Electric and hybrid drive systems and lightweight design. These closely interrelated themes are going to have a decisive effect on vehicle concepts of the future. At the IAA the EDAG Group, as an all-round development partner, presents solutions and concepts for further reducing the vehicle weight and CO² emissions for vehicles and production plants.
Besides new lightweight multi-material concepts, the company also will be presenting in Frankfurt its input to the international steel industry's "FutureSteelVehicle" project. For WorldAutoSteel, EDAG have developed a body concept for conventional and alternative drives, as a demonstration in lightweight, low emissions design. In the area of production technology, EDAG's expertise in tomorrow's energy efficient production can be seen in its in-house developments "light gripper" and "light clamping frame".
For the complex area of electric mobility, EDAG will be presenting solutions for the entire supply chain: starting with lightweight vehicle construction, the integration of components, the interface to the energy providers by means of an intelligent charging system; on to the integration of energy stores in the vehicle architecture and human-machine interface concepts; and finally a presentation of EDpowerdrive, our modular drive system.
Diet by new steel innovations and multi-material systems.
Vehicle lightweight construction is not just a fad in response tonew CO² levels; rather, it has always been the "royal" discipline in the automotive industry.
In addition to ever increasing economic requirements, this subject is gaining in importance because of the hybrid and electric drive train concepts coming onto the market. Created for the international steel industry consortium WorldAutoSteel, the "FutureSteelVehicle" impressively shows that steel construction methods have great potential for lightweight vehicle structures that reduce vehicle emissions. Steel lightweight construction achieved significant weight reduction to 188 kg for a Battery Electric Vehicle (BEV) body structure and reduced total life cycle emissions by as much as 70 percent, compared to an internal combustion engine vehicle, without significantly increasing cost.
Commencing in 2008 as a sequel to the ULSAB steel research project, the EDAG Group is responsible for FutureSteelVehicle's concept, development and engineering of optimised body structure concepts intended for series production using innovative steel applications and advanced design methodologies. The "FutureSteelVehicle" can be viewed at the EDAG stand in Frankfurt as a 1:4 model and is intended to instigate a dialogue between the international steel manufacturers and the OEM's. Cees ten Broek, Director of WorldAutoSteel, underlined in his presentation "the express willingness to present the FSV's steel innovations to automobile manufacturers for incorporation into their new developments."
As an expertise example for fibre-reinforced plastics EDAG is showing its development expertise for fibre-reinforced plastics in particular its solutions for calculating methods. Thanks to the in-house accredited test laboratory static and dynamic material parameters for new composite materials can be determined and can be presented to CAE as FEM material cards. Between partners processes ready for series production, e.g. RTM procedures with short cycles can be integrated into the development or shown as prototypes. Roding Automobile is showing their GRP 1:3 Monocoque on the EDAG stand, it was made by EDAG. With a hybrid solution using endless fibre-reinforced thermoplastic (Organosheet) as an exhibit EDAG shows an R&D contribution for an affordable lightweight construction for middle and larger volume.
EDAG has identified the thin-walled low pressure cast steel as another future subject for energy efficient lightweight construction. Currently the thin-wall casting is mainly conducted for aluminium or magnesium, but using steel it offers attractive perspectives for light, production-optimised and above all environmentally friendly components.
The presentation of the "light" gripper and the "light" clamping frame shows that the EDAG Group have taken the thought of lightweight construction from vehicle development and carried it into production technology. In production a greater weight leads to higher energy costs and finally to a greater investment. Heavier tools mean the use of larger and therefore more expensive robots in production. The in-house development of a "light" gripper allowed the EDAG Group to significantly reduce the weight.EDAG substituted the aluminium chord profile (EGT system) with a body of GRP: Weight saving of up to 66%. This GRP body is not only lighter, but also offers maximum structural design possibilities in placing the clamps. With a grid system no longer necessary a simpler construction is possible even with larger more complicated grippers.The lower weight allows the "light gripper" to have the best possible inertia features, which allows the use of smaller, cheaper and more energy efficient robots. The light gripper developed in 2011 will be subject to practical tests until the end of the year and a market launch is planned for the beginning of 2012. The lightweight philosophy was also used by EDAG for the clamping frame, which is used in framer stations. Again the conventional assembly - in this case steel - was replaced by the weight optimised GRP body.
As an example of its expertise in developing and building flexible manufacturing technology the EDAG Group is presenting the new generation of the tried and tested framing station.
The "GeoTack 2010" was specially developed for production lines with high product variation. The "GeoTack 2010" allowed for the production of a lorry cabin with 30 different versions. The system offers a manoeuvrable pallet which moves the base frame of the clamping technology in X-direction. The actual base frame can be moved in Y-direction, the changing of the clamping segments is aided by robots. The framing concept is also built modularly and can be extended as needed. Aside from the flexibility of the "Geotack 2010" it also needs 15% less surface than customary framing stations and this leads to a cost reduction of 20-30%.The system was successfully used in lorry production and for type and model flexible car production.
EDAG "Light Car Sharing" - Purpose Design for car-sharing vehicles
With its acclaimed EDAG Light Car concept, the EDAG Group has for the last two years been working on its vision of the electrically driven car of the future. In the spring EDAG developed its far reaching mobility concept at the Geneva Motor Show which will break down barriers between private and other transport systems, and provide the customer with a new, intelligent form of mobility. The development of the past months has shown that car sharing offers in Germany are increasing. Reason enough to show the "EDAG Light Car - Sharing" at the IAA again. After all the focus of the mobility concept is concept based specifically on the needs of an electrically powered rental vehicle. The "EDAG Light Car - Sharing" offers comfort when getting in and out because of the height of 1.90 m, a reduced self-explanatory operating concept, robust and easy to change interior and exterior parts and up to six folding seats offering the maximum space.
With the "EDAG Light Car Sharing", we will be presenting not only a new, powerful and up-to-date vehicle concept at the Geneva Motor Show, but also a new attitude to mobility. A vehicle concept specifically designed for effortlessly getting from A to B, and moreover one which can easily be booked and combined with other means of transport via mobile Internet solutions. Due to the high cost of electric cars today, electric mobility could well take the form of vehicle sharing in the immediate future, and I view vehicles for this purpose as capital goods rather than consumer goods. We invite our customers from the automotive industry and potential market partners to join the discussion on this different form of mobility, and seek out future business models," says Jörg Ohlsen, CEO of the EDAG Group.
With EDpowerdrive we are presenting an electric drive system that can be retrofitted in lightweight delivery vehicles. The modular system has been developed specifically for use in urban delivery transport, making it the first drive system to permit bivalent operation of the vehicle, using fossil fuels and electric power - the latter independently of the standard powertrain.
The original-state diesel engine in the carrier vehicle - a VW Caddy - on show guarantees maximum efficiency on motorways and other major roads. And the newly developed exhaust-free, low-noise electric modular power unit, which has been integrated into the area of the former fuel tank takes over in residential and urban areas.
This example shows EDAG bridging technology and finding a current use for electric mobility.
With the EDcharge concept EDAG shows a charging system, that doesn't only supply electric vehicles with electricity but also makes the exchange of information between vehicles, energy providers and Car Sharing suppliers possible.
The sharing vehicles can be charged on special car parking places: As well as recharging vehicle information is sent over the power supply
system and has created the possibility for the car sharing operators to employ the vehicle pool efficiently. Questions like: Is the vehicle fully charged?
How great a range is currently available? When is the next maintenance due? can be easily retrieved over a special portal.
The necessary development of power electronic components are part of the range of services from the EDAG Group as well as the integration of innovative energy storage into the vehicle. EDAG's presence in the VDA special hall for electric mobility is all about the charging of electric vehicles. EDAG view the system concept electric mobility as networking between vehicles and infrastructure with the goal of achieving a standardised interface which can determine the perfect charging time regarding the availability of renewable energy and mobility performance. New services such as automated legitimation and the selection of individual tariffs or prices per minute are just a few of the options that become available as a result of the energy provider and vehicle being intelligently linked. On the one hand, for instance, it gives the energy provider the chance to make use of energy storage and in this way reduce load fluctuations in the grid due to electric cars being connected. While on the other ensuring that there is sufficient resource-saving energy to charge the share vehicles whenever necessary. The comprehensive portrayal of charging scenes is also a part of the EDAG presentation at the IAA. Further emphasis is laid upon charging with alternating current through a cable, charging with direct current and charging without a cable.
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