A New Innovative Automobile Concept in the Compact Car Class

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The A2 1.2l TDI has a stop-start drivetrain managementsystem, which switches off the engine when the car isstanding at traffic lights or in a tailback and the footbrakeis held down for more than three seconds. As soon as thebrake is released, the engine starts again.TRANSMISSIONSThe transmissions were developed for the specificrequirements of the engines:• A lightweight 5-speed manual gearbox withmagnesium casing has been chosen for the 1.4l55 kW spark-ignition engine.• The higher-torque 1.4l 55 kW Diesel engine has areinforced 5-speed manual gearbox with aconventional aluminium casing.• In view of the engine's high efficiency, the A2 1.2lTDI is supplied with an automised, five-speedmechanical gearbox with aluminium casing. Inconjunction with its Economy program, whichconsistently strives to establish the lowest possibleshifting speeds, and a high overall ratio for fueleconomy, it is able to operate at the best specific fuelconsumption in any given situation.The 1.4l TDI accelerates from 0 to 100 km/h in 12.3 s,and reaches the same top speed of 173 km/h as with theA2 1.4l Thanks to its pump-injector technology, the 1.4lTDI achieves fuel consumption of only 4.3 litres ofDiesel fuel per 100 km. Compared to similar vehicles theA2 1.4l TDI has approximately 13% up to 53% less fuelconsumption, Fig. 9. Its CO 2 emissions are 116 g/kmand it satisfies the EU 3 emission standard.The 1.2l TDI achieves fuel consumption of only 2.99l/100 km for the MVEG cycle, accelerating from 0 to 100km/h in 14.8 seconds and is reaching a top speed of 168km/h [5].Relative fuel consumption for MVEG-cycle [%]160%150%140%130%120%110%100%90%80%4,3 l/100 km3 4 5 6Comparison Vehicles10A2 1,4l TDI1 2 7 8 9Fig. 9: Fuel consumption for the A2 1.4l TDI.VEHICLE PERFORMANCE / FUEL CONSUMP-TIONAfter 12.0 seconds the A2 1.4l is accelerated from 0 to100 km/h. This is an outstanding low value in comparisonto similar cars, Fig 8.1817161514comparison vehiclesSERVICE MODULEThe A2 has a new functional feature that also has thedouble role of a design element: the service module, Fig.10. The conventional radiator grille has been replaced bya folding cover behind which the oil dipstick and the filleropenings for engine oil and washer fluid are to be found.It is now no longer necessary to open the enginecompartment lid to check the engine oil level and to topup oil or washer fluid.If more extensive servicing work involving access to theengine compartment is required, the engine cover –known as the "front top" – can easily be removed byreleasing the quick-acting couplings.1312A2 1,4l TDIA2 1,4l1140 45 50 55 60 65 70 75 80Engine Power [kW]Fig. 8: Acceleration from 0 to 100 km/h.The driver gets an agile feeling up to a top speed of 173km/h. The fuel consumption nevertheless is 6,0 litres per100 km. The emission standard EU IV is satisfied and theCO 2 emissions are 144g/km.Fig. 10: A2 Service Module.6
ENVIRONMENTIn order to achieve also environmental objectivesespecially such as the reduction of CO 2 emissions, it isessential to view the broader context. Therefore it has tobe focused on the entire life-cycle of the car, from itsproduction, through its operation, to its ultimate recycling.As the bulk of the energy required throughout the lifetimeof a vehicle is consumed during its operation,consumption-cutting measures focusing on resistance tomotion, such as the reduction of the vehicle's weight, areparticularly significant. On the Audi A2, measures aimingin this direction were implemented systematically throughthe use of the Audi Space Frame body and the lowconsumptionengines. The bigger amount of energyrequired for the initial Aluminium Space Frameproduction in comparison to a conventional steel body isalready compensated after a driving distance ofapproximately 85.000 km.The tare weight of the Audi A2 (with 1.4 l, 55 kW sparkignitionengine) is only 895 kg, thanks to the use ofmodified weightsaving materials such as aluminium,magnesium and plastics. According to the materialsclassification of VDA guideline 231, the overall proportionof the weightsaving materials aluminium/ magnesium/polymers is 52%. The proportion of steel and ferrousmaterials is about 34% by weight.With regard to the more and more eminent air pollutionproblem, the A2 vehicle concept, Fig. 11, represents anadequate technical solution, because the amount of CO 2emissions for this vehicle concept is on a very low level.The Audi A2 is a sophisticated, progressive andresponsible vehicle, which satisfies the rising expectationsof the individual customer, while meeting the increasinglychallenging requirements of society and the legislative.ACKNOWLEDGMENTWe thank the colleagues of the Audi A2 Team, who allsupported the success of this sophisticated project.The collegues of the plant and of the AluminiumTechnical Centre in Neckarsulm also merit our thanks fortheir expertise which provided the very basis for volumeproduction of the Audi A2.The ASF body's large castings as well as the extrudedsections and alloy panels, made from the same alloy, canbe cut away completely without undue effort, allowingthese special aluminium alloys to be recycled separately.Following their removal, the castings can be used in theproduction of new cast-alloy components.Along with the rise in the number of vehicles with a highaluminium content such as the Audi A2, the world's firstvolume-production car with an all-aluminium body, thesupply of secondary aluminium from scrap vehicles willoutstrip demand for primary aluminium. In anticipation offuture developments in the field of scrap-vehiclerecycling, Audi has established the basis for effectiverecycling of aluminium by providing scope for thesegregation of cast and wrought alloys through suchtechniques as filleting and new cut detection methods.CONCLUSIONThe expertise in aluminium technology that Audi AG hasacquired over the past decade was an essential basis forbuilding the world's first aluminium car, the Audi A2, ona large scale.The use of the ASF aluminium body and the exploiting ofsecondary weight reduction measures is resulting in alower vehicle weight that is used to the customer'sbenefit. The low weight of the A2, combined with highlyefficient engines, results in a particularly agile, low fuelconsumptionvehicle concept. The A2's interiordimensions are nevertheless generous, and its variabilityclearly above-average.Fig. 11: The very low CO 2 emissions of the A2 are oneof the important technical highlights.REFERENCES[1] Kaiser, M.: Aluminium as a body in white material, 6.Aachener Kolloquium Fahrzeug- und Motorentechnik,1997[2] Radiative Forcing of Climate Change. The 1994Report of the Scientific Assessment Working Group ofIPCC, 1995.[3] Der neue Audi A2, Special edition ATZ/MTZ, ISSN0001-2785, March 2000.[4] Paefgen,F.-J.; Leitermann, W.: Audi Space FrameASF. Ein neues Pkw Rohbaukonzept in Aluminium, VDIReport 1134, 1994.[5] Engelhart, D.; Mödl, C.: The Development of the AudiA2, a new Vehicle Concept in the Compact Car Class,VDI Report Nr. 1505, 19997
Page 1 and 2: Seoul 2000 FISITA World Automotive
Page 3 and 4: laser welding, which is much faster
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A New Innovative Automobile Concept in the Compact Car Class

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