Vehicles of Tomorrow 2019

Technological progress based on digitalization and automation opens up opportunities for a variety of new mobility and vehicle concepts. Beside that, the way we use and understand mobility in modern society is underlying a drastic change. As a consequence, user-oriented mobility services with high flexibility are piloted and rolled out in urban areas. Within the article, we discuss different types of autonomous and shared concepts and their potentials in modern transport. Based on the use case of so-called Robocabs, results of an international user survey are presented with a strong focus on user acceptance. Furthermore, new mechanisms and models to generate additional revenues linked with the vehicle concept like new forms of advertisement are discussed. A data-driven analysis shows that there lies substantial revenue potential in value-added services, though the value distribution varies to a significant extend. Whereas static or recurring advertisement allows only for limited revenues, geo-located advertisement with tailored offers and context specific options for interacting with the customer hold the potential to multiply the average advertisement revenues.

Growing demand for on-demand mobility services such as ride hailing, taxis and car sharing is giving rise to a new category of vehicles: cars focused on the passengers rather than the driver and whose flexible interiors can be individually tailored to the needs of users. The addressable market for these purposebuilt mobility vehicles will reach almost 1.3 million vehicles by 2020, with demand already expected to double to about 2.6 million by 2025. By then, all these vehicles will also be electric. Established carmakers and new players alike have announced plans to introduce these vehicles in the years ahead. This article outlines how the market is developing and examines the issues device manufacturers must tackle to end up on the winning side. This paper is an update of Roland Berger's 2018 publication "A new breed of cars – Purpose-built electric vehicles for mobility on demand".

The automotive industry is subject to fundamental change through the extension and modification of the powertrain, as well as through diversification of vehicle concepts. Complex tasks are already causing increasing challenges in industrialization of conventional vehicle projects. Today's successful market presence is often based on a consistent implementation of platform, modular and modular construction kit strategies. In addition, manufacturers endeavor to shorten the automobile product development process by so-called frontloading.

From various research activities exist sometimes excellent results, which are indeed confirmed on a laboratory scale to have promising potential for automotive applications, but so far experienced no industrial conversion. This is partly due to the named manufacturing strategies and furthermore in the subsequent process chains with diverse supplier structures. The disadvantage of this established methodologies is the prevention of possible innovations through the manifested production cycles.

Intention of the presented new development concept is the combination of functional and design-optimized product design with multiple functional integration. Through the holistic consideration of the whole vehicle life cycle and by using newest technologies an integrative concept should break up current development and manufacturing structures to fulfill the challenges of future vehicle requirements.

This paper is motivated by the recent technology leaps in the area of electric mobility as well as autonomous and connected driving and focuses on utilizing tools of digitalization and agile development along with approaches from literature of open innovation to enable a more customized mobility. We used digital technologies with regards to the innovation concept of technology push and market pull to identify and develop an agile strategy towards a market pull orientation. Hence, by implementing these technologies in organizations, agile structures and processes are required. Also, an innovative culture as a key for future product and service development against the background of technology acceptance represents a further foundation. Finally, to absorb external knowledge and resources from the outside of organizational boundaries, we propose the product and service development according to the principles of agile development both for software and hardware development. We conclude our research with the approach of using Natural Language Processing for integrating customer feedback in terms of multilateral product and service interactions directly into the development process. Beyond that, we present our experience from the ‘Living Lab Aachen’ which keeps up the opportunity of initiating and managing open innovation networks for organizations to gain innovative solutions for the customer.

Amloy is an acronym for amorphous alloy, also known as metallic glass or amorphous metal. It is an undercooled frozen metallic liquid with an amorphous, chaotic atomic order, offering superior properties in comparison to crystalline metals and alloys used in today’s applications. The high strength combined with a high elasticity and comparatively low density to steel allows by example the manufacturing of more robust, smaller, thinner and lighter components. Injection molding or additive manufacturing technologies allow the near net shape processing of Amloy in industrial scale. The development of a completely new injection molding process allows the manufacturing of net shape amorphous parts within 60-90 seconds at tight tolerances and without necessarily required post processing. 3D printing enables completely new designs using honeycomb or bionic structure elements and by taking advantage of the high strength of the material, weight reduction up to 30% in comparison to Titanium alloys are within reach allowing a further optimization of high-performance light weight components.

Dual-curing adhesives offer a high precision, and, due to their manifold curing mechanisms a unique process speed and flexibility in production processes. To reach short cycle times, fast UV fixation is utilized allowing for an immediate continuation of the production process. This initial fixation step is followed by a second final curing step. The example of the production process of a camera for e.g. autonomous driving shows how to finally obtain the adhesive’s properties in the second process step. We present a new hybrid system, a lightfixable 2-component adhesives that allow final curing at room temperature. It therefore saves time, energy and space in the production plant.

The global megatrends of mobility have a strong influence on the cockpit interface between human and machine. The user experience of the driver and passengers in future connected cars will be the result of totally new vehicle qualities and cockpit functions. Based on a centralized E/E architecture, the hardware and software of the IIP provides the basis for a fully connected and empathic interior. Together, many innovative building “bricks” establish the human-machine interface. To develop this breakthrough interior technology the development processes for software, overall product design, and even the organization of a Tier 1 are also changed. The underlying technology provides hardware-software separation, open-source and third party software integration, OTA updates and the use of artificial intelligence. As a result the vehicle can become a Digital Companion which ensures a positive user experience for all use cases of mobility.

The automotive industry is in a major transition phase. Changing market demands, complete new concepts of mobility, new production concepts and new emerging technologies as such trigger the need for adjustments, improvement and even evolution of existing or new joining technologies.

Adhesives and adhesive tapes provide several advantages as a joining technique. However, there is a rising demand in the market for further improvement of existing performance levels of adhesives. Further on the demand for combining the pure “adhesion” properties with different additional functionalities such as conductivity, insulation etc. is growing. In addition efficiency and supply chain optimization is a core requirement for adhesives and adhesive tape suppliers today and in the future.

Lohmann is a solution provider covering the value chain from adhesive formulation over coating and converting till die cutting and integration into customer ´s production. By doing so, the above mentioned today´s and future market requirements get addressed.

Recent brand new technologies from Lohmann do not only focus on technical properties as part of the car component but also on improvements in production processes along the supply chain. This paper provides further details of three new developments from Lohman in detail.

Hem flange bonding is widely used in the automotive body shop, especially in the manufacturing of hang-on parts such as doors, hoods and tailgates. By combining the hemming and adhesive bonding processes, components can be joined by material fit and form fit. In this way, new properties are integrated into the assembly, such as higher load-bearing capacity and improved resistance to corrosion. However, both processes also influence each other in the joining process and in the further production process chain, which makes the hem flange bonding process really challenging.

The paper gives an overview of the state of the art. For this purpose, based on the structure of the bonded hem flange, the requirements and criteria for quality evaluation are described. The common hemming technologies and adhesive application methods as well as the industrial process chain, in which the hemming operation takes place, are presented. Essential correlations between component / process parameters and the quality in the hem flange bonded joint are discussed.

Fraunhofer IWU has been researching various aspects of hemming and hem flange bonding for many years and supports the industry in the analysis of assemblies and processes. Our aim is to systematically increase the quality and appearance of hem flange bonded assemblies and the robustness of hem flange bonding processes. Two current examples from research practice will provide a brief insight:

Hemming adhesive dimensioning: Adhesive application plays a decisive, quality-defining role in the hemming process. At every point of the circumferential hem seam of an assembly, the adhesive quantity and adhesive position have to match the existing geometry precisely. The paper shows how the adhesive dimensioning can be carried out. Current test results on the effect of glass beads in the adhesive layer to ensure a defined adhesive layer thickness are also discussed.

Hem testing: A testing device was developed at Fraunhofer IWU to carry out quasi-static strength tests on hem flange bonded joints. For the first time, the influence of various hem and process parameters on the joint strength can be determined. The functional principle of the test and first results are presented.

In the context of automated driving a variety of different technologies will hit the market. Increasing levels of automated driving will have an influence on functions and styling of future steering wheels and layout of restraint systems. Based on a general view on possible automation levels and boundary conditions, three different automated vehicle types have been identified. Those needs and requirements for steering wheel and restraint systems will be discussed in this paper. Ranging from increased sensing functions for driver state, additional input and communication technologies to new steering wheel shapes and foldable steering wheels as well as restraint systems for spacious interiors and relaxed sitting positions.

Automatization and robust manufacturing processes for composite aerospace structures are getting into the focus. Thermoplastic composites could be a good opportunity for robust and automated processes. Additive manufacturing technologies like the thermoplastic tape placement combined with welding technologies gives the possibility in manufacturing complex, highly integrated parts for cost efficient structures. By reducing single manufacturing steps the part costs could be reduced significantly compared to thermoset technologies. Highly automated processes allow a significant data evaluation of process parameters. These data could be evaluated in-situ. Defects could be recognized during the process. A entire NDT process afterwards isn’t necessary any more. The welding technology could replace the riveting technology that is appropriate for the composite material. A deep understanding concerning the cooling and melting behavior of the thermoplastic materials (PPS, PEEK, PAEK) are necessary for sufficient laminate quality regarding performance and tolerances. Therefore investigation on material level is supporting the process and technological development.

In the past, the evolution of automotive needs and regulations used to be quite foreseeable and the technologies would be, step-by-step, continuously improved. The situation is now different as the cars of tomorrow have to be Connected, Autonomous, Shared and Electric (CASE). Changing the powertrain from internal combustion to electric, adding a massive battery in the floor area, multiple sensors and large ECUs, offering the possibility to the passengers to interact with their vehicle by voice with a digital butler or to share the vehicles between hundreds of users, is not without consequences for the receiving car body and trim. New engineering measures must be found to fight the massive weight increase, the new unpleasant noise sources and to extend battery life and vehicle range. New smart thermal management solutions must be invented to optimize passenger comfort. All these technical developments have finally to deliver a car in tune with the broad societal demand of sustainability and for millennials, minimalism. OEMs are starting to react to these mega trends by developing ambitious sustainability strategies targeting CO2 reduction or increase of recycled content without compromising on performance requirements. Mastering sound and heat, as well as sustainable textile solutions, has enabled Autoneum to develop a range of products for the interior, engine bay and underbody addressing the new challenges and requirements posed by the CASE trends and delivering tangible sustainable benefits.

Die ATZ-Fachtagung "Fahrzeuge von morgen" möchte Orientierung geben, welche neuen Materialien und Verbindungstechniken es in die Umsetzung schaffen. Dazu gehören auch innovative Exterieur- und Interieurdesigns.