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ISSN (Online) 2192-9076
WORLDWIDE
03 March 2021 | Volume 123
BODY
Composite Use of
CFRP, Steel and Aluminum
LIGHTER DOOR MODULES GREATER RANGES MORE SAFET Y
Made of Organic Sheet for of High-performance Vehicles in Autonomous Driving with an
Stricter Crash Requirements Due to Better Charging Power Evaluation by Maximum Entropy
/// INTERVIE W Seiichi Hirano [UACJ] /// GUEST COMMENTARY Marco Philippi [Audi]
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ISSN (Online) 2192-9076 ISSN (Online) 2524-8774 ISSN (Online) 2524-8804
heavyduty electronics
WORLDWIDE W O R L D W I D E W O R L D W I D E
09 September 2019 | Volume 121
01
March 2019 | Volume 12
ON- AND OFFHIGHWAY COMMERCIAL VEHICLES 07-08 July-August 2019 |
Volume 14
SEMICONDUCTORS
Failsafe Electronics
Will Pay off
AUTOMATED DRIVING CONSTRUCTION MACHINES AND VEHICLES
Driverless on the Road to the Future Electrification and Digitalization
ISSN (Online)
2192-9114
OBJECTIFICATION WHEEL BEARING DAMAGE ROAD ILLUMINATION POWERTRAIN INDUSTRIAL TRUCKS SIMULATION VEHICLE COMPUTERS 800-V TECHNOLOGY AUTONOMOUS DRIVING
of Assistance Systems during Car Transportation for Object Detection under Hybrid Drive Concept for Intelligent Passenger Assistant High Speed Components Require Fundamental Changes Offers Performance Benefits Places New Challenges
10
with Humans at the Center on a Truck Peripheral Vision Off-highway Applications for Counterbalanced Trucks for Hydraulic Power Supply in E/E Architectures While Increasing Demands on the Driver
October 2019
| Volume 80
/// INTERVIE W Jochen Tüting [Chery Europe] /// GUEST COMMENTARY Hans-Hermann Braess /// INTERVIE W Ronald Kruth [AVL] /// GUEST COMMENTARY Arndt Schumann [TriboPlast] /// INTERVIE W Frank Schütte [dSpace] /// GUEST COMMENTARY Peter Gresch [PGUB Management Consultants]
E L EC T RI C DRI
VES | H Y BRI D DRI V
ES | C O M BU S T I O N
ENGINES
SUPE RCHA
RGIN G
Turbochargers as
Ef ficiency Booste
SINTER ED MATER
Made of Iron
IALS
rs ROTAR Y SHAFT
for the Reduct SEALS
of Cobalt Consum ion
Specia lly Design FUEL ADDITI VES
ption ed for Use in
High-speed Electri for Biodiesel
c Motors to Increase
Oxidat ion Stabilit
/// INTERV IEW y
Victor Olivera
s Merida and
Mark Hoffma
nn [Audi]
/// GUEST COMME
NTARY Frank Atzler
[TU Dresden]
WATCH OUR VIDEO AND GET TO LEARN MORE:
www.atz-magazine.com/automotive-package
OEMs Suppliers Service Universities
providers
EDITORIAL
VISIONS.
The Emperor’s DEVELOPMENT.
MOBILITY.
New Hybrid The world of mobility is changing. The
challenge facing automotive developers is
to acquire the knowledge they will need
tomorrow without losing sight of future
Dear Reader, journeys, they emit much more CO2 than technologies. The complexity of the mobility
the calculations of German greenhouse
transformation process calls for ground-
After carrying out careful investigations, gas emissions in 2030 were previously
breaking solutions. ATZelectronics provides
German government advisors and minis- based on. The calculations showed that,
ters repeatedly assured us that the prod- in the light of market forecasts, an in- the latest information from across the entire
uct was of very high quality and that the crease of up to 4.3 million t of CO2 emis- spectrum of automotive electronics. Take
project was making very good progress. sions can be expected in the transport advantage of the interactive e-magazine
“It’s excellent,” everyone said. And so the sector from plug-in hybrids in 2030. and benefit from the extensive information
cabinet approved even more funding on in our unique online archive, which gives
a large scale for the promising program. Why is the hybrid currently so popular
you the option of downloading PDF files.
Finally, the electrification concept was with company car drivers in particular?
presented personally by the head of gov- The answer is breathtakingly simple.
ernment to the speechless and astonished In order to boost sales of the wannabe
people of the country. “But he has noth- EVs, the tax on hybrids in private use electronics W O R L D W I D E
ing on!” a little child cried out at last. In is only half the amount of the tax on
Hans-Christian Andersen’s folktale “The cars with diesel and gasoline engines.
Emperor’s New Clothes,” it is initially As the fuel costs are almost always
just one single voice which highlights the paid in full by employers in Germany,
problem that is so obvious to everyone. it makes absolutely no difference to the
employees whether or not their cars are
How does this bring us to plug-in hybrids? running in electric mode. The stories of
Well, the voices that have been expressing hybrid cars being handed back at the end
more than just moderate criticism of the of their lease with the charging cable
ongoing state subsidies for this technol- still in its packaging will therefore come
ogy have recently become louder again. as no surprise.
A persuasive example is a study that was
commissioned by the emperor, sorry the
federal government, from the Institute
for Energy and Environmental Research DAYS
(ifeu), the Oeko Institute and the NGO FREE TR
IAL!
Transport & Environment. The results, Frank Jung
which were published in mid-January Editor kISSN (Online) 2524-8804
under the title “Too often in combustion electronics
W O R L D W I D E
06 June 2019 | Volume 14
engine mode: plug-in hybrids put trans-
port sector’s climate targets at risk,” show
once again that the hoped-for effects of
hybridization are likely to be barely notice-
able or even completely non-existent. SENSORS AND DIAGNOSTIC S
Driver Assistance Systems
Require Valid Data
As the experts explained, one of the
SENSOR DEVELOPMENT DIGITAL T WINS AND BIG DATA RAPID PROTOT YPING
Validated Using Flexible Used for the Dynamic Realization Drives the Development
Recorder Systems of Driving Functions of xEV Vehicles
/// INTERVIE W Alejandro Vukotich [BMW] /// GUEST COMMENTARY Georg Scheidhammer [Dräxlmaier]
reasons for this is that the current boom
in electrified cars in Germany involves
mainly large plug-in hybrids, more than
three quarters of which are registered www.atzelectronics-magazine.com
as company cars. As they primarily use
their combustion engines on their daily
ATZ worldwide 03|2021 3
C ONTENTS IS SUE 0 3 | 2021
BODY
Composite Use of CFRP,
Steel and Aluminum © Porsche
Hybrid designs are being used
more and more frequently in body 14 Introduction
Frank Jung
development to compensate for an
increase in car weight. This is because
additional comfort and assistance 16 First Body-in-White Made from Composites
for a Chinese Electric Car
systems as well as lithium-ion batteries Zheren Wang, Michael Käferböck [Forward Engineering], Hui Zhao,
Haibo Chen [Changan]
are making cars heavier and heavier.
To counteract this, not only steels and
aluminum but also plastics such as INTERVIEW
CFRP are being used. For greater 22 „We can reduce carbon emissions
by using sustainable aluminum“
lightweighting effects, multi-material
© Haruya Katada
Seiichi Hirano [UACJ]
and modern sensitive design methods
are required.
26 Global Sensitivity Matrix for Vehicle Development
Jana Büttner [Porsche and University of Wuppertal], Stefan Schwarz
[Porsche], Axel Schumacher [University of Wuppertal], Thomas Bäck
[divis intelligent solutions and University of Leiden]
4 www.springerprofessional.com/automotive
© Brose
© Magna
© UAS Esslingen
36 Door modules with innovative carrier material 56 To achieve greater ranges for battery electric 62 The Fernuniversität in Hagen and the
can help meet crash test requirements. Brose vehicles, Magna is investigating how to shorten UAS Esslingen are developing simulation concepts
uses carrier plates made of continuous glass-fiber- the charging process by increasing the charging based on maximum entropy to better evaluate
reinforced thermoplastics. power to 400 kW, for example. safety in autonomous driving.
CON T E N T S DE V E L OP MEN T R E S E A RCH
3 Editorial DOORS SECURITY
36 Organo Sheet Door Technologies 62 Safety in Autonomous Driving –
for Tougher Crash Standards Evaluation by Maximum Entropy
NEWS Marcus Klopp, Michael Thienel, Hans Braun [Fernuniversität Hagen und
6 People + Companies Eike Ritthaler [Brose] Hochschule Esslingen], Michael Gerke
7 Impulses [Fernuniversität Hagen], Reiner Marchthaler
HMI [University of Applied Sciences Esslingen]
40 Virtual Driving Tests of Powertrain
IN T HE S PO T L IGH T Systems in the Driving Simulator
Edward Kraft, Andreas Viehmann, S ER V ICE
8 The Car as an Stephan Rinderknecht [Technical
Energy Storage System University of Darmstadt], Philipp Erler 68 Imprint, Scientific Advisory Board
Susanne Roeder [Technical University of Darmstadt and 69 Preview
Karl Mayer Stoll R&D]
CO V E R S T ORY 46 Holistic, Context-sensitive
Human-machine Interaction GUEST
BODY for Automated Vehicles COMMENTARY
14 Composite Use of CFRP, Tobias Hesse, Michael Oehl, 70 The Opportunity
Steel and Aluminum Uwe Drewitz, Meike Jipp [DLR] of Chemical
Recycling
ELECTRIC MOBILITY Marco Philippi
© Audi
NEWS 50 Vehicle Dynamics of [Audi]
32 Products Battery Electric Vehicles
Mario Oswald, Georg Schrank,
Joachim Ecker [AVL]
56 Technical Aspects of
High-performance Electric Vehicles
Inés Cuenca Jaén, Chirstian Paar
[Magna]
COVER FIGURE © Haruya Katada | Alumirai
ATZ worldwide 03|2021 5
NE WS PEOPL E + C OMPANIES
Messring | Company Headquarters Started Operation
Messring has moved into its new corporate headquarters on the Air-Tech Campus in Ober-
pfaffenhofen (Germany). The site has 7200 m² of office and hall space and provides the
150 employees with modern workplaces 5 km from their former location. The highlight of
the complex is the large hall including the company’s crash test facility and two sled test
facilities. They are used not only for pre-assembly of customer orders but also for inter-
© Messring
nal and external tests from research and development projects. In addition, there is suffi-
cient space in the crash hall and on the open-air site for tests in the field of active safety,
New building complex in Oberpfaffenhofen (Germany) offers which are becoming increasingly important for Messring and involve the validation of (par-
7200 m² of office and hall space tially) automated driving functions.
CTS | Kistler | Cooperation in
the Development of Dummies
The Kistler Group and CTS have agreed to collaborate on the development of
realistic substitutes for the human body. The combination of a biofidelic crash
test dummy and precise measurement technology offers greater possibilities
for crash tests, product development, operational training or the modeling
© Kistler
and reconstruction of dynamic processes. The first jointly developed model,
called Primus, has bones, ligaments and joints that are modeled on those
of humans. Equipped with Kistler’s technology, the combined evaluation of Mirko Dobberstein (Managing Director CTS), Peter Schimmelpfennig
precise measurements and real damage provides very accurate test results, (Managing Partner CTS), Lars Hannawald (HTW Dresden) and Jens Wolking
for example for accident reconstructions, expert reports and insurance cases, (Business Driver Vehicle Safety, Kistler) (f. l. t. r.) have jointly advanced
or for obtaining certifications. the biofidelity crash test dummy Primus
Faist | Acquisition by Paguasca Paguasca Holding in Zug (Switzerland) has acquired the entire Faist Anlagen-
bau Group, which is headquartered in Krumbach (Germany), and its subsidi-
aries. Faist is an expert in industrial sound insulation and, with its Acoustic
Systems business unit, supplies acoustic measurement and test rooms as well
as aeroacoustic wind tunnels for customers in the automotive sector, among
others. The owner family led by Michael Faist has decided to sell the company,
which has been in existence for almost 120 years, and Faist himself is retiring
for personal reasons with the goal of enabling the Anlagenbau Group to con-
tinue to grow and to secure the sites and jobs. “We are pleased to have found
© Faist
a buyer in Paguasca, who aims to further develop the Faist Anlagenbau Group,”
Faist headquarters in Krumbach (Germany) said Faist.
HZDR | Rovak | Start-up for Electrode Production Founded
The Helmholtz-Zentrum Dresden-Rossendorf (HZDR) anode and integration into existing battery produc-
and the company Rovak have jointly launched the tion chains within a few years. The goal is to install
start-up NorcSi for the production of silicon elec- the new anodes in high-performance batteries
trodes for future battery generations. The silicon as standard in two years. The patented technology
© NorSci
anode from the new company based in Halle/Saale is said to increase the energy density of today’s
(Germany) is created in a physical process of coat- lithium-ion batteries by more than 40 %, replace
ing and thermal treatment using flash lamps and conventional graphite and thus significantly extend- Commissioning of the flash lamp system in
laser annealing. Plans call for industrial use of the ing the range of e-vehicles. February 2020: Dr. Marcel Neubert, Georg Ochlich,
Udo Reichmann, Dr. Charaf Cherkouk (f. l. t. r.)
6 www.springerprofessional.com/automotive
ATZ/MTZ Group | Gutzmer Joins
Liebl as Editor in Charge
On January 1, 2021, Prof. Dr.-Ing. Peter
IMPULSES
Gutzmer became Co-editor in charge of the Dr. Johannes Liebl
Editor in Charge
magazines ATZ, MTZ, ATZelectronics and
ATZ | MTZ | ATZelectronics | ATZheavyduty
ATZheavyduty. He will also provide support
for the ATZlive conferences. Gutzmer, who
is well known in the automotive industry
because of his roles as associate lecturer
and honorary professor at Karlsruhe Institute
of Technology (KIT) and as former board
member of Schaeffler AG over many years
Systems Thinking
© Schaeffler
and also as a result of his many other activ-
ities, will be working alongside Dr. Johannes
Liebl, who has been Editor in Charge for the
last ten years. “ATZ and MTZ have been Germany can only secure its strong position as
Peter Gutzmer
prominent information and communication an export nation in global competition if prog-
platforms for technical and engineering issues in the automotive and powertrain indus- ress is made on the key social issues of mobility,
tries over a period of more than 120 years. The opportunity, after more than 40 years of climate protection, energy, security and health.
The climate protection targets set in Paris are
professional experience in this field, to help to shape these media as part of a compe-
thus coming into even sharper focus. National
tent team during a time of major global change and against the background of the shift
and international markets require an open approach
toward connected and sustainable mobility is very attractive,” says Gutzmer describing
to technology in order to meet mobility and trans-
his new challenge. Liebl is enthusiastic about the appointment of his expert colleague.
portation needs.
“I am pleased that Peter Gutzmer, who I have known for a long time, will be joining the
Springer Nature team and that we will be able to share our workload in these uncertain
Electrified drives and efficient car and commer-
times. This will give me the freedom to spend more time with my family in the future.”
cial vehicle engines in a system network with
Both editors in charge will work closely with the Editor in Chief of the ATZ/MTZ Group,
new fuels are key technologies for CO2-neutral
Dr. Alexander Heintzel.
individual mobility with low emissions. Demand-
ing test cycles under real driving conditions are
tightening the legal requirements and call for
new and holistic approaches in all disciplines.
NEVC | Easelink | Partnership The electrification of powertrain and chassis
for Charging System in China in a vehicle with several electrical voltage layers
and different degrees of networking leads to in-
creasing complexity. In order to master this com-
plexity, current expert knowledge is no longer
sufficient. An understanding of functional inter-
actions in the overall vehicle is becoming a crite-
rion for success.
One key to building this understanding is sys-
© Easelink
tem simulation. It helps to understand the highly
interconnected interactions in a virtual vehicle
and thus promotes systems thinking. In addition,
Easelink Managing Director Hermann Stockinger (left)
the ATZ/MTZ Group supports companies with its
and the Managing Director of NEVC Yuan Chengyin
magazines and events in building up the neces-
sary knowledge. Systems thinking thus becomes
The National New Energy Vehicle Technology Innovation Center (NEVC) in China
a driver for innovations and further expands our
and Easelink in Austria have signed a memorandum of understanding to make
competitive advantages in global markets.
the Matrix Charging automated conductive charging system the leading charg-
ing technology in China. The solution from the Graz-based company includes
the integration of charging technology into the parking space surface. NEVC is
supported by companies such as the car manufacturers Baic, BYD and Geely,
as well as Valeo and the battery developer Catl, among others. Thanks to close
cooperation with the Chinese government and industry, NEVC is expected to
play a major role in determining how e-vehicles will be charged in the future.
ATZ worldwide 03|2021 7
IN THE SP OTLIGHT The Car as an Energy Storage System Mobility in Germany is undergoing a period of disruptive change with the move toward electrification, hydrogen and synthetic carbon-neutral fuels. Most people are familiar with these developments, but fewer are aware that electric cars can help to stabilize the power grid by acting as temporary energy storage facilities. Over the past ten years, more than 50 pilot projects of different sizes involving bidirectional charging have been successfully completed in locations all over the world. 8 www.springerprofessional.com/automotive
has highly ambitious goals. It represents electricity in cities by using electric cars
the most radical restructuring of the as buffers in the form of storage facilities
automotive industry since the invention outside the power grid. The technology
of the motor car by Gottlieb Daimler and will allow the vehicles to share energy
Carl Benz 134 years ago. The Plug-in with the grid and will transform them
Hybrid Vehicle (PHEV) is often seen as into a potentially valuable resource for
a transition technology on the road to the national grid in Turin, which is op-
pure electric mobility. Whether or not erated by Terna.
that is the case will soon become clear, This technology is not new, but it
but PHEVs, with their 6- to 15-kWh bat- has never been used on a large scale.
teries, already offer an additional benefit. The FCA project aims to introduce a
This view is not shared by all experts, new approach to energy worldwide and
disregarding for the moment the subject to turn Italy into the market leader for
of bidirectional charging and charging intelligent energy supply systems. This
in general. The result has been disagree- approach is based on the simple fact
ments about the right route to take and that cars are stationary for up to 95 %
about whether synthetic fuels and hydro- of the time and offer huge potential for
gen can and should play a prominent use as decentralized energy storage fa-
role in personal transport. cilities while they are not being driven.
The batteries of electric cars have huge The European Commissioner for
potential for use as buffers for the power Energy, Kadri Simson, has given the pro-
grid. The possibility of bidirectional char- ject her blessing and is confident that
ging is there, but none of the car manu- V2G will become widespread in Europe.
facturers seem prepared to make the op- However, she cannot put in place regula-
tion widely available in their vehicles. In tions that would require other countries
technical terms, it is not a problem. The to launch projects on a similar scale and
obstacles are legislative and regulatory would make V2G a part of everyday life
in nature. While international standards in Europe in the near future. She can
form the basis for the work of the auto- only issue recommendations.
motive industry, the energy sector is gen- In contrast to the situation in Italy,
erally governed by national regulations. Germany’s red tape has so far prevented
A large number of market players, with the widespread use of the technology.
every car owner becoming a power sta- In Germany V2G will always be possible
tion operator, would make energy man- in small niche markets, “but an attrac-
agement very complex, particularly in tive market for customers and carmakers
Germany. In the Netherlands cars can is being blocked by the regulations,” says
already make smart, bidirectional use Markus Rosenthal from the German
of charging stations, but in Germany Energy Storage Association (BVES).
© FCA this is not yet the case.
CARS AS FREQUENCY REGULATORS
WHAT IS THE POTENTIAL OF V2G?
In response to the question of what
The V2G process is regarded as promis- benefits electrified vehicles could offer
ing but not absolutely essential. How- apart from their function as mobility
ever, it could transform the energy service providers, Michael Danzer,
industry in the future. No one has yet holder of the Chair of Electrical Energy
g Until now, Germany has focused explained how a power grid that can Systems at the University of Bayreuth,
on one-directional charging of its electric no longer rely on nuclear or coal-fired has identified three key scenarios. One
cars and on setting up the necessary power stations will be able to maintain of these is the balancing market, which
charging infrastructure. Not all electric its stability when millions of additional regulates the difference between what
cars come as standard with an inverter, electricity consumers appear on roads is produced and consumed. Here it is
as the example of the new Citroën ë-C4 all over the world. V2G can make a very important to ensure that the 50 Hz fre-
demonstrates. It appears that the subject important contribution in this respect. quency of the grid is always maintained.
of Vehicle-to-Grid (V2G) is not being Italy is the European pioneer in the If too much electricity is fed in, the fre-
taken very seriously in Europe. field of V2G and by the end of 2021 aims quency increases, while if the supply
to set up the world’s largest project on is too low, the frequency falls. The bal-
the Fiat Mirafiori site, which will consist ancing market is responsible for making
LEGISLATION IS NEEDED
of 350 charging stations for up to 700 permanent adjustments.
Germany’s mobility and energy policy is electrified cars. The goal of this unique Even with artificial intelligence, the
closely aligned with that of the EU and pilot project is to stabilize the supply of planning process will never be perfect
ATZ worldwide 03|2021 9
IN THE SP OTLIGHT
the number of public fast chargers
had doubled to 3600 by the end of 2020.
Despite this, the German government
is continuing to increase its support for
the charging network and making more
and more funding available. According
to Ebinger, the large number of charging
points currently being installed in pub-
lic spaces does not represent a viable
model for the future. Because of his
background in electrical engineering,
his view is that there should be some-
thing similar to fast charging filling
stations at assembly points where
cars could be charged very quickly.
“Most of the charging processes will
take place at work or at home.”
ITALY PLAYS A PIONEERING ROLE
IN THE INTERNET OF ENERGY
In the meantime, in Italy data is being
collected to identify the best form of
interaction between energy companies
and vehicles, because the bidirectional
technology can only function efficiently
if the car and the charging infrastructure
speak the same language. A communica-
tion protocol that has been standardized
with the use of AI should be in place by
© FCA
the end of 2021.
“The Italians are pioneers in the
Bidirectional charging columns on the premises of the FCA plant in Mirafiori (Italy) world of smart meters,” says Danzer,
who firmly believes in the importance
of electric cars for buffering power.
“The energy system of the future will
and there will always be a certain differ- Modern AC charging stations can charge always be linked with a communication
ence. Until now the large coal-fired and in both directions, but the car must sup- system, the Internet of Energy. But in
nuclear power stations have been able port the charging process. “If all cars Germany this is a long way off.”
to support the grid. However, with the had bidirectional charging activated Enisyst has identified one key factor.
move to wind and solar energy, the dif- and we could communicate with them, “In rural areas, everyone will install
ference will not necessarily increase, but we could do as much charging in both their own charging post, but in cities
storage facilities are urgently needed to directions as we wanted,” says Dieter this will definitely not be possible,” ex-
enable the balancing market to function Ebinger from Enisyst, a company in the plain Ebinger and his colleague Dr. Dirk
effectively in the future. Stuttgart area that specializes in con- Pietruschka. “I believe that V2G will
The second scenario is aimed at indus- necting energy systems in the smart grid have a big role to play in the field of
trial firms with electric fleets. For these with its intelligent measurement and self-generated energy, which will allow
“it would be possible to bring the electric control systems. The potential for doing everyone to optimize the system to meet
vehicles together in a regional group in a this in Italy is very high. “If only 5 % their own requirements,” says Ebinger.
certain district of a city or in a business of all the cars on Europe’s roads were The two experts regard self-generated
park. Not all the vehicles will be there, electrified in 2030, they could revolution- energy as a huge market, where V2G
but some will always be parked and they ize the power grid and play a decisive will become increasingly important.
can be used for energy management pur- role in balancing the European energy The scenario involves producing elec-
poses,” says Danzer. markets,” says Carlalberto Guglielmi- tricity during the day with your own
notti, CEO of Engie Eps. This situation photovoltaic system and storing excess
still seems to be a long way off, but one capacity in your car battery. In the eve-
THE ELECTRIC CAR AS
thing is clear: charging stations are ning you will be able to use the stored
THE CRITICAL POINT
springing up everywhere like mush- energy to meet your own needs.
The problem with bidirectional char- rooms. There are currently 35,000 offi- A sample calculation illustrates the
ging is not the charging post but the car. cial charging points in Germany and huge storage capacity available in largely
10 www.springerprofessional.com/automotiveimmobile electrified cars. After 2035, ufacturers do not want to bring another FCA is taking an optimistic approach
when no more new cars with combustion uncertainty into the equation in the to bidirectional charging. From an over-
engines can be registered, the market form of a bidirectional charging post, all perspective, the cars parked on the
penetration of electric cars could reach which would set a process going that is company’s site can be transformed from
50 %. If you take an average battery not under their control.” a disadvantage to a financial advantage.
capacity of 50 kWh and work on the In the foreseeable future, these benefits
assumption that in 2035 around 40 mil- could also be available to fleet managers,
BATTERY SERVICE LIFE AND
lion cars will be registered in Germany – as Roberto Di Stefano, head of e-mobility
BIDIRECTIONAL CHARGING
according to the German Association of at FCA, suggests. The car’s function as
the Automotive Industry (VDA) the cur- Most people will be familiar with the an external provider of grid stability ser-
rent figure is 70 million – this gives a stor- concept from their smartphone. The vices could be financially beneficial for
age capacity of one billion kWh (or one storage capacity of the battery reduces car owners who have a bidirectional
terawatt hour). Even if 20 million of these after a few years because of constant wallbox at home.
vehicles are not available for storage pur- use and charging processes that are not “We want to show our customers that
poses because they are being driven, you always ideal. However, there is not yet V2G works,” explains Lodovico Cavazza
only need to deduct a maximum of 10 % enough information available about the Isolani, e-mobility program manager at
from this figure. This leaves 900 mil- use of V2G with cars over a period of FCA and head of the project. For this rea-
lion kWh available, which will provide several years. The normal eight-year son, he and Di Stefano are pushing for
significant support for the smart grid. or 160,000-km warranty for the battery the rapid introduction of legal regula-
of a BEV or PHEV only covers one-direc- tions to allow V2G technology to be
tional charging. extended to fleet management in the
AVOID OVERWHELMING DRIVERS
The subject of the warranty is an near future, with the aim of reducing
WITH TOO MANY CHANGES
important one. Who is using the batter- the operating costs of the cars.
Calculations of this kind are affected by ies? Who will take responsibility if they
three major limitations. The first of these are overloaded and if they suddenly start
FLAGSHIP PROJECT
is that the charging infrastructure is not to malfunction, for example? “There is
AT MIRAFIORI PLANT IN TURIN
yet designed for this type of use. In addi- a lot of uncertainty in this area and the
tion, the cars do not have the necessary manufacturers want to build up confi- The team in Turin do not believe that
software for bidirectional charging. The dence among consumers and drivers in the batteries will wear out more quickly.
third problem is the subject of the war- order to persuade them to move to elec- But equally if a battery is not used for
ranty for the service life of the car bat- tric vehicles,” says Danzer. To sum up, a long period, chemical processes can
teries. For the batteries to provide the the warranty problem is currently the take place that cause it to deteriorate
power grid with the necessary flexibil- biggest obstacle in the path of a publicly and reduce its performance. A compro-
ity, they will need to be charged and available V2G system. mise needs to be found. Extensive re-
discharged more frequently and this The concern remains that the lifetime search is underway in this field in Italy
will reduce their service life. of the batteries in electric cars could suf- together with a search for a business
In addition to the need to find a legal fer as a result of more frequent charging model that allows everyone involved to
solution to the warranty issue, Danzer and discharging and the manufacturers benefit financially.
has identified another reason why car- are taking this seriously. “We need more The faster wear and tear on the battery
makers are currently ignoring the ques- experience of this and some flagship is counteracted by the claim that it is
tion of bidirectional charging. “Everyone projects with positive results in order always discharged to a level that is bat-
is still discovering how mobility with to permanently overcome these reser- tery-friendly, but this has not yet been
battery electric cars will work. The man- vations,” says Pietruschka. proven. For example, if the battery is
The batteries of electric
vehicles can be used
as buffer storage for
regeneratively generated
energy with V2G
© Enisyst
ATZ worldwide 03|2021 11IN THE SP OTLIGHT
discharged to maintain the frequency (UAS). Pietruschka has set it up with duced first in a local area of a manage-
of the power grid, this results in very funding from the German Federal Minis- able size. It is also crucial that players
fast cycles, in other words, rapid char- try of Economics. In addition to the from different organizations can work
ging and discharging. Many people be- municipality of Wüstenrot, the other well together, including car manufac-
lieve that this is a critical problem and participants are Enisyst, the company turers, automotive industry suppliers,
are concerned that it will have negative that belongs to Pietruschka and Ebinger, energy and technology companies, pri-
effects on the service life of a car battery. Oxygen Technologies from Freiburg vate transport providers, such as fleet
“Private car users may not want their and Mitsubishi Motors Germany, plus operators, and municipalities.
batteries to be used frequently, because Castellan AG, which specializes in sys-
they will probably worry that the batter- tem solutions for electric mobility.
ENERGY COMPANIES BLOCK V2G
ies will not last as long as a result,” says Only a few cars, manufactured by
Pietruschka. But they might take a dif- Nissan and Mitsubishi, currently allow Power generation companies also have
ferent view of this if they can use the bidirectional charging. As the municipal- an interest in the stability of the grid.
batteries to supply their own house. ity of Wüstenrot already had a very good However, they are not in favor of the
Making their battery available for the relationship with Mitsubishi Germany, idea of districts that are largely inde-
public grid “may be a step too far for the choice was a simple one. The com- pendent and only need a little electric-
many people,” comments Pietruschka. pany made its PHEVs available for the ity from the grid every now and then.
At Fiat’s Mirafiori plant, at its French project and the cars will be used in elec- This is precisely the objective of the
partner Engie Eps, which is responsible tric mode only. The combustion engine project in Wüstenrot.
for decentralized energy generation, and will function exclusively as a range In addition to the factors described
at the Italian power grid specialist Terna, extender to generate electricity in an above, the obvious financial concerns
the mood remains optimistic, including emergency. Of course the capacity of the of the energy suppliers also have to be
with regard to public acceptance of the PHEV battery is not as big as that of a taken into consideration. Districts of
scheme. To increase acceptance, many BEV battery. “The battery size is per- this kind can also provide useful ser-
other projects are needed, like the ones fectly adequate for our project,” says vices for the grid by using electricity
in Mirafiori and Wüstenrot, that promote Pietruschka. In Japan by contrast, the when there is an excess available.
bidirectional charging. engine is also used as an emergency gen- The car batteries would enable the
erator. This means that PHEVs have the system to be managed much more
advantage that the electricity generated flexibly. The entire cell, as a district
WÜSTENROT: SMART2CHARGE
by the engine can be used as a power like Wüstenrot is referred to in terms
IN RURAL AREAS
supply for a house in an emergency, such of the power grid, can interact with
Smart2Charge in the municipality of as a natural catastrophe. the grid. Energy generation companies
Wüstenrot in Germany’s Heilbronn The motto “act local, think global” have the opportunity to earn from
district is a V2G project being run by also applies to the bidirectional charging decentralized models by investing
Stuttgart University of Applied Sciences technology, which needs to be intro- in systems of this kind themselves.
2 QUESTIONS FOR …
What is your assessment Is bidirectional charging more
of the potential of V2G? than just a marketing gimmick?
Danzer _ I believe that over the next few Danzer _ In the near future there will al-
years and decades a giant fleet of battery ways be places where excess electricity
storage units will become available. This is generated from wind and solar energy
© University of Bayreuth
fleet will have huge potential but will be and places where there is not enough
standing around unused. It is not only in electricity available. We need to balance
Mirafiori that people are thinking seri- out these energy flows. Larger storage
ously about how a business model can be capacity in the grid would be the ideal
set up on the basis of this battery capacity way of doing this. This is why it makes
and what economic benefits it can offer. sense to bring in electric vehicles.
Prof. Michael Danzer
Holder of the Chair of Electrical Energy Systems
at the University of Bayreuth and Director of the
Bavarian Center for Battery Technology
12 www.springerprofessional.com/automotive© Mitsubishi Motors
The Mitsubishi Outlander PHEV is one of only a few models already suitable for bidirectional charging
That is exactly what Terna is doing in Mirafiori, where V2G
is regarded as a win-win situation for everyone involved.
OPINION
SIMULATION MODELS OF BIDIRECTIONAL CHARGING
To be able to determine more precisely what happens when “The charging infrastructure in
a large number of electric cars suddenly move into a district,
Stuttgart UAS has created simulation models of the power
Germany will have undergone signi-
grid to investigate different scenarios relating to the increase ficant changes in five years’ time,
in electric vehicles. “We want to discover when problems oc-
cur in the grid and how bidirectional charging of cars can partly because Volkswagen, which is
counteract these problems and ultimately avoid the need for
the expansion of the grid,” explains Pietruschka.
focusing exclusively on electric ve-
Another subject of the research at Stuttgart UAS is accep- hicles and strongly promoting them
tance. “We want to know what the residents think about this
and our aim is to involve them in the whole process.” One objec- via the VDA, has discovered that it
tive is also to set up an electric car sharing scheme in Wüstenrot. can use the energy sector’s business
This is much more difficult in a rural area than in a city. But
even in cities these schemes are not yet cost-effective. “We are model in its subsidiary Elli (Electric
investigating how we can organize this with the help of the resi-
dents and maybe even encourage them to invest in the system,
Life). V2G will play a role in all of
run it themselves and also take part in it.” this and will attract attention to this
Municipalities are involved in the project as well as private
individuals and another important group is tradespeople. option. However, the question is
The four levels of the Wüstenrot V2G project are municipalities,
private households, tradespeople and the carsharing model.
whether too much emphasis is being
This goes beyond the concept in Mirafiori. placed on the heavily subsidized bat-
Ebinger and Pietruschka, who have been working in the
field of renewable energy for several years, believe that V2G tery electric vehicle sector. Given fair
“is achievable in the foreseeable future.” One requirement
for everything to function smoothly is that the grid operators
competition in the form of techno-
invest billions of euros in better power lines after the phase- logy neutrality, hydrogen, fuel cells
out of coal.
To give electric mobility a helping hand in general terms, and synthetic fuels will also have
the German Association of the Automotive Industry (VDA) is
calling for the electricity used for charging to be exempt from
made significant progress by then.”
the renewable energy surcharge in Germany. The idea behind
this is another nail in the coffin of diesel cars and has been
described in these terms by VDA president Hildegard Müller
who said: “Electricity for charging cars must be cheaper than
diesel.” But what if the electricity stored in the car is used in
the car owner’s home? The major obstacles to V2G remain the
many legal issues relating to the warranty for the batteries
and the electricity and how it is used.
Dr. Susanne Roeder
Susanne Roeder is a Freelance Journalist.
ATZ worldwide 03|2021 13C OVER STORY INTRODUC TION
BODY
Composite Use of CFRP,
Steel and Aluminum
16 First Body-in-White
Made from Composites
22 by“Weusing
can reduce carbon emissions
sustainable aluminum”
26 Global Sensitivity Matrix for
Vehicle Development
for a Chinese Electric Car Seiichi Hirano [UACJ] Jana Büttner [Porsche and University
Zheren Wang, Michael Käferböck of Wuppertal], Stefan Schwarz [Porsche],
[Forward Engineering], Hui Zhao, Axel Schumacher [University of Wupper-
Haibo Chen [Changan] tal], Thomas Bäck [divis intelligent
solutions and University of Leiden]
14 www.springerprofessional.com/automotiveAlfred Wilm was a highly qualified metallurgist in one of
the leading research institutions in the German Reich at
the start of the last century. He was a member of the
freemasons’ lodge known as “Teutonia zur Weisheit.” But
one of his most important discoveries was the result of the
forgetfulness of his apprentice, who left an aluminum
casting sample next to the furnace over the weekend. On
the Monday, the material proved to be much stronger than
it had been on the Saturday. Three years later, Wilm
applied for a patent for his lightweight alloy which became
a huge success under the name “Duralumin,” initially in
the field of airships and aircraft.
The product was developed further in Japan and “Extra
Super-Duralumin” was created. Nowadays, the Japanese
company UACJ is a global supplier of lightweight mate-
rials. In the interview, its Research & Development
Director and Board Member Seiichi Hirano gives an
insight into the applications of different types of mate-
rial: “UACJ is a specialized manufacturer of rolled alu-
minum, but we are advancing research and development
of composite techniques”.
In the past, composite materials of this kind were of only
limited interest to Chinese car manufacturers. However,
during the development of the electric Changan Eado ET
model, a multi-material architecture was used. The
design resulted in a body shell with 100 CFRP com-
ponents, an additional aluminum frame and a steel core.
The body shell was over 30 % lighter than a steel equiv-
alent. The prototype underwent the China-NCAP 2018
tests and was awarded five stars.
Because vehicles are highly complex systems, the depart-
ments involved in the development process cannot act
© Porsche
independently of one another. What each department
does influences all the others. The extent of this interac-
tion can vary. It can also affect the requirements of other
disciplines in both a positive and a negative way. How-
ever, the strength and the nature of the influence cannot
always be predicted. But there is now a tool that can
identify these connections: the global sensitivity matrix,
which is described in detail by Porsche.
Frank Jung
ATZ worldwide 03|2021 15C OVER STORY BODY
AUTHORS
Dipl.-Ing. Zheren Wang Michael Käferböck Dr. Hui Zhao Haibo Chen, M. Sc.
is Eado ET Project Leader is Deputy Eado ET Project is Eado ET Program Director is Eado ET Program
Composite Body-in-White and Leader Composite Body-in-White and Chief Expert (VP) at Manager and Platform
Project Manager at Forward and Project Manager at Changan Automobile Co., Ltd. in Planning Manager at Changan
Engineering GmbH in Forward Engineering GmbH in Chongqing (China). Automobile Co., Ltd. in
Munich (Germany). Munich (Germany). Chongqing (China).
g Composites (multi-material struc- critical to realize high-volume vehicle only limited availability throughout the
tures) like Fiber-reinforced Polymers applications of FRP composites. Histori- manufacturing value chain.
(FRP) offer the potential to reduce mass cally, given the limited demand for FRP The Eado ET compact car project,
and improve vehicle performance and composites in the Chinese market, Chi- with one of its foci being on structural
battery electric range, especially import- nese automotive OEMs did not allocate composite application, was initiated by
ant in Battery Electric Vehicle (BEV) resources to the development of FRP Changan to close this gap and acceler-
applications. From raw material to fin- composite parts. This resulted in a lack ate the development of a capable FRP
ished product, a capable supply chain is of know-how across the industry and composites supply chain in China. For a
16 www.springerprofessional.com/automotiveFirst Body-in-White
Made from Composites
for a Chinese Electric Car
Forward Engineering and the subsidary KDX Design Center developed a
CFRP-intensive body-in-white for the Chinese automotive OEM Changan.
This multi-material structure obtained a five-star rating in the China-
NCAP assessment (CNCAP 2018). Thus, the Eado ET passenger car is
g an
han
©C China’s first battery electric vehicle with extensive applications of carbon
fiber composites, aluminum and steel in safety-critical structures.
realistic project scenario, a five-star frame as a common platform for the The vehicle front and rear ends are
China-NCAP rating and a weight reduc- CFRP upper body (premium lightweight defined as main deformation zones for
tion of 30 % compared to the identi- design version of the Eado ET) and for energy absorption during a crash. Here,
cal steel-based vehicle, the Changan the steel upper body (high-volume ver- the favorable crash characteristics of
Eado, was defined as target. These sion). On the other hand, this utilizes aluminum enable it to absorb the peak
goals could only be achieved by an the advantages of aluminum for BEV energy in a crash case and transfer the
FRP dominated multi-material layout structures by providing an ideal protec- loads into the backing structure. For
for the Eado ET and a focus on integral tion and mounting platform for the bat- passenger safety, the passenger com-
component design. In order to enable tery housing and other chassis and pow- partment of the BiW requires higher
the rapid succession of project mile- ertrain components. rigidity and allows only smaller defor-
stones, a development method acceler-
ated by simulation (simulation-driven
design) had to be chosen.
MULTI-MATERIAL CONCEPT FOR
BODY-IN-WHITE STRUCTURES
For the Eado ET, the entire Body-in-
White (BiW) structure together with its
doors and hoods primarily consists of
two modules: The upper body (passen-
ger compartment) is made mainly from
Carbon-fiber-reinforced Polymer (CFRP)
which was strengthened with high/ultra-
high-strength steel. The lower frame is
made entirely from aluminum, FIGURE 1.
This structure layout allows Changan
on the one hand to use this aluminum FIGURE 1 Multi-material concept of the passenger car Eado ET from Changan (© Changan | Forward Engineering)
ATZ worldwide 03|2021 17C OVER STORY BODY
FIGURE 2 Overview of all CFRP parts in the Eado ET project stiffer and the outer side frame would
(© Changan | Forward Engineering) require a redesign. These changes would
prevent the use of the existing seat
belt arrangement and the use of other
important interior carry over parts in
the new vehicle.
FRP-DOMINATED UPPER BODY,
DOORS AND HOODS
The upper body, the four doors and
the two hoods (in front and rear) are
mainly composed of FRP. To realize the
FRP value chain, a variety of locally pro-
duced materials (four resin types ranging
from fast curing to normal prepreg resin
as well as three textiles/semi-finished
products) and technologies (HP-RTM
with preforms, WCM, PCM, prepreg,
Vacuum Assisted Resin Infusion (VARI))
were considered for the composite body
mation. Here, the carbon fiber has more in order to combine the benefits of both structure. In the design phase, all parts
advantages in terms of its excellent stiff- materials. were designed with technologies suitable
ness/strength properties. Especially in The steel core is the primary structure for high-volume production processes.
areas with high loads and clear load for the B-pillar and acts as a reinforce- An equivalent VARI process was used for
direction, this fiber composite material ment in the areas of roof frame, A-pillar the manufacturing of most of the proto-
can utilize its anisotropy advantages and side sill. The typical ductile proper- type parts for functional validation due
best. In case of a side crash, the vehicle ties, combined with the good perfor- to its cost and time efficiency. The main
structure needs to withstand the barrier mance of the used ultra-high strength composite and CFRP parts are shown in
intrusion and absorb the intrusion steel, are best suited to absorb and trans- FIGURE 2.
energy by keeping the structural integ- fer the impact energy into the surround-
rity intact. The brittle CFRP material ing structure in a very limited deforma-
PART COUNT AND WEIGHT
is not ideal for such peak energy absorp- tion space.
REDUCTION THROUGH INTEGRATION
tion. To overcome this, a material com- It would take a much higher effort
bination of CFRP and steel was created. to achieve this if a 100-% CFRP con- The extensive use of FRP not only makes
This so-called steel core structure was cept was used. The lower aluminum the vehicle structure lighter, but also
embedded into the CFRP side frame frame would need to be created much allows to make it more integrated. The
FIGURE 3 Integration: composite
structure of front floor and rear floor
(© Changan | Forward Engineering)
18 www.springerprofessional.com/automotiveFIGURE 4 Modular approach of material characterization according to [1] (© Forward Engineering)
composite upper body integrates various core and an additional aluminum lower card development strategy, a full charac-
functions (regarding occupant safety, frame as a common platform. As a result, terization (1A, 2A and 2B) was carried
global/local stiffness, local attachment over 30 % weight reduction from 469 kg out for the materials in crash-related
points, NVH/comfort) by using adhe- (steel reference) to 322 kg (Eado ET proj- zones while some post-failure assump-
sives as well as easier sealing due to ect) for the entire BiW was achieved. tions were made for the less critical mate-
less joining steps while reducing the rial cards (only 1A or 1A + 2A tested).
part count significantly. For example, On the basis of such a material card
SIMULATION-DRIVEN DESIGN AND
the entire floor structure, FIGURE 3, is development, a wide range of calcula-
BUILDING BLOCK APPROACH
composed of two integrated CFRP parts tions and hardware tests starting from
– the front floor and the rear floor. The The keys for the successful development coupon/plaque level, over component/
front floor integrates twelve metal parts of this fast track project were the tailored sub-system level to system/vehicle level
and reduces the weight by more than simulation-driven design and the build- were conducted to further improve the
50 % (7.8 kg for CFRP front floor). At ing block approach. This was forced on predictability on different load cases for
the same time, the geometry and fiber the project by the need to concurrently the vehicle, especially for investigations
orientation were optimized. The middle develop the component geometry while for the crash load absorbing areas. The
tunnel area was reinforced using unidi- creating validated material cards for the concurrent building block approach,
rectional fibers in lateral direction to required CAE simulation. FIGURE 5, with iteration loops ensured
improve the stability of the body during Given the limited available project time that both the cost and performance ob-
a frontal crash and to increase the global and the requirement for more than ten jectives were met by testing on a num-
bending stiffness. For the rear floor in different material cards (combinations ber of less expensive specimens. Simul-
similar, the FRP design substitutes six of different materials, technologies and taneously, a plausible data base could
metal parts while reducing the weight grammages) in a first step, Forward be built at different complexity levels
to 5.9 kg which is more than 50 % less Engineering has classified similar mate- of the development.
compared to the steel reference. In addi- rial cards depending on the predefined
tion, local reinforcements are applied in production process and fiber volume
FIVE STARS IN
transverse direction in the second seat content, which allowed reducing the
CHINA-NCAP CRASH TEST
row area (C torsion ring) to support the number of tests by keeping a reasonable
BY VALIDATION TEST
global BiW torsion. accuracy of the material cards and still
The part count was significantly covering the variation of technologies. For validation purposes, hardware
reduced in the shown integrated design In the second step, the load conditions tests were carried out by Changan.
despite using a lot of cost-efficient of the different BiW zones (crash rele- While meeting the targets of stiffness
carry-over steel parts. There were over vant, strength or stiffness dominated) and strength requirements, the vehi-
577 BiW parts in the steel reference were analyzed to assess the level of cle successfully achieved the required
vehicle, of which 159 are carried over to demand for material cards for each part. five-star crash test rating according to
the composite intensive solution. The re- This could be best described as a modu- China-NCAP 2018 regulations. The vali-
maining steel parts (418) have been re- lar approach of material characterization, dation regimen contained a full width
duced to 100 CFRP body parts, the steel FIGURE 4. Based on this specific material frontal impact, a frontal offset impact
ATZ worldwide 03|2021 19C OVER STORY BODY
FIGURE 5 Building block approach,
tailored for Eado ET development,
with improving predictability in
FEM simulation and test
(© Changan | Forward Engineering)
with the Offset Deformable Barrier frame absorbed the main energy and the ation was below 35 g. The test curves
(ODB) and a side impact with Mobile FRP passenger compartment provided correlated well with the FEM simula-
Deformable Barrier (MDB). The results sufficient stiffness to hold the alumi- tion result, FIGURE 6, thanks to the vali-
of FEM simulations and crash tests num structure in place. Consequently, dated material cards. Similar results
also showed a good correlation with a the intrusion in the front wall was con- and behaviors could be observed from
maximum deviation of about 6 %. trolled well and the passenger compart- the front crash with a full-width rigid
As laid out in the structural concept, ment structure could keep a very good barrier which is generally less critical
during the ODB test, the aluminum structural integrity. The peak acceler- than the ODB load case.
FIGURE 6 Result comparison of ODB and MDB crash with point score (simulation versus test) (© Changan | Forward Engineering)
20 www.springerprofessional.com/automotiveThanks to the multi-material steel- core concept and the remaining steel beam in the door structure, the vehicle could absorb the MDB side impact energy. The deformations were within the allowable limits and its structural integrity remained intact. The simulation accurately predicted main damages on the front and rear door panels. The dif- ference (simulation versus test) in the point score (19.1 versus 17.9) is mainly in the rear door upper area (chest), as the crash test dummy (SID-IIs) chest was more heavily compressed than the simulation predicted. Several post-crash analyses have been performed to ana- lyze the reasons in detail as well as to propose optimized solutions. A better correlation is expected for the official tests later at the China Automotive Tech- nology and Research Center (Catarc) in Tianjin (China). CONCLUSION AND OUTLOOK All project and technical targets could be met within the given time frame. The BiW of the Changan Eado ET was developed using a composite-intensive multi-material architecture. The high integral design lead to a BiW (including doors and closures) with only 100 CFRP parts, an additional aluminum frame and the steel core. As a result, the weight of the BiW was reduced from 469 to 322 kg which is more than 30 % compared to the steel reference vehicle. The Eado ET prototype was validated by Changan with a five-star rating, accord- ing to the China-NCAP 2018 regulations. Last but not least, 100 % of the FRP parts and technologies were sourced in China. The initial goal of the project was clearly demonstrated. The composite value chain in China moved a big step forward and was confirmed ready for major large-scale manufacturing. A batch of prototype vehicles is deliv- ered to Catarc for official crash-test certi- fications by the end of 2020. The most promising multi-material structure con- cepts are expected to be transformed into high-volume production applications at Changan Group. REFERENCE [1] Klug, J.; Dehn-Neef, S.; Halsband, A.; Moser, L.; Potyra, T.: Modular Approach to Material Card Gen- eration Accelerating Composite Part Development. SPE ACCE Conference, Detroit, September 5 to 7, 2018 ATZ worldwide 03|2021 21
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