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Themes

CO2reduction
TrackingdowneverygramofCO2andquantumofenergy:Volkswagenwants
tobemostsustainablecarmakerby2018
Progressivedrivesystems:fourcylinderenginewith272PSandthefirst
10speedDSG
Perfectioninthedetails:lightweightdesignlikeinmotorsportand
hightechinnovations
VolkswagenAGhassetthegoalofbecomingtheworld'smostsustainablecarmaker
bytheyear2018.Oneinstrumentalongthepathtothisgoal,forVolkswagenasa
brand,isthe"ThinkBlue."environmentalstrategy.Itembodiesthedecisiontomake
thecompany'ssustainabilitycampaigntraceable,transparentandcapableofbeing
experienced.Thecomprehensive"ThinkBlue."approachconsistsofthreepillars:
developingefficientproductsandtechnologiesactivelyinvolvingpeopletopromote
environmentalawarenessandsupportingenvironmentallyrelevantprojectsand
initiativesglobally.

ThinkBlue.Engineering.
Theparametersfordevelopingefficientproductsandtechnologiesaresetforthin
"ThinkBlue.Engineering."The"TechnicalDevelopment(TE)"departmentat
Volkswagenaddressessustainabilityissuesearlyoninthecontextofproduct
development.Oneofitsgoalsistocontinuallyimprovetheenvironmental
compatibilityofallVolkswagenproductsandbusinesssitesenvironmentallyrelevant
aspectsmustbeconsideredinallareasofthetechnicaldevelopmentandthroughout
thetotalproductlifecycle.Inpursuingthisstrategy,"TechnicalDevelopment"wants
tomakeasignificantcontributiontowardsclimateprotection,resourcepreservation
andhealth.Veryspecifically,itwantstoreducewastematerials,emissions,water
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usageandCO2emissionsby25percent(comparedto2010figures)by2018.In
addition,Volkswagenhassettheclaimofofferingthemostecofriendlyautomobilein
everymarketsegment.Therefore,basedon"ThinkBlue.Engineering."eachnew
productshouldbedevelopedtoembodycomprehensiveenvironmentalproperties
overitsentireproductlifecyclewhicharebetterthaninthepreviousmodel.Tothis
end,Volkswagenisimplementingawholeseriesofinnovativetechnologies.Thelatest
systemsindetail:

Mildhybrid
MildhybridtechnologyfromVolkswagenshutsoffthecombustionengineincoasting
phasessuchaswhenthedrivertakesthefootfromtheacceleratorpedaleitheron
descentsorwhenanticipatingastop.Itcreatesanallianceofefficiency,comfortand
convenience.Theengine,whichisjoinedtoadualclutchgearbox(DSG),isrestarted
verycomfortablyviaabeltdrivenstartinggenerator(RSG).
Whentheengineisshutoff,itisdisengagedfromthedrivetrainwhichenablesa
"coasting"modeinwhichthecarisdrivenwithzeroemissions.Inthiscase,thetext
message"Coasting"appearsonthemultifunctiondisplayandthefamiliarsymbolfor
theactive"stopstartsystem".This"coastingwithengineofffunction"extendsthe
availabilityofthe"stopstartsystem"toanydrivingspeeds.Animportantdifference:
Intoday'sstopstartsystems,theenginemustfirstreachzerorevsbeforeitcanbe
restarted.However,intheVolkswagenmildhybrid(alowvoltagesystem)theengine
canberestartedatanyenginespeed("changeofmindsituation").So,thissystem
convenientlyisabletosmoothlyhandlesituationssuchaswhenthedriverreleases
theacceleratorpedal,butthensuddenlypressesitagain,e.g.togetthroughan
intersectionwhilethetrafficlightisstillyellow.AnelectricoilpumpintheDSGalso
ensuresthatthegearboxcanstillshiftwhilethecombustionengineisdeactivated,so
thatthepropergearratioisimmediatelyavailableatrestart.
Inaddition,theamountofenergyrecoveredbyregenerativebrakinghasbeen
significantlyincreasedinthemildhybrid.Alightweightlithiumionbatteryservesas
theenergystoragedevicehere.Therecoveredenergyinthemildhybridisnotonly
usedtosupplythevehicleelectricalsystemduringstopstartandcoastingmode
phasesandtorestarttheengine.Itisalsousedforwhatisknownastheminiboost.
Thisshiftstheengine'sloadpointwhichfurtherreducesCO2emissions.

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Startstopsystem2.0
The2.0generationstartstopsystemismakingitsdebutinthenewPassat.Thestart
stopsystem2.0extendsfunctionalitytostoppingoperationsinthespeedrangebelow
7km/h.Theengineisnotonlyshutoffwhilethevehicleisatastandstill,ratheritis
alreadyshutoffwhilecoastingtoastopthisrepresentsasystematicextensionof
thinkingaboutefficiencymeasureswithintheVolkswagenpowertrainstrategy.
Volkswagenintroducedthefirststopstartsystemin2008.Thetechnologywasfurther
developedwiththedebutofthecurrentGolf(2012).Thekeycharacteristicofthisnew
2.0generationofthestopstartsystemisitsfurtherimprovedfueleconomywhich
reducesCO2emissionsbasedonthedescribedearlyengineshutoffasthevehicle
deceleratestoastop.Asmuchas1.7gCO2perkmadditionalsavingsarerealisedin
theNEDC,dependingonthespecificengine.Thismayappeartobemodestprogress,
butitmustbeconsideredinanoverallcontext.Thegoalistoexploitthemaximum
savingspotentialofthedrivetrain.
Stoppingtheengineduringcoastdowntoastopposesaspecialtechnicalchallenge.
Thesystemmustbeabletodetectwhetherthedriveractuallywantstostoporisjust
drivingveryslowlyforashortperiod,suchasinnormalstartupofvehiclesintraffic.
Invehicleswithamanualgearbox,thedrivercontinuestoassumecontrol.Inthis
state,theengineisshutoffatspeedsbelow7km/hinresponsetothedrivershifting
toneutralfromthegivengearandreleasingtheclutchpedal.Here,thedriverdecides
onthesituationsinwhichshutoffshouldoccur.Incarmodelswithautomaticdual
clutchgearboxes(DSG),detectionofa"wishtostop"ismuchmorecomplex,because
essentiallyonlyactivationofthebrakepedalisavailableasfeedback.Andyetthat
workstoo:theinnovativesystemdetermineswhetherthedriverwantstostopand
whetheritmakessensetostoptheengineinagivendrivingsituationbasedonan
evaluationofvehiclespeedanddeceleration,thesteeringinputangleandthebrake
pressurecurve.Ifitdoesmakesense,theengineisstoppedatspeedsbelowthe7
km/hlimitasdescribedabove.
Thereare,however,numerous"changeofmindsituations"inwhichthedrivermay
suddenlyaccelerate,suchaswhenthelightturnsgreenonanapproachtoatraffic
light.Thesecondgenerationstopstartsystemcanhandlethesesituations,becauseof
improvementsthatmakeenginerestartingveryfastandcomfortable.
Highperformance2.0TDIdieselengine(biturbowith240PS)
The2.0TDIwith176kW/240PS(at4,000rpm)inthenewPassat(1),whichisa
completelynewdevelopment,isthemostpowerfulfourcylinderturbodieseldirect
injectionengineeverofferedbyVolkswagen.Inordertoachieveitshighspecific
outputof120PSperlitreenginedisplacement,acompactbiturbomodulewas
developedfortheenginewithonehighpressureandonelowerpressure
turbocharger.Themoduleenablesboostpressuresofupto3.8bar.Thecylinder
crankcase,crankshaft,connectingrodsandpistonswereadaptedtothehighpeak
combustionpressureof200bar.Inaddition,anewhighperformancecylinderheadis
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alsobeingusedforthefirsttime.Anothernewfeatureistheinjectionsystemwith
piezoinjectorsthatwasrecentlydeveloped.Thisfuelinjectionsystemenables
injectionpressuresofupto2,500bar.ConformitytothefutureEU6emissions
standardisguaranteedbytheuseofanSCRsystem.Inordertooptimisecomfortat
lowenginespeeds,Volkswagenisemployinganothernewconcept:acentrifugal
pendulumabsorberinthe2.0TDImodel'sgearbox.Itenablesevenfurtherlowering
ofthegearshiftpointswhichreducesenginerevlevelsandcontributestothe
excellentfuelconsumptionfiguresoftheTDI.
Thesaloonwiththisnew2.0TDIreachesatopspeedof240km/h,whiletheestate
reaches238km/h.Duetothe240PSengine'shighmaximumtorqueof500Nm
(1,750to2,500rpm),thePassatandPassatEstateareequippedwith4MOTIONall
wheeldriveanda7speedDSGasstandard.Consideringthehighpoweroutput,its
fuelconsumptionfiguresareremarkablylow:5.3l/100(saloon)and5.4l/100km
(estate).CO2emissionsare139and140g/km.

Highperformancedieselengine:2.0TDI(biturbowith272PS)
Thenew2.0TDIofthePassatwith240PSachievesatopvalueamongdieselengines
withapowerdensityof120PSperlitredisplacement.ButVolkswagenis
demonstratingthatevenherethereisstillroomforupwardgrowthbyrevealinga
prototypeenginethatattainsapowerlevelof200kW/272PS.Suchahigh
performanceengineinthemodulardieselsystem(MDB)ismadetechnicallyfeasible
byextendingthetwostagechargingbywhatisknownasan"electricbooster"a
thirdcompressor,butonethatispoweredelectrically.Inthis272PSprototype,
Volkswagenhasalsoincreasedthechargepressureofthebiturbosystemandthe
injectionpressureofthecommonrailsystem.Othermodificationsincludeavariable
valvetrainandoptimisationstothegasexchangecycle.

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10speedDSG
AhighlightamongthenewdualclutchgearboxesistheDQ511itisthefirst
VolkswagenDSGtofeaturetenforwardgears.Intermsofitsmechanicaldesign,this
10speedDSGisanadvanceddevelopmentofthe7speedDSGwiththeinternal
designationDQ500.Bothgearboxesaredesignedforpeaktorquesof550Nm.Despite
theadditionofthreegears,the10speedDSGisjustascompactasitscounterpart
withsevengears.OnegoalindevelopingthenewDSGwastodesignitforuseinthe
modulartransversematrix(MQB)atechnicalplatformthatisalreadyusedforthe
GolfandthePassattoday.
Reversingthepowerflowwithinthegearboxwasenabledwithoutadditionalpairsof
gearwheelsbyemployinganentirelynewshiftingstrategyandaddingtwoshifting
elementsandareversingwheel.Thisenablestheimplementationoftenprogressively
steppedgears.Gearboxdeveloperswereabletofurtherimprovedriveoff
performancethankstotheshortratiosofthelowgears.Duringacceleration,thefinely
graduatedstepsofgears3through9enableefficiencygains.Thetenthgear'slong
gearratioreducesrevssignificantlywithanassociatedpotentialforCO2reduction.
Alongwiththeten"loadshifting"gears,theDQ511alsomakesitpossibletointegrate
additionaldrivinglevelsforimplementingspecialfunctionssuchasa"crawlergear"
oraspeciallong"superoverdrive".ComparedtotheDQ500,thesystemefficiencyof
theDQ511wasfurtherimprovedbyspecialcoatingsonthegearwheels,lowfriction
bearingsandaspeciallydevelopedlowfrictionoil.Likeallofthelatestgeneration
DSGunits,theDQ511enablesthe"coastingengineofffunction"aswellduring
coastingphasesitdecouplestheenginefromthegearboxandshutstheengineoff.

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Lightweightdesignwithlightweightpanels
Levelsofpassivesafety,comfortandconveniencehaveincreasedsignificantlyin
recentyears.Foralongtime,progressmadeintheseareascouldhardlybe
implementedweightneutrally.Volkswagenhaschangedpreciselythis.Thecompany
wasoneoftheworld'sfirsttosuccessfullyreversetheupwardweightspiralbymeans
ofinnovativelightweightdesigneveninpricesensitivehighvolumeproduction
models.AfrontrunnerinthisregardisthecurrentGolfcomparedtotheprevious
model,itisupto100kglighter,yetitoffersmoresafety,comfortandconvenience.
VolkswagenhasmadesimilarprogresswiththelatestgenerationPassatthatwas
presentedjustafewweeksagoitwasmadeupto85kglighter.
Now,Volkswagenistransferringalightweightdesigninnovationfromlowvolumeto
highvolumeproduction.Thesource:thestreetversionofthePoloRWRC.Inthiscar,
athreelayersandwichpanelisusedfortheenginebonnetitconsistsoftwosteel
coverlayersandamiddlepolymerthermoplasticlayer.Thiscompositematerial
enablesaweightreductionofupto30percentwhilemaintainingidenticalbending
andbucklingstrength.Thesandwichpanelisatypicalexampleofaninnovationin
whichexperiencewasfirstacquiredinexclusivelimitedseriesproductionandthen
transferredtohighvolumeproduction.

Infraredreflectingdashboard
Thesunheatsupdarksurfacesmorethanlightsurfaces,becausetheyabsorbmore

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lightenergy.However,darksurfacesarebettersuitedforthedashboardarea,
becausetheyminimisewindscreenreflectionsthisproducesaviciouscircle,which
Volkswagenisnowcombatingbydevelopinganewinfraredreflectingdashboard.
Thatisbecauseitistheinfraredradiationinsunlightthatisprimarilyresponsiblefor
heatingthesurfaces.Therefore,Volkswagenisnowusingspecialpigmentstodyethe
newlydevelopeddashboardsurfaceslushskininsteadoftheusualdyingmethod
withsoot.Whilesootabsorbstheentirespectrumofsunlight(UV&VIS&NIR),the
nearinfraredcomponent(NIR)islargelyreflectedbythemetallicoxidepigmentation
introducedhere.
Whilepreservingtheblackcolour,engineershaveobtainedlessheatingofthe
surfaces,andthissignificantlylowersundesirableinteriorheatinthevehicle.This
solutionyieldsmanypositivebenefits:Thereducedradiationheatimprovescomfortin
thevehicleandshortensthetimerequiredtoreachcomfortabletemperaturesusing
theairconditioning,becausetheinteriorcomponentsheatupwithlowerintensity.In
turn,thereducedenergyconsumptionoftheairconditionerreducesCO2emissions,
anditimprovesthedrivingrangesofelectricandhybridmodels(thelatterinE
mode).

LowEglasssunroof
"LowEglass"isshorthandfor"lowemissivityglass".Itreferstoglassuponwhichan
extremelythinoxidefilm(indiumoxideorfluorinedopedtinoxide)isappliedby
vapourdepositionthathasathicknessofaround400nm.Thisfilmservesasaform
ofsunlightprotection,becauseitallowsshortwaveradiation,orlight,topassthrough,
butitreflectslongwaveinfraredradiation.Thiscausesthevehicleinteriortoheatup
lessintenselyinthesummer.Inthewinter,ontheotherhand,warmthisretained
betterintheinterior.Especiallyincrispcoldweatheritreflectsthebodyheatof
occupants,keepingitinsidethevehicleandthisleadstoamuchhigherperceptionof
comfort,especiallyintheheadarea.
Overall,theexcessheatload(inwarmweather)orheatdemand(incoldweather)
canbereducedbyasmuchas15percentbyusingalowEglasssunroof.The
results:noticeablybetterclimatecomfort.Inaddition,lowerloadsontheheatingand
airconditioningsystemmeanfurtherreductionsinCO2emissions.Lastbutnotleast,
withalowEglasssunroof,theroofshadecanbeeliminated,whichreducesvehicle
weight.

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Rangemanager
Drivingrangeplaysacrucialroleinelectricvehicles.ThatiswhyVolkswagenis
developingsystemsthatcanoptimisethemaximumdrivingrange.Effectivetoolshere
aretherangemanagerandrangemonitor.Workingtogether,theyenablevery
precisecomputationofdrivingrangewhichtakesintoaccounttheroute,traffic,
environmentalconsiderationsanddrivingstyle.Therangemonitorintuitivelydisplays
therangethatcanbeachievedatagivenpointintime,andadditionalpotentialfor
rangeoptimisation.Inaddition,thedrivercanusevehiclespecificsettingstoinfluence
drivingrangetherangemonitorassiststhedriverhere.Itrecommendsactionsthat
thedrivercantaketoincreaserange.Forexample,thesystemofferstipsfor
optimisingdrivingstyleandthedrivingroute,anditmightsuggestlesscoolingofthe
interiorwithinacceptablelimits.Ifthedestinationisstilloutsideofthecalculated
range,activating"Automode"cannowbehelpful.Inthismode,therangemanager
intervenestooptimiserangebyadjustingparameterssuchasthedrivingprofile,
enginepowerandroute.
Needbasedairconditioningandheatpump
EfficientairconditioningintheMQB.Eitheramechanicalorelectricalairconditioning
compressorisusedtosatisfycoolingneedsinthevehicle,dependingonthetypeof
drivesystem.TheClimatronicautomaticallyregulatestheinteriortemperature.Based
onoutdoorweatherconditions,theinteriorairisnotonlycooled,itisalso
dehumidified.Nonetheless,thereareweatherconditionsinwhichtheairflowinginto
thecardoesnotneedtobecooledordehumidified.Thisrealizationledtoan
innovationinproductioncars:whentheClimatronicsystemsensorsdetectsuch
conditions,theairconditioningcompressoristemporarilydeactivated.Studieshave
foundthatsuchconditionsmayexistinGermanyforasmuchas40percentoftotal
drivingtime.NeedbasedairconditioningoftheGolfandPassatimplementedviathe
MQBsavesenergybyautomaticallyshuttingofftheairconditioningcompressorand
withoutanycompromisesincomfort.
Increasingtherangeofelectricvehiclesbyheatpump.Climatecontrolrequirements
inelectricvehiclesarenotonlyhighforcooling,butalsofortheheatingmode,
becauseverylittleheatisgeneratedbythehighlyefficientdrivesystem.Ifthe
energyforheatingisdrawnfromthelithiumionbattery,thishasadirecteffectonthe
car'sdrivingrange.Therefore,wellcoordinatedthermalmanagementisabsolutely
necessary.Volkswagenismeetingthischallengeheadonwithaheatpumpthatwas
speciallydevelopedfortheeGolf.Thethermalsystemisextremelyinnovative.For
instance,theclimatecontrolsystemknowswhichvehicleseatsareunoccupiedthis
letsitreduceheatingfortheseunoccupiedspaces.Overall,useoftheheatpumpcuts
electricheatingneedsinhalf,anditimprovesdrivingrangebyaround30percent.
Technically,theheatpumpisaspeciallydevelopedairconditioner.Theairconditioner
refrigerantiscompressedunderhighpressureinacompressor.Thiscausesarisein
temperature,whichevaporatesthecoolant.Thenowgaseousrefrigerantisroutedto
acondenserthroughwhichcoldairflows.Thiscausestherefrigeranttogiveoff
energyintheformofheat,anditcondenses.Theheatedambientairthenflowsinto
thevehicleinteriorasheatingair.Afterpassingthroughthecondenser,theliquid
refrigerantflowstoanexpansionvalvewhereitspressureisloweredsubstantially.Its
temperatureisnowbelowthatoftheambientair,anditabsorbsenergyfromits
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surroundings.Therefrigerantisthenreadytobeevaporatedagain.Thegaseous
refrigerant,whichisnowatalowtemperatureandpressure,flowsbacktothe
compressorwhichcompletestheloop.Theheatpumpconceptalsoutiliseswasteheat
fromthemotorandpowerelectronicstoheattheheatingair.Theheatpumpconcept
increasesvehiclerange,whilestilldeliveringoptimalheatingcomfort.

1)Passat2.0TDIBMT176kWFuelconsumptioninl/100km:combined5.3/
urban6.4/extraurban4.6CO2emissionscombineding/km:139efficiency
class:B
Notes:
TDI,TSIandDSGareregisteredtrademarksofVolkswagenAGorother
companiesoftheVolkswagenGroupinGermanyandothercountries.
Featuresandtechnicaldataforproductionmodelsapplytomodelsoffered
inGermany.Theymaydifferinothercountries.

Backtopage1:Innovationworkshop2014
Backtopage2:Innovationworkshop2014
Skimthroughto:InnovationsbyVolkswagenNetworking

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