SUVs can be seen in every segment of the car market nowadays and now, Honda has even developed a SUV racing car with a hybrid powertrain. While SUVs have been used in competition before, this particular one is a special one-off project vehicle which is a sneak preview of the Honda’s technology to come.
Developed by Honda Performance Development (HPD), the racing arm of Honda’s North American subsidiary, the CR-V Hybrid Racer will make its debut at the 2023 Firestone Grand Prix of St. Petersburg. In 2024, hybrid power units will officially debut in the NTT INDYCAR SERIES, bringing electrification to the event.
Like other types of motor vehicles, trucks too are electrifying. Some companies like Ford and GM have already begun selling fully electric trucks and eventually, the bestselling truck outside North America will also go electric. This is the Toyota Hilux, a popular model in many countries for decades, which has built up a strong reputation for durability and reliability.
Toyota already has a development program ongoing for an electric Hilux as evident by a prototype shown in Thailand recently. On the occasion of the 60th anniversary of Toyota Thailand, Toyota President Akio Toyoda personally presented the Hilux Revo BEV to give a preview of a future Hilux with electric power.
The first prototype developed by BMW M Motorsport in 25 years was unveiled yesterday at the Petersen Museum in Los Angeles, USA. It was the first time the BMW M Hybrid V8 was shown uncamouflaged and in its iconic racing colours.
Like the camouflage livery seen during the earlier testing phase, the design of the livery for the 2023 racing season also comes from BMW Group Designworks. The livery represents a significant departure from the heritage-based ‘Icons of IMSA’ camouflage with a future-facing coat of arms comprised of modern, bold, fractal blocks of the iconic M colours and the M logo.
Before finally appearing in showrooms and being delivered to customers, one of the final stages in the development of a new model is extensive testing in all kinds of conditions representative of the real world. The testing will identify areas that need to be improved or changed and also validate many operating parameters.
Every manufacturer has a similar process and at Kia, the new EV9 is going through this final phase. As the model designation indicates, this is an electric vehicle (EV) and will be the second dedicated EV from the Korean carmaker after the EV6. Its launch date is set for the first quarter of 2023 so there’s about 6 months left to complete testing.
One year ago, at IAA Mobility in Munich, Germany, the BMW Group displayed a special X5 which runs on hydrogen. Known as the iX5 Hydrogen, it uses the X5 bodywork but has a hydrogen fuel-cell electric drivetrain.
The iX5 Hydrogen is under development because BMW sees hydrogen fuel-cell technology as having the potential to become a further pillar in the BMW Group’s drivetrain portfolio for local mobility without CO2 emissions. Provided the gas is produced using renewable energy and the necessary infrastructure is available, this technology can complement the BMW Group’s electrified drivetrain portfolio in future.
Fuel-cell + BMW eDrive technology The iX5 Hydrogen combines fuel-cell technology with a fifth-generation BMW eDrive. The drive system uses hydrogen as fuel by converting it into electricity in a fuel-cell. The electric output can be up to 125 kW/170 bhp, with water vapour as the only emission.
The electric motor was developed from BMW eDrive technology also used in the BMW iX. In coasting overrun and braking phases, it serves as a generator, feeding energy into a power battery. The energy stored in this power battery can deliver a system output of 275 kW/374 bhp to provide the driving experience that the brand has been known for.
The hydrogen needed to supply the fuel cell is stored in two 700-bar tanks (the two cylinders in the picture above) made of carbonfibre reinforced plastic (CFRP), which together hold almost 6 kgs of hydrogen. “Filling up the tanks only takes three to four minutes – so there are no limits on using the BMW iX5 Hydrogen for long distances, with just a few, short stops in-between,” said Juergen Guldner, Head of BMW Group Hydrogen Fuel Cell Technology and Vehicle Projects.
Built in-house The carmaker recently commenced fuel-cell system production at its competence centre in Munich. By the end of this year, it will have a small fleet iX5 Hydrogen SAVs that will be run around the world for test and demonstration purposes
“As a versatile energy source, hydrogen has a key role to play on the road to climate neutrality. And it will also gain substantially in importance as far as personal mobility is concerned. We think hydrogen-powered vehicles are ideally placed technologically to fit alongside battery-electric vehicles and complete the electric mobility picture,” said Oliver Zipse, Chairman of the Board of Management of BMW AG. “By commencing small-scale production of fuel cells today, we are demonstrating the technical maturity of this type of drive system and underscoring its potential for the future.”
“Our many years of research and development work have enabled us to get the very most out of hydrogen technology,” added Frank Weber, Member of the Board of Management of BMW AG, Development. “We have managed to more than double the fuel cell’s continuous output in the second-generation fuel-cell in the BMW iX5 Hydrogen, while weight and size have both decreased drastically.”
So far, the iX Hydrogen prototype has already successfully demonstrated its excellent everyday usability, even at very low temperatures, during the final round of winter testing in Sweden at the start of this year.
Technological expertise, high efficiency standards A chemical reaction takes place in the fuel cell between hydrogen from the tanks and oxygen from the air. Maintaining a steady supply of both elements to the fuel cell’s membrane is of crucial importance for the drive system’s efficiency. In addition to the technological equivalents of features found on combustion engines, such as charge air coolers, air filters, control units and sensors, the BMW Group also developed special hydrogen components for its new fuel cell system. These include the high-speed compressor with turbine and high-voltage coolant pump.
The individual fuel cells required for manufacturing the iX5 Hydrogen are supplied by from the Toyota Motor Corporation, which has been selling a hydrogen fuel-cell electric vehicle (the Mirai) since 2014. The two companies have been collaborating on fuel-cell drive systems since 2013.
Acura, Honda’s premium and performance brand mainly sold in North America, has had a long presence in endurance racing with prototype models. Next year, at the Rolex 24 at Daytona, it will debut an all-new electrified racing car, the ARX-06, the sixth generation of a successful line of Acura endurance racing prototypes.
The ARX-06 has custom bodywork and aerodynamics based around an all-new ORECA LMDh chassis. The chassis carries an electrified hybrid power unit with an equally new, bespoke twin-turbocharged 2.4-litre V6 engine designed, developed and manufactured by Honda Performance Development (HPD), the racing arm for Acura Motorsports in North America.
Smallest combustion engine With its 2.4-litre displacement, the AR24e power unit is the smallest displacement internal combustion engine conceived by HPD for endurance racing. It still meets the performance target of 500 kW as measured at the rear axle by torque meters. It features a 90-degree V-angle to reduce its centre of gravity and polar moment of inertia, and can run on sustainable low-carbon fuel.
The hybrid powerplant includes an IMSA-specified electric Bosch Motor Generator Unit (MGU) and Williams Advanced Engineering battery pack. The MGU is contained in a common transmission casing and gearbox internals provided by Xtrac.
“We’ve taken the challenge presented by this new rule package from IMSA, and developed what we believe is a very competitive solution,” said Pierre Descamps, who led HPD’s powertrain design team for the ARX-06. “We’ve gone in a new direction for HPD in the design of the ICE. It is still a V6, which of course for Honda is well-known, but we have incorporated several new elements which we believe will make best use of the electric MGU and battery pack. Our new engine will rev to the maximum 10,000 rpm set by the rules, so it also makes a wonderful sound!”
Both IMSA in North America and FIA World Endurance Championship (WEC) rules require manufacturers to use one of four approved prototype chassis, fitted with IMSA-homologated, manufacturer-designed and branded bodywork and engines.
Continued partnership with ORECA In the case of the ARX-06, HPD and Acura have elected to continue their successful relationship with ORECA. Since moving into chassis design and construction in 2007, ORECA has produced a series of winning sports prototypes, including the Acura ARX-05.
HPD’s Vehicle Performance Group worked closely with the ORECA design team and engineers to simulate chassis layout geometries and lap time optimization studies. They also ‘coded’ the new car into HPD’s static and dynamic Driver in the Loop simulators to begin development of the car’s vehicle dynamics and vehicle dynamic control systems.
Critical to the projects was a clean sheet hybrid powertrain control system, brake-by-wire and vehicle dynamics control system – all written in-house at HPD. This control system architecture was implemented on a Formula 1-spec ECU hardware platform. HPD also utilizes its custom, in-house developed ultra-high speed data-logging system.
Styling by Acura Design Studio The exterior styling of the ARX-06 was led by the Acura Design Studio in Los Angeles, in conjunction with ORECA, which is also one of the chassis suppliers approved for prototype competition in both the IMSA WeatherTech SportsCar Championship and the WEC.
Driver and team input was also sought throughout the design process. One effective change was a revision to the placement of the rearview mirrors. This is a seemingly minor adjustment but actually has a large effect on vehicle aerodynamics. Using VR headsets, the drivers were able to sit in the car virtually and recommend a much lower placement for the side mirrors, improving both the aero efficiency of the ARX-06 and visibility for the drivers.
Acura will continue its partnerships with the successful Wayne Taylor Racing and Meyer Shank Racing teams to campaign a pair of ARX-06 entries in the GTP category of the 2023 IMSA WeatherTech SportsCar Championship.
The sale of electric vehicles (EVs) in high volumes began 12 years ago, when Nissan introduced its LEAF. Since then, the number of EVs in use has grown rapidly and the question of what to do with the batteries at the end of their life powering vehicles is becoming a serious matter. The batteries can still be used for other purposes and some manufacturers are exploring practical ways of reusing them.
One possible second-life use case is being tested in India by a German–Indian start-up called Nunam. The aim of the project is to explore how modules made with automotive high-voltage batteries can be reused by installing them in electric rickshaws.
“The old batteries are still extremely powerful,” says Nunam co-founder Prodip Chatterjee. “When used appropriately, second-life batteries can have a huge impact, helping people in challenging life situations earn an income and gain economic independence – everything in a sustainable way.”
3 prototypes The non-profit start-up based in Berlin and Bangalore is funded by the Audi Environmental Foundation. Nunam developed the three prototype rickshaws in collaboration with the training team at Audi’s Neckarsulm site which, in turn, benefits from the intensive intercultural exchange. This is the first joint project between both AUDI AG and the Audi Environmental Foundation in addition to Nunam.
The 3 electric rickshaws are powered by used batteries taken from test vehicles in the Audi e-tron test fleet. They will appear on Indian roads in early 2023 when the pilot project gets underway with a non-profit organization. Women in particular will be able to use the all-electric rickshaws to transport their goods to market for sale, all without the need for intermediaries.
Looking for new uses The start-up’s primary goal is to develop ways to use old batteries as second-life power storage systems, thus both extending their lives and using resources more efficiently. “Car batteries are designed to last the life of the car. But even after their initial use in a vehicle, they still have a lot of their power,” Chatterjee explained. “For vehicles with lower range and power requirements, as well as lower overall weight, they are extremely promising.”
“ In our second-life project, we reuse batteries from electric cars in electric vehicles; you might call it electric mobility ‘lite’. In this way, we’re trying to find out how much power the batteries can still provide in this demanding use case,” he said.
Reusing e-waste E-rickshaws have an ideal eco-efficiency. With a high-energy-density battery pack and comparatively low vehicle weight, the electric motor doesn’t have to be particularly powerful – especially since rickshaw drivers in India travel neither fast nor far. While electrically-powered rickshaws are not an uncommon sight on the roads of the sub-continent today, they often run on lead-acid batteries, which have a relatively short service life and are often not disposed of properly.
At the same time, rickshaw drivers charge their vehicles primarily with public grid electricity, which has a high proportion of coal-fired power in India. Nunam has a solution for this as well: The e-rickshaws charge using power from solar charging stations. The solar panels are located on the roofs of the local partner’s premises. During the day, sunlight charges an e-tron battery, which acts a buffer storage unit. And in the evening, the power is passed on to the rickshaws.
This approach makes local driving largely carbon-free. The benefit is that the electric rickshaws can be used throughout the day – and still be charged with green power during the evening and night. In India, where the sun shines all year round, placing solar panels on the roof is an obvious solution.
Open-source platform encourages imitators Nunam will continuously monitor the e-rickshaws’ performance and range. The social entrepreneurs make all the e-rickshaw data they collect available to potential imitators on the open-source platform. In fact, imitation is expressly encouraged.
“Initiatives like the one pioneered by Nunam are needed to find new use cases for e-waste. Not only in India, but worldwide. So Nunam shares its knowledge to motivate more initiatives to develop products with second-life components that can drive the eco-social revolution forward,” said Audi Environmental Foundation Director Rudiger Recknagel.
And even after the battery has spent its first life in an Audi e-tron and its second in an e-rickshaw, it has not necessarily reached the end of the road. In a third step, the battery could still be used for stationary applications such as LED lighting. “We want to get everything possible out of each battery before recycling,” said Chatterjee.
The Cayenne was Porsche’s first SUV and has been extremely successful over the 20 years it has been on sale. The success of the Cayenne brought forth the smaller Macan, which has also been selling very well.
While the Cayenne has remained in its 5-door SUV form all this while, there was a period in the early years when other bodystyles were considered – a coupe, a version stretched by 20 cm with an additional row of seats, and even a convertible. And surprisingly, what might have appeared the least conventional option – a Cayenne-based convertible approximately 4.8-metres long – was not immediately discarded. In fact, it was even built.
Today, there is still a single example of the open-top Cayenne kept in storage at the Porsche Museum. It is not a roadgoing prototype, however, but what is known as a Package Function Model – or PFM for short. The designers had the roof removed, but dispensed with the body-stiffening measures necessary for a convertible. Incapable of providing a safe and stable drive, the vehicle is transported to its destination when required. Test drives were never planned, as the convertible PFM was only built to assess four criteria.
The criteria were: Is the seating comfortable throughout the vehicle when the roof tapers in a more coupé-like way towards the rear and when the windscreen and A-pillars are shortened? How practical is the Cayenne as a 2-door model with doors which are 20 cm longer? Is it possible to accommodate an elegant, high-quality soft top that can also be folded quickly? And how should the rear end be designed?
There was still disagreement on the final issue in 2002, and two different rear sections were designed for the Package Function Model. The left-hand tail light was set low on the rear of the car, while the right-hand one was noticeably higher.
Had the car reached production, a single rear design would, of course, have been settled on in the end, and the technical issues would undoubtedly have been resolved. A now-familiar soft-top mechanism was envisaged: the luggage compartment lid of the Cayenne-PFM was attached at the front and rear, allowing it to be opened in both directions. The roof would travel over the fixed roll-over bar and be ‘swallowed’ in the rear by the luggage compartment lid, which opened in the opposite direction, folding in a z-pattern.
It has worked in a very similar way to this on the 911 Targa since the 991-generation model. The mechanism never got past the computer simulation stage for the Cayenne convertible, however, and was never fully constructed. Today, the fabric top is stowed in the luggage compartment of the museum piece and must be fitted manually if required.
While the coupe idea of 2002 was later taken up again and implemented in 2019 in a production model, Porsche did not pursue the convertible idea further. Forecasts regarding profitability were not particularly promising and doubts remained as to whether the car would look as appealing as a Porsche should.
“An SUV as a convertible is a challenge both aesthetically and formally,” said Michael Mauer, who was not yet in office in 2002, looking at the concept today. “An SUV always has a large and heavy body. You combine this with a small top half and then cut off the roof – you get very strange shapes emerging from that!”
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.
