Fuel cell electric vehicle (FCEV) technology is not new to Hyundai Motor. In fact, the company was already carrying out R&D on such vehicles, which use hydrogen, from the early 2000s. By 2013, it was able to commercialise a FCEV in the form of the iX35, the first carmaker to do so.
Since then, development on FCEVs has advanced further and the company has accumulated even more experience and feedback through the use of its FCEVs over millions of kilometres in many parts of the world.
Hyundai N, the performance arm, is also looking at FCEV technology for the future and has developed the N Vision 74 as a high-performance hydrogen fuel cell hybrid rolling laboratory. While it is the first such high-performance rolling lab for Hyundai N’s engineers to use, it is not the first time for N where FCEV technology is concerned.
In 2015, the company also created the N 2025 Vision Gran Turismo with the launch of the N brand to envision the future of hydrogen-based high performance. The futuristic N 2025 was conceived to represent Hyundai in the Vision Gran Turismo program, a series of fictional concept cars for the Gran Turismo videogame by Polyphony Digital. While it was never produced as a real-life running model, it had advanced technologies that gave extremely high performance which gamers could experience.
For the N Vision 74, Hyundai’s engineers developed a hybrid structure of a battery-electric vehicle (BEV) in combination with an FCEV system, placed in an all-new layout. By having a fuel cell system and battery-electric system powering the car together, the cooling efficiency is improved.
The two different power sources can be used together or independent, depending on different driving conditions. This fine-tuned logic system enables better torque vectoring by twin motors on the rear, allowing a precise and responsive cornering experience. Moreover, the N Vision 74 explores the balance between the performance and cooling with a 3-channel cooling system.
Measuring 4952 mm long, 1995 mm wide and 1331 mm tall on a 2905 mm wheelbase, the design of the concept car is inspired by the Hyundai Pony Coupe concept of 1974. This concept car developed by the designer Giorgetto Giugiaro was a proposal for a sportscar based on the very significant model in Hyundai Motor’s history. The concept car was then built into prototypes for what was to be Hyundai’s first production sportscar. Although it could not reach production in the end, the daring attitude set the tone for the entire company.
The N Vision 74 inherited the pure surface, dynamic proportioned profile and the unique B-pillar from the Pony Coupe concept. In addition, the lighting units have Parametric Pixel lighting, a feature which is seen on the latest models.
“N Vision 74’s future-oriented design reflects the respect and appreciation we have for the dedication and passion that went into the Pony Coupe concept,” said SangYup Lee, Executive Vice-President and Head of Hyundai Design Centre.
Hyundai will launch its first all-electric high-performance model in 2023. This will be based on the IONIQ 5 and is currently being developed by the carmaker’s N high-performance division. For the development work, the engineers are using two high-performance concept cars — the RN22e and N Vision 74 – as ‘rolling laboratories’.
Hyundai Motor’s ‘rolling labs’ are where it tests and verifies the company’s advanced technologies to apply them to future production models. In this case, a lot of work is being done on electrification and how to provide models with the type of performance the N brand is known for.
Adapt from IONIQ 6
The RN22e, which possesses track-ready performance, uses the Hyundai Motor Group’s E-GMP and a design based on the IONIQ 6 Electric Streamliner. As Hyundai N’s first rolling lab based on the E-GMP, the RN22e shows the N brand’s vision and direction in an electrified future. The concept received its designation because it is the rolling lab of N brand developed in 2022 and is an EV performance.
Testing of the RN22e focusses on the brand’s three performance pillars. These start with ‘corner rascal’, a cornering capability since the brand launch that makes use of e-LSD, Corner Carving Differential for most N models. The RN22e enhances the ‘corner carving’ feel with heavier weighting by exploiting torque vectoring. 3D-printed parts reduce weight and keep the rigidity high for better handling. With AWD, there is optimized torque distribution whatever the drive mode and the driver can customise the amount of torque going to the front and rear wheels.
Enhancing racetrack capability
To enhance the RN22e’s racetrack capability, the N engineers focused on cooling and braking endurance. Track-optimized settings let drivers go to the limit with 4-piston monobloc calipers and 400-mm hybrid discs to ensure plenty of stopping power is available. In addition, the engineers will use the RN22e to study how to deliver dynamic movement with regenerative braking that can precisely controls yaw and corner attack. Once verified, the new state-of-the-art technologies can be transferred to N production models.
Hyundai N Sound+
Sound is also part of the emotional driving experience – but electrified models don’t have the type of sound that excites enthusiasts. So the RN22e has N Sound+ which generates sound from speakers inside and outside the car. In addition, the N e-shift integrates the vibration and shifting feel with N Sound+.
By adapting the IONIQ 6’s streamliner design, the RN22e will leverage on the new EV’s aerodynamic features. In order to maximize the performance, Hyundai N added motorsport-inspired details that add visual dynamism and also improve cooling performance and aerodynamics.
These days, there’s a new electric vehicle (sometimes even more than one) being launched or previewed every month and the technical aspects sound pretty much the same. The technologies to are generally similar with each company having some advancements of its own to shout about.
So with the new IONIQ 6, Hyundai Motor seems to skirt the technical parts and instead draws attention to the inside of the first sedan in its EV sub-brand. The interior of the ‘Electrified Streamliner’ is developed to serve as a comfortable and personalized ‘hideaway’, providing a unique and distinctive experience for drivers and their passengers.
“IONIQ 6 is designed and engineered to seamlessly enhance our daily lives as space to awaken your potential,” said Thomas Schemera, Executive Vice-President, Global Chief Marketing Officer and Head of Customer Experience Division, Hyundai Motor Company. “The innovative interior is meticulously thought out as a cocoon-like personal space, enhanced with the latest technologies to create a safe, fun, and stress-free driving experience. The spacious interior, with sustainability and usability at its heart, once again represents a step forward for electric vehicles, in line with the values of our customers.”
The cabin takes advantage of the E-GMP (the Hyundai Motor Group’s Electric Global Modular Platform) which allows an extremely long 2950 mm wheelbase, supported by a choice of 20-inch or 18-inch wheels. The E-GMP supports a streamlined body with an overall length of 4855 mm, 1880 mm width and 1495 mm height, which puts it in the D-segment.
A modular touchscreen dashboard integrates a 12-inch full-touch infotainment display and 12-inch digital cluster that houses advanced technologies for an enhanced digital user experience that can be customized to meet their needs. The infotainment system provides real-time travel radius mapping based on the current state of charge, while connected car services help search and plan the best route to include a charging station along the way.
Apple CarPlay and Android Auto bring favourite smartphone apps to the widescreen display. For those without compatible smartphones, there’s also Bluetooth multi-connection support available. Two devices can be paired at the same time — one for phone calls and one for music streaming.
The premium Bose sound system’s 8 speakers, including a subwoofer, are strategically placed throughout the vehicle for a high-quality listening experience. Complementing this is a ‘spaceship-like’ sound with a sound texture that changes based on the vehicle’s driving status. How this will be received by the occupants of the car remains to be seen. Perhaps the new generation of car-buyers brought up in the digital age will appreciate such sounds!
The optional Relaxation Comfort Seats in the first row promote leisure by simply adjusting the seat angle. In addition, all of its seats are specifically-manufactured for all-electric models, and they are approximately 30% thinner than those in other conventional models, providing more space for passengers.
Dual Colour Ambient Lighting allows a driver to customize the look and feel of the interior space by selecting from a spectrum of 64 colours and 6 pre-selected themes. The Speed Sync Lighting mode adds emotion to the driving experience by changing the brightness of the interior lighting in the first row based on the car’s travelling speed.
The IONIQ 6’s personalized driving experience is further enhanced by the EV Performance Tune-up system. This allows the driver to freely adjust steering effort, motor power, accelerator pedal sensitivity and driveline mode. Drivers can create a variety of different combinations with just a few button clicks to meet their individual needs.
Of course, we still need to tell you something about the technical aspects and here, the powertrains are varied. Customers can choose a long-range 77.4-kWh battery with 2 electric motor layouts, either rear-wheel-drive (RWD) or all-wheel-drive (AWD). The top-of-the-line dual motor set-up is an AWD option producing a combined power output of 325 ps/605 Nm, with a claimed 0 to 100 km/h of 5.1 seconds.
Hyundai Motor claims an impressive energy consumption rate of under 14 kWh/100 kms, with the 53-kWh standard battery pack, 18-inch tyres and RWD. It supports 400V and 800V charging infrastructures and with a 350 kW charger, the recharging time from 10% to 80 percent is said to be within 18 minutes. A fully charged battery pack should be good for over 610 kms.
The IONIQ 6, like the IONIQ 5, is also able to function as a mobile power station to charge electric devices. This would be ideal not only for camping but also when there is a disruption to power supply. In addition to the external power outlet, there is a second outlet under the back row seat which can be used for charging laptops, phones and other devices.
This EV Is Hyundai Motor’s first model to offer the Over-the-Air (OTA) Software Updates for various controllers. This allows owners to upgrade the car’s controllers for electric devices, autonomous driving, battery, maps (and more) without having to go to a service centre. As such, the systems will be kept up to date and optimised.
In the Korean market, the IONIQ 6 is priced between 55 million – 65 million won (about RM185,000 – RM218.000). Production is to begin production in the third quarter of 2022. Sales are expected to begin before the end of the year with exports to selected markets starting in early 2023.
The IONIQ name began as a model name in Hyundai Motor’s range. And it also had an interesting approach as Hyundai offered a choice of three types of powertrains in the same body – combustion engine, hybrid or battery electric. In 2020, however, the company decided to make ‘IONIQ’ (a combination of ‘ion’ and ‘unique’) a sub-brand that would be used for purely electric models.
Second of three models
When Hyundai announced the creation of the sub-brand in 2020, it said that it would come out with three new models and now, after the IONIQ 5, comes the IONIQ 6. It is adapted from the Prophecy concept car and is described as an ‘Electrified Streamliner’ with its aerodynamically sculpted form.
The clean, simple lines and a pure aerodynamic form present ‘Emotional Efficiency’ and the streamliner typology and mindful cocoon-like interior embody a silhouette for the new era of electric mobility. The unique design language has been used to pursue energy efficiency and sustainable material usage.
“IONIQ 6 connects an emotional convergence of functionality with aesthetics,” said SangYup Lee, Executive Vice-President and Head of Hyundai Design Centre. “The distinctive streamlined design is the result of close cooperation between engineers and designers, with obsessive attention to detail and customer-centric values at the core. We have created the IONIQ 6 as a mindful cocoon that offers personalized places for all.”
Human-centric design
As with most cars, the human-centric basis was set from the start, with the interior space developed simultaneously with the exterior form. Efforts were made to maximize and optimize the interior space, stretching it at the front and rear, resulting in a unique streamliner silhouette and spacious interior.
Like the IONIQ 5, this new model uses the Hyundai Look design strategy that gives each model a unique appearance, like chess pieces. By taking a customer-centric direction, Hyundai designs with diverse lifestyles in mind rather than with a one-style-fits-all approach.
Sleek and functional aesthetics
The IONIQ 6’s form has an impressively low drag coefficient of just 0.21 Cd. This is achieved by assisted by its low nose, active air flaps at the front, wheel gap reducers, and slim digital side mirrors.
Also contributing to reduced resistance is its elliptical wing-inspired spoiler with winglet, slight boat-tail structure, and separation traps on both sides of the rear bumper. On the underside of the car, a flat surface is evident with a full cover, optimized deflectors and reduced wheel-arch gap.
Parametric Pixels are the IONIQ brand’s identity and there are over 700 of them in various places on the bodywork as well as within. These include the headlamps, rear lamps, front lower sensors, air vent garnishes and centre console indicator.
The rear wing’s Parametric Pixel High-Mounted Stop Lamp (aka third brake light) has an eye-catching light execution when the brakes are applied. To further highlight the IONIQ 6’s uniqueness, a newly designed Hyundai ‘H’ badge is applied on the front and rear of the vehicle.
Personal space on wheels
The cocoon-shaped interior serves as both a comfortable hideaway and personal space, replete with practical features and sustainable materials to facilitate a mindful, eco-friendly mobility experience and lifestyle.
The Electric Global Modular Platform, optimised for electric vehicles, enabled the designers to stretch the interior, front and rear. This maximises legroom and spaciousness, with a completely flat floor giving expansive feeling.
The user-centric interior architecture is exemplified by an ergonomically designed control unit that is centrally located to reduce distraction and support safe, intuitive driving. The modular touchscreen dashboard integrates a 12-inch full-touch infotainment display and 12-inch digital cluster. A bridge-type centre console provides convenient and generous in-car storage.
Dual Colour Ambient Lighting provides overall illumination for IONIQ 6 interior. Users can choose from a spectrum of 64 colours and 6 dual colour themes developed by experts to help drivers and passengers feel relaxed and comfortable. The 4-dot Interactive Pixel Lights on the steering wheel enable easy communication between the driver and vehicle.
The removal of buttons from the front doors provides extra elbow space as well as adds storage capacity. Transparent accents on the crash pad garnish, door map pocket and console lower cover further accentuate the sense of spaciousness and uniqueness.
Eco-friendly materials
In line with the IONIQ 6’s Ethical Uniqueness theme and inspired by today’s eco-conscious consumers, the designers applied sustainable materials to the exterior, including recycled pigment paint from end-of-life tyres to the cladding and bamboo charcoal pigment paint to the body.
The interior is also trimmed in sustainable materials and colours. These include eco-process leather (seats), recycled PET fabric (seats), bio TPO skin (dashboard), bio PET fabric (headliner), bio paint derived from vegetable oils (doors), and recycled fishing net carpet — the latter a first for the IONIQ brand.
Technical details have not been released yet as the midsize model, likely to take over the place of the Sonata in future, will be officially launched later this month. The IONIQ 7 will likely be a larger crossover and make its debut in 2024.
The Hyundai Motor Group (HMG) aims to capture a 7% share of the electric vehicle (EV) market by 2030, by which time it expects to be selling 1.87 million vehicles annually. To achieve this goal, the Korean carmaker will invest around 19.4 trillion won (US$16.10 billion) in EV-related businesses.
Besides its own investments, it will also work with other parties in various fields of expertise and one of them is Michelin. A MoU (Memorandum of Understanding) was signed recently for collaboration on R&D for innovative tyre technologies over the next 3 years. These technologies will be used in the development of next-generation tyres optimized for premium EVs.
The MoU is the second one between the two companies, following the successful completion of their first partnership. This collaboration will lead to a new journey towards developing next-generation tyres to be equipped with the Group’s clean, smart and sustainable mobility solutions.
“This partnership with Michelin will result in real innovations in tire technology, solidifying Hyundai Motor Group’s position as a leader in the smart mobility industry,” said Bong-soo Kim, Vice-President and the Head of Chassis Development Centre at the Hyundai Motor Group. “By fully leveraging our mobility technology and Michelin’s tyre expertise, we are confident in our ability to achieve ground-breaking innovations in tire performance enhancement and create synergies in this organic collaboration.”
In the previous 5-year partnership that began in November 2017, the companies jointly developed an exclusive tyre for the IONIQ 5 EV. There were also joint experiments and analysis methods carried out which were related to tyres as well as technology exchange.
Over the next 3 years, HMG and Michelin will jointly develop the following innovations: eco-friendly tyres with increased use of eco-friendly materials; tyres optimized for next-generation EVs; and a real-time tyre monitoring system which will help advance autonomous driving technology.
The tyres for the IONIQ 5 EV were jointly developed by Hyundai and Michelin.
“The collaboration between Hyundai Motor Group and Michelin over the past 5 years contributed to the successful launch of the Hyundai IONIQ 5,” said Georges Levy, Executive Vice-President of Automotive Original Equipment at Michelin. “We are pleased to announce that the relationship has been extended for 3 more years to continue our work together on new technologies in favour of safer, cleaner mobility. The association between Hyundai Motor Group and Michelin is founded on the same vision and on a shared passion for excellence, performance and innovation that have become increasingly essential factors as we rise to the mobility-related challenges we all face today.”
The next-generation tyres will be installed on future premium EV models of HMG. The new tyre technology is critical to meet the durability requirements of tyres, as well as driving performance and electric efficiency under high load as the driving range of EVs continues to increase.
There will also be joint research to analyse tyre wear, tyre load and road friction beyond the current standards of tyre temperature and air pressure. The new tyres are also expected to significantly improve ride comfort by reducing vibration and noise generated by EVs at high speeds.
Additionally, there will be research into ways to increase the use of eco-friendly materials in tyres to about 50% of the total tyre weight from 20% currently.
There are 6 levels (include level 0) of autonomous driving technology established by the US Society of Automotive Engineers (SAE), and currently, many vehicles are able to offer up to Level 2 but the driver must still give attention. Beyond Level 2, the requirement for the driver to be ready to take over control when necessary becomes less. By level 5, the vehicle can operate entirely on its own and the driver can even read a book or watch TV while moving.
For the higher levels to be introduced requires that other elements of the environment around the vehicle must also be ready. For instance, signage must be clear so that the cameras can capture important information and road markings must also be well defined for the vehicle to travel in a precise position.
For this reason, even though there are some vehicles already able to operate at level 4 where driver control is not needed, they can only do so within a limited area of a city or highway. As such, they are currently being used for vehicle-sharing purposes where the public can use them as autonomous transport around the city.
The Hyundai Motor Group (HMG) is one of the companies that has a vehicle ready to operate with level 4 technology and it will be running a pilot service in the Gangnam area of Seoul, South Korea’s capital city. Called the RoboRide car-hailing service, IONIQ 5 battery electric vehicles (BEV) fitted with the necessary equipment will be used. The pilot RoboRide will be the first car-hailing service with autonomous driving vehicles to operate in Gangnam, one of the most congested areas in metropolitan Seoul.
For the pilot service, the Group has obtained a temporary autonomous driving operation permit from the authorities. It will collaborate with Jin Mobility, a Korean startup operating the artificial intelligence (AI)-powered car-hailing mobility platform ‘i.M.’. Jin Mobility will be in charge of operating the two IONIQ 5 RoboRide units on its i.M application.
HMG also plans to expand the pilot service, while further developing autonomous driving technology with consideration for various conditions, such as driving stability.
“At Hyundai Motor Group, we are developing level 4 autonomous driving technology based on the internally developed Advanced Driving Support System, whose functionally and safety are verified through mass production and successful commercial launch,” said Woongjun Jang, Senior Vice-President and Head of the Autonomous Driving Centre of HMG. “We expect this RoboRide pilot service will be an important inflection point that will enable us to internalize autonomous driving technology.”
Through this pilot PROGRAM, HMG expects to collect valuable autonomous driving data and plans to further develop the level 4 autonomous driving technology to navigate safely and flexibly in complicated urban environments. To prepare for such a complicated driving environment, HMG has also worked with Seoul Metropolitan Government to establish a system that can connect traffic signals with autonomous vehicles.
In addition, an in-house developed remote vehicle assist system will be provided to ensure safety. The system monitors autonomous driving status, vehicle and route, and supports the trip with remote assist functions, such as changing the lane under circumstances where autonomous driving is not feasible. Based on the level 4 autonomous driving technology, a RoboRide vehicle will perceive, make decisions, and control its own driving status, while its safety driver will only intervene under limited conditions.
The RoboRide pilot service will operate from 10 am to 4 pm, Mondays to Fridays, to minimize any possible inconveniences on the road. Up to 3 passengers can be on a ride, and there will be a ‘safety driver’ present in the vehicle as well to respond to any emergencies.
Besides RoboRide, the company has also been conducting a test operation of its RoboShuttle service since August last year. The demand-responsive, high-occupancy vehicle service, powered by autonomous driving and Artificial Intelligence (AI) technology, operates along a 6.1-km route in Korea’s Sejong Smart City.
RoboShuttle service which has been operating since August 2021.
The pilot operation is conducted using a H350 van equipped with autonomous driving technology. This technology has a range of Level 4-comparable core technologies and is developed in-house by the Autonomous Driving Centre. Based on its self-driving capabilities, the vehicle is designed to perceive its surroundings, make decisions, and control itself while driving on the road, requiring minimal intervention from a safety driver.
The 2022 World Car of the Year – the Hyundai IONIQ 5 – which is just starting to appear on Malaysian roads has received enhancements for better performance and new features. The battery-electric vehicle (BEV), which is just over a year old in the global market, is the first model to use the Hyundai Motor Group’s first dedicated BEV platform, Electric Global Modular Platform (E-GMP).
A major upgrade is the capacity of the lithium-ion polymer battery pack; when launched, it was available with a 58 kWh or 72.6 kWh battery pack but now, there is an additional battery pack with a greater 77.4 kWh capacity. Compared to the 58 kWh battery pack which has 24 modules/288 cells, and the 72.6 kWh battery pack with 30 modules/360 cells, the new one has 32 modules/384 cells. It also operates on the 800V system and is available for both RWD and AWD versions.
Hyundai Motor Group E-GMP platform with the battery pack in the middle.
Better performance and range
The new 77.4 kWh pack has an increased range of up to around 500 kms (with RWD) and a power increase of 11 ps compared to the 72.6 kWh battery pack. An 80% recharge should be possible in 18 minutes using ultra-fast chargers.
The operating temperature of the battery pack is extremely important to performance and its service life. The conditions cannot be too hot or too cold and to maintain an optimum environment, there is a new battery heater and conditioning feature. This will enable the system to adapt its battery temperature while on the move to achieve optimal charging conditions when reaching the charging point. Ultimately, the owner benefits with improve charging performance in hot or cold ambient conditions.
Three digital camera-based mirrors
Besides the more powerful battery pack, the latest IONIQ 5 will be available with video-based digital interior and exterior mirrors. Instead of using conventional reflective surfaces, the mirrors will display real-time imagery from small cameras. For the inside rearview mirror, the camera is mounted on the IONIQ 5’s rear spoiler.
The Digital Side Mirrors have already been available for Korean-market models and are now being offered outside the country in a Hyundai Motor Group vehicle for the first time.
Namsan Edition
In some markets, there will be a special Namsan Edition of the IONIQ 5. This has a very generous equipment level and top technical specifications. The Namsan Edition is named after Namsan Mountain in Seoul, from which where there are expansive views across the skyline of the capital city and a national park covering over 3.3 million square metres
The IONIQ 5 Namsan Edition honours the Korean landmark with its full-length vision roof presenting an unobstructed panoramic view, whilst there is leather upholstery, relaxation seats and spacious interior cossets occupants within.
The first batch of IONIQ 5 owners in Malaysia recently received their BEVs.
Design is an art form that goes back centuries, and it has been used for all kinds of things in our lives. In the auto industry, it is an important element at the start of a new model project where the first ideas are given form and then explored to become the shape of the vehicle. Designers have traditionally commenced the initial creative phase by creating pencil sketches on paper, reflecting a certain kind of vehicle.
Many initial sketches will be prepared and then evaluated and eventually, one or two promising ones will be identified. These will then be developed as scale models from clay, a process that can take anywhere between 4 weeks and 2 months. Afterwards, the scale model would then be scanned and milled in a full-size. However, this approach is not without its drawbacks as some lines might be altered in the process.
Developing a new model still begins with sketches and then a clay model (below) is also built to provide a 3-dimensional view of the whole design.
As in other car companies, Hyundai’s designers were required to work together with clay modellers to refine the final design of an upcoming model. However, lines and surfaces had to be marked out using tape. On top of this, the company’s engineers were unable to work simultaneously with the designers, as they could only receive data after scanning the model with a photogrammetry system. Both of these factors made the process very time-consuming and cost-intensive.
In recent years, the design approach at Hyundai has undergone something of a revolution. While sketching remains fundamental for the designers, they can also draw upon a range of advanced tools such as virtual reality (VR) and 3D gravity sketching. These tools create a streamlined digital process which speeds up vehicle development by stepping away from a traditional design approach.
The VR revolution
Today, Hyundai no longer produces scale clay models; instead, it utilizes technologically advanced tools that are more intuitive, such as 3D digital design software. These enable the company’s engineers to mill full-scale models using 3D data, which significantly speeds up the design process.
The software enables the designers to work in collaboration across multi-user and multi-location environments. They can create models and immersive environments in VR that look extremely close to the real thing. The difference between modern design and the traditional approach is stark, and can be compared to the revolution cars undertook before and after ABS appeared, as an example.
VR technology also opens up a host of new opportunities for the designers. For example, the gravity sketching tool enables designers to create more human-centric vehicle designs by working in 3D from the start. Designers swap their paper and pencils for a headset and controllers to become immersed in VR, imitating gestural interactions through motion tracking. By working in 3D, they can experiment with different proportions and build variations based on their ideas. Meanwhile, a 360-degree view of the vehicle allows them to sketch from any angle – in contrast to the traditional 2D process.
3D gravity sketching also enhances the collaboration between the exterior and interior designers. Through this technology, the two teams are able to work together simultaneously. While the exterior design team refines the digital model, the interior designers can work in parallel by virtually stepping inside the car to develop features or make quick adjustments.
Another advantage of this technology is the ability to test unlimited colour options and material applications, including fabrics and leather, ambient lighting and other types of materials. As well as saving time, this also reduces shipping and travelling costs. In addition, this approach is much more sustainable as significantly less waste is produced, resulting in a significant reduction of CO2 emissions.
The VR design evaluation system
Hyundai’s design journey in multi-user wireless VR spaces started in 2017. By 2019, Hyundai and Kia (which is part of the Hyundai Motor Group) had established an ambitious new VR design evaluation system which has now been fully implemented. The system demonstrates a heightened focus on enhancing vehicle development processes through the implementation of VR technology. It simulates many aspects relating to a model under development, including interior and exterior design elements, as well as lighting, colours and materials.
Interior designers can ‘enter’ and look around the cabin with VR equipment, getting a better ‘feel’ of the environment.
The advanced tools are used at the company’s R&D facilities in Korea, Germany and the USA, as well as design centres in Europe, India, China and Japan. They allow the designers to review a multitude of design concepts earlier in the developmental process, and in ways that were previously physically impossible. VR headsets allow team members from the Design and Engineering departments to enter into a virtual conference in real-time and simultaneously undertake vehicle design quality assessments and development verification processes, no matter where they are in the world.
Getting around the lockdowns
These changes were already underway before COVID-19 emerged and sent the world into lockdown in early 2020. According to Simon Loasby, Hyundai’s Head of Styling, the pandemic served as a catalyst for the carmaker’s global design workforce, accelerating the transition to digitalisation and agile working.
“When our studios across the world were keeping all the designers home, we were fortunate that we were already operating a very well-oiled machine in terms of remote virtual connection, where we could all connect across 3 different continents and 5 different locations into a virtual working space and walk around the cars,” he recalled.
This partly enabled the completion of the SEVEN concept car project (shown above) in time for the 2021 AutoMobility LA event. It is the first fully-digitally designed model of the group and benefited from this virtual process. “When we completed the digital design sign-off of the car, Luc Donckerwolke (Executive Vice President for Design and Chief Creative Officer of Hyundai Motor Group), SangYup Lee (Senior Vice President at HMC and Head of Hyundai Global Design Center) and I were all in completely different locations, while our European team were in the discussion, too. We were in the same virtual location looking at the model, and did a complete virtual sign-off of the whole car: both exterior and interior. Remarkably, I hadn’t seen the physical model at that point, which must be a world-first for a lead automotive designer!” said Loasby.
Loasby’s ‘James Bond suitcase’
To enable Loasby to connect from anywhere, he has a specially built portable device which he refers to as his ‘James Bond suitcase’. Shaped inconspicuously like a travel bag, it is equipped with a laptop, VR goggles, cables and handsets. He is able to take it anywhere and participate in virtual design reviews with colleagues from all around the world.
“I’m very fond the carry-on bag I call my ‘James Bond suitcase’, because it ensures I can connect to our virtual conferencing space and conduct design reviews from anywhere, at any time,” he revealed. “In fact, one of the craziest design reviews I did was at Incheon Airport [in Korea]. I was about to fly somewhere but I needed to check in on the progress of a development quickly. So I took the gear out, plugged it in and set up my virtual studio next to a Starbucks and conducted a review from the departure terminal!”
Technology with a sustainable future
VR technology is continuing to evolve and in the future, it will offer much higher levels of detail and operate at far quicker speeds. It is therefore set to play an increasingly prominent role for Hyundai’s designers and engineers. In addition, advances in AR and mixed reality will enable the company’s colleagues to interact with one another even more immersively.
However, one fundamental benefit that should not be overlooked is its positive environmental impact. A digital design process produces a much lower carbon footprint, as far fewer clay, paper and waste materials are used in the process. For the development of SEVEN concept, Hyundai produced just one clay model for verification at the end, rather than a multitude of scale clay models. By meeting in a virtual conference space, Hyundai’s designers are no longer required to frequently travel around the globe, expending thousands of air miles in the process.
By the end of this decade, Hyundai Motor, like other major carmakers, aims to capture a sizable share of the global market for battery electric vehicles (BEVs). Of the 9.5 trillion Korean won it plans to spend during the decade, 20% will be spent on R&D in electrification of its products and related facilities.
It has set a target of selling 1.87 million BEVs annually by 2030 and to do this, it will offer a broad line-up that will consist of 17 new models (11 for the Hyundai brand and 6 for the Genesis brand). The new Hyundai BEV models will include 3 sedan models, 6 SUVs, a light commercial vehicle as well as a model of a new type. Genesis, its luxury brand, will get 2 new passenger cars and 4 SUVs; from 2025, all newly launched models from Genesis will be electrified.
Integrated Modular Architecture
In order to achieve the sales targets, the products will have to be priced competitively, which means that production costs will have to be brought down as much as possible. Key to this will be the Integrated Modular Architecture (IMA), a new platform evolved from the electric global modular platform (E-GMP) that is currently used for models such as the IONIQ 5 and GV60.
The IMA, revealed recently, will be utilized not only to as Hyundai’s passenger BEV platform but also as its exclusive purpose-built vehicle (PBV) platform, helping to streamline production processes and reduce cost. It will standardize not only the chassis but also the battery system and motor. In this way, economies of scale can be higher with many parts being shared by a larger volume of models.
Standardisation of battery packs
Hyundai also aims to standardize battery packs which can be attached to any models, also improving cost efficiency. This differs from the existing BEV development system which has different types of battery packs for each model. Through the cell-to-pack system, the new architecture can secure sufficient energy density and shorten charging time.
5 types of electric motors
The same approach of standardisation will be applied to electric motors, with no more than 5 types being used, depending on the model. This modular motor system will help achieve competitiveness in terms of cost and weight as well as motor efficiency.
Details of the powertrains shown in a presentation indicate that four of them will have 800V systems with a fifth one having 400V system, possibly for use in more specialised vehicles operating in demanding conditions (perhaps light commercial vehicles).
Comprehensive battery strategy
Batteries are, of course, a vital part of BEVs and as more BEVs are sold, demand will increase rapidly. In anticipation of this, Hyundai is trying to increase the local procurement rate of batteries through strategic alliances with battery companies in major regions to ensure sufficient battery supply. Through these alliances, the company expects to obtain more than 50% of its next-generation lithium-ion batteries for BEVs starting in 2025.
In addition, Hyundai will also diversify battery sourcing to consolidate the competitiveness of future BEVs. The company has secured sufficient battery supply to meet its sales targets by 2023. With a comprehensive battery strategy, Hyundai plans to continue cooperation with various battery companies with an aim of securing 170 GWh of batteries for its models. For the next-generation batteries, such as solid-state types, Hyundai is cooperating with various global partners to improve energy density and cost efficiency
Hyundai factory in the Czech Republic.
Expanding manufacturing footprint
To meet the growing demand for BEVs, Hyundai aims to establish a high efficiency manufacturing process to accelerate its transition into electrification. A human-centered manufacturing innovation platform is expected to bring dramatic innovation in production efficiency through a flexible production system, advanced level automation and digital twin technology. The innovation will be expanded to global plants in the future.
The existing BEV production facilities in Korea and the Czech Republic will be complemented by additional factories in other locations. One of them is in Indonesia which will start BEV production and contribute to the global volume.
