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Hyundai Motor Group aims to take lead in technology for future hydrogen society

Hydrogen is the most abundant element on earth and when used as an energy source, it does not generate carbon dioxide which is known to cause negative climate change. It thus has great potential as a zero-emission energy source for a variety of products. For this reason, a number of leading global companies are carrying out R&D to develop processes to produce hydrogen efficiently and cost-effectively as well as to make use of it widely.

The Hyundai Motor Group (HMG) is among these companies and has announced its Hydrogen Vision 2040 to popularize hydrogen by 2040 for ‘Everyone, Everything and Everywhere’. Hydrogen Wave represents the group’s plans for a new ‘wave’ of hydrogen-based products and technologies toward a hydrogen society.

“By developing advanced technologies and innovative systems – as well as encouraging close collaboration between public and private sectors across the globe – it is possible to make this sustainable vision a reality for all,” said the Chairman of the HMG, Euisun Chung, at the Hyundai Wave global forum online today.

He explained that Hyundai Motor Group’s vision is to apply hydrogen energy in all areas of life and industry such as homes, workplaces and factories. “The goal is to make hydrogen readily used for everyone, everything, and everywhere,” said Mr. Chung. “We want to offer practical solutions for the sustainable development of humanity and with these breakthroughs, we aim to help foster a worldwide Hydrogen Society by 2040.”

Electrification of commercial vehicle models
In the context of the auto industry, HMG revealed unprecedented plans that will see the electrification of all new commercial vehicle models – featuring fuel cell electric or battery electric powertrains, as well as the application of fuel cell systems – to all models by 2028. Other future product concepts featuring fuel cell technologies include Trailer Drone, a high-performance sportscar, and fuel cell-equipped vehicles for emergency relief and rescue missions.

Since the development of its first (Fuel Cell Electric Vehicle (FCEV) in 1998, HMG has been preparing for the future of hydrogen. In 2013, the Tucson FCEV (ix35 Fuel Cell) was introduced, opening the door to the mass production of FCEVs. Then, in 2018, the company launched the next-generation fuel cell SUV, the NEXO, with the world’s first heavy-duty fuel cell truck, the XCIENT Fuel Cell, being unveiled last year. After 2 decades of fuel cell technology development, HMG will expand its fuel cell technologies for wider applications of its vehicles, including additional mobility solutions and various energy utilization.

Bringing costs down
Fuel cell systems using hydrogen to generate electricity are not only being used commercially for vehicles today but also have the potential for deployment across diverse applications by 2040. To achieve this, HMG is planning to introduce a new generation fuel cell system in 2023 with a reduced price and volume while also having significantly improved durability and output.

Through ongoing R&D gains, engineering teams have been able to reduce fuel cell costs drastically over the last 20 years. By ensuring price competitiveness, the goal is to achieve a fuel cell vehicle price point comparable to a battery electric vehicle (BEV) by 2030. Economies of scale of hydrogen production can be realised by continuous technological innovation of fuel cell systems as well as close collaboration with other organizations and governments across diverse business areas.

Next-generation fuel cell systems
HMG has developed a series of new fuel cell systems including a new prototype of its third-generation fuel cell stack. This is a higher-powered, efficiently packaged successor to the NEXO system that is planned for market introduction in 2023. Currently still in development, the third-generation fuel cell stack has 2 power versions – 100 kW and 200 kW.

The 100 kW stack has reduced in size by 30%, making it easier to apply to different vehicle types and applications. The 200 kW version is intended for commercial vehicle applications and is similar in size to the current NEXO system, but the power output has doubled.

Fuel cell technology for high-performance vehicle applications is showcased with a concept hydrogen-powered plug-in hybrid sportscar named the Vision FK. With a maximum output of over 500 kW, the Vision FK concept can accelerate from 0 – 100 km/h in less than 4 seconds. Combining a fuel cell energy converter with a high-power, RWD, plug-in powertrain, the Vision FK aims to achieve over 600 kms in range. The prototype is being developed in partnership with Rimac Automobili of Croatia (which HMG invested around US$90 million in).

High durability stacks for commercial vehicles will achieve 500,000 kms of drive range. Furthermore, the price of the third-generation fuel cell stack will be dramatically reduced – with projections being more than 50% – which will be the key factor to achieving cost parity of FCEVs with BEVs by 2030.

HMG will continue to develop hydrogen mobility, expand the production system of fuel cells and establish infrastructures for a global hydrogen society. “The degree and frequency of environmental disasters is rising fast, and we now face a code red warning for humanity,” said Mr. Chung. “The Group seeks to offer powerful and pragmatic solutions for combatting climate change via the tremendous potential of hydrogen energy.”

HydroVILLE to showcase hydrogen vision
Following the Hydrogen Wave forum, HMG will be presenting its plans for hydrogen energy and a global hydrogen society at its ‘Hydrogen Village’ (HydroVILLE) exhibition in Goyang, Korea, this week. HydroVILLE’s various zones will illustrate the Group’s future hydrogen vision. The exhibition space features several fuel cell concepts for future mobility and power generation, including 18 models from Hyundai Motor Group affiliates such as Hyundai Motor, Kia, Hyundai Mobis, Hyundai Rotem, Hyundai Steel, Hyundai Wia and Hyundai Kefico.

Hyundai IONIQ 5 EV to be used for fully autonomous robotaxi by Motional

Hyundai Motor Group unveils Electric-Global Modular Platform (E-GMP)

While still improving and innovating its technologies for models with internal combustion engines, the Hyundai Motor Group (HMG) is also investing substantially in battery electric vehicle (BEV) technology. Such vehicles will grow in numbers in coming years and HMG has been developing core technologies for them.

One of these is the new Electric-Global Modular Platform (E-GMP) which is specifically for BEVs. The E-GMP is ready to be used and from 2021, the E-GMP will support a range of new BEV models. These include the Hyundai IONIQ 5 and Kia’s first dedicated BEV. The platform will be used for as many as 23 BEV models in HMG with the sales target of more than 1 million BEVs worldwide by 2025.

The E-GMP provides various advantages compared to the Group’s existing platforms which have engineering oriented towards internal combustion engines. With a brand new approach that is dedicated to the electrified powertrain, there is increased development flexibility, stronger driving performance, increased driving range, strengthened safety features, and more interior space.

“Today our front-wheel driven Hyundai and Kia BEVs are already among the most efficient ones in their segments,” declared Albert Biermann, President and Head of R&D Division for Hyundai Motor Group. “With our rear-wheel drive E-GMP, we are extending our technological leadership into segments where customers demand excellent driving dynamics and outstanding efficiency.”

*EV variants of the Hyundai Kona (left) and Kia Soul (right) are currently available in some countries.*

Maximizing development flexibility
The E-GMP reduces complexity through modularization and standardization, allowing rapid and flexible development of products which can be used across most vehicle segments. Moreover, flexible development can satisfy various customer needs for varying levels of vehicle performance.

The new platform will also enable the company to enlarge its EV line-up over a relatively short period through modularization and standardization. This will satisfy consumer expectations of variety and choices.

Driving performance and safety
With optimal weight distribution between front and rear, a low centre of gravity thanks to its low-mounted battery pack, and the adoption of electric motors, handling can also be enhanced. A 5-link rear suspension system, which is typically used for medium and large vehicles, and the world’s first integrated drive axle enhance ride comfort and handling stability.

The platform secures battery safety through a battery support structure made of ultra-high strength steel. Hot-stamped steel components surround this structure for additional rigidity. Collision energy can be absorbed efficiently by energy-absorbent sections of the body and chassis, effective energy load paths, and a central section of the battery pack tightly bound to the vehicle body.

The battery pack itself – mounted between the front and rear wheel axles – will be the most power-dense system that HMG has ever created. It has enhanced cooling performance with a new separate cooling block structure which helps make the battery pack more compact. With energy density enhanced by around 10% compared to existing EV battery technology, the battery packs are lighter, can be mounted lower in the body, and liberate more cabin space.

From the early 1980s, the industry moved towards front-wheel drive which offered space-saving benefits. The E-GMP, however, will have rear wheel drive although there can also be all-wheel drive (with an additional electric motor).

Charging System
Most existing EVs and the fast-charging infrastructure provide 50 kWh ~ 150 kWh charging for EVs equipped with a 400V system; however, the development of 800V infrastructure, with up to 350 kWh charging, will gradually enable even more fast-charging.

In line with this trend, Hyundai Motor Group has invested in IONITY, Europe’s leading high-power charging network, as a strategic partner and shareholder. IONITY operates 298 high-power charging (HPC) stations – using a charging capacity of up to 350 kWh – along highways in European countries. The company plans to increase this number to 400 HPC stations by 2022, including 53 currently under construction.

The E-GMP offers 800V charging capability as standard and enables 400V charging, without the need for additional components or adapters. The multi-charging system is a world’s first patented technology which operates the motor and the inverter to boost 400V to 800V for stable charging compatibility.

A BEV using the E-GMP will be capable of a maximum range of over 500 kms with a fully charged battery pack. If the pack is completely empty, it can receive a high-speed recharge up to 80% capacity in 18 minutes; up to 100 kms of driving range can be available with a recharge of just 5 minutes.

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Future Hyundai/Kia models to get additional airbag in the middle

Since the early 1980s when airbags started to be installed in cabin, millions of people have benefitted from the extra protection and experienced reduced injuries during accidents. The contribution of airbags to saving lives cannot be understated and as new technology has been developed, the effectiveness of airbags has increased.

Preventing head injuries
Now the Hyundai Motor Group (HMG) has developed a new centre side airbag, further enhancing the safety of its vehicles’ occupants. This airbag works to separate the space between driver and front passenger by expanding into the space between the front seats to prevent head injuries of the two occupants.

If there is no one in the front passenger seat, the airbag will protect the driver from the effects of a side collision coming from the opposite side. The centre side airbag is installed inside the driver’s seat and will deploy once the impact is sensed.

The new centre side airbag is expected to diminish head injuries caused by passengers colliding with each other by 80%. According to the European Automobile Manufacturers’ Association’s statistics, the rate of secondary damage caused by these kinds of collisions or from hitting interior materials is about 45%.

Lighter and simpler
The airbag has an internal component called a tether which allows the airbag to maintain its form and withstand the passenger’s weight. HMG has developed a new technology to simplify the design and reduce the weight of components to produce an airbag which is about 500 gms lighter than the competing products. Thanks to the smaller size of the airbag, the design teams will have more flexibility in the type of seat design they envision for future products.

HMG has applied newly patented technology to maintain reliability but reduce the weight and size of the airbag which will be offered in selected models to be introduced in future. Upcoming Euro NCAP assessments are expected to include side impact into its consideration beginning from 2020 and HMG’s airbag is expected to work favourably in such evaluation.

Hyundai Motor Group develops lightweight wearable robot to help workers

The increased automation, particularly the use of robots, is feared to reduce the number of humans needed to do work in factories. It has a lot of implications and companies are trying to find a balance in their workforce. However, humans are still needed for some types of assembly work, especially where it involves variations. Robots work more efficiently when the work is constantly similar (eg welding bodies) so customisation of specifications is harder to programme.

Therefore there will still be a need for humans in the factory and the dream of the former General Motors CEO, Roger Smith, of a factory with no humans at all, building cars non-stop all day long will likely remain just a dream for some time to come.

Long hours in difficult environments
Though the work humans will do will be suited for them physically and less dangerous, they may still spend long hours working in difficult environments. To reduce fatigue, the Hyundai Motor Group (HMG) has developed a Vest EXoskeleton (VEX) which is a wearable robot to assist them.

The VEX helps by imitating the movement of human joints to boost load support and mobility. The wearable vest the polycentric axis – combining multiple pivot points with multi-link muscular assistance – to function, eliminating the need for a battery.

Attached like a backpack
At 2.5 kgs, it weighs 22 – 42% less than competing products and is worn like a backpack. The worker places his or her arms through the shoulder straps of the vest, then fastens the chest and waist buckles. The back section can adjust in length by up to 18 cm to fit a variety of body sizes, while the degree of force assistance can be adjusted over 6 levels – up to as much as 5.5 kgf.

“VEX gives workers greater load support, mobility, and adaptability when operating in overhead environments,” said DongJin Hyun, Head of Robotics team of HMG. “Workers will also appreciate how light VEX is to wear and work with.”

The newly-developed product is targeted at production-line workers whose job is primarily overhead, such as those working on the underside of vehicles – fitting brake tubes, attaching exhaust systems, etc.

Already used in 2 US plants
The development of the VEX included a pilot program in two HMG plants in the USA. The trial was widely successful in assisting workers and boosting productivity and both plants have incorporated VEX systems in their production lines.

Hyundai US factory — *One of the two Hyundai Motor Group factories in the USA where the VEX is already assisting workers.*

The Group is considering introducing the VEX in plants around the world. It is expected to go into commercial production in December and is projected to cost as much as 30% lower than existing products which usually costs around US$5,000 (about RM21,000).

Growing demand for wearable robots
According to the International Federation of Robotics, the wearable robotics industry is growing 14% annually, a rate which is accelerating. By 2021, approximately 630,000 commercial robots will be sold worldwide, with the greatest demand coming from the automotive sector. Recognizing the market trend, HMG is making active investments and strengthening its presence within the growing robotics industry by securing relevant technologies.

Click here for other news and articles about Hyundai on PISTON.MY

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HMG

Hyundai Motor Group aims to take lead in technology for future hydrogen society

Hyundai Motor Group unveils Electric-Global Modular Platform (E-GMP)

Future Hyundai/Kia models to get additional airbag in the middle

Hyundai Motor Group develops lightweight wearable robot to help workers

Hyundai Motor Group aims to take lead in technology for future hydrogen society

Hyundai Motor Group unveils Electric-Global Modular Platform (E-GMP)

Future Hyundai/Kia models to get additional airbag in the middle

Hyundai Motor Group develops lightweight wearable robot to help workers

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