Honda Malaysia is inviting everyone to celebrate their “Road to 900,000th Unit Milestone Campaign” Grand Finale on the 28 and 29 September 2019 at the Bukit Jalil National Stadium open car park (free entry for all). There will be loads of activities as they celebrate 17 successful years since their establishment here in the country. (more…)
After playing a starring role in Land Rover’s 70th anniversary celebrations last year, the ‘missing’ original launch Land Rover demonstration vehicle from the 1948 Amsterdam Motor Show has returned to the road for the first time since the 1960s, following a year-long restoration.
Rebuilt by a team of experts at Land Rover Classic at its Classic Works facility in England, which is dedicated to preserving Land Rovers out of production for 10 years or more, it was renovated using a mixture of traditional skills, original drawings and 21st century technology.
Found in a garden after decades
The historically important pre-production vehicle, which had vanished for decades but was found in 2016 in a garden near the Solihull factory where it was built, has been kept as authentic as possible and returned to its correct 1948 specification – including left-hand drive configuration, prototype braking system and all-wheel drive controls.
This approach required the team to strip the vehicle down to its bare chassis and begin a painstaking process of testing and checking which components could be reused and rebuilt following decades of decay and rust.
“It was important to strike the right balance when restoring the launch Land Rover. While there was a need to replace some parts, we were keen to keep as much of the original vehicle as possible in order to retain the unique characteristics of this 70-year old model. The team has done an incredible job and the end result is a testament to the unique expertise and tireless passion of the experts at our Classic Works facility,” said Calum McKechnie, Head of Land Rover Classic.
While the front axle required no significant repairs, the rear axle showed signs of extreme damage and fatigue. To understand the extent of the problem, the original part was X-rayed and depth-tested using state-of-the-art techniques and found to be strong enough to keep, rather than be replaced. During this process, the technicians even uncovered the original axle number, which was thought to be lost.
Original 4WD system
The original through-dash selectable 4WD system controls, known by enthusiasts as the ‘Organ Stops’ due to their similarity with the controls found on church organs, were also reinstated. The trio of pull-push knobs on the dash panel operate the 2 and 4-wheel drive transmission and High and Low range gear selection. This system was only fitted to some early pre-production Land Rovers, before being replaced by a simpler set-up for production. Land Rover Classic technicians used their expert knowledge to reinstate the original combination of rods, levers and linkages to replicate the design of the vehicle when it made its first appearance in 1948.
Pre-production Land Rovers were also fitted with a Lockheed braking system, while customer vehicles featured Girling brakes. Over the intervening decades, the rare set-up on the ‘missing’ Land Rover had been removed, so Land Rover Classic referenced period drawings to restore the authentic Lockheed design. This meant engineering replacement master and wheel cylinders, drums, pads and backplates before the brake pipes were carefully hand-fitted to match the routes followed on the original vehicle.
Year-long restoration of flaking paintwork
The flaking exterior paintwork doesn’t look like it has been subject to a year-long restoration but the goal was always to retain the patina of this important vehicle. Minor repairs were made to the original panels to remove tears and sharp edges. Where new panels were needed, they were recreated in original 2 mm thickness aluminium – unique to pre-production models – and painted in the original light green paint, colour matched from the underside of the original seat base, before being aged to complement the original panels.
“Bringing this historically important Land Rover back to life was a huge challenge, given its wear, tear and decay from the elements since the 1960s, but also a real pleasure. Being able to open up our archive and revisit the original Land Rover engineering programme from over 70 years ago was a great privilege for the whole team,” noted Michael Bishop, one of the engineers on the restoration team.
With the original badge missing, the team went to great lengths to ensure this was recreated exactly as it was more than 70 years ago. To do this, they digitised a photograph of another Land Rover on the stand at the 1948 Amsterdam Motor Show. In-house Computer-Aided Design specialists then transposed the photograph to calculate the size of the lettering and its position on the front wing to cast an accurate replacement.
Interesting discoveries…
Interesting discoveries during the work included an original sixpence coin from 1943 which had been deliberately left under the galvanised capping of the rear tub, as a hidden memento. The team also worked with the Forestry Commission to identify the wood type used for the sections at the rear of the front seats. These ash elements were then replaced like-for-like.
With a fully-rebuilt engine incorporating specially-made pre-production-specification high-compression pistons, the result is a vehicle that drives just like it did when it left the factory and retains the unique patina acquired over more than 7 decades of use and disuse.
Related story: The Last Overland Expedition For The First Land Rover Driven From London To Singapore
Drinking water is good for you and many take water bottles with them in their car or bag when they go out. However, where the empty bottle ends up is not always certain. Those who care for the environment will make sure they dispose of the plastic bottle in the right place, like a rubbish bin if not a recycling centre. Many though will just throw it by the roadside without a thought and if not collected, it will remain there for the next 450 – 1,000 years, depending on the type of plastic used.
In coastal areas, the bottle may wash into a drain and then into the sea where it joins other rubbish – and more plastic bottles – that float around. Sea creatures are at risk and in areas such as the Pacific gyre, there is a floating mass of plastic bigger than the size of Mexico in the Pacific Ocean!
Carmakers undertake recycling activities
It’s a big challenge getting mankind to stop such pollution so car companies like Ford are helping by using recycled plastic bottles for auto parts. Ford’s use of recycled plastics dates back to the 1990s. In the past decade, aerodynamics has driven the need for underbody shields, and the use of plastics in vehicle parts is used globally and has grown exponentially. Ford uses about 1.2 billion recycled plastic bottles per year – about 300 bottles per vehicle on average.
One area where the plastic bottles are used is the underbody shield of the car. “The underbody shield is a large part, and for a part that big, if we use solid plastic it would likely weigh 3 times as much,” said Thomas Sweder, a design engineer at Ford Motor Company. “We look for the best materials to work with to make our parts, and in this case, we are also creating many environmental benefits.”
Ideal material
Due to its light weight, recycled plastic is ideal for the manufacture of underbody shields, engine under shield, and front and rear wheel arch liners that can help improve vehicle aerodynamics, which impacts fuel efficiency.
Here’s how it works: when plastic bottles are thrown into a recycling bin, they are collected with thousands of others, and shredded into small pieces. That’s typically sold to suppliers who turn it into a fibre, by melting the bottle and extruding it. Those fibres are mixed together with other various types of fibre in a textile process and used to make a sheet of material – which is then used to make the automotive parts.
“Ford is among the leaders when it comes to using materials such as this, and we do it because it makes sense technically and economically as much as it makes sense for the environment,” Sweder said. “This material is very well suited for the parts we’re making with it and is extremely functional.”
The folks from BMW Malaysia has unveiled their latest addition into the locally assembled premium selection in the form of the new BMW 330i M Sport. Priced at RM288,800 (OTR without insurance), the new seventh-generation model is assembled at their facility located in Kulim, Kedah. Simply put, the new 330i is lighter, faster, and designed with better aerodynamics than ever before. (more…)
The Proton 1 Tank Adventure is back for its second year running and to kick things off, the first opening preliminary round took place over the Malaysia Day weekend where 30 cars took part in a 650km adventure from Proton’s Centre of Excellence (COE) to Johor Bahru AND back! (more…)
Geely Auto’s global flagship SUV, the Bo Yue, has already drawn over 750,000 users in China alone since its launch in 2016. It has also found great success in Malaysia as the X70 sold by Proton which is Geely’s affiliate.
In Russia, the Geely brand is also growing fast and has the Bo Yue as its flagship SUV – but sold with the name of Atlas. As in Malaysia, the SUV is presented as a smart SUV with Yandex Auto functionality. This gives new intelligent mobility experience to Russian speaking markets through a smart cockpit system jointly developed by Geely’s strategically invested technology company, ECARX and Russian internet giant, Yandex.
Produced in Geely Auto’s plant in Minsk for the Russian and Belarus market, the model’s interface has been specially developed for Russian-speaking users based on the GKUI Geely Smart Ecosystem. The GKUI was developed by ECARX and first launched on the Geely Bo Yue in China. It is now installed in over 22 Geely Auto vehicles. In the newly formed partnership, Yandex is responsible for software development and application localization with ECARX providing the platform.
‘Hi Alice’
To meet the demands of Russia users for localized digital services, ECARX has modified the GKUI in the locally produced Atlas with Yandex Auto and Russian digital voice assistant ‘Alice’ (in the Malaysia X70, the command is ‘Hi Proton‘). Users can utilize the intelligent voice assistant for navigation, search, and entertainment needs as well as control more functions of the Atlas in Russian.
Through the partnership, the two sides will be able to give full play to ECARX’s experience in intelligent connectivity and Yandex’s Russian digital services infrastructure. The strategic cooperation with Yandex marks the beginning of ECARX’s entry into the European market.
With the addition of the new dedicated E-series chips, the updated GKUI19 adds greater AI capabilities to the system. In the latest platform, the GKUI cloud has been upgraded to an AI cloud, GKUI mobile phone inspired desktop has been upgraded to a smart desktop which utilizes AI to intuitively configure itself depending on the user’s needs, GKUI One-ID has been upgraded to all-round ID with support for different application ecosystems from GKUI’s eco-partners, and GKUI ecosystem has been upgraded with a developer platform allowing greater integration across the internet. GKUI is now able to connect seamlessly with Xiaomi smart devices, Baidu smart devices, JD.com smart devices and other smart devices allowing users to control their home or office appliances from their car.
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It was a very good weekend for Citroën as their C3 WRC teams consisting of Sébastien Ogier / Julien Ingrassia and Esapekka Lappi / Janne Ferm achieved a magnificent one-two finish at the Rally Turkey. The results obtained over the weekend also means that the French manufacturer and team are back in the running for the drivers’ and co-drivers’ world titles. (more…)
The much-loved Volkswagen Beetle ceased production twice – the first time in 2003 after a 39-year run and the second time in July this year. With the second event, Volkswagen made it clear that the model line will not have a successor.
However, as with any model that is so iconic, fading into history is not going to happen easily. Even with the first and original generation, there are many units preserved by collectors which will be around for decades to come.
Electrifying the Beetle
And even at Volkswagen, a subsidiary known as Volkswagen Group Components has come up with a holistic concept for the electrification of the historic model. The conversion exclusively uses new parts they have mutually agreed on from the mass production of Volkswagen Group Components. The electric drive, the 1-speed gearbox and the battery system are based on the new VW e-up!. The conversion of the historic Beetle is being carried out by the specialist company eClassics.
“The electrified Beetle combines the charm of our classic car with the mobility of the future. Innovative e-components from Volkswagen Group Components are under the bonnet – we work with them to electrify historically important vehicles, in what is an emotional process,” explained Thomas Schmall, Member of the Board of Management of Volkswagen Group Components. “We are also providing Beetle owners with a professional conversion solution, using production parts of the highest quality.”
New VW e-up! as technical basis
The technical basis for the conversion is provided by tested production parts from Volkswagen’s new e-up! These are manufactured at Volkswagen Group Components production sites. The components work together in the e-Beetle as an electric drive that reaches performance peaks of 60 kW/82 ps. The lithium-ion battery pack is built into the underbody and consists of up to 14 modules, each with a capacity of 2.6 kWh, cumulatively delivering energy of up to 36.8 kWh.
The higher performance and the increased weight due to the extent of electrification require the adaptation and reinforcement of the chassis and the brakes. Despite the new total weight of 1,280 kgs, the e-Beetle accelerates to 50 km/h in just under 4 seconds and to 80 km in just over 8 seconds.
The range of the e-Beetle, which reaches top speeds of up to 150 km/h, is 200 kms – a comfortable distance for a relaxing day out in a classic car with a ‘new heart’. In the event that the e-Beetle runs out of electricity during the trip, fast charging is possible via a combined charging system. As a result, the e-Beetle can store enough energy for a journey of over 150 kms after recharging for around an hour. That would be about the time spent at a cafe along the way.
Concept can be transferred
Based on this concept, the subsequent electrification of other historic vehicles will also be possible. We are already working together to prepare the platform for the Bus. An e-Porsche 356 could also be pursued in the future,” Mr. Schmall hinted. The use of the modular electric drive matrix (MEB) is also being considered. This creates additional opportunities regarding performance and range.
About Volkswagen Group Components
As an entrepreneurially independent business unit under the umbrella of Volkswagen AG, Volkswagen Group Components is responsible for the development and production of strategic components for the Group’s vehicle-producing brands. 80,000 employees work in over 60 plants at 47 production sites worldwide in five business areas – Engine and Foundry, Gearbox and Electric Drive, Chassis, Seats and Electric Mobility. They develop and manufacture vehicle components, shape future topics such as charging infrastructure and battery recycling – and thus make a decisive contribution to the value of the Volkswagen Group, its brands and products.
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Ever since the 1990s, when increasingly intense competition forced carmakers to bring their production costs down as much as possible, one of the approaches taken was to create common platforms which could be used for a variety of models. Before, each model might have its own platform with unique or different parts and systems but this gave poor economies of scale and higher costs. Thus from what might have been 10 platforms, the entire range would use perhaps 6, on which would sit models for different size and bodystyle segments.
The use of common platforms meant that many engineering items and electronics systems could be shared. Customers didn’t really care anyway: they didn’t see platforms and architecture; they saw what was on top of the platforms and that was where talented designers earned their money. Their experience of the model was how it drove and how it felt to them, so the engineers worked hard on driving dynamics.
Toyota New Global Architecture
Toyota, like the other carmakers, rationalised its platform strategy and over the past decade, its new platforms under the Toyota New Global Architecture (TNGA) philosophy has delivered a step-change in the ride, handling and styling of a series of recent new models.
The first, the GA-C platform for mid-sized cars – is the foundation for advances in the driving character and appeal of the latest generation Prius, the C-HR and the latest 12th generation Corolla. Similarly, the TNGA philosophy has demonstrated its capability for larger sedans and SUVs, with the GA-K platform underpinning the new Camry and the new RAV4 to great effect. It is also used for the newer Lexus models.
GA-B for smaller cars
Now, Toyota is preparing to apply the philosophy and technology of TNGA to elevate the design and driving performance of its small cars with the GA-B platform. In common with the GA-C and GA-K platforms, the new GA-B platform is designed to deliver better driving dynamics with more comfort.
This is achieved through a number of techniques. First of all, the platform features advanced joining technologies that contribute to high levels of underbody rigidity whilst maintaining a focus on weight and cost.
Secondly, the MacPherson strut front suspension features low friction dampers and a variety of spring types. The rear suspension can be specified as either torsion beam or multi-link design, depending on vehicle character and type. This gives the chassis engineers a degree of flexibility which they didn’t have before.
Last, but not least, the GA-B platform also positions the driver’s seat low and back towards the centre of the car, helping to lower the vehicle’s centre of gravity. This also creates an engaging driving position with a steering wheel that can be set close to the driver at an optimised angle.
Smart packaging
The new GA-B platform has also been designed to maximise interior space through its approach to smart packaging delivering a spacious and comfortable interior. The TNGA philosophy positions non-visible components to simplify vehicle design in key areas. As a result, vehicle designers will have the freedom to give each new GA-B model a visually distinctive and individual look with a low stance and appealing proportions.
In addition, the upper body hard points and the driver’s hip point are positioned low to give designers further freedom to create vehicles with a low height and wide stance. This kind of visual appeal is aided by the positioning of the wheels at the platform corners, with very short overhangs. And the combination of a long wheelbase architecture and a smart approach to packaging ensures that interior space is not compromised despite possible compact exterior dimensions.
Modular system
The new GA-B platform offers a great deal of modularity, with a variety of wheelbase lengths, vehicle heights and track widths, allowing designers and engineers to create vehicles of different sizes and body types. This is important since consumers like to have variety, and it can be achieved without having to engineer separate platforms at extra cost.
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In the early years of the auto industry, the factories that produced cars and the parts for them were once confined only to the countries that the manufacturer was established in (BMW in Germany, Toyota in Japan, Ford in the USA, etc). However, as the auto industry rapidly expanded around the globe and cars were being sold in other countries as well, it made sense to produce them closer to the markets. And from the 1960s onwards, as more countries began industrialising – like Malaysia – incentives were also offered to carmakers to invest in local production.
Globalisation of the industry has led to factories being set up all over the world, some to serve a few markets and some as production hubs for regions or even the entire world. The need to have huge volumes for economies of scale that drive down costs is one reason for this approach. There are also political considerations which come into play as exports of vehicles from one country to another need to be ‘balanced’.
While the construction of new factories to make vehicles is ongoing, there is now a wave to establish factories to supply parts and systems for the coming era of electrification. The next decade will see a leap in hybrid and electric vehicles and demand will be great, so the factories must start up now in order to be able to meet that demand.
Incentives matter as well as policy clarity and stability
Choosing a country to build a new factory requires not just careful planning but also consideration of the incentives offered by the government. The investments and job opportunities as well as export potential are also attractive enough to governments to offer investments to attract carmakers. Clarity and stability of automotive policies is also important as carmakers plan over many years and they need to be assured that changes are not made just because a new minister has taken over and had other ideas about the direction.
Thailand has been good at policy stability, which is probably on reason why a number of global players built their production hubs there. Changes of government may occur but policies are maintained and that’s what matters.
BMW chooses Thailand
Following on from BMW Group Thailand’s earlier endorsement for incentives by Thailand’s Board of Investment (BoI) for a 700 million baht (about RM96 million) outlay in BMW plug-in hybrid electric vehicle (PHEV) production, the company has jointly invested with DRAXLMAIER Group in this battery assembly plant, worth 500 million baht (about RM69 million).
“This new beacon for e-mobility innovations will further unlock the competence of Thailand’s automotive industry. The incentives from BoI also symbolize the unity between the public and private sectors in this undertaking towards a sustainable future,” BMW notes.
BMW Group Thailand has thus marked another historic milestone with the inauguration of a local high-voltage battery production plant in partnership with the DRAXLMAIER Group, one of the world’s leading automotive suppliers and a partner of BMW Group since 1966. BMW Group Thailand launched the local assembly lines in July 2019 at the plant in WHA Chonburi Industrial Estate 2. The high-voltage battery assembly plant is assembling both battery modules and the battery itself.
Uwe Quaas, MD of BMW Group Manufacturing Thailand said: “One of the pillars of BMW Group’s global strategy is electrification, and BMW Group Manufacturing Thailand is underlining its commitment to this mission by taking another big step forward in our electro-mobility strategy. The start of local battery production enables us to better respond to growing domestic demand for electrified vehicles in Thailand. This new capability also strengthens the performance of Plant Rayong in fulfilling the country’s mission of sustainable mobility.”
Fully trained workforce
The high-voltage battery is a central element of partially and fully electrified vehicles and a highly sophisticated component that requires specialized skills to produce. Thanks to the advanced training and qualification programs initiated in September 2018, the staff from the DRAXLMAIER Group who have participated in the battery production training program at BMW’s Group Plant Dingolfing – the BMW Group Competence Centre for e-drive production – and the BMW Group pilot plant for e-drivetrains in Munich, are now ready for the high-tech assembly work to produce the latest generation (Gen4) of the BMW Group high-voltage batteries
This involves the use of cutting-edge production technologies onsite including laser welding, plasma activation, robotics, gluing, automated optical and electrical inline quality inspection along with end-of-line testing. The training is also focused on supporting a highly automated process, which is an important part of battery module production, as well as comprehensive quality assurance, product methodology and technology, rework, and analysis.
World-class standards and quality
Equipped with a strong grasp of battery production skills, the staff will work on battery cells provided by a supplier in the Asian region along with other imported parts – such as aluminium housing, electronics, and cables – to roll out high-voltage battery packs that meet BMW Group’s world-class standard and are in full compliance with Thailand’s local content requirement regulation.
Completed battery packs will then be transported to Plant Rayong for the production of the entire range of BMW 5-Series Plug-in Hybrid Vehicles, which has been in operation since July 2019. Since 2017, BMW Group Manufacturing Thailand has assembled four BMW plug-in hybrids at Amata City Industrial Estate, Rayong province.
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