20 years ago, Proton established a second factory in the Tg. Malim area of Perak with a plan to develop a ‘Proton City’. This was to be an automotive zone with suppliers nearby to provide parts and systems directly to the factory. Parts of that original plan were realised but not to the grand plan envisaged as a production hub.
But the idea has not been forgotten and a year ago, DRB-HICOM announced its intention to develop an Automotive Hi-Tech Valley (AHTV) in the Tg. Malim area with the aim of becoming an industry hub for the ASEAN region.
Besides supporting Proton, the AHTV is expected to attract businesses which are involved in new technologies and systems relevant to the global automotive industry. These would include electrification, Artificial Intelligence, autonomous technologies and advanced connectivity.
Honda, like other responsible carmakers, has been committed to ensuring that road accidents caused by motor vehicles are reduced, if possible to zero. After all, it supplies those vehicles and therefore has to ensure that they are not only safe to use but also safe to other road-users.
It has constantly introduced new safety features and systems in its vehicles as new technologies have been developed. Today, its Honda SENSING system integrates many active safety systems to work more effectively and intelligently to assist the driver and also prevent accidents. The Honda SENSING suite was first introduced in 2015 with the CR-V and has been included with new models since then.
Honda SENSING is being continuously improved and apart from the basic system – which already consists of a number of active systems – there are additional versions such as Honda SENSING 360 and Honda SENSING Elite for more sophisticated applications in certain models.
Ford has always urged drivers to keep ‘eyes forward and hands on the wheel’. It’s obvious that maintaining attention on the road ahead is important to immediately spot any danger. At the same time, both hands should be on the steering wheel to always be able to take avoiding action in an emergency. That’s why using a mobilephone when driving is dangerous and in many countries, an offence.
Over the years, various technologies have been introduced to help drivers stay focussed ahead. Head-up Displays (HUDs) are one of them, the technology having been taken from fighter aircraft. By projecting important information on the windscreen, the driver can be informed while still looking ahead.
Now Ford researchers have developed a new headlight technology that could help ensure those behind the wheel literally keep their eyes on the road. The new technology can project directions, speed limits or weather information onto the road so the driver keeps looking ahead.
The technology is intended for use at night, of course, as that is when driving can be riskier. Statistics in the UK show that 40% of collisions happen during the hours of darkness, even though there are far fewer people driving than in the daytime.
This risk is increased whenever a driver takes their eyes off the road. A vehicle travelling at 90 km/h covers 25 metres per second, meaning even a short glance at the navigation screen on the dashboard can result in ‘driving blind’ for 10 metres or more. On an unlit road, this could potentially mean missing an important sign or a bend in the road.
Ford’s researchers have therefore come up with a system that projects important information onto the road using high-resolution headlights. The technology could even provide the driver with information about changes in weather, such as rain falling, fog, slippery conditions, or a slippery road ahead.
Connecting the headlight to the navigation system could display upcoming turns, while the width of the vehicle could be projected onto the road, helping the driver to judge whether the vehicle will fit through a gap or into a parking space.
The technology could benefit other road users too. For example, a pedestrian crossing could be projected onto the road, both for the view of the driver and the pedestrian, in situations where the existing road markings are faded or unclear. Other possibilities include showing a path for the driver to follow to ensure cyclists are passed at a safe distance.
“What started as playing around with a projector light and a blank wall could take lighting technologies to a whole new level. There’s the potential now to do so much more than simply illuminate the road ahead, to help reduce the stress involved in driving at night. The driver could get essential information without ever needing to take their eyes off the road,” said Lars Junker, Features and Software, Advanced Driver Assistance Systems, Ford of Europe.
Although wind tunnels have been associated with aeronautical research and development, such facilities existed long before the first aircraft flew, and they were used by scientists in the 19th century to study airflow. Aircraft designers then used wind tunnels to see the effects of different shapes that would be used for aircraft bodies and wings.
Wind tunnels were also used by other industries and by the 1930s, as cars started to go at high speeds, the wind tunnel was used to study how air flowed over their bodies. It was a Prof. Dr.-Ing. Wunibald Kamm at the Technische Hochschule Stuttgart in Germany who was the first to use a wind tunnel for aerodynamic design studies which would be pioneering.
From then on, carmakers would add aerodynamic studies to the development process of a new model, using scale models in small wind tunnels and full-sized models in larger tunnels. Various types of equipment measured airflow so that it could be optimised because it was understood that smoother airflow could improve performance and also reduce noise levels. By having a wind tunnel, the engineers could also study the behaviour of the car design (eg stability) at high speeds without actually having to drive the prototype on the track.
In earlier years, carmakers didn’t yet have their own wind tunnels, so they used those in other research facilities. In time, some started to build their own so they could conduct testing with more secrecy and also without having to pay for renting facilities. Some built small tunnels and some built big ones, depending on how much they could spend.
Pininfarina, the automotive design consultancy, also decided to build its own wind tunnel and it was large enough to test full-sized vehicles. At the time it began operations, it was Italy’s first wind tunnel to be built for testing full-sized cars, and one of only seven in the world. That was in the year 1972 and this year sees it celebrating its 50th anniversary.
“Without a doubt, Pininfarina has a real passion for aerodynamics. And it’s a passion that has lasted more than 50 years, long before my father decided to build the structure. It all began with my grandfather Pinin, whose visionary intuition in aerodynamics is exemplified since the Lancia Aprilia Aerodinamica produced in 1936,” said Chairman Paolo Pininfarina, whose father was Sergio Pininfarina.
While it was initially used for motor vehicles, Pininfarina’s wind tunnel would become a powerful tool for testing and developing products across all sectors in which the company is fully involved. These include aircraft, high-speed trains, yachts, buildings, wind engineering, industrial design and even sporting goods. With the advent of electric mobility, there is even greater emphasis on aerodynamics as well as aeroacoustic development.
It is one of the few wind tunnels in the world to have a TGS – Turbulence Generator System – able to create various conditions of controlled turbulence associated with gusts of wind, overtaking manoeuvres, cross-winds and vortices generated by cars ahead.
There is also a Ground Effect Simulation System allows reproduction of real vehicle motion conditions. This is achieved by having 4 rollers and 3 mats to allow the wheels of the vehicle and the ground to move at the same wind speed. This system was developed to make the tunnel test conditions as faithful as possible to the road conditions, and to analyze the movement of air underneath.
While most cars have closed cabins, there are also convertibles with open tops as well as the increasingly popular fitment of sunroofs that create an opening on the roof. These all have significant implications on airflow and noise generation, as those who have been in such cars will know. In the wind tunnel, the turbulence generated can be studied and solutions developed to make things more comfortable.
When it first started operation, the wind speed inside the tunnel was less than the 250 km/h maximum of today. It was upgraded with the addition of 13 fans, with each fan able to spin at a different speed or have a different blade pitch. Noise levels were also reduced allowing better aeroacoustic studies with new noise measuring techniques. Aeroacoustic tests are becoming a fundamental element for increasing driving comfort, particularly for hybrid and battery electric vehicles.
The wind tunnel is equipped with three external microphone arrays and also cameras, helping to identify the sources of noise and consequent definition of countermeasures. Noise Vision and Beam Forming support enables visualization to aid analysis. In addition, the wind tunnel is also equipped with 4 acoustic dummies for internal acoustic comfort evaluation.
“The Wind Tunnel has given our company a considerable competitive edge, being the only design company to own one. Born as a tool with which Pininfarina developed its own projects, today it’s a strategic asset for the group, thus expanding the portfolio of services that we offer to the market: an activity that supports other sectors beyond the automotive, from transportation to architecture, from nautical to industrial design,” said CEO Silvio Pietro Angori.
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 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.
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.
Wouldn’t it be nice to have the colour of your car change as you wish, with just the touch of a button? It’s still an idea in science fiction but the BMW Group has developed a technology which can do it. The technology, known as E Ink, was demonstrated on a BMW iX Flow at the Consumer Electronics Show (CES) 2022 in Las Vegas this year.
“Since then, we have already introduced further improvements for the technology,” said Stella Clarke, project lead of the BMW iX Flow. “Previously, the changes between colour patterns only took place in a gradual transition. Now, the control electronics have been tweaked to enable instantaneous transformations, resulting in an even more stunning visual effect.”
Neurotechnology to change colours
In a one-off collaboration with the BMW Group, a Munich-based start-up called brainboost has developed a new and improved colour-changing effect using brainwaves. With the help of brainboost, the BMW iX Flow was connected directly to the brain of the delegates at a dialogue platform using an electroencephalograph (EEG), which records the brain’s electrical activity.
“The colour patterns of the BMW iX Flow react to brain activity and reflect the level of activity,” explained brainboost CEO Philipp Heiler. “Once the brain is at rest, the changes of patterns on the iX Flow also become calmer and more rhythmical.”
A special animation was activated if delegates managed to maintain this state for several seconds. Thus, the participants were able to gradually calm and relax their brains under the guidance of the brainboost experts and with the help of neurofeedback via the iX Flow.
Technology behind the colour change
The body of the BMW iX Flow is laminated in a special film containing millions of colour capsules. When stimulated by electrical signals, negatively charged white pigments or positively charged black ones will collect at the surface, thereby changing the exterior colour.
The innovative E Ink technology opens completely new ways of changing the vehicle’s appearance in line with the driver’s aesthetic preferences, the environmental conditions or even functional requirements. By making it possible to alter the body colour and display different patterns, the BMW iX Flow featuring E Ink opens up a whole new way of personalising the driving experience.
Apart from a greater degree of personalisation, a customer will also not have to settle for just one colour – he or she can have many more for different occasions! “This gives the driver the freedom to express different facets of their personality or even their enjoyment of change outwardly, and to redefine this each time they sit into their car,” said Clarke.
Colour variability enhances efficiency
A variable exterior colour can also contribute to wellness in the interior and to the efficiency of the vehicle. This is done by taking account of the different abilities of light and dark colours when it comes to reflecting sunlight and the associated absorption of thermal energy. A white surface reflects a lot more sunlight than a black one. By implication, heating of the vehicle and passenger compartment as a result of strong sunlight and high outside temperatures can be reduced by changing the exterior to a light colour. In cooler weather, a dark outer skin will help the vehicle to absorb noticeably more warmth from the sun.
In both cases, selective colour changes can help to cut the amount of cooling and heating required from the vehicle’s air conditioning. This reduces the amount of energy the vehicle electrical system needs and with it also the vehicle’s fuel or electricity consumption.
In an all-electric car, changing the colour in line with the weather can therefore also help to increase the range. In the interior, the technology could, for example, prevent the dashboard from heating up too much.
E Ink technology itself is extremely energy efficient. Unlike displays or projectors, the electrophoretic technology needs absolutely no energy to keep the chosen colour state constant. Current only flows during the short colour changing phase.
The technology is still under development and as with many new advanced technologies, it will be expensive when it is initially offered. But over time, the cost could come down and then everyone can have a colour-changing car (the police won’t be happy!).
In the early 1980s, Honda was looking at a new generation of engines for the mainstream market. It was a period when multivalve cylinder heads (more than one intake and one exhaust valve) were beginning to enter mainstream engine design and Honda was looking at something which would enhance performance further. This effort brought forth the New Concept Engine (NCE) program in March 1984 which had specific targets that included high torque in both the low and high rpm ranges and dramatic increases in horsepower per litre. The program was a success, resulting in a series that included the DOHC engine found in the 1985 Civic and Integra, and the SOHC centre-plug engine in the 1987 City.
Ikuo Kajitani, an engineer in Honda’s Tochigi R&D Centre, was involved in the development of these 4-valve engines. Through his experience in engine design, Kajitani had become convinced that Honda’s next engine should offer a mechanism that could alter the timing of the valves. “Characteristically,” Kajitani said, “4-valve engines are known as high-revving, high-output machines. And for that reason, we knew it would be quite difficult to achieve low-end performance if the engine’s displacement were too small.”
Understanding the challenges
There were various problems during the process of development, eg a reduction in the valve’s interior angle, attempted in order to increase low-end torque, resulted in a broken timing belt and valve spring as the unit reached the upper rpm range. To address the problem, the development team put in long hours studying how to balance these two critical areas of engine performance. They knew they had already succeeded with their DOHC and SOHC powerplants, but to develop a new unit that would outperform its predecessors they would have to bridge the gap between the low end and the upper limit.
One group examined the idea of ‘switchable valve timing’ and in January 1983, a year before the NCE program began, a research team was formed to study the mechanism as a means of enhancing fuel economy… even though by the end of 1982, Honda engines were already capable of a world-beating 17.7 kms/litre.
A possibility was identified through the study of a new valve mechanism. Specifically, it was believed that the installation of a new set of cam followers and rocker arms for high-speed operation on the intake and exhaust sides would help, along with the switching of cam hills according to engine speed. This was to be their solution to higher engine efficiency and was the so-called “valve stopping + variable valve timing” mechanism employed in the NCE program.
The mechanism underwent a program of study and refinement. Eventually, it evolved into Honda’s VTEC (Variable Valve Timing & Lift Electronic Control System) engine that would become a key feature of Honda engines up till today. The new technology, which offered a new level of performance, made its debut in the 1989 Integra.
New technology for future engines
“Find a new technology to lead the next generation of Honda engines.” This was the directive issued by top management at Honda R&D and, in response, a project was proposed to expand the variable valve-timing approach. Since it had originally been created to improve fuel economy, the engineering staff’s new assignment would be to combine outstanding mileage with impressive output across the entire powerband.
Approval was given in November 1986 with the first objective being to develop a new engine for the Integra. Kajitani, a lead engineer of the engine development project, knew that working on VTEC technology would not merely solve many problems he had experienced in development of the DOHC and SOHC engines, but would play a major role in the creation of future powerplant designs.
100 bhp per litre
He believed the specification for Honda’s new engine – 90 bhp per litre (or 140 bhp from a 1.6-litre unit) – was not really reflective of the 1990s approach. After all, the DOHC engine already produced 130 bhp but the new engine would only have 10 bhp more than that. He was not satisfied with that level and as if to read Kajitani’s mind, Nobuhiko Kawamoto, then president of Honda R&D made a thoughtful suggestion: “Why don’t you raise your target to 100 horsepower per litre?”.
It had always been thought that a normally-aspirated engine could not be made to produce 100 bhp/litre. But Kawamoto was an experienced engineer and his words inspired Kajitani. The new target would mean 160 bhp from only 1.6 litres, and at a maximum of 8000 rpm. “We’ll make that our goal,” he declared.
“Conventional engines in those days could only produce 70 or 80 bhp per litre. But here we were, being asked to increase it all the way to 100 bhp… it wasn’t going to be easy,” Kajitani recalled. “An engine becomes subject to a higher load as you increase its rpm. So we had to keep in mind the quality-assurance target of 15 years, or 250,000 kms, for a mass-production engine. We all wondered how on earth we were going to reach that number while ensuring the required quality of mass production.”
When Kajitani sat down with his associates and told them the target, he was immediately swept back by a barrage of questions. For example, the target of 8,000 rpm was almost 20% higher than the maximum output of 6,800 rpm achieved by the 1.6-litre DOHC engines of that time. Moreover, the inertial force upon various engine parts would increase by 40% and the engine would be subject to considerably higher loads due to its increased interior heat. Therefore, to reduce inertial mass under such high revolutions, the weight of each part would have to be reduced. Discussions were held daily for 3 months.
Finally, after everyone had expressed their opinions and proposed ideas, it was time to align all vectors in a single direction. The team identified some 30 new mechanism and technologies they would need to introduce in order to secure a stable VTEC system. These included a valve-operating system with a hydraulic timing selector pin, a small hydraulic tappet mechanism built into the rocker arm, and weight-reduction techniques to achieve higher revolutions and output.
Is it genuine technology?
But Kajitani was not certain which technologies should be used and which should be set aside. He kept asking himself, “Is this technology genuine?” It was a question Kawamoto asked too. Kajitani’s personal view was that a technology would be ‘genuine’ if it had been in the market around for 10 years. “Even so, a technology that’s been for around 10 years is one that’s accepted by society. In that sense, there shouldn’t be any problem adopting such a technology to all models,” he said.
The difficulties the team endured through its discussions with the committee helped bring the VTEC engine to life. But there was often fear in Kajitani’s mind, as well. “I thought we might not be able to achieve it because the goal was too high,” he said.
It was quite difficult, for example, to balance the valve-timing lift against the load placed on the timing belt, which would increase at high rpm due to the spring and other factors. Although it was a problem needing a solution in order to achieve the target output, such an answer would not be easy to find.
One of the approaches taken to increase output across the full rev range was by widening the diameter of the intake valve. Also, the team adopted valve timing and lift settings that were comparable to Honda racing engines in order to enhance volumetric efficiency. The improved output resulting from that technique actually served to improve performance at high speeds. Additionally, measures were taken to reduce intake resistance. At last, the goal was reached, with a full 160 bhp at 7600 rpm and a redline of 8,000 rpm.
Low-speed torque, an initial project objective, was obtained by changing the low-speed cam’s setting. This permitted the intake valve to close early, drastically improving the engine’s volumetric efficiency. Since the engine now had higher efficiency at low speeds of operation, a broader torque band could be realized.
The implementation of new materials was certainly a factor in the successful application of these technologies. For example, since the VTEC engine’s three cam followers must be positioned in a single bore, the camshaft offers relatively limited cam width. Therefore, the shaft must be designed to withstand high surface pressures. To achieve this, the team developed a new camshaft of cast steel.
Ensuring reliability
The VTEC engine program then went into a critical phase. In order to ensure absolute reliability in mass production and introduce the engine to the market with confidence, the team had to guarantee the functions of all mechanisms and parts. In addition to a significant responsibility for product reliability, the team had special expectations regarding the VTEC engine. “We all shared the determination to apply these technologies to every Honda model,” said Kajitani. The team’s view was that VTEC technology shouldn’t be limited to the Integra alone but further improved for use on future Honda models.
Honda’s new Integra, equipped with the DOHC VTEC engine, was introduced to the market in April 1989. The VTEC technology drew considerable praise as the world’s first valve mechanism capable of simultaneously changing the valve timing and lift on the intake and exhaust sides. In addition to its impressive output and high-revving energy, the VTEC powerplant offered superior performance at the low end-including a smooth idle and easy starting-along with better fuel economy.
Evolution of the VTEC engine
The DOHC VTEC engine was subsequently adapted for use in the NSX as well as the Accord and Civic. Following the SOHC VTEC engine, and then the VTEC-E in 1991, the technology evolved into the 3-stage VTEC engine introduced in 1995, which demonstrated an even greater degree of efficiency in output control. By 2001, the K-series engine family incorporated the first i-VTEC cylinder with an automatic self-adjusting cam gear to continuously optimize valve overlap for all rpm ranges. A number of the latest Honda models have the 1.5-litre VTEC TURBO engine, a powerplant that retains the fuel economy benefits of a small engine and yet produces torque exceeding that of a 2.4-litre engine.
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.
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.
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.
‘Range anxiety’ was something which concerned many who were considering a battery electric vehicle (BEV). The earlier models could go just a 100+ kms on a fully charged battery pack but the distance gradually increased as battery technology advanced. As battery packs were made more energy-dense to store more electricity, the vehicle could go further and further before recharging was needed. Today, the average is around 350 kms but just as with the consumption of fuel by combustion engines, range is affected by driving conditions and driving style.
But range anxiety is now less concerning not only as cruising distances increase but the network of recharging stations is also growing. So it is possible to ‘refill’ along the way on a long journey and now, it is more a matter of how long that takes – and manufacturers are also reducing the time.
Battery technology has come a long way in the past decade and if we take the Nissan LEAF as an example, the range with the first generation launched in 2010 was under 200 kms; today, the latest generation is claimed to be able to go up to 385 kms.
Breaking through technological barriers
In future, the distance will be even greater and Mercedes-Benz has proven that it is possible to go up to 1,000 kms on a single charge. This was achieved with the VISION EQXX technology demonstrator which the company is using to test technologies under development. This software-defined research prototype is part of a far-reaching technology programme that combines the latest digital technology with the brand’s pioneering spirit, the agility of a start-up and the speed of Formula 1. The mission in developing the VISION EQXX was to break through technological barriers across the board.
“The VISION EQXX is the result of a comprehensive programme that provides a blueprint for the future of automotive engineering. Many of the innovative developments are already being integrated into production, some of them in the next generation of modular architecture for compact and midsize Mercedes‑Benz vehicles. And the journey continues. With the VISION EQXX, we will keep testing the limits of what’s possible,” said Markus Schafer, Member of the Board of Management of Mercedes-Benz Group AG, Chief Technology Officer responsible for Development and Purchasing.
From Germany to the south of France
To show what is electrically ‘feasible’, the research vehicle completed a 1-day road trip across several European borders: from Germany across the Swiss Alps to Switzerland, on to Italy, past Milan and finally to its destination, the port town of Cassis in the south of France. The journey started in cold and rainy conditions and proceeded at regular road speeds, including prolonged fast-lane cruising at up to 140 km/h on the German autobahn and near the speed limits elsewhere.
The route profile set and the weather conditions presented the VISION EQXX with a wide variety of challenges. Different various sections of the route helped document the effect of the many efficiency measures. These measures include tyres specially developed by Bridgestone with extremely low rolling-resistance.
Throughout the journey of 11 hours and 32 minutes, it was not recharged and covered 1,008 kms in everyday traffic – with the battery’s state of charge on arrival shown as being around 15%. That was estimated to be good for another 140 kms or so, and the average consumption was a record-breaking low of 8.7 kWh per 100 kms.
Power from sunshine
However, Mercedes-Benz reveals that although it did not receive conventional recharging, it still received electricity from an external source – the sun. On its roof are 117 solar cells to collect sunshine which is converted to electricity and fed to the 12V battery. This battery does not power the electric motors but supplies power to auxiliary areas such as the navigation system. This this removes the demand from the high-voltage battery pack. The solar panel feature is said to increase the range by more than 2%, which adds up to 25 kms on a journey of over 1,000 kms.
Like most other BEVs, the VISION EQXX also uses recuperation – the recovery of braking energy – to provide some energy to the battery pack while on the move. The recuperation effect occurs on any type of gradient and during every braking manoeuvre.
The VISION EQXX was driven in real-life conditions and to have independent proof, the charging socket was sealed, and the car accompanied by a representative from TUV Sud, the independent German certification body.
Technological advancements accelerating
In the early era of the PC (personal computer) in the 1980s, the processing power doubled every two years, but this has accelerated as time passed. It might be the same for battery and EV technology which is continuously advancing each year so from the 500 kms possible in some models today, the increases might be greater and who knows, by the next decade, the 1000-km range which is amazing today might be possible in BEVs for sale to the public.