A couple of months back, we wrote about Everrati Automotive Limited and its new flagship 500-bhp Signature adapted from a Porsche 911. The British company, which specialises in converting iconic cars to run with electric powertrains, has now teamed up with Superformance to build an electrified version of the GT40.
Superformance is a specialist in 1960s-era continuation component sports cars and the GT40 will be the first new model from the partnership. The iconic endurance racing car will be ‘future-proofed’ with a high-performance electrified powertrain and join Everrati’s offerings. The range includes EV versions of the Porsche 911 (964), Land Rover Series IIA and Mercedes-Benz SL Pagoda.
The 500-bhp Signature adapted from a Porsche 911 (left) and GT40.
The original Ford GT40 which was raced at Le Mans and Daytona.
Furthering the legacies of iconic cars
Everrati was founded to further the legacies of some of the most desirable and iconic cars in the world, redefining and precision re-engineering them with state-of-the-art electric drivetrains, maintaining and enhancing the character of the original.
Each Everrati is fitted with a custom-designed electric power unit and battery system, leading to enhanced performance and a zero-emissions future. A prototype chassis has been built and is being comprehensively adapted from combustion engine powertrain to advanced electric propulsion at Everrati’s UK development centre located at a former US airbase in England.
Superformance already offers a full line of high-performance component cars based on some of the most iconic vehicles of all time. All vehicles are built under license from trademark holders including GM and SAFIR GT40, adding authenticity and value. Sold as a rolling chassis, a Superformance car can be configured with heritage or modern drivetrains.
As with all Everrati vehicles, meticulous attention to detail is being applied to key factors such as battery location and weight distribution to maintain and enhance the character and soul of the original.
Angle-American partnership
“So many legendary cars were created by Anglo-American partnerships during the 1960s. In fact, the very first GT40 was brought to life in the early Sixties by a UK-based team led by British engineer, Roy Lunn, at Ford Advanced Vehicles in the UK. Its body was even made by Abbey Panels in Coventry, before the finished car was shipped to the US for its unveiling the day before the New York Auto Show, in April 1964,” noted Justin Lunny, Founder & CEO of Everrati.
“So, it feels highly appropriate for Everrati to be partnering with Superformance, furthering not only the legacy of automotive icons but the partnership between the UK and US. Another cross-Atlantic connection is that our development HQ is located on a former US air base in the Oxfordshire countryside,” he added.
The Superformance factory in California is one of the world’s largest specialty car production facilities. It has produced and distributed more than 5,500 rolling chassis through 25 independent dealerships worldwide.
Mercedes-Benz is getting ready to go all electric by the end of the decade – but only where market conditions allow. The carmaker, like a few others, understands that there will be some markets where electrification may not be sufficiently wide and conventionally powered vehicles will still be in demand.
Mercedes-Benz began in journey to electrification some years back and by 2022, it will have battery electric vehicles (BEV) in all segments which the brand competes in. From 2025 onwards, all newly launched vehicle architectures will be electric-only and customers will be able to choose an all-electric alternative for every model the company makes.
“The EV shift is picking up speed – especially in the luxury segment, where Mercedes-Benz belongs. The tipping point is getting closer and we will be ready as markets switch to electric-only by the end of this decade,” said Ola Kallenius, CEO of Daimler AG and Mercedes-Benz AG. “This step marks a profound reallocation of capital. By managing this faster transformation while safeguarding our profitability targets, we will ensure the enduring success of Mercedes-Benz. Thanks to our highly qualified and motivated workforce, I am convinced that we will be successful in this exciting new era.”
To facilitate this shift, Mercedes-Benz has a comprehensive plan which includes significantly accelerating R&D. In total, investments into battery electric vehicles between 2022 and 2030 will amount to over €40 billion. Accelerating and advancing the EV portfolio plan will bring forward the tipping point for EV adoption.
The Technology Plan
In 2025, Mercedes-Benz will launch three electric-only architectures – MB.EA, AMG.EA and VAN.EA. These will cover a broad spread of products, including those in the commercial vehicle sector. MB.EA will be for all medium to large size passenger cars, establishing a scalable modular system as the electric backbone for the future EV portfolio. AMG-EA, as the three letters hint, will be a dedicated performance electric vehicle platform, while VAN.EA will usher in a new era for purpose-made electric vans and Light Commercial Vehicles.
The eATS is the engine unit of electric vehicles. The eATS consists essentially of the three subsystems: an electric motor, its power electronics and the transmission part for power-transmission.
After reorganising its powertrain activities to put planning, development, purchasing and production under one roof, Mercedes-Benz will deepen the level of vertical integration in manufacturing and development, and insource electric drive technology. In-house electric motors, such as the eATS 2.0, are a key part of the strategy with a clear focus on efficiency and the overall cost of the entire system. China, the world’s largest new energy vehicle market, which is home to hundreds of companies and suppliers specialized in EV components and software technologies, is expected to play a key role in accelerating the Mercedes-Benz electrification strategy.
Ensuring supply of batteries
To ensure that there will be an assured supply of batteries, Mercedes-Benz will need a battery capacity of more than 200 Gigawatt hours. This calls for setting up 8 Gigafactories for producing battery cells, and is in addition to the already planned network of 9 plants dedicated to building battery systems.
Battery production is a very important part of electrification since batteries are needed in every vehicle. Mercedes-Benz has already established a network of battery production sites around the world, with the one in Thailand (below) having started operations in 2019.
Next-generation batteries will be highly standardized and suitable for use in more than 90% of all Mercedes-Benz cars and vans while being flexible enough to offer individual solutions to all customers. Cell production will give Mercedes-Benz the opportunity to transform its established powertrain production network. By continuously integrating the most advanced battery cell technology in cars and vans, Mercedes-Benz aims to increase range during the production lifecycle of a model.
The recharging network
For EV owners, the issue of recharging is an important one and unless they can be assured of a convenient and widespread network, switching to an EV will not be readily considered. In this area, Mercedes-Benz is also working on setting new standards in charging that will allow customers to plug-in, charge and unplug without extra steps needed for authentication and payment processing.
As for networks, Mercedes me Charge is already one of the world’s largest charging networks and currently has more than 530,000 AC and DC charging points worldwide. Mercedes-Benz is also working with Shell on expanding the charging network which will have over 30.000 charge points by 2025 in Europe, China, and North America.
Right from the start, the battery pack has been a crucial element for the development of electric vehicles (EVs). The earliest EVs in the 1930s used very heavy batteries which made them unappealing, apart from the fact that performance was poor. Not much development of batteries took place in the decades that followed as the internal combustion engine dominated the auto industry and the battery’s role was minimal – mainly to start the engine.
It was only by the end of the 20th century that development of batteries started picking up, as interest in EVs started growing. Although the lead-acid type (the small one in the engine bay of cars) was used, it was totally unacceptable as its storage capacity was small and it was heavy. But R&D into this area accelerated and it was possible to use other chemical processes that could achieve a higher density and capacity for battery packs. Currently, it is the lithium-ion battery pack that is widely used in many EVs and hybrids.
Second generation of the Prius Aqua/Prius c
Now, Toyota has come out with another type of battery with a high output bipolar nickel-hydrogen battery. This is installed in the all-new Aqua (also known as Prius c) that is launched in Japan today and it is the first vehicle in the world to use this type of battery. Compared to the nickel-hydrogen battery that was used by the previous generation of the Aqua, the new more compact battery can provide approximately twice the output while enhancing performance and range.
Since the launch of the first-generation Prius in the late 1990s, Toyota has accumulated expertise both in the technological development and the quality management of batteries and hybrid systems. One subsidiary, Toyota Industries Corporation, has developed proficiency in analysis technologies for the development and performance assessment of materials through many years of developing batteries for electrified forklift trucks. By combining their respective fields of knowledge, the companies have worked to develop better batteries and their efforts have led to the development of bipolar nickel-hydrogen batteries.
First generation of the Prius c was sold in Malaysia for a few years when the government allowed full tax exemption on hybrid vehicles.
What is a bipolar battery?
In bipolar nickel-hydrogen batteries, a cathode is applied to one side of the current collector, and an anode to the other; several of these structures, which are known as ‘bipolar electrodes’, are stacked together to form the battery architecture. Compared to non-bipolar nickel-hydrogen batteries, bipolar versions consist of fewer current collectors and other parts, enabling them to be made more compact. It is possible to stack a larger number of cells in bipolar nickel-hydrogen batteries than in non-bipolar nickel-hydrogen batteries of the same size.
In addition, since bipolar batteries have a greater active surface area and a simpler construction, there is lower resistance within the battery itself. This enables the flow of larger currents, leading to increased output. As an example, the bipolar nickel-hydrogen battery equipped to the all-new Aqua has an output approximately 2 times higher than the non-bipolar nickel-hydrogen battery used in the previous Aqua.
Toyota’s own battery factories
Toyota has its own battery manufacturing subsidiaries but it’s not known which company is producing these new batteries. Back in 1996, Toyota formed a joint-venture with Panasonic to develop and manufacture batteries for electrified vehicles. It was first known as the Panasonic EV Energy Company but changed its name to Primearth EV Energy Co., Ltd. (PEVE) in 2010 when Toyota became the majority shareholder.
Primearth EV Energy, Toyota’s first joint venture with Panasonic to develop and produce batteries for its hybrid vehicles.
PEVE focussed on making prismatic nickel–metal hydride (NiMH) as it worked on improving the quality of lithium-ion batteries. It began mass production of these higher performance batteries in early 2011.
Toyota also has a second joint-venture with Panasonic which was established just last year. Known as Prime Planet Energy & Solutions (PPES), it will handle development, manufacture, and sales of high-capacity and high-output prismatic lithium-ion batteries, solid-state batteries and next-generation batteries for automotive application.
Prime Planet Energy & Solutions is the second joint venture that Toyota has with Panasonic to make batteries for electric powertrains in motor vehicles. The company has two factories with the one in Japan (below) to have a capacity of 80,000 batteries annually and a second one in China which is expected to supply batteries for up to 400,000 hybrid electric vehicles per year.
PPES has an ambitious target to reduce battery costs by up to 50% this year. This will be achieved by expanding production capacity at two factories – one in Japan which will supply up to 80,000 battery electric vehicles annually, and a second one in China which is expected to supply batteries for up to 400,000 hybrid electric vehicles per year.
The auto industry is accelerating towards electrification of products, ultimately leaving behind the combustion engine that has been blamed for causing pollution of the environment and bringing on climate change. However, unlike previous transitions, this one is a radical one that calls for a change in the ecosystem of the industry. The existing ecosystem has evolved over 100 years around the combustion engine and now, with electrification, manufacturing processes and supply chains need to be changed.
Different carmakers are taking different approaches and Nissan will make a total investment of £1 billion (about RM5.82 billion) in establishing a flagship Electric Vehicle (EV) Hub as a world-first EV manufacturing ecosystem. To be known as Nissan EV36Zero, the core of this hub will be at its 35-year old manufacturing complex at Sunderland in the United Kingdom.
The transformational project has Envision AESC, a global player in world-leading battery technology, and the Sunderland City Council as partners. Made up of three interconnected initiatives, Nissan EV36Zero brings together electric vehicles, renewable energy and battery production, setting a blueprint for the future of the automotive industry.
“This project comes as part of Nissan’s pioneering efforts to achieve carbon neutrality throughout the entire lifecycle of our products. Our comprehensive approach includes not only the development and production of EVs, but also the use of on-board batteries as energy storage and their reuse for secondary purposes,” said Nissan President & CEO, Makoto Uchida. “The experience and know-how gained through the project will be shared globally, enhancing Nissan’s global competitiveness.”
Building on Nissan’s historic presence in Sunderland, the projects represent 6,200 jobs at Nissan and its UK suppliers, including more than 900 new Nissan jobs and 750 new Envision AESC jobs at its new smart, low-carbon battery plant. Longer-term, the transformational project modernises and expands Nissan’s EV production capability in the UK.
Envision AESC will deploy integrated AIoT smart technology to monitor and optimize energy consumption, manufacturing and maintenance at its new gigafactory, enabling it to rapidly increase production and provide batteries to power up to 100,000 Nissan electric vehicles a year.
New-generation electric crossover
As part of the investment, Nissan will invest up to £423 million to produce a new-generation EV in the UK. Utilising the Alliance CMF-EV platform, it will be designed for global markets with forecasted production capacity of up to 100,000 units to be installed.
Next-generation EV batteries
Envision AESC already owns and operates Europe’s first battery plant in Sunderland, established in 2012 for the localisation of Nissan LEAF battery production. The factory’s UK team therefore has 9 years’ expertise of supplying batteries to the Nissan LEAF and eNV200, having produced enough cells, modules and packs to power over 180,000 electric vehicles in 44 countries, meeting global benchmark levels of quality, performance, safety, reliability and cost.
Supporting this new model allocation, Envision AESC will invest £450 million (about RM2.62 billion) to build the UK’s first gigafactory on the International Advanced Manufacturing Park, adjacent to the Nissan plant, powered by renewable energy and pioneering next-generation battery technology. This new plant will increase the cost-competitiveness of EV batteries produced in the UK, including through a new Gen5 battery cell with 30% more energy density which improves range and efficiency. It will also make batteries cheaper and EVs more accessible to a growing number of customers in the future.
Nissan LEAF battery pack.
Used battery packs have second life
There are also plans for a 1MW battery storage system using second-life Nissan EV/Envision AESC batteries, which will also allow for excess energy generated during daylight hours to be captured and used at another time, helping to balance demand on the grid.
UMW Toyota Motor (UMWT) has announced plans to assemble Toyota hybrid models in Malaysia, joining the still-small group of companies that are doing so. The move is driven by Toyota Motor Corporation’s (TMC) global commitment to deliver ‘mobility for all’ and produce ‘happiness for all’ through its commitment towards a ‘Clean, Safe and Secure Society’.
On a larger scale, TMC is aiming for carbon neutrality by 2050 in all its processes. Carbon neutrality means almost zero emissions of carbon dioxide (CO2) which is a ‘greenhouse gas’ that is known to have a significant effect on global warming, causing climate change.
TMC’s reduction of CO2 emissions will encompass the lifecycle of manufacturing, transporting, operating, fuel and/or charging, and recycling and disposal of vehicles. This is in line with the global approach towards lifecycle assessments of the potential environmental impact of a product throughout its lifecycle.
The Prius – one of the many models in Toyota’s range of hybrid electric vehicles.
Full line of Low Emission Vehicles
As part of this strategic initiative, the carmaker will produce a full line-up of Low-Emission Vehicles which will have electrified powertrains. There will be various powertrains to meet diversified mobility demands all over the world as well as the different rates of vehicle electrification.
“Toyota’s global direction is to achieve carbon neutrality by 2050. This is also in line with the Malaysian government’s aspirations to position the country as a progressive nation that promotes more green technology and environmental sustainability,” said UMW Toyota Motor’s Deputy Chairman, Akio Takeyama.
“This is indeed an exciting time for the Malaysian automotive industry and UMW Toyota Motor is fully charged and ready to champion this Malaysian dream. In order to achieve this, the most realistic, practical and immediate solution is Toyota Hybrid Electric technology and vehicles,” he added.
Toyota is among the pioneers of mass-produced hybrid electric vehicles, having started selling them in the late 1990s. The hybrid technology has also been used in Lexus models like the CT-200h (shown below).
A pioneer in hybrid technology
Toyota has long experience in electrification and was a pioneer in the production and marketing of hybrid vehicles. Since the late 1990s, the company has sold more than 17 million hybrid electric vehicles as well as Hydrogen Fuel Cell Electric Vehicles (FCEV) worldwide.
This number of vehicles with low emissions has made Toyota’s cumulative contribution to CO2 reduction amounting to 140 million tonnes of CO2, or approximately 1.5 million conventional passenger vehicles per year over the past 20 years.
The CO2 reduction will continue and even increase as TMC aims to sell 8 million electrified vehicles annually by 2030. In April this year, the company announced an electric vehicle strategy that will see 15 new Battery-Electric Vehicles (BEVs) introduced by 2025. Including FCEVs, the total number of electrified vehicle models will be 70 by 2025.
Located in Bukit Raja, Selangor, Assembly Services Sdn Bhd (a subsidiary of UMW Toyota Motor) currently assembles the Yaris and Vios models. It began operations in January 2019.
RM270 million additional investment
Toyota’s operations in Malaysia, via the 39-year old joint-venture UMWT, will support the ‘big picture’ in achieving carbon neutrality by investing RM270 million in its manufacturing operations. This amount includes, amongst others, the introduction of a new and technologically-advanced generation of hybrid models.
“We are ready [with the introduction of Hybrid Electric Vehicles], and the technology; service support; current infrastructure; global and domestic policies; the level of affordability and cost effectiveness; and, consumer awareness and demand, particularly in Malaysia, are now at its most ideal conditions to pursue a new and exciting journey towards achieving carbon neutrality,” said Mr. Takeyama.
While neighbouring countries are encouraging the introduction full electric vehicles, Mr. Takeyama said that research has shown that the reduction in CO2 emission levels between fully electric and hybrid electric vehicles are almost similar when considering electricity source, and from production and throughout ownership.
For Malaysian consumers, the local assembly of Toyota hybrid vehicles will mean they are offered at a price point that is practical and accessible to the greater masses. “While time is still needed for full electrification, the hybrid electric technology is ready today and the current infrastructure permits it to be rolled out on a greater scale in Malaysia,” added Mr. Takeyama.
The locally-assembled Camry Hybrid introduced in 2015.
The time-frame for the introduction of locally-assembled hybrid models is not known yet, but this will not be the first time that UMWT is selling and assembling hybrid models for the Malaysian market. During the period when the government provided full duty exemption on hybrid and electric vehicles, UMWT imported models such as the Prius, Prius c and Lexus CT-200h. Later on, it assembled the Camry Hybrid which could be sold at a competitive price due to incentives offered by the government.
The investment will be additional to the RM2 billion that was made the construction and commissioning of a second assembly plant in Bukit Raja, Selangor, which began operations in January 2019. The original assembly plant, which continues to operate in Shah Alam, was among the earliest assembly plants in Malaysia and was one of the largest as well.
Other environment-related initiatives
“As a manufacturer, the immediate steps we can take to prevent global warming are to address our vehicles and manufacturing processes. But the initiatives do not and cannot stop here. It involves a conscientious change in mindset in society, educating the young of the importance of protecting the environment and requiring the active participation of all stakeholders,” said Ravindran K., President of UMW Toyota Motor
He added that that the interests of both Toyota and UMWT have gone beyond the automotive realm to offset the effects the CO2 emissions. For example, UMWT continues to be at the helm of numerous environmental initiatives. For 20 years, it has organised the Toyota Eco Youth program to cultivating environment consciousness and innovation amongst the youth of the nation involving schools, secondary school students and teachers.
“The ultimate goal will not rest solely on vehicle electrification, but to achieve carbon neutrality and zero emissions on all fronts – from putting cleaner vehicles on the road and addressing manufacturing processes, to helping to create greater awareness for the protection of the environment,” said Mr. Ravindran.
Mr. Ravindran believes the introduction of Hybrid Electric technology will quickly transform the automotive landscape in Malaysia for Malaysians. “We hope that our endeavours to popularise tomorrow’s technology today through the mass introduction of Hybrid Electric Vehicles (HEV) will receive due support from the government in the pursuit of a full-scale realisation of vehicle electrification. We hope that the government will also consider UMW Toyota Motor’s efforts to be included in the National Low Carbon Mobility Blueprint alongside Battery Electric Vehicles which is in line with the government’s plans,” he added.
Since the 1970s, Volvo Cars has displayed many concept cars and design studies. Many have been just studies while a handful, like the ECC of 1992 and the XC60 Concept of 2007, have been previews of near-term production models. In many cases, if you look at the new models that come out, there will be elements of concept cars in their design even if the concept car’s looks do not become a reality.
New paradigm in car design
With the Volvo Concept Recharge, the Swedish carmaker is giving a preview of its new paradigm in car design, a manifesto for the next generation of all-electric Volvos to be led by the next XC90 SUV to be launched next year.
True to the heritage of Scandinavian design, the Concept Recharge has the mantra of ‘less but better’ at its core. For example, with an electric powertrain removing the complexity of the internal combustion engine, the designers have been able to evolve the car’s proportions to increase interior space while also improving aerodynamic efficiency.
Architecture purely for electric powertrains
This isn’t Volvo’s first range of electric cars but before this, the designers have had to utilise architecture developed with combustion engine-powered cars in mind. That meant that the full benefits of an electric powertrain were not exploited as there was a need for a balance in proportions and space to be able to accommodate both a battery pack and an internal combustion engine.
The Concept Recharge breaks free of this association, using a completely new electric-only technology base. By removing the engine and replacing it with a full battery pack under the flat floor, the designers have extended the wheelbase and the wheel size of the car. The result is shorter overhangs, as well as a lot more interior space including a large storage area between the front seats.
In the Concept Recharge, these advancements have led designers to reposition the seats, optimise the roof profile and lower the bonnet of the car, while retaining the high eye point beloved by drivers of SUVs. This approach creates efficiency gains in aerodynamics compared to a typical SUV, which improves range.
New Volvo design language
This concept car also introduces a new Volvo design language. Continuing the theme of ‘less but better’, all unnecessary elements have been removed and what remains is treated with a high-precision, flush execution.
The traditional grille has been replaced with a shield-like structure; there is no longer the need for openings in the nose to let air in to help in cooling the radiator and engine. At either corner is a new interpretation of Volvo Cars’ Thor’s Hammer headlight design. These lighting units include the latest HD technology-enabled pure graphic which open at night to reveal the main lamp units.
The rear view also shows signature slim vertical rear lamps which first appeared on the 850 Wagon in the late 1990s. A visual connection to the brand’s strong design heritage, they have been reimagined with a set of wings that extend at higher cruising speeds to further improve overall aerodynamics.
“Our Concept Recharge represents a manifesto for the all-electric future of Volvo Cars, as well as a new type of vehicle,” said Robin Page, head of design. “It displays new and modern proportions that go hand-in-hand with increased versatility and shows what technology can enable in terms of design.”
New user experience inside
The Volvo design language also takes a new form inside. The flat floor provides more space and a better seating position for all those inside the car. A large, 15-inch standing touchscreen is the centre of the user experience for the company’s next-generation connected infotainment system.
“Inside the Concept Recharge, we create a truly Scandinavian living room feeling,” said Page. “The interior integrates our latest user experience technology with beautiful, sustainable and natural materials. Each part of the interior is like a piece of art and could stand alone as individual furniture in a room. We use the latest technologies but not for their own sake. We always focus on the benefits that technologies can bring.”
It doesn’t need to be said that the Concept Recharge also reflects Volvo Cars’ safety ambitions in coming years. A LiDAR sensor, built by technology company Luminar and a critical part of Volvo Cars’ plan for forthcoming safe autonomous drive technology, is placed in an optimal position on the roof to collect data on the environment around the car.
In April this year, Honda announced that by 2040, it will sell only fully electric vehicles (not even hybrids), a bold move that will end its relationship with the internal combustion engine much loved by Soichiro Honda.
While different regions may move at different speeds along the road to electrification of their vehicles on a national basis, advanced markets like North America are likely to start having a higher proportion of electric vehicles (EVs) in the coming years.
New BEV series for North America
Honda will therefore be focussing on products for that market and has announced that it is working on a new series of high-volume battery electric vehicles (BEV) to introduce in North America in early 2024. The range will be known as PROLOGUE and will be led by an all-new SUV and herald the new electrified era for the company.
The carmaker already has a range of electrified vehicles on sale, but these are mostly with hybrid powertrains, apart from the Clarity which uses hydrogen fuel cell technology to generate electricity for powering the car.
In addition to the Prologue, the company will introduce an all-electric model under the Acura brand as well. Acura currently has hybrid models as well, including the 573-bhp NSX and the new all-electric model will be a SUV as well.
GM Ultium platform and battery pack (below).
GM’s Ultium platform for EVs to be used
Both the Honda and Acura vehicles will utilize the highly flexible global EV platform powered by Ultium batteries developed within the strategic partnership with General Motors. The platform will be engineered to support Honda’s driving character. As part of the agreement to jointly develop electric vehicles, Honda will incorporate GM’s OnStar safety and security services into its new SUVs, seamlessly integrating them with HondaLink.
Production of the SUVs will combine the development expertise of both companies, and they will be manufactured at GM plants in North America. In the second half of the decade, Honda also plans to launch a new series of EV models based on a new e:Architecture, with development led by the Japanese carmaker. These new models will be launched in North America first, followed by other regions.
Honda’s EV History
Though EVs have grown in prominence in recent times, Honda has been involved in developing and producing such vehicles for almost 25 years. In 1997, it introduced the EV Plus, a small electrically-powered hatchback which was the first BEV from a major automaker to use nickel-metal hydride batteries instead of heavy lead-acid batteries.
EV Plus was produced between 1997 and 1999.
After the limited production of the EV Plus, Honda came out with the Insight in 1999. This was one of the first volume-produced hybrids in the market. The FCX came out in 2002 and it was the industry’s first commercialised vehicle using fuel cell technology that was originally developed for the space program. The FCX was succeeded by the Clarity in 2017.
First generation of the Insight, one of the early volume-produced hybrids. This unit was driven from Thailand to Singapore in January 2001 to demonstrate the high fuel efficiency.FCX – the first hydrogen fuel cell vehicle (FCEV) which was commercialised.
“We know customers who have a good experience with a hybrid vehicle are more likely to buy a battery electric vehicle in the future,” said Dave Gardner, Executive Vice-President of American Honda. “Our strategy is focused on introducing a higher percentage of hybrids in core models in the near term, making a committed effort to achieve higher volume leading to the introduction of our Honda PROLOGUE.”
Almost every day, there’s news about the electrification in the auto industry, if not the introduction of a new electric vehicle (EV). The industry, especially in Europe, has fast-tracked plans to move existing model fleets from using internal combustion engines to either hybrid or fully electric powertrains. Some companies even plan to stop selling vehicles with combustion engines before the end of this decade.
But there are also some companies that will look for a balance in the rush to electrification, focussing more on overall carbon neutrality (which can address climate change) for their entire operations, rather than just the products alone. Akio Toyoda, President of Toyota Motor Corporation, is one of those who feels that the rush to switch to zero emission vehicles is too excessive, demands massive investments and will damage the industry in some ways.
Whole world won’t ‘electrify’ at the same time
While governments are forcing the corporate hands of the carmakers to make the changes and cut emissions from vehicles, there will still be models with combustion engines on sale for a while. We don’t know yet how fast the infrastructure to support EVs can be developed and grow because, in some places, it doesn’t even exist yet. In Malaysia, for example, the number of recharging stations already set up is really just ‘a handful’ and an absence of a coherent policy to encourage sales and use of EVs has yet to be formulated.
While motorists in regions like Europe are steadily switching to electric vehicles, there are many millions elsewhere in the world who will continue to use vehicles running on fluid fuels for many more years.
So while some carmakers may feel that they can get by (in future) selling just EVs, there will be some who will still be developing models with combustion engines for the rest of this decade at least. Engineers can still push emissions down further to meet stricter regulations and a new generation of fuels will also help in this respect.
Renewable low-carbon fuels
These are renewable low-carbon fuels and following on from R33 Blue Diesel which has been around since 2018, Bosch, Shell, and Volkswagen have now come up with low-carbon petrol. Their new fuel, called Blue Gasoline, similarly contains up to 33% renewables, ensuring a well-to-wheel reduction in carbon emissions of at least 20% per kilometre driven. This means a fleet of 1,000 VW Golf Mk.8 1.5 TSIs alone could save more than 230 metric tons of CO₂ per year, assuming an annual mileage of 10,000 kms each.
Shell will offset the remaining carbon emissions from the use of Blue Gasoline through certified offset arrangements. The initial plan is to make the fuel available at regular filling stations over the course of the year, starting in Germany.
“On the road to climate-friendly mobility, we must ensure we don’t leave any technical opportunities untapped, starting with electromobility and ending with renewable fuels. Every bit of CO₂ we save can help us achieve our climate targets,” said Dr. Uwe Gackstatter, President of the Bosch Powertrain Solutions division.
“Blue Gasoline is another building block in the effective reduction of CO₂ emissions from the vehicle fleet. Blue Gasoline’s high storage stability makes the fuel particularly suitable for use in plug-in hybrid vehicles. In the future, the expansion of the charging infrastructure and larger batteries will mean that these vehicles predominantly run on electrical power, and thus that fuel may remain in the fuel tank for longer periods of time,” explained Sebastian Willmann, Head of Internal Combustion Engine Development at Volkswagen
Highest standards set for fuel quality and sustainability
Blue Gasoline fuel complies with the EN 228/E10 standard and even exceeds it in key parameters such as storage stability and boiling behaviour. High-quality additives also keep the engine extremely clean and protect it against corrosion. This means not only that the fuel can be distributed via the existing filling station network, but also that it can be used in all new and existing vehicles for which Super 95 E10 petrol has been approved.
The proportion of up to 33% renewables is made up of biomass-based naphtha or ethanol certified by the International Sustainability and Carbon Certification (ISCC) system. One source of such naphtha is what is known as tall oil, a by-product in the production of pulp for paper. But naphtha can also be obtained from other residual and waste materials.
Low-carbon fuels at Bosch company stations
In the Blue Gasoline project, the three partners jointly defined the fuel specification to be achieved, taking into account engine requirements and sustainability. They put the product they developed through intensive testing on engine test benches and in trial vehicles – with consistently positive results. Bosch has begun supplying Blue Gasoline at its company filling stations for the past month, with other stations scheduled during for rest of 2021.
The supply of conventional Super 95 E10 petrol will then be gradually phased out. Since the end of 2018, R33 Blue Diesel has been the only diesel fuel that Bosch company filling stations offer for company cars and internal delivery vehicles. R33 Blue Diesel is also becoming available at more and more regular filling stations in Germany. At present, it is offered at 8 filling stations belonging to different brands nationwide, with more set to follow.
Not a substitute for electromobility
For Bosch, renewable low-carbon and carbon-neutral fuels will not replace electromobility but complement it. In principle, the use of these fuels makes sense in all modes of transport, but especially in those for which there is as yet no clear and economical path to electrification. In addition to ships and aircraft, this applies primarily to heavy goods vehicles and existing vehicles, but also to the millions of vehicles with internal combustion engines or hybrid powertrains that are on the world’s roads today or will be built in the coming decades.
To promote rapid market uptake for these fuels, the focus is on renewable biomass and synthetic fuel components that can be blended into regular fuel in high proportions in line with existing fuel standards.
Electrically-powered cars are not new to Volvo but the new C40 Recharge will be the first such vehicle that the public can buy. It’s the first Volvo model in history designed as pure electric only, spearheading the future of the Swedish brand. Its SUV elements and benefits combined with a lower profile means that Volvo Cars also enters a new segment – and it does so with cutting-edge design and features not previously seen on Volvo cars.
“The C40 is a car that symbolises electrification and delivers on it,” said Robin Page, head of design at Volvo Cars. “It has the personality of the XC40, which proved to be attractive to many, but it’s dialled up even more through its dynamic expression and sleek profile. It’s a really attractive product for people who are looking for the easy-to-live-with aspects of an SUV with more of a modern statement.”
Though it seems like a variation of the XC40, it is actually much more that than (apart from the fact that it has an electric powertrain), adopting only the fundamental building blocks of the XC40. Similar to the birth of the XC40, the C40 started as a spontaneous sketch by one of the designers in the team. It was Yury Zamkavenka’s sketch which ‘hit the ground running from the initial idea’, according to T. Jon Mayer, Head of Exterior Design.
“That doesn’t happen very frequently. When it does, it’s always some of the more characterful ideas that flourish, because it’s such a pure statement from that first sketch,” Mayer explained, adding that the uniqueness of the car – its commanding seating position combined with a streamlined form – becomes very clear when it’s on the road next to other cars.
“One of my favourite views of the car is the rear seven-eighths, which gives you a view of the side and the coupé line profile,” he said. “You see the SUV elements as it sits on these really big wheels, and it’s this tough little character but with a very sleek approach to the roof. It’s built upon the solidity of the XC40, but in a more dynamic way. These combinations give it a totally different expression, while still carrying on our DNA.”
Breaking new ground
The idea of breaking new ground with something familiar is mirrored in individual details. For example, the signature Thor’s Hammer headlights are augmented with new pixel LEDs, which automatically adjust to light conditions and switch on and off independently to optimise the light pattern. The equally emblematic vertical rear lights are segmented, providing a testament to the engineering challenge of extending one big lamp along the roofline, while also creating a modern take on a classic design.
The DNA is distinguished by a Scandinavian approach in the form language: sections are shaved and carved out of the solid form, creating a sense of purity and refinement; an understated confidence. “It communicates a solidity, which can also link to a feeling of safety,” Mayer said. “Subconsciously, this is a powerful beast that’s protective, yet we sculpt it in a way to make it as lightweight and efficient as possible.”
Rear ends of C40 Recharge (blue car) and XC40 (silver car).
Nature and light
Using these design principles – as well as inspiration from the Scandinavian landscapes with their quiet atmospheres, light and freedom of space – the confidence of the exterior design is tied together with an interior design characterised by the calming effects of nature. There’s the large, panoramic glass roof that enhances the airiness of the cabin, making the most out of short winter days, while blurring the line between outside and inside during bright summer nights.
“In Sweden, it’s dark and grey most of the year – but when the sun shines, the colours come to life much more vibrantly than anywhere else,” said Lisa Reeves, Head of Interior Design. “The grass looks greener, the sea looks bluer. You see this reflected in the architecture here: houses have a lot of glass, designed to really let in the light and the open floor plans spread the light within the house. Light and nature are strong parts of the culture and are important themes for the C40 interior.”
The Fjord Blue colour, inspired by the deep inlets on the Scandinavian west coast, flows from the exterior and creates a continuation inside by colouring the large swathes of carpet that extends up from the floor to the sides of the tunnel console and the front doors. This provides a foundation for the backlit translucent graphics on the dashboard and front door panels, which are a nod to the dramatic, yet serene mountain sceneries in Sweden’s Abisko national park.
“We traced the topography of the park and used the contours to create an abstract digitalised design with a layered pattern,” explained Rekha Meena, Senior Design Manager, colour and material. “When the light from LED lamps comes through across the surface, it creates this really nice, atmospheric three-dimensional effect.”
Sustainable materials
Hand-in-hand with nature as a source of inspiration is the high amount of sustainable materials used for the interior. The topography trim panels are partly made of recycled plastic, while the carpet is made of 100 per cent recycled PET plastic bottles. The C40 offers Volvo Cars’ first leather-free interior, with one upholstery option containing naturally renewable wool fibres, and a second option using a combination of suede textile (also made of recycled plastic) and micro-tech material.
The layout of the interior gives a sense of organisation and thoughtfulness, where functionality is key. The C40 repeats the XC40’s ‘uncluttering’ approach, providing smart and thoughtful ways to store all important belongings within arm’s length. Minimalism is an overarching theme, which becomes even more evident when looking at the instrument panel.
Symbolism and function
Using renewable and recycled material is one part of the sustainability equation, and the car being fully electric is another. But to really get the message of electrification across, the C40 needs to look the part as well, and it does so with features that blend symbolism and function together.
The new wheel design, influenced by the Volvo 360c concept car from 2018, helps with aerodynamics while creating a dynamic look fitting the driveline; the rear spoiler both characterises and supports downforce on the car; and the roofline boosts aerodynamic efficiency, giving it a functional as well as a visual relationship to range. And then there are the elements where messaging slightly takes the upper hand, like the closed grill and the contrast roof.
“To symbolise the electric car, the face is really important,” said Page. “Part of our design language is about honesty, and the reality is that we don’t need a large air intake for an electric car. This car originates from the XC40 – which does have a grill – so it’s not a case where we can just ignore that and do a super low, fully moulded front. And we wouldn’t want to do that on this car anyway, because the C40 has a characterful face. We achieved a good solution, with strong, pure graphical lines. Together with the contrast roof, which we’ll use to distinguish our 40 cluster electric cars, it’s one of the ingredients that communicates our journey towards full electrification.”
Aiming for net zero carbon emissions by 2039, in line with the Reimagine strategy announced last month, Jaguar Land Rover’s (JLR) aim includes zero tailpipe emissions from its vehicles by 2036. This means that internal combustion engines will no longer be used. Electrical power is the most viable solution for future powertrains as they will have zero emissions, and JLR is developing various prototypes.
Fuel cells, spin-offs from the space program, are being considered by a number of manufacturers, some of whom already have commercialised fuel cell electric vehicles (FCEVs). JLR is also looking to use a hydrogen fuel cell and is developing a prototype FCEV based on the latest Land Rover Defender.
Advantages of hydrogen FCEV
FCEVs, which generate electricity from hydrogen to power an electric motor, are complimentary to battery electric vehicles (BEVs) on the journey to net zero vehicle emissions. Hydrogen-powered FCEVs provide high energy density and rapid refuelling, and minimal loss of range in low temperatures, making the technology ideal for larger, longer-range vehicles, or those operated in hot or cold environments.
Since 2018, the global number of FCEVs on the road has nearly doubled while hydrogen refuelling stations have increased by more than 20%. By 2030, forecasts predict hydrogen-powered FCEV deployment could top 10 million with 10,000 refuelling stations worldwide.
JLR’s advanced engineering project, known as Project Zeus, is partly funded by the government-backed Advanced Propulsion Centre, and will allow engineers to understand how a hydrogen powertrain can be optimised to deliver the performance and capability expected by its customers: from range to refuelling, and towing to off-road ability.
The Defender’s platform, which can accommodate combustion engines as well as hybrid powertrains, is also being used for the development of a fuel cell electric vehicle.
The project also has other partners involved such as Delta Motorsport, AVL, Marelli Automotive Systems and the UK Battery Industrialisation Centre (UKBIC) to research, develop and create the prototype FCEV with testing scheduled to begin this year. The testing, in the UK, will verify key attributes such as off-road capability and fuel consumption.
“We know hydrogen has a role to play in the future powertrain mix across the whole transport industry, and alongside battery electric vehicles, it offers another zero tailpipe emission solution for the specific capabilities and requirements of Jaguar Land Rover’s world class line-up of vehicles. The work done alongside our partners in Project Zeus will help us on our journey to become a net zero carbon business by 2039, as we prepare for the next generation of zero tailpipe emissions vehicles,” said Ralph Clague, Head of Hydrogen and Fuel Cells for Jaguar Land Rover.
A Land Rover factory in the UK.
Producton facilities are carbon neutral
JLR was the first UK automotive manufacturer to have met the internationally recognised PAS 2060 standard for carbon neutrality across its vehicle manufacturing assembly operations and product development sites. In January last year, its facilities completed a second consecutive year being certified as carbon-neutral by the Carbon Trust. Together, these sites represent 77% of JLR’S global vehicle production.
The Carbon Trust re-certification is part of the carmaker’s journey to ‘Destination Zero’, after it was originally achieved two years ahead of a commitment to operate carbon-neutral UK manufacturing by 2020.
