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CO2reduction

TrackingdowneverygramofCO2andquantumofenergy:Volkswagenwantstobemostsustainablecarmakerby2018

Progressivedrivesystems:fourcylinderenginewith272PSandthefirst10speedDSGPerfectioninthedetails:lightweightdesignlikeinmotorsportandhightechinnovations

VolkswagenAGhassetthegoalofbecomingtheworld'smostsustainablecarmakerbytheyear2018.Oneinstrumentalongthepathtothisgoal,forVolkswagenasabrand,isthe"ThinkBlue."environmentalstrategy.Itembodiesthedecisiontomakethecompany'ssustainabilitycampaigntraceable,transparentandcapableofbeingexperienced.Thecomprehensive"ThinkBlue."approachconsistsofthreepillars:developingefficientproductsandtechnologiesactivelyinvolvingpeopletopromoteenvironmentalawarenessandsupportingenvironmentallyrelevantprojectsandinitiativesglobally.

ThinkBlue.Engineering.

Theparametersfordevelopingefficientproductsandtechnologiesaresetforthin"ThinkBlue.Engineering."The"TechnicalDevelopment(TE)"departmentatVolkswagenaddressessustainabilityissuesearlyoninthecontextofproductdevelopment.OneofitsgoalsistocontinuallyimprovetheenvironmentalcompatibilityofallVolkswagenproductsandbusinesssitesenvironmentallyrelevantaspectsmustbeconsideredinallareasofthetechnicaldevelopmentandthroughoutthetotalproductlifecycle.Inpursuingthisstrategy,"TechnicalDevelopment"wantstomakeasignificantcontributiontowardsclimateprotection,resourcepreservationandhealth.Veryspecifically,itwantstoreducewastematerials,emissions,water

Themes

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usageandCO2emissionsby25percent(comparedto2010figures)by2018.Inaddition,Volkswagenhassettheclaimofofferingthemostecofriendlyautomobileineverymarketsegment.Therefore,basedon"ThinkBlue.Engineering."eachnewproductshouldbedevelopedtoembodycomprehensiveenvironmentalpropertiesoveritsentireproductlifecyclewhicharebetterthaninthepreviousmodel.Tothisend,Volkswagenisimplementingawholeseriesofinnovativetechnologies.Thelatestsystemsindetail:

Mildhybrid

MildhybridtechnologyfromVolkswagenshutsoffthecombustionengineincoastingphasessuchaswhenthedrivertakesthefootfromtheacceleratorpedaleitherondescentsorwhenanticipatingastop.Itcreatesanallianceofefficiency,comfortandconvenience.Theengine,whichisjoinedtoadualclutchgearbox(DSG),isrestartedverycomfortablyviaabeltdrivenstartinggenerator(RSG).

Whentheengineisshutoff,itisdisengagedfromthedrivetrainwhichenablesa"coasting"modeinwhichthecarisdrivenwithzeroemissions.Inthiscase,thetextmessage"Coasting"appearsonthemultifunctiondisplayandthefamiliarsymbolfortheactive"stopstartsystem".This"coastingwithengineofffunction"extendstheavailabilityofthe"stopstartsystem"toanydrivingspeeds.Animportantdifference:Intoday'sstopstartsystems,theenginemustfirstreachzerorevsbeforeitcanberestarted.However,intheVolkswagenmildhybrid(alowvoltagesystem)theenginecanberestartedatanyenginespeed("changeofmindsituation").So,thissystemconvenientlyisabletosmoothlyhandlesituationssuchaswhenthedriverreleasestheacceleratorpedal,butthensuddenlypressesitagain,e.g.togetthroughanintersectionwhilethetrafficlightisstillyellow.AnelectricoilpumpintheDSGalsoensuresthatthegearboxcanstillshiftwhilethecombustionengineisdeactivated,sothatthepropergearratioisimmediatelyavailableatrestart.

Inaddition,theamountofenergyrecoveredbyregenerativebrakinghasbeensignificantlyincreasedinthemildhybrid.Alightweightlithiumionbatteryservesastheenergystoragedevicehere.Therecoveredenergyinthemildhybridisnotonlyusedtosupplythevehicleelectricalsystemduringstopstartandcoastingmodephasesandtorestarttheengine.Itisalsousedforwhatisknownastheminiboost.Thisshiftstheengine'sloadpointwhichfurtherreducesCO2emissions.

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Startstopsystem2.0

The2.0generationstartstopsystemismakingitsdebutinthenewPassat.Thestartstopsystem2.0extendsfunctionalitytostoppingoperationsinthespeedrangebelow7km/h.Theengineisnotonlyshutoffwhilethevehicleisatastandstill,ratheritisalreadyshutoffwhilecoastingtoastopthisrepresentsasystematicextensionofthinkingaboutefficiencymeasureswithintheVolkswagenpowertrainstrategy.Volkswagenintroducedthefirststopstartsystemin2008.ThetechnologywasfurtherdevelopedwiththedebutofthecurrentGolf(2012).Thekeycharacteristicofthisnew2.0generationofthestopstartsystemisitsfurtherimprovedfueleconomywhichreducesCO2emissionsbasedonthedescribedearlyengineshutoffasthevehicledeceleratestoastop.Asmuchas1.7gCO2perkmadditionalsavingsarerealisedintheNEDC,dependingonthespecificengine.Thismayappeartobemodestprogress,butitmustbeconsideredinanoverallcontext.Thegoalistoexploitthemaximumsavingspotentialofthedrivetrain.

Stoppingtheengineduringcoastdowntoastopposesaspecialtechnicalchallenge.Thesystemmustbeabletodetectwhetherthedriveractuallywantstostoporisjustdrivingveryslowlyforashortperiod,suchasinnormalstartupofvehiclesintraffic.Invehicleswithamanualgearbox,thedrivercontinuestoassumecontrol.Inthisstate,theengineisshutoffatspeedsbelow7km/hinresponsetothedrivershiftingtoneutralfromthegivengearandreleasingtheclutchpedal.Here,thedriverdecidesonthesituationsinwhichshutoffshouldoccur.Incarmodelswithautomaticdualclutchgearboxes(DSG),detectionofa"wishtostop"ismuchmorecomplex,becauseessentiallyonlyactivationofthebrakepedalisavailableasfeedback.Andyetthatworkstoo:theinnovativesystemdetermineswhetherthedriverwantstostopandwhetheritmakessensetostoptheengineinagivendrivingsituationbasedonanevaluationofvehiclespeedanddeceleration,thesteeringinputangleandthebrakepressurecurve.Ifitdoesmakesense,theengineisstoppedatspeedsbelowthe7km/hlimitasdescribedabove.

Thereare,however,numerous"changeofmindsituations"inwhichthedrivermaysuddenlyaccelerate,suchaswhenthelightturnsgreenonanapproachtoatrafficlight.Thesecondgenerationstopstartsystemcanhandlethesesituations,becauseofimprovementsthatmakeenginerestartingveryfastandcomfortable.

Highperformance2.0TDIdieselengine(biturbowith240PS)

The2.0TDIwith176kW/240PS(at4,000rpm)inthenewPassat(1),whichisacompletelynewdevelopment,isthemostpowerfulfourcylinderturbodieseldirectinjectionengineeverofferedbyVolkswagen.Inordertoachieveitshighspecificoutputof120PSperlitreenginedisplacement,acompactbiturbomodulewasdevelopedfortheenginewithonehighpressureandonelowerpressureturbocharger.Themoduleenablesboostpressuresofupto3.8bar.Thecylindercrankcase,crankshaft,connectingrodsandpistonswereadaptedtothehighpeakcombustionpressureof200bar.Inaddition,anewhighperformancecylinderheadis

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alsobeingusedforthefirsttime.Anothernewfeatureistheinjectionsystemwithpiezoinjectorsthatwasrecentlydeveloped.Thisfuelinjectionsystemenablesinjectionpressuresofupto2,500bar.ConformitytothefutureEU6emissionsstandardisguaranteedbytheuseofanSCRsystem.Inordertooptimisecomfortatlowenginespeeds,Volkswagenisemployinganothernewconcept:acentrifugalpendulumabsorberinthe2.0TDImodel'sgearbox.ItenablesevenfurtherloweringofthegearshiftpointswhichreducesenginerevlevelsandcontributestotheexcellentfuelconsumptionfiguresoftheTDI.

Thesaloonwiththisnew2.0TDIreachesatopspeedof240km/h,whiletheestatereaches238km/h.Duetothe240PSengine'shighmaximumtorqueof500Nm(1,750to2,500rpm),thePassatandPassatEstateareequippedwith4MOTIONallwheeldriveanda7speedDSGasstandard.Consideringthehighpoweroutput,itsfuelconsumptionfiguresareremarkablylow:5.3l/100(saloon)and5.4l/100km(estate).CO2emissionsare139and140g/km.

Highperformancedieselengine:2.0TDI(biturbowith272PS)

Thenew2.0TDIofthePassatwith240PSachievesatopvalueamongdieselengineswithapowerdensityof120PSperlitredisplacement.ButVolkswagenisdemonstratingthatevenherethereisstillroomforupwardgrowthbyrevealingaprototypeenginethatattainsapowerlevelof200kW/272PS.Suchahighperformanceengineinthemodulardieselsystem(MDB)ismadetechnicallyfeasiblebyextendingthetwostagechargingbywhatisknownasan"electricbooster"athirdcompressor,butonethatispoweredelectrically.Inthis272PSprototype,Volkswagenhasalsoincreasedthechargepressureofthebiturbosystemandtheinjectionpressureofthecommonrailsystem.Othermodificationsincludeavariablevalvetrainandoptimisationstothegasexchangecycle.

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10speedDSG

AhighlightamongthenewdualclutchgearboxesistheDQ511itisthefirstVolkswagenDSGtofeaturetenforwardgears.Intermsofitsmechanicaldesign,this10speedDSGisanadvanceddevelopmentofthe7speedDSGwiththeinternaldesignationDQ500.Bothgearboxesaredesignedforpeaktorquesof550Nm.Despitetheadditionofthreegears,the10speedDSGisjustascompactasitscounterpartwithsevengears.OnegoalindevelopingthenewDSGwastodesignitforuseinthemodulartransversematrix(MQB)atechnicalplatformthatisalreadyusedfortheGolfandthePassattoday.

Reversingthepowerflowwithinthegearboxwasenabledwithoutadditionalpairsofgearwheelsbyemployinganentirelynewshiftingstrategyandaddingtwoshiftingelementsandareversingwheel.Thisenablestheimplementationoftenprogressivelysteppedgears.Gearboxdeveloperswereabletofurtherimprovedriveoffperformancethankstotheshortratiosofthelowgears.Duringacceleration,thefinelygraduatedstepsofgears3through9enableefficiencygains.Thetenthgear'slonggearratioreducesrevssignificantlywithanassociatedpotentialforCO2reduction.Alongwiththeten"loadshifting"gears,theDQ511alsomakesitpossibletointegrateadditionaldrivinglevelsforimplementingspecialfunctionssuchasa"crawlergear"oraspeciallong"superoverdrive".ComparedtotheDQ500,thesystemefficiencyoftheDQ511wasfurtherimprovedbyspecialcoatingsonthegearwheels,lowfrictionbearingsandaspeciallydevelopedlowfrictionoil.LikeallofthelatestgenerationDSGunits,theDQ511enablesthe"coastingengineofffunction"aswellduringcoastingphasesitdecouplestheenginefromthegearboxandshutstheengineoff.

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Lightweightdesignwithlightweightpanels

Levelsofpassivesafety,comfortandconveniencehaveincreasedsignificantlyinrecentyears.Foralongtime,progressmadeintheseareascouldhardlybeimplementedweightneutrally.Volkswagenhaschangedpreciselythis.Thecompanywasoneoftheworld'sfirsttosuccessfullyreversetheupwardweightspiralbymeansofinnovativelightweightdesigneveninpricesensitivehighvolumeproductionmodels.AfrontrunnerinthisregardisthecurrentGolfcomparedtothepreviousmodel,itisupto100kglighter,yetitoffersmoresafety,comfortandconvenience.VolkswagenhasmadesimilarprogresswiththelatestgenerationPassatthatwaspresentedjustafewweeksagoitwasmadeupto85kglighter.

Now,Volkswagenistransferringalightweightdesigninnovationfromlowvolumetohighvolumeproduction.Thesource:thestreetversionofthePoloRWRC.Inthiscar,athreelayersandwichpanelisusedfortheenginebonnetitconsistsoftwosteelcoverlayersandamiddlepolymerthermoplasticlayer.Thiscompositematerialenablesaweightreductionofupto30percentwhilemaintainingidenticalbendingandbucklingstrength.Thesandwichpanelisatypicalexampleofaninnovationinwhichexperiencewasfirstacquiredinexclusivelimitedseriesproductionandthentransferredtohighvolumeproduction.

Infraredreflectingdashboard

Thesunheatsupdarksurfacesmorethanlightsurfaces,becausetheyabsorbmore

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lightenergy.However,darksurfacesarebettersuitedforthedashboardarea,becausetheyminimisewindscreenreflectionsthisproducesaviciouscircle,whichVolkswagenisnowcombatingbydevelopinganewinfraredreflectingdashboard.Thatisbecauseitistheinfraredradiationinsunlightthatisprimarilyresponsibleforheatingthesurfaces.Therefore,Volkswagenisnowusingspecialpigmentstodyethenewlydevelopeddashboardsurfaceslushskininsteadoftheusualdyingmethodwithsoot.Whilesootabsorbstheentirespectrumofsunlight(UV&VIS&NIR),thenearinfraredcomponent(NIR)islargelyreflectedbythemetallicoxidepigmentationintroducedhere.

Whilepreservingtheblackcolour,engineershaveobtainedlessheatingofthesurfaces,andthissignificantlylowersundesirableinteriorheatinthevehicle.Thissolutionyieldsmanypositivebenefits:Thereducedradiationheatimprovescomfortinthevehicleandshortensthetimerequiredtoreachcomfortabletemperaturesusingtheairconditioning,becausetheinteriorcomponentsheatupwithlowerintensity.Inturn,thereducedenergyconsumptionoftheairconditionerreducesCO2emissions,anditimprovesthedrivingrangesofelectricandhybridmodels(thelatterinEmode).

LowEglasssunroof

"LowEglass"isshorthandfor"lowemissivityglass".Itreferstoglassuponwhichanextremelythinoxidefilm(indiumoxideorfluorinedopedtinoxide)isappliedbyvapourdepositionthathasathicknessofaround400nm.Thisfilmservesasaformofsunlightprotection,becauseitallowsshortwaveradiation,orlight,topassthrough,butitreflectslongwaveinfraredradiation.Thiscausesthevehicleinteriortoheatuplessintenselyinthesummer.Inthewinter,ontheotherhand,warmthisretainedbetterintheinterior.Especiallyincrispcoldweatheritreflectsthebodyheatofoccupants,keepingitinsidethevehicleandthisleadstoamuchhigherperceptionofcomfort,especiallyintheheadarea.

Overall,theexcessheatload(inwarmweather)orheatdemand(incoldweather)canbereducedbyasmuchas15percentbyusingalowEglasssunroof.Theresults:noticeablybetterclimatecomfort.Inaddition,lowerloadsontheheatingandairconditioningsystemmeanfurtherreductionsinCO2emissions.Lastbutnotleast,withalowEglasssunroof,theroofshadecanbeeliminated,whichreducesvehicleweight.

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Rangemanager

Drivingrangeplaysacrucialroleinelectricvehicles.ThatiswhyVolkswagenisdevelopingsystemsthatcanoptimisethemaximumdrivingrange.Effectivetoolsherearetherangemanagerandrangemonitor.Workingtogether,theyenableveryprecisecomputationofdrivingrangewhichtakesintoaccounttheroute,traffic,environmentalconsiderationsanddrivingstyle.Therangemonitorintuitivelydisplaystherangethatcanbeachievedatagivenpointintime,andadditionalpotentialforrangeoptimisation.Inaddition,thedrivercanusevehiclespecificsettingstoinfluencedrivingrangetherangemonitorassiststhedriverhere.Itrecommendsactionsthatthedrivercantaketoincreaserange.Forexample,thesystemofferstipsforoptimisingdrivingstyleandthedrivingroute,anditmightsuggestlesscoolingoftheinteriorwithinacceptablelimits.Ifthedestinationisstilloutsideofthecalculatedrange,activating"Automode"cannowbehelpful.Inthismode,therangemanagerintervenestooptimiserangebyadjustingparameterssuchasthedrivingprofile,enginepowerandroute.

Needbasedairconditioningandheatpump

EfficientairconditioningintheMQB.Eitheramechanicalorelectricalairconditioningcompressorisusedtosatisfycoolingneedsinthevehicle,dependingonthetypeofdrivesystem.TheClimatronicautomaticallyregulatestheinteriortemperature.Basedonoutdoorweatherconditions,theinteriorairisnotonlycooled,itisalsodehumidified.Nonetheless,thereareweatherconditionsinwhichtheairflowingintothecardoesnotneedtobecooledordehumidified.Thisrealizationledtoaninnovationinproductioncars:whentheClimatronicsystemsensorsdetectsuchconditions,theairconditioningcompressoristemporarilydeactivated.StudieshavefoundthatsuchconditionsmayexistinGermanyforasmuchas40percentoftotaldrivingtime.NeedbasedairconditioningoftheGolfandPassatimplementedviatheMQBsavesenergybyautomaticallyshuttingofftheairconditioningcompressorandwithoutanycompromisesincomfort.

Increasingtherangeofelectricvehiclesbyheatpump.Climatecontrolrequirementsinelectricvehiclesarenotonlyhighforcooling,butalsofortheheatingmode,becauseverylittleheatisgeneratedbythehighlyefficientdrivesystem.Iftheenergyforheatingisdrawnfromthelithiumionbattery,thishasadirecteffectonthecar'sdrivingrange.Therefore,wellcoordinatedthermalmanagementisabsolutelynecessary.VolkswagenismeetingthischallengeheadonwithaheatpumpthatwasspeciallydevelopedfortheeGolf.Thethermalsystemisextremelyinnovative.Forinstance,theclimatecontrolsystemknowswhichvehicleseatsareunoccupiedthisletsitreduceheatingfortheseunoccupiedspaces.Overall,useoftheheatpumpcutselectricheatingneedsinhalf,anditimprovesdrivingrangebyaround30percent.

Technically,theheatpumpisaspeciallydevelopedairconditioner.Theairconditionerrefrigerantiscompressedunderhighpressureinacompressor.Thiscausesariseintemperature,whichevaporatesthecoolant.Thenowgaseousrefrigerantisroutedtoacondenserthroughwhichcoldairflows.Thiscausestherefrigeranttogiveoffenergyintheformofheat,anditcondenses.Theheatedambientairthenflowsintothevehicleinteriorasheatingair.Afterpassingthroughthecondenser,theliquidrefrigerantflowstoanexpansionvalvewhereitspressureisloweredsubstantially.Itstemperatureisnowbelowthatoftheambientair,anditabsorbsenergyfromits

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surroundings.Therefrigerantisthenreadytobeevaporatedagain.Thegaseousrefrigerant,whichisnowatalowtemperatureandpressure,flowsbacktothecompressorwhichcompletestheloop.Theheatpumpconceptalsoutiliseswasteheatfromthemotorandpowerelectronicstoheattheheatingair.Theheatpumpconceptincreasesvehiclerange,whilestilldeliveringoptimalheatingcomfort.

1)Passat2.0TDIBMT176kWFuelconsumptioninl/100km:combined5.3/urban6.4/extraurban4.6CO2emissionscombineding/km:139efficiencyclass:B

Notes:TDI,TSIandDSGareregisteredtrademarksofVolkswagenAGorothercompaniesoftheVolkswagenGroupinGermanyandothercountries.FeaturesandtechnicaldataforproductionmodelsapplytomodelsofferedinGermany.Theymaydifferinothercountries.

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