension
The axle design of the new Audi
A1 Sportback delivers agile han-
dling and a sporty, poised driving
experience. The front suspension
is a McPherson construction; A
compact, lightweight torsion
beam axle is used at the rear. Be-
sides the basic suspension, there is
an option for a tauter sport sus-
pension.
Audi A1 Sportback – Cockpit Dynamic packages, individually
configured for every engine ver-
or design selection” and “Interior are standard. Audi offers four dif- sion, bundle equipment options to
S line,” Audi is additionally afford- ferent engines for the A1 Sport- give the A1 Sportback an even
ing customers numerous possibi- back. As a three-cylinder engine sportier trim. The “Basis” dy-
lities to select colors and materials with 1.0 l of engine displacement, namic package for the 25 TFSI
accordingly. there is the 25 TFSI (combined includes a sport suspension, red
fuel consumption in l/100 km: 4.7- brake calipers and larger brake
New look: the interior design 4.6 ) (50.0–51.1 US mpg); combin- discs. Audi offers the “Perfor-
“The sportiest interior in the ed CO2 emissions in g/km: mance” dynamic package for the other
compact class,” that was the stated 106–104*) (170.6–167.4 g/mi)) with engine versions. This also in-
aim of the design. The interior is 70 kW (95 metric horsepower) cludes red brake calipers and lar-
accordingly driver-focused, with and the 30 TFSI (combined fuel ger brake discs as well as a suspen-
its emotive, customizable design. consumption in l/100 km: 4.9- sion with adjustable dampers, a
The eye is drawn in particular to 4.8*) (48-49 US mpg); combined sound actuator and Audi drive select.
the sporty compact unit of air vent CO2 emissions in g/km: 111- The brakes of the new A1 Sport-
nozzles, hood and the digital 108*) (178.6-173.8 g/mi)) with 85 back can be precisely metered and
instrument cluster. All of the con- kW (116 metric horsepower) of provide a responsive, taut pedal
trols and the optional MMI touch power. The A1 Sportback 35 feel. The optional hold assist
display are strongly driver-orient- TFSI (combined fuel consump- enhances safety on uphill and
ed, thus emphasizing the distinc- tion in l/100 km: 5.1–5.0*) (46.1- downhill slopes by preventing the
tive cockpit character. 47.0 US mpg); combined CO2 car from rolling after stopping.
The display and the air vent strip on emissions in g/km: 116-115*) Wheels are available in sizes from
the front passenger side are integra- (186.7–185.1 g/mi)) is a 1.5-liter 15 to 18 inches.
ted into an area in black glass look. four-cylinder that boasts 110 kW
The optional contour and ambient (150 metric horsepower) and the Four modes for an individual
lighting package brings the interior cylinder on demand efficiency driving sensation:
design to life in the dark, if desired, system. Audi drive select
through LED light elements in 30 The 40 TFSI (combined fuel The new A1 Sportback rolls off the
selectable colors. consumption in l/100 km: 6.0*) production line with the Audi drive
(39.2 US mpg); combined CO2 select dynamic handling system as an
Powerful and efficient: emissions in g/km: 137–136*) option. With it, drivers can select
the engines (220.5–218.9 g/mi))– also a four- from four modes that influence the
Whether running around town or cylinder – is the Audi A1‘s most driving characteristics: Auto, dyna-
going on a weekend excursion – powerful engine with 147 kW mic, efficiency and individual.
its powerful engines in particular (200 metric horsepower) and 320 Fuel consumption and CO2 emission figures given
in ranges depend on the tires/weels used.
make driving the new Audi A1 Nm (236.0 lb-ft).
Sportback so much fun. Audi is making a manual transmis- Contact:
There is a choice of efficient sion or the S tronic dual-clutch
Tobias Söllner
TFSI engines with outputs rang- transmission available depending I/GP-P3
ing from 70 kW (95 metric horse- on the engine. The four-cylinder
D-85045 Ingolstadt
power) to 147 kW (200 metric variants, which are equipped with Phone: +49 841 89-36188
horsepower). Turbocharging, di- the S tronic as standard, are an tobias.soellner@audi.de
www.audi.com
rect injection and a particle filter exception to this.Ready
for the
next level
From specialist for power seat structures to system supplier of dynamic interiors:
In preparation for the next stages of autonomous driving, automotive supplier
Brose is expanding its expertise in interiors. The family-owned company is doing
this in part through joint ventures and research partnerships.The combination of
Brose expertise in the fields of vehicle interiors and vehicle access offers special
added value for customers.
With the push of a button, autopilot Brose already presented this vision Since then the automotive sup-
takes over control of the car and the of a dynamic interior at the Interna- plier has continued to push for-
steering wheel disappears into the tional Motor Show (IAA) in 2017 as ward with its strategy to become
dashboard. Now the vehicle user the mechatronics specialist‘s answer the preferred development part-
can decide how he or she wants to to one of the most interesting ques- ner of OEMs for innovative
enjoy the ride. The vehicle interior tions right now in the industry: vehicle interiors.
is flexible: seats, screens and con- How will users’ demands on the
soles slide and adapt to the desired interior change when cars begin New adjustment systems
use. Various modes for working, driving themselves? The future- for the interior
relaxing, entertaining and for enter- oriented “Brose Interior Experi- The most obvious step is to
ing and exiting the car offer maxi- ence” exhibit generated great expand the adjustment possibili-
mum comfort and flexibility. interest from car manufacturers. ties of seats: concealed guide rails
Dynamic Interior
The interior of the future adapts to changing driving situations. New kinematics and additional adjustments allow maximum
flexibility.Dynamic Interior
Innovative sensors Another partnership is focused
The family-owned company‘s on the development and supply
expertise in electronics will play of completely upholstered ve-
a key role in dynamic interiors: hicle seats through the joint ven-
dozens of adjustment systems ture Brose AUNDE Fahrzeug-
need to be linked and securely sitze.
coordinated. Cooperation partner AUNDE
Thanks to its more than 30 years provides its know-how in foam,
of experience in the field of elec- upholstery and trim. The collab-
tronics, where it has around 600 oration is an opportunity for both
employees and supplies over 75 companies to grow and develop
million electronic systems and technological innovations – like
sensors annually, Brose can also seat foams with integrated massage
From 2020, Brose will manufacture struc- take advantage of its expertise as systems, new kinds of luxury
tures for moving center consoles. a world market leader in mecha- headrests or 3D printed seat
tronic systems for doors and lift- covers. This leads to entirely
for length adjustment, fold-out leg gates. new seat concepts.
rests and retractable control ele- And to meet the special safety
ments in the armrest allow for new requirements for flexible interi- Focus on cross-system
adjustment scenarios from a four- ors, the supplier is partnering customer experience
person meeting to a comfortable with sensor specialist Vayyar, The vehicle user is always at the
reclining or working position. which makes the 3D radar image center of all further develop-
Brose will also expand its compe- sensors that Brose embeds in the ments.
tence in mechatronics to the entire electronics environment. In addi- Brose brings together expertise in
vehicle interior – including the tion to anti-trap protection, pre- seat, door, drive and electronic
center console, which will be very cise interior monitoring adds systems to offer end customers a
flexible in the future. It will divide, functions such as anti-theft pro- unique experience. An example
swivel, slide forward and backward, tection and gesture control. It is of this is vehicle access, which will
convert into a table or integrate an also able to detect if children be more comfortable and con-
adjustable screen. The company have been left in the vehicle, venient than ever before when
has already received the first order which could become a legal re- the vehicle is able to recognize
in this new field: from 2020 Brose quirement in the very near futu- the user, open the door and move
will supply the structure for a re. Also, this eliminates previously the seat into a “welcome” position
moving center console to a carmaker needed components such as seat automatically for easy entry. Brose
in North America. The supplier is occupancy mats. Customers like supplies OEMs with the neces-
also responsible for the motor this approach: several companies sary technologies – perfectly
development and the electronic have already equipped test vehic- coordinated and from a single
anti-trap protection. les with the sensors. source.
Author:
Sandro Scharlibbe
Executive Vice
President Seat
Brose Group
Brose Fahrzeugteile GmbH & Co. KG, Coburg
Max-Brose-Str. 1
D-96450 Coburg
Phone: 09561/21-0
The interior sensors from Brose and Vayyar provide reliable collision protection for info@brose.com
flexible interiors and other applications such as airbag control or theft protection. www.brose.comHolistic Quality Assurance
System for Highly Flexible
Production Systems in the Body
Shop of the Future
Innovative Sensor Technology and Data Evalua-
tion Using Artificial Intelligence as an Enabler
for Highly Flexible Joining Technologies
Requirements for ants, ever shorter product life change therefore generally require
(automotive) production cycles and an increasingly volatile a great deal of effort. Due to the
systems of the future sales market pose major challeng- constant increase in complexity
The increasing variety of models es for conventional production and increasing volatility, the
and variants with which automo- structures. [1] flexibilization of production sys-
bile manufacturers meet the Today’s production systems in tems is gaining strategic impor-
increasing demand for customer- body construction are rigidly tance. Resistance spot welding is
specific products requires pro- interlinked and model-specific. currently used to a large extent as
duction technologies that allow a Particularly in the field of joining one of the central technologies in
flexible production of body vari- technology, vehicle-specific clamp- body construction. Together with
ants within an economic frame- ing fixtures are used which allow the typically used fixture-based
work. In addition to the increas- only very little geometry flexibi- clamping technology for posi-
ing complexity caused by the lity. Changes to the body struc- tioning the components, this
growing number of vehicle vari- ture during a model or variant method offers only very limited
TU München
Fig. 1: Functional demonstrator within the research project RoKtoLas for the realization of a highly flexible system based on remote
laser beam welding (left) as well as a schematic sketch of short coherence interferometry (right)TU München
flexibility - both with regard to
geometric changes to the body
structure and with regard to
changes to the production pro-
cess.
Technological leap in auto-
motive body construction
Fig. 2: Process zones in laser beam welding
At the Institute for Machine
Tools and Industrial Manage- allow only an indirect assessment number of quality criteria for the
ment (iwb) of the Technical Uni- of the highly dynamic processes weld seam can be derived without
versity of Munich, together with during welding and the resulting further test steps using suitable
partners from industry, research seam properties or require very evaluation algorithms.
is being carried out to increase complex subsequent test steps. A
the flexibility of car body con- system based on Optical Coher-
struction. The focus of the ence Tomography (OCT) allows Artificial Intelligence
for real-time data
approach is the partial substitu- for the first time a direct observa- evaluation and
tion of resistance spot welding by tion of the interaction phenome- process control
remote laser beam welding, na in the process zone by record- Although the measuring principle
which is particularly suitable for ing geometrical information. The allows a high-precision distance
the realization of adaptive and interferometric principle enables measurement with an accuracy of
networked production systems distance measurements with high a few micrometers and a temporal
due to its highly dynamic and temporal and spatial resolution, resolution in the order of 100
flexible process control. The which are largely independent of kilohertz, a major challenge is to
concept of a highly flexible pro- electromagnetic process emissi- evaluate the recorded data in a
duction cell using remote laser ons and metal vapor or plasma
beam welding and the functional generated during welding. By a
principle of the optical sensor suitable deflection of the measu-
unit are shown in Figure 1. With ring beam, topographic scans of
regard to the numerous effects of the process zone and the sur-
this technology substitution – rounding areas (see Figure 2) can
from vehicle design through the be recorded in real time during
entire production chain of body- welding.
in-white to subsequent produc- The topographic recordings can
tion steps – a unique consortium be used for process observation,
Fig. 3: OCT-based edge tracking and
of sensor developers, system process control and quality assur- topographic measurements for quality
developers and automotive ance: The exact position of the assurance (according to [2])
OEMs has come together. With- butt edge can be determined
in the framework of the publicly from the height measurements in suitable way to be able to use the
funded RoKtoLas research pro- the pre-process zone, in order to inline measured welding depth
ject, a comprehensive plant and compensate for any component signal for process control. The
production concept based on the or path tolerances (see Figure 3). characteristics of a typical welding
novel optical sensor unit is being In the process zone, the depth of depth signal are shown in Figure 4.
researched and the industrial the vapor capillary can be mea- The challenge is the correct and
feasibility of this approach is sured as a decisive influencing universal interpretation of the sig-
being demonstrated. factor on the resulting mechanical nal structure under the require-
properties of the weld seam. In ment of a real-time capability.
Universal sensor concept for the post-processing zone, topo- Investigations of the signal char-
holistic quality assurance graphic scans allow an exact acteristics showed that the scat-
For a large-area industrial use of reconstruction of the weld surface tering in the welding depth does
remote laser beam welding, a for quality assurance purposes. not only follow stochastic fluctua-
comprehensive assurance of the In addition to geometric informa- tions of the vapor capillary, but is
quality of each weld seam is a tion about the vapor capillary, caused by characteristic process
mandatory prerequisite for many which is one of the central influ- phenomena and can be reliably
applications. Conventional quality encing factors with regard to the correlated with them. Conven-
assurance systems, however, either resulting weld properties, a large tional approaches to signal proces-TU München
within the process zone. Rather,
suitable training algorithms can
be used to automatically recognize
dependencies and interactions
and make them usable for future
applications. Modern approaches in
data evaluation thus enable
flexible and universally applicable
systems that can guarantee a valid
evaluation of the highly dynamic
and complex processes in laser
beam welding independent of the
application and without prior
design attempts.
Fig. 4: Determination of the welding depth (blue) during laser beam welding based on
the OCT signal and Machine Learning methods Remote laser beam welding
for the body construction
sing and analysis can only approxi- beam welding. If, for example, of the future
mate the welding depth in a very the material of the joining part- A reliable method for process
limited range with the given data ners changes or other process monitoring is the basis for a
structure, for which detailed parameters are applied, new com- robust process control and a valid
investigations must be carried out prehensive investigations are quality assurance in laser beam
in advance. For deviating process usually necessary to gain a suffi- welding. Optical Coherence
states, the signal characteristics cient understanding of the pro- Tomography in combination with
can change considerably and cess (e.g. to evaluate the influence suitable methods of Machine
require a correspondingly adapted of the radiation characteristic, see Learning allows a very robust and
evaluation. Also, effects whose Figure 5). In contrast, data evalua- direct observation of the process.
influence on the fluctuations in tion using Machine Learning Compared to conventional ap-
the welding depth signal cannot does not require a fundamental proaches for quality assurance in
be quantified by simple statistical understanding of the physical laser material processing, the
parameters cannot be reliably interactions and phenomena direct measurement of the pro-
detected. An alternative approach
is the use of Machine Learning
methods. Without being able to
quantify the underlying signal
patterns, artificial neural net-
works, for example, are able to
reliably find correlations between
signal characteristics and process
effects.
Machine Learning as
enabler for highly flexible
production systems
The highly dynamic processes in
laser beam welding require a high
level of understanding of the
exact processes to be able to vali-
date the corresponding process
data. An exact study of the pro-
cesses, however, is usually limited
to the individual application and
can only be transferred to a very
limited extent due to the com-
plex measures for a comprehen- Fig. 5: Influence of the radiation characteristic on the weld penetration depth measurement
(left: multimode laser radiation, right: singlemode laser radiation (according to [3])
sive process observation in laserTU München
cess zone greatly reduces inter- Acknowledgements Authors:
pretation errors. The extensive The results presented were
generation of process data also achieved within the RoKtoLas Christian Stadter
allows the evaluation of a large project, which is supported by the Research Field
Intelligent Joining
number of quality criteria based German Federal Ministry of Edu- System Technology
on the data recorded inline. cation and Research (BMBF) with- christian.stadter
This makes it possible to obtain a in the Photonics Research Ger- @iwb.mw.tum.de
+49 89 289 15560
valid statement immediately after many funding program (contract
the welding process regarding the number 13N14555) and super-
compliance with process limits. vised by the VDI Technology
The universality of the sensor Center (VDI TZ). We would like
concept allows a continuous and to thank the BMBF and the VDI Maximilian
comprehensive process data re- TZ for their support and for the Schmöller
cording and thus a complete effective and trusting cooperation. Research Field Laser
Manufacturing
traceability throughout the pro- Technology
cess chain. In addition to the Literatur maximilian.
schmoeller@iwb.
evaluation of the process stability [1] Erler, F.: Downstream-Risiken in mw.tum.de
and the resulting weld seam der automobilen Wertschöpfungskette: +49 89 289 15492
properties, the creation of a Instrument zur Risikobewältigung in
knowledge base enables a process der Kundenbeziehung von Automobil-
zulieferern. Dissertation. Technische
qualification for many applica- Prof. Dr.-Ing.
Universität Chemnitz (2015).
tions for which extensive investi- Michael F. Zäh
Head of Institute
gations are still required today. By [2] Stadter, C.; Schmoeller, M.; Zeitler, michael.zaeh@iwb.
qualifying the highly flexible pro- M.; Tueretkan, V.; Munzert, U.; Zaeh, mw.tum.de
cess for the use in body construc- M. F.: Process Control and Quality +49 89 289 15502
Assurance in Remote Laser Beam
tion, highly adaptive systems are
Welding by Optical Coherence Tomo-
possible. Within the framework graphy. In: ICALEO Conference Pro-
of the project, a concept for the ceedings (2018).
realization of intelligent joining Technical University of Munich
system technology in the sense of [3] Schmoeller, M.; Stadter, C.; Liebl, Department of
a fully digitalized production will S.; Zaeh, M. F.: Inline Weld Depth Mechanical Engineering
Measurement for High Brilliance Laser Institute for Machine Tools and
be demonstrated and validated on
Beam Sources Using Optical Coheren- Industrial Management (iwb)
the basis of serial component ce Tomography. In: ICALEO Confer- www.iwb.mw.tum.de/en/roktolas
assemblies. ence Proceedings (2018).The truck
of the
future
"Truck2030": Technical University of Munich
presents concept for efficient cargo transport
Trucks will remain essential to cargo transport in the upcoming decades. Scientists
at the Technical University of Munich (TUM) and their partners have developed a
concept for the truck of the future, including Europe-wide approval for the use of
LHV trucks (Longer Heavier Vehicles), diesel hybrid drives and a multifunctional
driver's cab.
According to a forecast by the
German Federal Ministry of
Transport and Digital Infrastruc-
ture, by 2030 the volume of truck
cargo transport will have risen by
39 percent compared to 2010.
This means efficient and environ-
mentally friendly transport con-
cepts are of continuing impor-
tance when it comes to reducing
road traffic and emissions such as
carbon dioxide, soot particles and
nitrogen oxides.
The truck of the future
In the project „Truck2030“ scien-
tists at TUM investigated all aspects An illustration of the truck of the future. (Image: Chair of Industrial Design / TUM)
of the truck of the future. Here
are the most important results in cise, already familiar from the Apps that record cargo informa-
the areas of People, Transport and health club. A game-oriented tion using scan codes or NFC
Logistics, Environment and Po- aspect will be added in order to could save time and resources
litics: increase motivation, for example during loading and unloading.
based on a virtual reward system.
People Environment
The researchers’ concept is based Transport and logistics The use of LHV trucks alone
on the assumption that the truck Long trucks with a length of 25.25 could cut CO2 emissions by 20
of the future will drive on the meters are ideal for efficient cargo percent due to lower fuel con-
highway automatically. Drivers transport. Here two LHV trucks sumption with the same cargo
would then be able to invest the can replace three normal-length loads.
time saved in their own health. trucks. This makes it possible to Using diesel plug-in hybrid drives
The driver’s cabin presented by save fuel, resulting in benefits to could reduce CO2 emissions by
the team is equipped among the environment and the economy. another 10 percent, the best solu-
other things with cables and pul- And the total number of trucks on tion from both the environmental
leys which can be used for exer- the road will also be reduced. and economic points of view. BasedThe truck of the future
on the current state of the art, a
solely electric drive train would not
be feasible, since a battery capable
of providing sufficient energy for
the necessary range would be too
large and too heavy.
Tires with optimized road resist-
ance and improved truck aero-
dynamics could reduce CO2
emissions by 10 percent.
Politics
The most important prerequisite
for realization of the concept is
the approval of the use of LHV
trucks in all of Europe. In their
investigations the scientists suc-
cessfully refuted counterargu-
ments such as lower driving safety
and increased road wear.
Another important point is infra-
structure: Use of the diesel plug-
in hybrid will require additional
charging stations on highways.
Electric cars will also be able to
use these charging stations.
The team is building a model of the driver's cabin.
More information (Image: A. Heddergott / TUM)
Truck2030 is a Technical Univer-
sity of Munich (TUM) research partners. The project receives tive Technology, the Chair of
project, conducted in collabora- support from the Bavarian Re- Internal Combustion Engines and
tion with the OTH Regensburg search Foundation. The Technical the Chair of Industrial Design.
(Ostbayerische Technische Hoch- University of Munich units partici- https://www.truck2030.tum.de/
schule) as well as five industry pating are the Chair of Automo- home/
High resolution images
mediatum.ub.tum.de/1453998
Contact:
Christian Mährle
Chair for Internal Combustion
Engines
Phone +49 89 289 16344
maehrle@lvk.mw.tum.de
Sebastian Wolff
Chair for Automotive Technology
Phone +49 89 289 15881
wolff@ftm.mw.tum.de
Simon Rauchbart
Chair of Industrial Design
Phone +49 89 289 28674
The driver‘s cabin is equipped with cables and pulleys which can be used for exercise.
simon.rauchbart@tum.de
(Image: Chair of Industrial Design / TUM)On the road
to a clean
combustion engine
OME: Researchers test synthetic fuel
Emissions-free combustion engine cars — synthetic fuels like oxymethylene
ether are bringing the idea into the realm of the conceivable. Researchers at the
Technical University of Munich (TUM) have tested how this kind of fuel behaves
in engines and have developed an optimized combustion process.
They generate carbon dioxide,
particulate matter and nitrogen
oxides: combustion engines are in
the cross-hairs of public opinion
and many inner cities have already
imposed driving bans for certain
kinds of diesel-powered vehicles.
But synthetic fuels like the group
of oxymethylene ethers (OMEs)
might hold the answer. They burn
virtually free of undesirable by-
products such as soot and hydro-
carbons, and thus provide an addi-
tional air-quality benefit over
other long-standing designer
fuels. However, they also have
disadvantages: production costs
are higher than those of fossil
fuels and there are no production Dominik Pélerin at the full-engine testbed. (Image: Moritz Ermert / TUM)
facilities available yet.
The XME Diesel project, funded From one cylinder adapted the injectors accordingly.
by the German Federal Ministry to a full-scale engine Furthermore, since the synthetic
Synthetic fuel
of Economics, aims to promote First, the researchers did com- fuel does not produce soot, large
the use of OMEs. Scientists from puter simulations and experiments amounts of exhaust gas can be
TUM's Chair of Internal Com- on a single-cylinder engine test- recirculated into the engine with-
bustion Engines are also in- bed. They determined the opti- out contaminating the intake.
volved in the project. They inve- mal parameters for efficient com- This approach inhibits the forma-
stigated the behavior of OMEs in bustion. For example, the synthet- tion of nitrogen oxides because
engines, the adjustments required ic fuel has a lower calorific value the recirculated exhaust gas pre-
to improve combustion efficiency than diesel, which means more vents very high temperatures
and the degree to which harmful fuel must be injected into the during combustion.
emissions can be reduced in com- engine to achieve the same per- Next, the scientists tested the
parison to fossil fuels. formance. The scientists thus parameters on a full-engine test-Synthetic fuel
drives, explains Härtl. Examples
include long haul trucks, energy
provision in remote areas and the
aviation and shipping sectors.
More information:
The tests were carried out as part
of the project „XME Diesel –
(Bio) Methyl Ethers as Alternati-
ve Fuels in Bivalent Diesel En-
gines,“ funded by the German
Federal Ministry of Economic
Affairs and Energy.
Further research in the field of
OMEs at the Institute of Internal
Combustion Engines is part of
Full-engine testbed in the engine laboratory of TUM's Chair of Internal Combustion the project „OME – Environ-
Engines in Munich-Moosach. (Image: Mortiz Ermert / TUM)
mentally Friendly Diesel Fuel
bed comprising a six-cylinder fuel. We are also convinced that Additives“ (funded by the Agen-
production engine that was adapt- high-performance exhaust after- cy for Renewable Resources with
ed specifically to run on syn- treatment can even reduce emissi- funds of the German Federal
thetic fuel. The tests on the full ons to almost zero.“ OME made Ministry of Food and Agricultu-
engine confirmed the previous from waste CO2 – carbon dioxide re) and the project „Sub-Zero-
results. generated in processes in the steel Emissions Diesel Engine“ (fun-
and cement industries, for exam- ded by the Bavarian Research
Emissions can be ple, or in coal and gas-fired plants – Foundation).
reduced to zero and electricity from renewable
„We determined that using this sources, would even be carbon Contact:
fuel can significantly reduce pol- neutral.
lutant emissions,“ explains Dr. Particularly interesting is the use Technical University of Munich
Institute of Internal Combustion
Martin Härtl, who coordinates the of OME in vehicles and systems Engines
project. „The Euro 6 level, the in which internal combustion
currently applicable limit, is easily engines cannot be readily replac- Phone: +49 89 289 24110
haertl(at)lvk.mw.tum.de
met when using the synthetic ed by battery-powered electricShaping Mobility
By Leveraging
the Transfer Potential
of Aerospace and Automotive!
At first glance, the modern aerospace industry would seem to have little in common with the auto-
motive sector. However, metrics like development cycle time, number of employees, sales and price per
aircraft/vehicle reveal major differences in some cases. Yet both industries are characterized by highly
sophisticated technologies and increasingly interconnected embedded systems. At the same time, the
two are increasingly converging as part of a trend toward multi-dimensionality in mobility – the
mobility of the future.
Definite synergy processes and the transferability of ment are comparable in the two
and transfer potential basic technology approaches and industries. These common fea-
A more holistic approach to solutions. tures thus certainly do allow find-
mobility is needed in order to As such, the main common de- ing promising leverage points for
meet the challenges arising in our nominator can be found in the area the automotive industry.
increasingly networked and glob- of approaches to problem solving The increasing importance of
alized world. It is thus key to – in other words, engineering. software in vehicles calls for a
identify the synergy and transfer The following are examples of software development process
potential latent in the aerospace this: At its core, ‚functional safety‘ that is efficient and robust in
and automotive sectors to be able is about how to create a function- equal measure. An increasing
to leverage these in targeted fash- ally reliable product that meets number of functions now need to
ion for mobility overall. the given requirements. And be realized by an increasing num-
Both industries deal with means ensuring functional safety is ber of players to increasingly
of transport that to some extent essentially an overarching process tight deadlines, while an increas-
involve extremely complex inter- not specific to either field. Re- ingly confusing set of parameters
functionalities. Realized as em- quirements management is simi- must also be taken into account.
bedded systems involving elec- lar in both, for which the same This makes the processes and
tronics and software, these func- standard tool can be employed. methods involved incredibly
tionalities must meet incredibly The basic solutions used are trans- complex; a factor that can only be
high demands for real-time appli- ferable, even for system architec- overcome by seamlessly inter-
Shaping Mobility
cations. Their respective integra- ture, which is more technical in twining the development steps in
tion into complex traffic control nature. the networks of vehicle manufac-
systems is also comparable. And turers, suppliers and service pro-
from an engineering perspective, Transfer processes done right viders and clearly defining the
the domain structures in the Transfer is not a simple matter division of roles in a way that is
bodywork & cockpit, drive and due to a number of fundamental transparent to all those involved.
platform control systems are large- differences between the automo- An important step toward achiev-
ly similar as well. tive and aerospace industries, such ing this is the standardization of
Of course, the specific functional as development time, innovation interfaces.
requirements – and thus the even- speed, production quantities, The aerospace industry has long
tual solutions derived – are usually costs and product service life. been aware of the great advant-
fundamentally different. There is However, the process steps in ages of standardizing non-differ-
great overlap however regarding electronics and software develop- entiated technical solutions, andShaping Mobility
and the hallmark of this change.
The highly sophisticated, top-
down architecture development
process employed in the aerospace
industry serves as an exemplary
model for this. The core elements
in this process are standardization,
interface uniformity and abstract-
ing upward from granular techno-
logical solutions. Key factor:
Safety and security can really only
be practicably realized on the
architecture side. The same
applies to system verification,
which also benefits from a strin-
gent architecture approach.
Attempting to do this at the sub-
system and component level is a
very hit-and-miss process, and
extremely time-consuming to
boot. Safety cannot be divided,
and must therefore be 'drafted' in
its entirety from the architecture.
has acted accordingly. Over such operational functions as With its focus on highly reliable
recent years, the digitization of steering, control and system relia- systems and safe functions, which
cars through the extensive use of bility, and administrator functions is born of years of experience, the
electronics and software has been like support for development, aerospace industry represents an
driven by a high innovation production and service processes). excellent role model for this.
speed, with the result that the A similar principle applies to the This can require great effort of
system complexity in a premium basic functions at the user level, course, but the benefits are real in
car with all the variants is now such as sensor and data fusion, terms of technology, functionali-
much higher than that of a system status detection, environ- ty, processes ... and profits, as we
modern commercial airplane, at mental awareness, centralized firmly believe!
least when based purely on the system coordination and maneu-
sheer amount of software and vering support and execution.
data involved. Standardization, as
seen in the aerospace industry, is
Top-down architecture
thus one way of removing part of development requires
the complexity from the develop- a holistic system concept
ment process, affording a model We have more or less undergone
to be emulated by the automotive a critical technological paradigm
industry! shift – away from traditional
mechanical engineering and
Author:
Technology transfer: added toward electronics, embedded
Jörg Ohlsen
value through experience systems and IT. However, drive
CEO
The technological foundations, as electrification, the ever-accelera- ESG MOBILITY
we have observed, are comparable ting growth in the use of software
(processors, programming lan- and the wealth of different new,
guages, sensors, actuators etc.). heavily networked assistance
However, like-for-like, outright systems – plus the elimination of
technology transfer is not fea- system boundaries due to the
sible, and cannot yield any break- advent of cyber-physical systems – ESG MOBILITY GmbH
throughs. Yet transferring experi- are all issues that demand new, Frankfurter Ring 211
ence does makes sense in prob- future-proof solutions. D-80807 München
Phone: +49 89 92161-0
lem-solving, with system and sup- A holistic system view in the mobility@esg.de
port functions for example, i.e. development process is the key toYou can also read
