Auto Monitor - 10 September 2012

I N D I A ’ S N O . 1 M A G A Z I N E F O R A U T O M O T I V E N E W S , V I E W S & A N A LY S I S

Auto Monitor ekly e W

Vol. 12 No. 29

10 September 2012

w w w.am o n l i n e.i n

FOCUS

32 Pages

CORPORATE

MACHINING

SOMBRE MOOD MARKS ACMA’S ANNUAL SESSION Pg 08

Pg 12

Auto sector looks for strategic boost

NEWS IN BRIEF A ‘Sunny’ day for Renault in India

Our Bureau New Delhi

Our Bureau New Delhi

R

enault India launched its fifth product, the new Scala sedan in four variants, two each with petrol and diesel engines recently. The base price for petrol engines is `6.99 lakh while the fully loaded model is `7.85 lakh. The diesel engine base model is `8.69 lakh and `9.57 lakh for the top model. The vehicle is a re-badged Nissan Sunny, yet it is dearer by around `one lakh over the latter. The French manufacturer is expecting to launch an automatic version in a few months. “Compact sedan will remain a high volume selling

segment in India, so we hope to get a good response, while there is a great potential in the belowPulse segment where we will see our products in the future,” said Managing Director, Renault India, Marc Nassif. The Sunny has sold well for Nissan, averaging around 2,500 units per month, thus Renault will expect the Scala to succeed to equal measure if not better.

DATA MONITOR Top 5 3W makers Company

Jul-11

Jul-12

` 50

Change

BAL

17,390

18,114

4.16%

Piaggio

16,552

15,746

-4.87%

M&M

5,395

5,149

-4.56%

ATUL AUTO

2,212

2,509

13.43%

TVS

1,072

1,251

16.70%

Top 5 3W-Exporters Company

Jul-11

Jul-12

Change

BAL

28,227

17,178

-39.14%

TVS

2,218

2,050

-7.57%

Piaggio

1,370

1,237

-9.71%

M&M

341

452

32.55%

Force Motors

-

126

#DIV/0!

* Source: SIAM/ ** Excluding exports/ *** all sub segments considered/ ^ excluding MRPL

T

he uncertainty in the auto sector reverberated at the 52nd Annual Convention that focussed on the ‘Auto Industry: India In The Changing World Order’ held in New Delhi recently. The event saw policy makers and OEMs discussing effective ways to tide over the looming economic uncertainty in India. Though wide ranging discussions on major issues kept the participants engaged, the convention fell short of providing any tangible direction.

In his opening remarks, SIAM President, S Sandilya touched upon four key issues that were uppermost on the minds of automobile manufacturers present at the convention. He highlighted the absence of firm resolve from the government’s side on the long term direction for the auto industry and perception

of dilution of the Automotive Mission Plan 2016 due to issues relating to governance and implementation.

He further pointed out that a clear direction regarding the fuel price differential between petrol and diesel and phased transition to Bharat Stage IV emission norms across the country would provide required reassurance to the auto manufacturers. He added that the government needed to pursue energy security in an earnest manner for reliable supply of fuel to drive automotive sector’s growth in the coming years.

Finally, he emphasised on the implementation of policies to jump start infrastructure development in the country for current and future transport and mobility needs of the country. He also expressed disappointment at the pushback of Goods & Services Tax (GST) implementation due to lack of consensus and stressed on its importance for smoother

movement of goods across states, thus directly and indirectly benefitting the auto sector.

Sandilya referred to subdued industry growth that led to successive downward SIAM revisions in the sales forecast. While 2012-2013 first quarter growth in the PV segment reached 9.71 percent, there was a fall in the heavy goods carrier. He also stressed on the need to address the dynamics of growth in all segments as they dip into negative territory (with Q1 decline of 17.88 percent). He drew a parallel to this sector’s 2008 performances.

“Emerging markets including Brazil, Russia and China along with India have been facing uncertain growth scenario in the automotive sector over the last few months,” pointed out Executive Director-Commercial Vehicles, Tata Motors, Ravi Pisharody during his address while emphasising the need for infrastructure related spending to spur growth.

Senior VP, Truck Joint Ventures, Volvo AB and Board Member, VE Commercial Vehicles, Philippe Divry suggested measures like mandatory scrapping of old trucks and other vehicles in order to jumpstart wider implementation of stricter emission norms, safety regulations and investment in road development projects for speedy revival of the auto sector, especially the commercial vehicle segment.

Union Minister, Kamal Nath pointed out that the large number of young customers in India are aspiration-minded customers with significant disposable incomes at their command and hence are an attractive market for global automobile majors.

He said the that his ministry is seeking to provide incentives for rapid adoption of IT-enabled traffic management systems across growing urban centres in the new urban renewal mission plan under implementation.

India forges German trust Nabeel A Khan New Delhi

T

here may be a volley of questions over India’s development stor y, however, German car makers—Volkswagen AG and Mercedes-Benz India strengthened their commitment and enhanced their investment plans towards the country.

Volkswagen will invest around `700 crore over the next two years to increase its output while luxury car maker Mercedes will boost its investment to `850 crore by 2014. It will scale up the initial investment of `250 crore to over `600 crore with the setting up of its own paint shop with waterbased painting facilities. The new paint shop is targeted to be operational by October 2012 and has an annual capacity of 20,000 units (which can be extended up to 40,000 units annually).

V W’s investments will be made in group companies such as Volkswagen India, Skoda India and Audi India to improve facilities and conducting minor model changes. A part of the investment will also go to its production facil-

ities in Aurangabad and Chakan.

VW has a 130,000 annual production capacity at Chakan, where it manufactures the Polo and the Vento and Skoda’s Fabia and Rapid models. The Aurangabad facility has a 6,000 unit annual capacity and makes hi-end models such as Superb, Laura, Jetta and Passat.

Volkswagen recently said it had put its `2,000 crore expansion plan on hold due to lack of clarity on the Maharashtra government’s recent rollback of tax incentives. This may prompt the company to invest in other states.

“The state government’s policy decision was not encouraging, so we are continuing to put investments in Maharashtra on hold,” said President & MD Volkswagen India, John Chacko.

Audi is setting up a dedicated production unit at the Aurangabad plant of Volkswagen Group firm Skoda in order to meet increasing demand in the Indian market. The company, which assembles sedans A4 and A6 along with SUV Q5 at the Aurangabad plant, is looking at additional capacity of 3,000 cars a year at the new unit. Audi will

start the assembly of SUV Q7 by the end of this year and might consider the same for Q3 from next year. Audi India is targeting to sell around 8,000 units this year and is expecting a 20 percent jump in sales by 2013.

Skoda is also targeting a fourfold rise in sales to reach 1.7 lakh cars sales annually in the next five years. The carmaker hopes to achieve a market share of around four percent from the current 1.5 percent (approx) in sales.

Talking about its investment plans, Managing Director & CEO, Mercedes-Benz India, Peter T Honegg said, “The investment of `850 crore will help us strengthen our production and operational capabilities with regards to our existing products and our exciting and aggressive product offensive, which we are readying for the Indian market. This investment will enable Mercedes-Benz India to be future ready.”

Presently Mercedes-Benz India locally manufactures its f lagship sedans the C-Class, the E-Class and the S-Class in its plant in Chakan, near Pune.

With Daimler AG recognising

Peter T Honegg, Managing Director & CEO, Mercedes-Benz India

the emergence of high potential growth markets including India, Mercedes-Benz India will earn the distinction of being amongst the first markets to start assembling the new M-Class, outside Daimler AG’s parent SUV plant in Tuscaloosa/Alabama, the US. Mercedes-Benz India through its dealer partners already carries an investment of over `80 crores spread across its 31 showroom and 41 service outlets located in 31 Indian cities. It is also aggressively and strategically expanding its network reach which is the densest by any luxury car maker in India.

EDITORIAL Helping hand

T

he effort to shield the auto sector from vagaries of the government policies appears to be faltering of late. This was clearly visible at the recent ACMA annual convention when auto component manufacturers hinted at the lack of decision making or the government’s ‘policy paralysis’—as it is commonly referred as—received sharp rebuttal from the minister present on the occasion. Praful Patel wasted no time in pointing out that the automotive industry was not the only sector at the receiving end of the economic downturn and it is unfair to blame the government at every juncture without doing some soul searching.

Apart from prompting the industry to embark on the path of technology upgradation and efďŹ ciency, he also pointed to the virtues of being frugal and the continuing contribution to growth of the manufacturing sector. The fact that the industry was still in positive growth territory, albeit slower compared to last year, did not escape the attention of any speaker from in the government or policy making arena.

However clearly, nobody wanted to be seen to be promising any bold policy measures for the auto industry this time around, which was a clear departure from the norm!

Deliberations at the recent SIAM convention in New

Delhi clearly pointed to heightened uncertainty for OEMs and suppliers alike. What makes the current downturn more worrisome is that the global factors (read European slowdown) are already having an impact on the auto sector, unlike the scenario in the late 2008-early 2009. Hence the auto sector may need to brace itself for a long, stretched journey on the path to a meaningful recovery.

The anxiety levels among OEMs and the auto component suppliers alike, are rising due to the absence of any major government-led initiative or concrete measures to revive the demand, and that may indeed be needed.

Comments can be sent to am.editorial@network18publishing.com

QUOTES Alan Mulally, Ford CEO on overcapacity on Europe to Bloomberg

John Chacko, Volkswagen Group Chief Representative, India in The Hindu Business Line

Europe had a lot of issues in the past and people did a lot of things to subsidise the industry. But you’ve got to size to the real demand so you can profitably grow. People are realising we all need to deal with that reality

As a group we had planned to invest `2,000 crore that is on hold since lots of policy decisions are confusing. We are however still putting pressure on Maharashtra government on various issues

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CONTENTS MACHINING Manufacturing crack-resistant lightweight components

12

A new process can determine, as early as the design stage, if critical conditions for cold cracking can be prevented helping lower development times and costs

12

GLOBAL WATCH Honda to invest £267 million in Swindon plant

18

Honda is looking to launch new CR-V model as part of a £267 million investment programme into new models and engines at its Swindon, UK plant

18

CORPORATE Mercedes boosts investment in India

09

Mercedes-Benz India has committed to an investment of another `850 crore towards expansion of its Chakan plant by 2014

09

Kia to develop alternate fuel powertrains

22

Kia is looking to make faster strides in the areas of alternative-fuel powertrains—hybrids, battery-electric vehicles and hydrogen fuel cells

22

Xenon pick-up launched

09

Tata Motors has launched a new single-cab version of the Xenon pick-up that is more suited for commercial applications than the existing dual-cab range

TMC, Denso to develop device enabling vehicle data collection

10

Toyota and Denso are looking to develop onboard communications network device - CAN-Gateway ECU1 that can take data gathered while driving and apply it to create a virtual simulation

Ford reveals new Fiesta with Sync, MyKey and EcoBoost engine

10

23

Ford recently revealed the new version of the Fiesta that features a sharper design and a host of exclusive technology features to its dealers

23

Varroc Polymers inaugurates Pithampur plant Varroc Polymers kicked off its Polymer plant at Pithampur in Madhya Pradesh to manufacture components and sub-assemblies for both two-wheelers and four-wheelers

10

Next-gen Mondeo with EcoBoost engine for efficiency Ford’s next-gen Mondeo for Europe will be equipped with the one-litre EcoBoost petrol engine, making it the largest-ever Ford vehicle to be fitted with the engine

23

Auto Monitor

10 SEPTEMBER 2012

C O R P O R AT E

8

Sombre mood marks ACMA’s 52nd Annual Session Our Bureau New Delhi

R

esearch & Development, partnership in design a nd development, testing and collaboration were identified as key areas of improvement for the auto component industry at the recently concluded 52nd Annual Session & National Conference of Auto Component Manufacturers Association based on the theme ‘Auto Component Industry: Ready for the Transition’ held in New Delhi.

Setting the tone for the events to come, President, ACMA, Arvind Kapur addressed the challenges that lie ahead of the component industry and revealed the transition that is required for uninterrupted growth. Focusing on testing and R&D as a necessary move, he said, “Not just operational efficiency, partner-

There is major uncertainty in the market at the current juncture and we would be reevaluating our capital expenditure plans for the coming year and may cut back on some capex.

We are not getting clear indications from OEMs on their production schedule and hence we are exercising great caution from our side on further expansion— L Ganesh, CEO & MD, Rane Engine Valves

ship in design, development and testing is required to grow. We have to promote R&D in India to find India specific solutions.”

He further pointed out that the uncertainty in economy, poor ROI, infrastructure and petrol versus diesel policy direction are some of the major challenges that the industry faces. He urged government for the need for stability and long term policies. Responding to his words, Minister, Praful Patel also mentioned in his speech, “About 22 percent of the manufacturing industry is auto related and the component industry will continue to grow and cannot be left to vagaries of policies.”

“There is major uncertainty in the market at the current juncture and we would be re-evaluating our capital expenditure plans for the coming year and may cut back on some capex. We are not getting clear indications from OEMs on their production schedule and hence we are exercising great caution from our side on further expansion,” said Chief Executive Officer and MD, Rane Engine Valves, L Ganesh.

Even as OEMs are pinning their hopes on the festive season for driving sales and are evaluating various promotional measures and other incentives, suppliers are not ver y optimistic regarding the revival of demand in the coming months.

“There is unlikely to be any major revival in the demand in coming months though there may not be a major cut back in production either. We are possibly looking at a stable scenario in the coming months,” said a supplier to the commercial vehicle segment.

Not just operational efficiency, partnership in design, development and testing is also required to grow. We have to promote R&D in India to find India specific solutions—Arvind Kapur, President, ACMA Drawing comparisons to the last downturn around late 2008, many suppliers pointed out that the OEMs are cautious this time around with their production schedules. The cautious attitude has created uncertainty and may even prove counterproductive if there is sudden spurt in demand and no matching capacity to meet the same from OEMs. Suppliers catering to the passenger car industry sounded much more optimistic regarding the demand scenario and are not envisaging any cutback in the capex in the current or the next fiscal.

Industrialists, Adi Godrej and Pawan Munjal also shared their perspectives on the transition required for continued growth of the component industry. While Adi Godrej envisaged 12-14 percent growth through national manufacturing policy in the next two decades to set good pace for economy, he also suggested, “Innovation, R&D, quality improvement and sustainability hold the key. SMEs also need special attention.”

Munjal also emphasised handholding for the SME seg-

ment to enable Tier IIs and Tier IIIs to move up to Tier I level in quality and deliver y capabilities.

While he considered entering into new and beneficial relationships as opportunities for component makers, he also added, “those who embrace uncertainty and execute rapid correction will grow”.

Tw o st udies, one each by McKinsey & Co and Ernst & Young detailed the necessary changes that needed to keep the momentum of growth going for component makers.

The McKinsey study, presented by partners, Parmeet Grover and Ananth Narayanan, emphasised on five cornerstone imperatives for the auto component industry as foreseeing global growth opportunities, leveraging mergers and acquisitions to gain customers and innovate newer technologies, building R&D and collaborating with OEMs to develop products jointly, serving adjacent markets like defence and construction and government collaborations to increase country competitiveness.

Senior MD, United Tech Corp India, Zubin Irani believed that adjacent markets can only be served easily if the organisations have similar capabilities. He further added, “To serve a non-auto customer, there needs to be a

Arvind Kapur, President, ACMA

dedicated setup so that any ups & downs in auto component manufacturing aren’t reflected on the adjacent industries.”

E&Y study, presented by National Leader-Automotive, Ernst & Young, Rakesh Batra, highlighted the opportunities that lie with India as an emerging auto product development hub. Envisioning India as the leader in auto world, he said, “Our vehicles are meeting global standards of quality and reliability however product and process development needs to be catered at the supply chain level.

Significant work needs to be done to improve India’s innovation quotient”. The study from Ernst & Young envisaged India as a product development hub by way of affordable R&D, supply-OEM collaboration and an ecosystem with applied research and testing facilities.

10 SEPTEMBER 2012

Auto Monitor

C O R P O R AT E

9

Xenon pick-up launched Refreshed Polo, Vento launched Our Bureau Mumbai

T

ata Motors has launched a new single-cab version of the Xenon pick-up that is more suited for commercial applications than the existing dual-cab range, since the absence of the second row seat creates more space in the loading bay.

The Xenon is now available in three engines options —a 2.2litre DiCOR engine producing 138 BHP for the dual-cab variant, a three-litre, 115 BHP engine and a 72 BHP direct injection motor in the single cab Xenon developing 72 BHP. Head of Sales and Marketing (LCV & SCV), Commercial Vehicle Business Unit, Tata Motors, Sandeep Kumar, said that eventually, the Xenon will be offered with four engine options, the fourth being another DiCOR unit that will be introduced soon.

From the double cab, Tata Motors has replaced the independent front suspension with simple and rugged semi-elliptical leaf springs. for the single cab In India, CVs are more often than

not overloaded. In such cases, leaf springs that are capable of carrying higher loads are preferred. The Xenon single cab, said Kumar, “has an official load carrying capacity of 1.2 tonne. But we have seen such LCVs carrying sometimes close to three tonne.”

The pick-up is being sold currently in four states— Maharashtra, Gujarat, Rajasthan and Tamil Nadu. From initial production of 200-250 units, production is being ramped up to 400-450 units. Once the plant reaches its maximum capacity of 1,000-1,200 units, the pick-up will be sold in more markets.

E xecut ive D i r e c t o rCommercial Vehicles, Tata Motors, Ravi Pisharody said at the launch, “The pick-up segment is growing rapidly and we see this trend continuing. With the launch of the Tata Xenon pick-up, we are strengthening our existing pick-up portfolio.”

The single-cab Xenon is priced at `5.44 lakh (ex-showroom Thane), and the dual-cab is priced at `6.34 lakh. Services are every 15,000 km and Tata is offering a three-year or three-lakh km warranty on the pick-up.

Ravi Pisharody, Executive Director-Commercial Vehicles, Tata Motors, At The Launch

V

olkswagen has given the Polo and the Vento a mid-cycle refresh.

The cars will go on sale by mid-September.

Minor tweaks to the exteriors to both cars include black headlight inserts and a new alloy wheel design. Changes to the interiors are more noticeable.

The Polo gets a leather-wrapped steering wheel, gearshift knob and handbrake lever handle, a new music system with a speed sensing volume control function and USB connectivity, steering mounted controls and Bluetooth connectivity. The Vento gets a set of four speakers and a navigation system with a

rear-view camera and Bluetooth.

Commenting on the occasion, MD, Volkswagen Passenger Ca rs, Volkswagen Group Sales India Pvt. Ltd, Arvind Saxena said, “The introduction of new features in the Polo and the Vento will further excite the customers as both the carlines will offer much more value now.” He further added, “The introduction of these features will pave the path for higher volumes for these carlines.”

The Polo and the Vento were launched in February 2010 and

August 2010 respectively. Both cars have shown dip in sales from 2011 so the updates should do it some good.

The fully loaded Polo Highline will cost `6.94 lakh (ex-showroom New Delhi) while the Vento Highline is priced at `9.89 lakh ex showroom New Delhi.

Mercedes boosts investment in India Our Bureau Mumbai

M

ercedes-Benz India has committed to an investment of another `850 crore towards expansion of its Chakan plant by 2014. With a slew of new launches lined up and the company’s latest funds infusion, Mercedes should expect to claw back some ground it has lost to its German counterparts in the recent past.

Managing Director & CEO, Mercedes-Benz India, Peter T Honegg commented, “We are bullish about the Indian market and this is reflected in our long term commitment towards the dynamic Indian market. The investment of `850 crore will help us strengthen our production and operational capabilities with regards to our existing

products and our exciting and aggressive product offensive, which we are readying for the Indian market. This investment will enable Mercedes-Benz India to be future ready.”

Mercedes started assembling cars at its 100-acre facility in Chakan in 2009. At the time, Mercedes used the Tata Motors paint shop but by the end of 2010, the German car major allocated over `200 crore towards a new paint shop at its own plant.

Mercedes announced in its statement that this paint shop will be operational by October.

The paint shop is capable of water-based painting and can paint 20,000 units annually, which can be later ramped up to 40,000 units.

In the last quarter, BMW was leading in the luxury segment with a total of 2,760 units and Audi stood a close second

at 2,527 units. Mercedes is trailing by a fair margin, selling just 1,633 cars in the same period.

But all is not lost for Mercedes; the company is now adopting a fresher approach to the Indian market with the introduction of the new B Class soon followed by the A Class. Both these models will be cheaper than the C Class saloon (currently the most affordable Merc in India) thus opening up the three-pointed star to a larger clientele.

Expect at least six models to be assembled at the Chakan facility. It includes the three existing models—C, E, S Class and the new M Class SUV. These along with the A and B Class will give Mercedes an enviable line up. The new 2013 S Class to be unveiled at the Paris Motor Show later this month will also eventually make it to the refreshed Mercedes line up here.

Auto Monitor

10

10 SEPTEMBER 2012

G L O B A L WAT C H

TMC, Denso to develop device enabling vehicle data collection Our Bureau Mumbai

T

oyota Motor Cor porat ion (TMC) and Denso Corporation (Denso) r e c e nt l y entered into a joint development venture of an onboard communications network device, CAN-Gateway ECU1, that can take data gathered while driving and apply it to create a virtual simulation that ena-

The device can wirelessly transmit the data to software installed on smartphones or other devices for real-time monitoring. As this data is accumulated, it can serve as a driving coaching guide

bles a new way to enjoy driving.

T he C A NGateway ECU captures driving data—including GPS data, accelerator pedal strokes, steering angles, brake operation signals, gear shift signals, engine rpm count, water temperature, and vehicle speed— from a dedicated onboard GPS as well as CAN information exchanged among onboard ECUs. The device can wirelessly transmit the data to software installed on smartphones or other devices for real-time monitoring. As this data is accumulated, it can serve as a driving coaching guide. Furthermore, software makers can use the data to create games or a wide

variety of other software using standard creation tools, with no need to deal with the complicated nature of the onboard CAN protocol.

The CAN-Gateway ECU can be fitted to the Toyota “86” rearwheel drive compact sports car and is scheduled to be tested in Japan in spring 2013 by people active in car racing, before the

scheduled Japan launch at the end of 2013.

Further development is underway to enable vehicle data from drives on major circuits in Japan such as Fuji Speedway to be recorded onto USB flash drives for input into the racing game Gran Turismo3, a PlayStation3 home entertainment console title. Driving scenarios can

then be recreated with the data and run simultaneously with other data to enjoy real-time, side-by-side track-run comparisons. Additionally, the user can reproduce aspects of a drive on a circuit—such as the steering path taken, and where and when the brakes and accelerator were used—in the game for analysis and critique.

Varroc Polymers inaugurates Pithampur plant Our Bureau Mumbai

A

urangabad based Varroc Polymers, a part of Varroc Group has recently inaugurated its eighth Polymer plant at Pithampur in Madhya Pradesh. The plant will primarily manufacture components and sub-assemblies for both two-wheelers and four-wheelers. The plant is reported to be equipped with moulding machines ranging from 450T to 850T. The Pithampur plant will also service the requirements of VECV as well as the needs of customers in the central and western hub of the automotive industry.

Speaking on the occasion, Managing

The plant will manufacture components and sub-assemblies for both two-wheelers and fourwheelers. The plant is reported to be equipped with machines ranging from 450T to 850T Director-Varroc Group, Tarang Jain said, “We are strongly committed to company’s philosophy of ‘being where the customer is’. Our strategically placed plants support the needs of rapidly growing passenger car and light commercial vehicle market.”

Varroc Polymers, apart from Pithampur, has two plants in North India, five plants in western India and is planning to establish its footprint in southern India. This is the 20th manufacturing plant for Varroc Group in India and the 31st plant worldwide.

Varroc is in the manufacturing of polymerbased products for the automotive industry with over two decades of experience plastic body parts and painted plastics.

A Range Of Varroc Components

Auto Monitor

10 SEPTEMBER 2012

MACHINING

12

Manufacturing crack-resistant lightweight components

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old cracking in highstrength steel presents major quality assurance challenges for the automotive and machine-building industries, since cracks are difficult to predict—until now.

A new process can determine, as early as the design stage, if critical conditions for such damage can be prevented. This lowers development times and costs.

Ca rs, roof st r uct u res and bridges should become increasingly lighter, with the same stability, and thus save energ y and materials. New high-strength steel is superbly suited for the needed lightweight design, because it can also withstand extremely heavy stresses.

Yet these materials also betray a disadvantage: with increasing strength their susceptibility to cold cracking rises when welded.

These miniscule fractures might form as the welded joints cool off—typically at temperatures below 200°C. In a worst case sce-

In the future, with this process, vehicle manufacturers could define non-critical welding parameters in advance, and thus establish a more efficient & safer production process nario, the welding seams would crack. For this reason, many industrial sectors are reluctant to employ these promising highstrength steel.

Manufacturing Crack Resistant Lightweight Components

Cracking The Code Scientists at the Fraunhofer Institute for Mechanics of Materials IWM in Freiburg, in conjunction with the Chair of Joining and Welding Technology LFT at Brandenburg University of Technolog y Cottbus (BTU) developed a new process for

making cold cracking more predictable. “We are able to compute the probabilit y of cold cracking as early as the design stage of a component, and immediately run through corrective measures as well,” explained Frank Schweizer of

IW M. Because whether such cold cracking occurs, and how quickly, depends on how high the concentration of hydrogen in the steel is, how the residual stress turns out, and how its microstructure is configured.

Predicting the probability of

cracking has been difficult until now.

Manufacturers used to conduct expensive testing, for example by applying an increasingly higher tensile stress to a sample component, and then analyse what stress level would

The new cold cracking approach could markedly reduce costly methods in the future—and lower production costs while shortening development phases cause cracking. Not only are these tests timeconsuming and cost-intensive, the findings cannot be applied to subsequent components on a one-to-one basis—because the geometry of the component has a decisive influence on crack formation. Even currently available computer simulations failed to deliver the desired predictive accuracy for real components.

Lowering Production Costs, Shortening Development Phases The new approach could markedly reduce such costly methods in the future—and thus lower production costs while shortening development phases. The experts at LFT set up a special test, in order to precisely determine the cracking criterion on samples of high strength steel. Beside typical influencing factors like hydrogen content, residual stresses and material structures that can be adjusted in at the same time, they also take into account the temperature gradients that emerge in the welding process.

The experts at IWM feed a computer simulation with this criterion in order to analyse the threat of cold cracking in random components and geometries. “This way, we can locate the areas on a welding seam at risk of cold cracking, for each point and at any time in the simulated welding process,” explained Frank Schweizer.

The researchers can also get a preliminary look at the effects of any countermeasures, and make the necessary adjustments. To do so, they transfer the results back into the simulation, in order to fine-tune them there.

In the future, with the aid of this process, manufacturers of vehicles and machines could be able to define non-critical welding parameters and limiting conditions for their materials in advance— and thus establish a substantially more efficient and safer production process.

This is especially relevant to materials that are difficult to weld, with very narrow processing windows regarding welding parameters or the pre- and post-heating temperatures.

Fraunhofer IWM and LFT, in cooperation with Robert Bosch GmbH and ThyssenKrupp Steel Europe AG, are currently testing their new process on laser beam-welded demonstration models made of high-strength steels.

(Courtesy: Fraunhofer Institute)

Auto Monitor

10 SEPTEMBER 2012

TECHNOLOGY

14

Fuel quality sensing for trucks

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ontinental recently unveiled product samples of its new fuel quality sensor to several truck OEMs for testing and vehicle integration at the recent IAA Truck Show held in Germany.

Commercial vehicles face many challenges as they are expected to have a low carbon footprint and ever lower emission levels. At the same time rising fuel prices necessitate increased truck fuel economy. Long-haul truck engines, for instance, are exposed to a growing number of changing blends of diesel and biofuels, which influence not only the combustion but also the post injection strategy required for exhaust gas aftertreatment.

Depending on the region, the fuel can be contaminated by unwanted substances as well. A high sulphur content, for instance, can damage the engine.

This creates new needs in the market. “There is an increasing demand for sophisticated truck engines around the globe”, said Head of the Exhaust & Emission Sensors segment within the Continental Business Unit

Sensors & Actuators, Mathias Miedreich. “The properties of fuel can have great influence on the efficiency and emission levels, and also the durability of modern diesel engines. Therefore we see a huge demand for solutions to detect important fuel quality parameters. Our new products address this issue. Detecting sulphur in the fuel is probably the most urgent requirement,” Miedreich added.

As commercial vehicles’ usage profiles more often contain use in multiple countries and world regions, there is higher likelihood to meet different fuel qualities than for passenger cars. This applies to long-haul trucks in particular. As the energy content of the fuel depends on its exact chemical composition, the sophisticated combustion processes of clean and efficient truck diesel engines are impacted by variations of the fuel quality. This can result in a lower than optimal fuel economy.

To overcome the new challenges, fuel quality sensing needs to address two main aspects. One is combustion control: The new

Continental Fuel Quality Sensor can determine the changing diesel/biodiesel blend in the tank and its actual cetane count with a targeted precision of less than ±5 percent biodiesel. Based on this information, the combustion strategy and the post injection strategy, which is part of aftertreatment, can be adjusted to achieve the maximum engine efficiency at minimum emissions.

The second challenge is ensuring emissions and system robustness. If this challenge is not overcome, contaminants in the fuel can reduce the engine durability and the efficiency of aftertreatment systems: To check the fuel for a comprehensive range of its chemical constituents, including sulphur, Continental has developed the Fuel Quality Sensor which is based on an optical measurement principle.

“This sensor is in fact a miniaturised fuel lab”, said Project Manager Fuel Quality Sensor, Hervé Richard, “It detects the optical fingerprint of the fuel and thus allows an exact fine tuning of the engine management but

it also measures the amount of problematic substances such as sulphur, water, or gasoline in the diesel fuel.” By delivering this information, the fuel quality sensor can help to detect contaminants early before they can cause such failures as sulphur poisoning of the aftertreatment system. Depending on the level of contaminants appropriate countermeasures can be taken to

avoid damage and resulting warranty issues.

With sales of €30.5 billion in 2011, Continental is among the leading automotive suppliers worldwide. As a supplier of brake systems, systems and components for powertrains and chassis, instrumentation, infotainment solutions, vehicle electronics, tires and technical elastomers, Continental con-

The properties of fuel can have great influence on the efficiency & emission levels, and also the durability of modern diesel engines. Therefore we see a huge demand for solutions to detect important fuel quality parameters— Mathias Miedreich, Head of the Exhaust & Emission Sensors, Continental tributes to enhanced driving safety and global climate protection. Continental is also an expert partner in networked automobile communication. Continental currently has approximately 167,000 employees in 46 countries.

Continental’s automotive group with its threedivision chassis & safety (sales of approximately €6.5 billion in 2011, 33,000 employees), powertrain (sales of approximately €5.8 billion in 2011, 31,000 employees) and interior (sales of approximately €6.1 billion in 2011, 32,000 employees) achieved sales of approximately €18.4 billion in 2011. The automotive group is present in more than 170 locations worldwide.

Eaton hosts Oil & Gas Technology Day

E

aton Corporation recently hosted Oil & Gas Technology Day to showcase solutions for oil & gas applications.

The company displayed its offerings including electrical solutions that ensure offshore safety by reducing the risk of arc flash accidents, UPS for offshore environments that guarantee reliable power supply to even the most remote rigs and hydraulic and filtration solutions that can help reduce stresses on hydraulic equipment in deep sea environments.

“Eaton has been providing solutions to the Oil & Gas industry for decades. Our product brand names, such as Vickers, Aeroquip and Cutler-Hammer are well known in the industry. We look forward to building major relationships in India and further extending our industry-leading offerings to the Oil & Gas businesses in the country. We are excited about the opportunities and would strive to play a key role in driving the industry’s growth in India more powerfully and sustainably,” said Managing Director-India, Eaton Corporation, Raja Kochar.

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10 SEPTEMBER 2012

G L O B A L WAT C H

Ford Motor goes full throttle

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ord Motor Company is launching aggressive product acceleration in Europe leveraging the company’s One Ford global portfolio and targeting opportunities for growth in the large car, SUV and commercial vehicle segments.

The car maker introduced a series of new passenger cars, commercial vehicles and new technologies at a special event in Amsterdam recently.

“Even with the near-term business environment, Europe presents a significant opportunity for profitable growth.

Today, we are accelerating the introduction of our new products in Europe, leveraging our One Ford plan—with a full family of vehicles offering the very best quality, fuel efficiency, safety, smart design and value—just like we did when we transformed our business in North America.” said Ford President and CEO, Alan Mulally.

Ford also confirmed that several additional vehicles from its global portfolio will come to

Today, we are leveraging our One Ford plan—with a full family of vehicles offering the very best quality, fuel efficiency, safety, smart design and value—Alan Mulally, President and CEO, Ford Europe in the near term—including the legendary American icon, the Ford Mustang.

“The European market holds potential for profitable growth that’s clouded at the moment by the economic crisis. The total European car and CV market, including Russia, is expected to grow 20 percent in the next five years to 23 million vehicles.

While others are backing off or cutting product investments, we at Ford are accelerating the introduction of new products, leveraging our One Ford global strengths.” said Stephen

Odell, Ford of Europe Chairman and CEO.

EcoBoost The company unveiled the new Fiesta and Mendo, with claimed to have improved fuel efficiency and a host of new technologies including Ford SYNC, and Active City Stop. Both vehicle is to be equipped with it EcoBoost engines. Making its

way to the Asia Pacific and Africa region, Fiesta will be equipped with one-litre EcoBoost petrol engine for an improved fuel economy.

With SUV sales expected to increase by 34 percent in Europe over the next five years. Ford plans to leverage its leadership in SUVs in North America and other regions around the world to quickly expand its line-up

in Europe. Ford expects to sell more than one million SUVs in Europe in the next six years with SUVs accounting for one in ten of all Fords sold in the region by 2016. It starts with the new Kuga on sale later this year.

Ford also announced that the new EcoSport, a global small SUV, will go on sale within 18 months. Modern and innovative, the new Ford EcoSport was designed to combine bestin-class design, technolog y, quality, safety and value aimed at attracting a new generation of consumers who want the utility of an SUV in a smaller vehicle. It will come available with the acclaimed 1.0-litre EcoBoost engine.

The company also confirmed that the Edge – a larger, more premium crossover that is a success in North America and other markets, including China – also will come to Europe.

Commercial vehicle sales in Europe are forecast to grow by more than 30 percent to nearly 4 million a year by 2017, with the small CV segment growing by more than 70 percent.

Fiat Professional introduces the new Doblò XL

F

iat Professional’s Doblò Cargo van range has just been expanded with the introduction of the New Doblò XL version. Following on from the Doblò Work Up launched last year, the New Doblò XL further strengthens and broadens the appeal of the Doblò Cargo range. The Doblò XL’s combination of a long wheelbase and high roof provides a load volume of 5.0 m3 and a payload of 1,000 kg, providing customers with a new proposition previously unavailable in this segment.

The new version’s high roof integrates seamlessly into the body providing an aerodynamic and elegant vehicle. The rear doors provide full access to the load compartment allowing customers to fully utilise the 5.0 m3 load volume.

The new Doblò XL Cargo versions are powered by a choice of three Euro 5 turbodiesel engines: 1.6 MultiJet 105 hp, 1.6 MultiJet 90hp MTA and 2.0 MultiJet 135 hp. Combi versions will be available with the 2.0 MultiJet 135 hp only.

The new XL version will sit between the Purpose Built Van and Small Panel Van segments and is likely to attract customers from the latter as it offers the same load capacity and payload (one tonne) but at a lower price. With its increase in load volume, ease of loading, low fuel consumption, reduced operating costs, safety and comfort, the Doblò XL will appeal to a variety of customers including utilities, service vehicles (with ladder stored internally), converters and wheelchair-accessible transport for example.

Fiat Professional’s Doblò Cargo Bi-Link suspension ensures a smooth ride, and its range of environmentally-friendly Euro V-compliant engines makes it cleaner and cheaper to run.

Options include Blue&Me with steering wheel controls, Blue&Me TomTom navigator and eco:Drive Professional software.

The New Doblò XL is available to order now with pricing starting at £15,765.00 (basic) for the Doblò XL Cargo Base 1.6 MultiJet 16v Diesel 105, rising to £19,045.00 (basic) for the Doblò XL Combi SX M12.0 MultiJet 16v Diesel.

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G L O B A L WAT C H

Honda announces ÂŁ267 million investment programme in Swindon plant

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onda ma rks t he launch of the new CR-V model as part of a ÂŁ267 million investment programme into new models and engines at its Swindon, UK plant. This is the single biggest investment into Honda‘s UK manufacturing base in over a decade.

With the investment supporting the introduction of New Civic (Dec 2011), New CR-V (Sept 2012), and New 1.6 litre diesel engine for Honda Civic (Dec 2012).

Honda has recruited and trained 500 new staff this year to

build these new products, taking the total workforce to 3,500. By the end of the year, production at the Swindon plant is forecast to have doubled on last year’s ďŹ gure, up to 183,000 units. Honda aims to increase that ďŹ gure to 250,000 units per year, within three years.

This announcement is also good news for the UK balance of trade with 60 percent of the production going for export.

Honda’s Swindon plant produces cars and engines for over 60 countries around the world, including Europe, Middle East, Africa and Australia.

TRIVIA s (ONDA OF THE 5+ -ANUFACTURING ,TD (5- IS A FULLY INTEGRATed car manufacturing facility, produces the CR-V, Civic and Jazz (Casting, Engine Assembly, Pressing, Welding, Painting and Frame Assembly) on a site in Swindon, Wiltshire. s ACRE SITE MILLION M s (ONDA -OTOR #O HAS INVESTED IN EXCESS OF aTWO BILLION IN ITS MANufacturing operation in Swindon, Wilts s !NNUAL 0RODUCTION #APACITY UNITS

Honda announces ÂŁ267 million investment programme in Swindon plant, New CR-V Honda

Business Secretar y, Vince Cable, who visited the Honda site recently, has commented, “This multi-million pound investment by Honda in its twentieth year of car production in the UK will help create a host

of new jobs, the investment supports Government’s ambition to encourage new investment and exports as a route to renewed growth and a more balanced economy.�

Managing Director, Honda UK,

Dave Hodgetts said, “This investment programme underpins Honda’s commitment to manufacturing in Britain. It also reafďŹ rms the Swindon plant’s position as the cornerstone of Honda’s European operationsâ€?.

Rolls-Royce to expand base in Thailand

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ollowing the recent opening of the ďŹ rst Rolls-Royce Motor Cars showroom at Rama 3 in Bangkok, the company announced plans to open a unique new boutique in Central Bangkok, the ďŹ rst of its kind in Asia.

This exclusive facility will be situated at the Siam Paragon, an upmarket luxury shopping destination. The boutique will provide easy access to Rolls-Royce products for customers and will complement the two storey Rolls-Royce showroom, which is already one of Asia’s largest. It is expected to be operational in the fourth quarter of the year.

On the first stop of a four-city tour of Asia Pacific, Rolls-Royce Motor Cars CEO, Torsten MĂźller-Ă–tvĂśs, said, “I am excited that RollsRoyce will be further developing its presence in such a new, vibrant market. The location and concept allows us to reach a broader audience, who will be able to view first-hand why the elegance, quality and craftsmanship of our cars earn them the title of the ‘best cars in the world’.â€?

Asia Pacific Regional Director, Paul Harris, added, “We are seeing significant interest in our brand in Thailand, and I thank Millionaire Auto for its commitment to investing yet another brand touchpoint for potential RollsRoyce customers. We hope that by bringing the marque to Central Bangkok it will impassion a Thai audience which already has great appreciation of craftsmanship in its own culture. With virtually unlimited bespoke variations, customers can commission their cars in as much meticulous attention to detail as the way they are built.�

Rolls-Royce Motor Cars Bangkok is owned

by Millionaire Auto (Thailand) Company Limited, a subsidiar y of Master Group Corporation (Asia). Like the showroom in Rama 3, the planned facility in Siam Paragon will break new ground for the marque, being the first in Asia to be located in a luxury retail hub.

Rolls-Royce Bangkok’s seven-car showroom was the first in the Asia Pacific region to have two storeys and secure underground parking for customers. It also incorporates a special delivery room for customers. “We again demonstrate our commitment to the Rolls-Royce brand in Thailand by ensuring customers have accessibility, choice and the latest product offerings,â€? commented General Manager for Rolls-Royce Motor Cars Bangkok, Chatvithai Tantraporn. The number of RollsRoyce showrooms in the Asia PaciďŹ c region (including China) is currently 27.

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10 SEPTEMBER 2012

G L O B A L WAT C H

The Peugeot 208 GTi announced

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ollowing the launch of the new 208 in June 2012, Peugeot has rejuvenated the diverse Supermini car segment. This new model revolutionises customer choice with its elegance, style, compactness, occupant space and equipment.

The 208 has been an instant success and the 208 GTi will deliver even stronger desirability with ex hi la rat ion, per for ma nce and panache.

Intended for demanding individuals, 208 GTi owners will benefit from sophisticated choices of the materials and colours employed. The car’s dynamism is expressed first of all by its external identity, specific and immediately recognisable, due to its characteristic posture. Defined on a widened track by 10 mm at the front and 20 mm at the rear, these three-door models are specially identified by bodywork components which enhance the overall effect, with wheels that hug the arches and with body sills and wing extensions that enhance its visual appearance.

Particularly eye catching and

visible both by day and night, the light signature of the front face is refined by new halogen headlamps, equipped with a latest generation light guide. These carefully designed lamps with a rectangular internal structure use LED technology for the directional indicators and daytime lighting. Tightly enclosing the main beam headlamps, the floating trim of which calls to mind a cat’s pupil, they give the expression of an iris.

These lamps frame a special 208 grille and on the GTi the mesh contributes to the dynamism, making the lamps stand out. The gloss black grille draws the eye with bright chrome inserts, which reinvent the sport chequered flag effect but in 3D. The end result is a front appearance which is technological and endearing while being sophisticated.

Attention to detail has also taken precedence in the design of the passenger compartment, to create a most pleasant environment. This applies even when stationary as it becomes evident at first glance when the door is opened, revealing the alumini-

um sill stamped with the Peugeot name. Dark colour schemes exist throughout the upper section and the 208 GTi offers a unique ambiance themed with red highlights.The dashboard houses a high-mounted instrument panel with an innovative and distinctive light signature.

Echoing the LED functions of the headlamps, the dials are surrounded with satin chrome beads backlit by LEDs, whereas the needles move on a brushed aluminium background.

The passenger compartment is also punctuated with carefully designed components. So,

the vents, the side decorations of the touchscreen, the dashboard decoration, the steering wheel insert, the seat belts, the front and rear door crossbars all blend with the same interior ambiance. The aluminium pedal bracket and footrest provide the final touch to this technological and refined interior.

208 GTi, Re-Generation Of The Legend Peugeot has made its mark in the history of motor sport.

Whether through its models, its success in competition or its infamy through advertising and

promotions, the Marque’s DNA has the best genes for creating the modern performance GTi. The expectation was simple: to create a playful and chic sports car, a contemporary interpretation of the legend that is a Peugeot GTi. At first glance, the eyes are impressed initially by presence, with a vehicle which affirms its identity: sporty and refined.

There can be no doubting the sportiness of this new 208 derivative. Crossing the gloss black rear skirt, the exhaust emerges with a trapezoid chromed double tailpipe, an innovative design emphasising the uniqueness of this model. The chromed trim strip decorates the window lower edge culminating in a signature accent that pays tribute to the illustrious 205 GTi. Furthermore, the quarter panel trim proudly bears the GTi logo, in bright chrome accentuated in red highlights. Regardless of the exterior colour chosen, this red punctuates throughout the vehicle: on brake callipers, grille lower bead, Peugeot lettering on the tailgate and on the grille.

Other Features In addition, the mesh of the grille has a 3D chequered motif, with chromed inserts in the gloss black grille. The whole is subtly enhanced by the touches of bright chrome on the fog lamp trim surrounds, the grille upper trim and the door mirrors. Opening the doors reveals a passenger compartment that reflects the paintwork.

From the sill, embossed with the name Peugeot, the passenger compartment is notably sporty.

With a colour scheme combining red, black and satin chrome and red GTi overstitching throughout, the interior is striking, down to the smallest detail.

Resolutely sporty, the seat combines full grain Club Nappa leather and Caro Weave cloth, made more dynamic by a red line detail. The dashboard with red overstitching has a decoration of red graduating to black, matching the door crossbars. The vehicle performance information is provided via the high-mounted instrument panel. Technological, it is equipped with a colour matrix, surrounded by dials with a chromed bead back-lit in red by LEDs. On their brushed aluminium background, decorated with a gloss black chequered motif, the white needles rise through to the red zone.

The 208 GTi delights its driver with an incisive driving experience due to the involving chassis dynamics, providing superb driving sensations. Springs, calibration of the shock absorbers, anti-roll bar, enhanced front subframe and rear crossmember rigidity, plus that the suspension and wheels are specific to this latest Peugeot GTi. The 1.6-litre THP 200bhp petrol engine expresses itself through a reworked exhaust system. As soon as the ignition is switched on, it emits an appealing sound that delights the ears, at all engine speeds. Coupled with a manual gearbox with six, close-ratio gears, the engine draws the full potential from this chassis. With its maximum torque of 275Nm and its maximum power of 147kW (200bhp), the 208 GTi[1] has the potential of acceleration to the highest level. 0 to 62mph is reached in less than 7.0 seconds. In-gear re-acceleration is equally impressive, with the 208 GTi accelerating from 50 to 75mph in less than 7.0 seconds in 5th gear.

This performance benefits from the improvement achieved from lightening the weight of the vehicle.

Light in weight, at 1160kg, the 208 GTi achieves a real feat by emitting CO2 at just 145g/ km. A playful sports car, powerful and safe, with an enchanting sound, which is also a practical hatchback, the 208 GTi will delight its drivers every day, the (fully disengageable) ESP watching over them.

The announcement of this new Peugeot 208 GTi follows closely on from the launch of 208 which has been an instant success, now with 9,000 UK orders since order books opened.

10 SEPTEMBER 2012

G L O B A L WAT C H

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Professional Driver Car of the Year Awards 2012: The winners

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olvo S80 D3 SE Lux is Professional Driver magazine’s Car of the Year for 2012. The Swedish executive saloon has been voted the number one choice for the Chauffeuring and Private Hire industry thanks to an outstanding combination of luxury, safety and versatility.

The Volvo S80 also won the Executive Car of the Year category in the Professional Driver Car of the Year awards, ahead of the Mercedes-Benz E220 and the BMW 530d Gran Turismo.

And the Volvo S80 was voted the overall winner ahead of the other category winners—including more expensive chauffeur cars, SUVs and MPVs. Editor of Professional Driver and Chairman of the judging panel, Mark Bursa said, “The Volvo S80 is a car for our times. It received a host of refinements last year. The sat-nav has been brought bang up to date, while subtle tweaks to the cabin have given a much more prestigious luxury feel.

Rear legroom is excellent, and softer seats have enhanced the rear-seat experience.”

Chauffeur Car of the Year 2012 This category was won by the Mercedes-Benz S350L, ahead of the Audi A8L and BMW 730Ld. Bursa said, “The S-class received consistent scoring from all the judges who tested it, and it’s a testament to its quality that a car toward the end of its product lifecycle can still outscore some newer rivals.” With the S-class

Professional Driver added a Luxury SUV of the Year category for 2012—a reflection of the need for chauffeur companies to keep operating through the winter snow and ice. And the winner was the Porsche Cayenne diesel, which was praised for its distinctive styling and superb dynamics.

The Porsche Cayenne finished ahead of the large and luxurious Audi Q7 3.0 TDI and the Lexus RX450h, which impressed the judges with its smooth and quiet petrol-electric hybrid powertrain.

drew consistent praise across the board—a comfortable interior, a large luggage space and a smooth powertrain all scored highly. And attention to detail really clinched the prize—DAB radio, a powered tailgate and an easy-to-use sat-nav with full postcode entry all made the car future-proof.

“In addition, good running costs and class-leading residual values made the Passat a good option for the bottom line,” said Mark Bursa. Passat’s closest challenge came from one the Hyundai i40 Tourer. Pitched somewhere between a hatchback and an estate, this comfortable Korean newcomer impressed with rear set comfort and ample loadspace, coupled with keen pricing and Hyundai’s excellent extended warranty.

MPV of the Year

Green Car of the Year

The Ford Galaxy, as ubiquitous as a TX4 black taxi in Central London thanks to Addison Lee, is once again voted the most suitable MPV for chauffeuring and private hire. Judges praised the quality of the transmission thanks to an excellent DSG automatic gearbox, and indeed, driveability, features and low onroad noise and vibration were the Galaxy’s strong suits.

Green Car of the Year was the second of our new awards

now matching its competitors pound-for-pound, it boils down to taste. And the three-pointed star still carries a lot of kudos in the chauffeur industry.”

Luxury SUV of the Year 2012

Private Hire Car of the Year The all-round competence of the Volkswagen Passat brought victory in the Private Hire Car of the Year category, ahead of the Hyundai i40 Tourer and the Ford Mondeo. The Passat

for 2012. Open to sub-99g CO2 cars with obvious “green” technology, this turned out to be a fascinating contest, with a range of different technologies going head-to-head.

As well as Toyota’s conventional parallel hybrid system, judges were able to try out Vau x ha l l’s ra nge-ex tender hybrid Ampera; Peugeot’s 508 and 3008 HYbrid4 diesel-electric models, where the diesel drives the front wheels and the electric motor drives the rear; and battery-electric Nissan Leaf and Renault Fluence ZE. The verdict was a resounding vote of confidence for Toyota’s tried-and-tested system, with the standard Prius edging out the new Prius+ compact MPV, with the Peugeot 508 HYbrid4 in third.

Mark Bursa said: “Toyota Prius is now well into its third generation, and the car outscored all conventional private hire cars too.”

Roll of Honour Car of the Year 2012 Volvo S80 D3 SE Lux Previous Winners 2011 BMW 730Ld 2010 Jaguar XJL 3.0D

Chauffeur Car of the Year 2012 Mercedes-Benz S350L Audi A8L 3.0TDI Quattro BMW 730Ld

Executive Car of the Year 2012 Volvo S80 D3 SE Lux Mercedes-Benz E220 BMW 530d GT

Luxury SUV of the Year 2012 Porsche Cayenne Diesel Audi Q7 Lexus RX450h

MPV of the Year 2012 Ford Galaxy Titanium X Toyota Prius Plus Volkswagen Sharan

Private Hire Car of the Year 2012 Volkswagen Passat SE Hyundai i40 Tourer Ford Mondeo Titanium X

Green Car of the Year 2012 Toyota Prius T Spirit Toyota Prius Plus Peugeot 508 Hybrid4

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G L O B A L WAT C H

22

Kia to develop alternate fuel powertrains

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ia has been working on alternative-fuel powertrains—hybrids, battery-electric vehicles and the Holy Grail that is hydrogen fuel cells for a while now. Already there are electrified Kia vehicles on sale in some markets. More are on the way, destined for ever-more regions.

Kia produced its first electric vehicle, based on the Vesta van, more than 25 years ago, at a time when the company had been making motor vehicles for only two decades, and developed its

first electric car, a Sportage, as long ago as 1999. In 2010-11 the company revealed three electric car concepts in less than 12 months—the Venga, Pop and Naimo—to show how serious it is about bringing EVs to the showroom.

Ray Showed The Way At the end of 2011, Kia began production of an electric car based on the Ray urban runabout for use by Korean government agencies. The Ray EV, in a global first, can be built

on the same production line as the petrol-engine model. It has a range of 86 miles and can be recharged in just 25 minutes at a fast-charge point, or in six hours through a domestic plug. Kia is supplying 2,500 Ray EVs to government and public offices as part of a real-world test programme.

Electric vehicles are best suited to short journeys in areas where their limited range is not an issue and the recharging infrastructure is most likely to be found, so Kia is also developing electrification solutions for cars which need to cover longer distances.

In Korea an unusual hybrid

system running on a mixture of liquid petroleum gas (LPG) and battery power is available in the Forte saloon, a car similar in size to the European cee’d. With a 1.6litre engine converted to run on LPG and a 15kW electric motor, it has CO2 emissions of only 94g/ km. Kia is also planning an LPG hybrid version of the new Picanto.

For the long term, Kia is putting its faith in the fuelcell vehicle (FCEV), which combines hydrogen and oxygen in a complex metal box called a fuel stack to create electricity on the move. Pure water vapour is the only waste product Technology That Fuels Cleaner Growth Since late 2011, the Optima has been available in some American states as a hybrid, powered by a 2.4-litre petrol engine and a 30kW electric motor driving through a hybrid-specific six-speed automatic gearbox. Uniquely among current hybrids, it has a lithium-ion polymer battery, which has a higher energy density than a nickel-metal hydride system, but is 30 perent lighter. It can accelerate the Optima Hybrid to more than 60 mph on battery power alone. For the longer term, Kia is putting its faith in the fuel-cell vehicle (FCEV), which combines hydrogen and oxygen in a complex metal box called a fuel stack to create electricity on the move. Pure water vapour is the only waste product.

Kia developed its first FCEV in 2003, based on the Sportage, and has now advanced the technology close to the production-ready stage through trials with the Borrego, a large SUV. The Borrego FCEV can cover more than 400 miles on a tank of hydrogen and manages the equivalent of 54 mpg. Most of the safety and reliability issues with fuel stacks have now been solved, leaving cost as the main obstacle—and that will come down with volume production.

Looking To The Future Seven major auto-makers have agreed to begin making fuel cell vehicles by 2015, and Kia is among them. With the vehicles will come a hydrogen refuelling infrastructure to support them. The plan is to be making 10,000 a year by the middle of the decade and to increase this to 100,000 a year as quickly as possible, by which time it is expected that costs will be comparable with those of a petrol or diesel car.

In 2011, Kia joined the Clean Energy Partnership to help promote the development and take-up of FCEVs across Germany and to showcase the company’s eco-friendly models and technologies. Kia has also signed a memorandum of understanding with four European countries to operate a fleet of fuelcell vehicles in Europe as part of its test and development programme.

10 SEPTEMBER 2012

G L O B A L WAT C H

Auto Monitor

23

Ford reveals new Fiesta; advanced technology includes Sync, MyKey and one-litre EcoBoost engine

F

ord recently revealed the new version of the Fiesta that features a sharper design and a host of exclusive technology features.

The new Fiesta is reported to have been on stage in Amsterdam at Ford’s special “Go Further” product event hosted by Ford President and CEO, Alan Mulally and attended by 2,500 dealers.

New Fiesta delivers an advanced package of technologies including voice-activated in-car connectivity systems like Ford Sync, Active City Stop and the European debut of MyKey. It will also be equipped with the acclaimed one-litre EcoBoost petrol engine to deliver expected best-in-class fuel economy.

“Fiesta has been one of the world’s best-loved small cars across five decades, and the sporty appeal of the last generation Fiesta inspired real passion among global compact car customers, contributing to its status as the world’s most

successful small car,” said Executive Design Director, Ford of Europe, Martin Smith. “We had to keep that vital part of Fiesta’s make-up—but we also wanted to give it a more sophisticated look.”

The new Fiesta marks the latest chapter in the journey of the popular small car. Ford launched the first Fiesta in 1976 and has since sold more than 15 million models around the world. New Fiesta features design cues inspired by the latest Ford global design language and concept vehicles.

The Fiesta’s face is dominated by a trapezoidal front grille, bracketed by lasercut headlamps with daytime running lamps that use LED technology, and features a power-dome bonnet design. The redesigned Fiesta also delivers harmonious and ergonomically optimised interiors.

Fiesta follows Ford’s approach of democratising technology— bringing advanced features to a

Next-gen Mondeo to combine with one-litre EcoBoost engine for efficiency

F

ord’s next generation Mondeo for Europe will be equipped with the onelitre EcoBoost petrol engine, making it the largest-ever Ford vehicle to be fitted with such a small displacement engine.

“Today’s smartest technology offers customers more from less,” said Vice President, Product Development, Ford of Europe, Barb Samardzich.

“This is as true of engines as it is of computers and smartphones, and by equipping the all-new Mondeo in Europe with our acclaimed one-litre EcoBoost engine we are delivering cutting-edge technology that delivers a very real and tangible customer benefit.”

This game-changing version of the next-generation Mondeo is expected to deliver best-in-class fuel economy and CO2em issions of less than 130g/km but with the power and refinement of a considerably larger engine. These latest plans formed part of Ford’s aggressive new product rollout strategy for Europe detailed at a special “Go Further” event today in Amsterdam.

Ford’s one-litre EcoBoost, the 2012 “International Engine of the Year,” is the most power-dense production engine the company has ever produced. With an engine block small enough to sit on a piece of A4 paper, it produces 125 PS and 170 nm of torque (and up to 200 nm in “overboost” mode), delivered from just 1,450 rpm.

The sophisticated engine features advanced technologies including twin independent variable camshaft timing (Ti-VCT), a compact, low-inertia turbo that spins at 248,000 rpm, direct fuel injection, an aluminium cylinder head with integrated exhaust manifold, low friction piston coatings, low tension piston rings, low friction crank seals and a cambeltin-oil design.

“Both ingenuity and affordability are part of our ‘Go Further’ brand promise, and we believe that having been the first to produce a compact engine capable of meeting the expectations of CD-segment customers, we can now establish a new benchmark for engine down-sizing within this competitive sector,” said Mondeo Assistant Chief Programme Engineer, Rolf Deges.

The New Fiesta delivers an advanced package of technologies including voice-activated in-car connectivity systems like Ford Sync, Active City Stop and the European debut of MyKey greater number of drivers for the first time—and will be unique among its European competitors in featuring Active City Stop, a system designed to help drivers avoid low speed collisions.

Ford Sync in-car connectivity system delivers an unprecedented level of connectivity, enabling owners to voice-activate phone calls and music selection from devices connected via Bluetooth or USB. The Sync system includes Emergency Assistance, which

directly connects the vehicle occupants to local emergency services operators after an accident, in the correct language for the region.

The new Fiesta will also feature the European debut of segment-first MyKey, which will enable parents in particular to encourage safer driving and limit their teenager’s exposure to risk at the wheel. The system allows owners to configure maximum speed and audio volume limits.

It also mutes audio until seat belts are fastened and ensures driver aids, safety systems and more vigorous alerts cannot be deactivated when used. The onelitre EcoBoost petrol engine is the 2012 “International Engine of the Year” and is expected to deliver best-in-class fuel economy.

Ford will reveal more details about the new European Fiesta range at the Paris Motor Show this month.

Auto Monitor

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10 SEPTEMBER 2012

G L O B A L WAT C H

Volkswagen unveils seventh gen Golf

V

olkswagen has revealed the seventh-generation Golf recently. The original Golf model stretches back 38 years and has already clocked up more than 29 million sales so far. The continuing has been built around new vehicle architecture and new engines, it is between 40 and 100 kg lighter than the Golf 6, despite being larger, and is up to 23 percent more fuel efficient.

The average fuel saving across the range is 14 percent.

The diesel Golf Bluemotion will be capable of more than 88 mpg and three models in

The new Golf will be shown publicly for the first time at the Paris Motor Show at the end of this month. It goes on sale in Germany, the strongest market for the car, in October and in the UK, at the start of 2013

the range will be able to manage around 75 mpg or more.

Carbondioxide emissions will be as low as 85g/km—a new low for a current non-hybrid car.

Volkswagen CEO, Dr Martin Winterkorn described the new car as “the greenest Golf yet”— but that did not stop Greenpeace demonstrating outside Berlin’s New National Gallery where the car was unveiled, continuing a year-long protest against what it sees as VW’s extravagant environmental claims. VW employees staged a counter-demonstration in support of the car.

The new Golf will be shown publicly for the first time at the Paris Motor Show at the end of this month. It goes on sale in Germany, the strongest market for the car, in October and in the UK, the third-best sales area, at the start of 2013.

“The Golf is a global phenomenon and whoever revises such a car assumes a great deal of responsibility,” said Winterkorn.

“The Golf is and will be the most important model for VW and the new one is a clear and unmistakable symbol of environmental

motoring.” It is built around the V W group’s new modular transverse assembly system, first used for the new Audi A3. Unlike the Audi, which is currently only a three-door car, VW will launch with three- and five-door models, both with the same wheelbase.

The weight savings have come from the body (23 kg), trim and seats (14 kg), engines and drivetrain (up to 40 kg), chassis (a

maximum of 26 kg) and even the electrical systems (six kilos).

The biggest weight-savings are with the 1.4-litre turbocharged petrol engine. One version of this shuts down two of the four cylinders when cruising to save fuel.

There are also two turbodiesels at launch.

VW is claiming more passenger and luggage space, higher

quality, improved infotainment systems and upgraded safety, with no increase in the base price in Germany. The new Golf will be able to avoid low-speed nose-to-tail accidents, maintain a set speed and distance to the car ahead, prevent the driver changing lanes into the path of an overtaking car and warn tired drivers to take a break.

JLR to demo advanced XJ_e plug-in hybrid vehicle at CENEX 2012

J

aguar Land Rover has been reported to have demonstrated the ultra-low carbon XJ_e plug-in hybrid engineering research vehicle at the 2012 CENEX Low Carbon Vehicle Event recently. The XJ_e project forms part of JLR’s strategy to develop best-in-class low-carbon premium products, and follows other successful hybrid research demonstrators including the Range_e project.

Part funded by the UK Government’s Technology Strategy Board through the REEVolution project, this advanced research vehicle has been engineered in partnership with leading UK technology companies to help develop expertise for ultra-low carbon vehicles within the supply chain. The XJ_e demonstrates how an advanced parallel plug-in hybrid design can deliver reductions in CO2 emissions of over 70 percent, without compromising vehicle performance. Capable of 0-100 kmh (62 mph) in under 6.5 seconds and with a limited top speed of 250 kmh (150mph), the XJ_e achieves CO2 emissions of less than 75g/km and a zero-emission range of 40 km (25 miles) on electric power.

The XJ_e combines the class-leading lightweight aluminium vehicle structure from the Jaguar XJ with an advanced plug-in hybrid electric vehicle (PHEV) system, featuring the efficient two-litre turbocharged direct-injection petrol engine which powers the Range Rover Evoque and a hybridised eight-speed automatic transmission.

The hybrid system uses a 69kW motor/generator and a 12.3kWh lithium Ion battery pack, which can be fully charged by an external 240V domestic supply in around four hours. The parallel hybrid design means that the XJ_e can run on petrol power, electric power, or a combination of the two, optimised by the car’s intelligent energy management system which selects the most efficient mode. With a maximum system output of 334PS, the XJ_e is still offers improved fuel economy of 3.2l/100km (87 mpg).

Auto Monitor

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10 SEPTEMBER 2012

CLASSIFIEDS

Anticorrosive Equipment Pvt. Ltd. Foundry Division

Capabilities Machine Molding Sand Core Shooter Green Sand Molding No Bake Process 200kg/hr melting Mechanized Pouring 6ton/hr sand plant Mold Box - custom size Parts weight 2kg-135kg Fettling Facility Vibro Finish CNC Machining VMC Machining Pattern Making Carbon Silicon Analyzer Spectro Analysis

Materials Cast Iron S.G. Iron

Quality Sand Casting Parts

We specialize in manufacturing 2kg-135kg sand cast parts as per requirement. Our highly mechanized plant is best suited for low weight high quantity parts to meet growing need of Indian Auto Industry.

Anticorrosive Equipment Pvt. Ltd. Foundry Division 730/731, G.I.D.C. Phase II, Gundlav-396 035, Dist: Valsad, Gujarat, India.

Ph: +91 99099 19155 www.anticofoundry.co.in info@anticofoundry.co.in

The leading source for automotive parts, components & accessories.

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