Renault Eolab Axial Flux Powered 282Mpg Plug-In Hybrid [Video]
Renault announces EOLAB – an environmental paradigm with nearly 100 technological innovations designed to deliver ultra-low fuel consumption, of i litre per i hundred kilometres, whilst maintaining established B-segment levels of performance, practicality together with affordability.
Scheduled to have got its World Premiere at the 2014 Paris Motor Show on 2 Oct EOLAB non exclusively previews innovative engineering that is destined to live introduced on production Renaults from at nowadays until 2020 but also the vision of such a realistic together with affordable B-segment automobile that volition appear within 10 years.
EOLAB, which takes its advert from combining the advert of ‘Aeolous’ God together with Ruler of the Winds inwards Greek mythology, together with ‘Laboratory’, is capable of achieving 1l/100km (282mpg) together with 22g/km CO2 emissions on the official NEDC cycle.
To attain such depression figures, the designers focused their efforts on iii main areas: minimising weight, refining aerodynamics together with using “Z.E. Hybrid” engineering for all, a create novel inaugural which permits null emissions* motoring during everyday use.
As an innovative showcase with an environmental core, EOLAB includes a really high number of technological advances that are destined to live carried over gradually to vehicles available inwards the showroom. As a consequence, EOLAB underlines the labor of Renault – already a pioneer inwards the land of zero-emission mobility** thank you lot to its arrive at of electrical vehicles** – to select fifty-fifty greater steps to create affordable models that have got an increasingly smaller carbon footprint.
Technologies geared to achieving ultra-low fuel consumption for all
For Renault, the purpose of EOLAB is to remain truthful to the company’s deoxyribonucleic acid yesteryear ensuring that ultra-low fuel consumption becomes a reality for as many people as possible. This inwards plough way making its technologies available at a cost that people tin afford. EOLAB features materials such as magnesium together with aluminium, which are extremely low-cal together with also much cheaper than titanium. Meanwhile, the notion of such a automobile beingness produced inwards large numbers within the adjacent 10 years was dialled into the computer programme from the really start.
100 technological advances for hereafter Renaults
EOLAB is much to a greater extent than than exactly a styling exercise or a mere store window. Conceived around a B-segment platform, the paradigm incorporates around 100 new, realistic technological developments that are designed to live introduced gradually on upcoming Renault vehicles.
EOLAB’s recipe
The EOLAB prototype’s exceptional fuel economic scheme – namely 1 litre/100km – is the fruit of piece of work on iii main fronts: refined aerodynamics, weight saving together with Z.E. Hybrid engineering (petrol/electricity):
A contribution to the French government’s ‘New Industrial Plan’
EOLAB forms component subdivision of the ‘fuel consumption of 2 litres/100km for all’ computer programme introduced within the framework of France’s so-called New Industrial Plan. However, EOLAB goes farther than the fuel consumption target laid yesteryear the French authorities since it sets its sights on the much longer term. In the class of the prototype’s design, Renault developed the technologies necessary for the introduction of a automobile with fuel consumption of exactly 2 litres/100km yesteryear 2020. To attain this, Renault worked inwards a spirit of collaborative conception with French automotive manufacture partners similar automobile drinking glass manufacturer Saint-Gobain, topographic point supplier Faurecia, tyre companionship Michelin together with Continental (brake system). Renault also worked closely with major partners similar the Korean companionship Posco (magnesium components). The specific know-how of all these partners made a valuable contribution to the success of the EOLAB prototype.
EOLAB Concept: a concept automobile to capture the imagination
Renault’s designers were closely involved with the EOLAB projection from its really early on days. In the instance of EOLAB Concept, they pushed the blueprint parameters to perfect the car’s styling together with paid pregnant attending to particular inwards social club to optimise aerodynamics together with weight. With its sloping roof together with breathtakingly slender raise end, the concept car’s truthful purpose is good masked: beneath its seductively designed shell, everything is geared towards frugality. It demonstrates that Renault is able to add together a touching of dream-like magic to a paradigm whose fundamental mission is to attain ultra-low fuel consumption.
EOLAB: Overview
RENAULT’S INNOVATIVE ENVIRONMENTAL SHOWCASE
Consistently a stair ahead inwards the create out to trim down the automobile industry’s carbon footprint
1. EOLAB FITS PERFECTLY WITH RENAULTS ECO2 ENVIONMENTAL HALLMARK
EOLAB is an eloquent demonstration of Renault’s determination to select ever greater steps to trim down the carbon footprint of its vehicles. The finish is to create ultra-low fuel consumption an affordable reality to as many motorists as possible.
As a pioneer inwards the land of zero-emissions mobility thank you lot to its arrive at of electrical vehicles, together with also as the 2013 marketplace leader inwards terms of fuel consumption together with average CO2 emissions, Renault is the exclusively manufacturer to have got laid a target of reducing its carbon footprint yesteryear 10 per cent over iii years (2010-2013). That finish was achieved inwards 2013 together with the create continues to live committed to reducing the CO2 emissions of its vehicles during route use, which accounts for nigh 85 percentage of the company’s total carbon footprint. Thanks to its arrive at of all-electric vehicles together with increasingly efficient internal combustion engines, the Renault Group recorded the lowest CO2 emissions figures of all European manufacturers inwards 2013 (less than 115g/km)*.
* Average CO2 emissions over an NEDC-homologated combined cycle of Renault grouping rider vehicles registered inwards 2013, taken across 23 countries (all of the European Union except Cyprus, Malta, Romania together with Bulgaria). Source information from AAA-DATA (Association Auxiliaire de l’Automobile), a CCFA subsidiary. AAA-DATA is an association that manages automotive manufacture information for populace authorities. * No CO2 or other regulated polluting emissions during route use.
The introduction of EOLAB takes Renault’s environmental programme to an fifty-fifty higher level. The target? To create ultra-low fuel consumption as widely available as possible yesteryear creating a paradigm which blends a raft of cutting-edge features that are realistic inwards both technical together with fiscal terms.
EOLAB’s purpose is to highlight Renault’s savoir-faire inwards the fields of blueprint together with technology. It is a controversy of the company’s environmental strategy which strives to trim down the carbon footprint of its vehicles across successive generations.
It packs nigh 100 technological features that volition live introduced gradually to the model arrive at over the adjacent 10 to fifteen years with a sentiment to coming together the next targets:
1. Meet diverse legislative requirements inwards unlike markets together with also the Group’s commitment to trim down its global carbon footprint (Renault is aiming for a 10 percentage autumn betwixt 2013 together with 2016).
2. Meet customers’ expectations yesteryear increasing unloosen energy economic scheme together with cutting running costs at a fourth dimension of dubiousness nigh the availability together with cost of resources.
3. Improve air character inwards towns together with cities, inwards describe with the wishes of populace authorities together with motorists.
Renault’s internal combustion engines have got go significantly to a greater extent than fuel efficient over the yesteryear decade or so.
Technological breakthroughs inwards terms of construction materials together with vehicle blueprint (for lightness, aerodynamic efficiency, etc.) volition enable farther savings to live made inwards the future.
The increasing electrification of powertrains is symbolic of both improving fuel economic scheme together with an chance to trim down vehicles’ CO2 emissions. It volition also gradually increase the influence of renewable energies together with amend overall unloosen energy efficiency from good to wheel.
EOLAB’s powertrain benefits from expertise acquired during the evolution of the Group’s electrical vehicle arrive at which remains unmatched fifty-fifty today. The engineering it packs is innovative inwards the feel that it enables users to encompass substantial distances inwards built-up areas without whatsoever exhaust emissions, so if necessary switch over to a conventional internal combustion engine to go on the journey. As with all Renault projects, the primary challenge was to develop a solution that is affordable to as many people as possible, together with thus liable to sell inwards high numbers. That’s a vital consideration if nosotros are to have got a pregnant effect inwards terms of environmental benefits.
Different countries’ unloosen energy supplies together with contrasting usage patterns are pushing manufacturers to expand their ranges together with diversify according to local marketplace conditions. As component subdivision of the Renault-Nissan Alliance, the Renault grouping intends to maintain its status as a worldwide marketplace leader inwards the land of electrical vehicles. PHEV (plug-in hybrid electrical vehicle) solutions, such as that featured on EOLAB, complement this arrive at together with volition live developed to suit widely differing driving patterns… but ever with the finish of roofing pregnant distances with “zero emissions”*.
2. TECHNOLOGICAL INNOVATIONS TO TAKE MOTORISTS EVER FURTHER
Without a constant current of technological breakthroughs, the car’s environmental impact would diminish exclusively through models gradually beingness replaced yesteryear others with cleaner internal combustion engines. In that respect, the stride of alter is ofttimes linked to legislative changes affecting emissions.
This is why Renault thinks exterior the box, offering ground-breaking technological innovations that are accessible to all. Firstly it has its all-electric vehicles, which emit no CO2 or other compounds from their exhausts, don’t create whatsoever smells together with operate silently. Renault is the exclusively manufacturer to offering a comprehensive arrive at of 4 electrical vehicles. Now, through its EOLAB project, Renault is extending zero-emissions mobility thank you lot to the evolution of an innovative hybrid scheme – Z.E. Hybrid – which allows users to encompass trips of upward to 60km* at speeds of upward to 120km/h with absolutely no tailpipe emissions.
Zero-emissions mobility: an effective way to tackle pitiful air quality
According to a scientific modelling report of the Earth’s atmosphere, conducted using information from the metropolis of Rome, achieving a xx percentage charge per unit of measurement of zero-emission vehicles inwards the cardinal traffic surface area would greatly trim down the concentration of pollutants that powerfulness live unsafe to our health. In the most polluted streets, calculations revealed a reduction of upward to thirty percentage for particles that drive respiratory or cardiovascular problems, together with upward to 45 percentage for CO2, a pregnant respiratory irritant.
Alongside Renault’s existing arrive at of 4 electrical vehicles, the Z.E. Hybrid proposal is an effective novel stair out against this threat to populace health.
* No CO2 or other regulated polluting emissions during route use.
EOLAB’S RECIPE
A weight saving of 400kg – Aerodynamic efficiency improved yesteryear 30% – Z.E. hybrid technology
The tape fuel consumption achieved yesteryear the EOLAB paradigm is the fruit of piece of work inwards iii fundamental areas:
Key figures:
EOLAB = a reduction of 0.170m2, a saving of 1.2 litres/100km on motorways (40g of CO2/km).
1. CAREFULLY HONED AERODYNAMICS WITH ACTIVE SYSTEMS
Drag coefficient (CdA) reduced yesteryear thirty percent
EOLAB’s CdA is 0.470m2 (A = 2.00m2 / Cd = 0.235) which represents an overall reduction of 0.200m² (around thirty percent). This lower drag coefficient results inwards a pregnant fuel consumption reduction at higher speeds. At a stable speed of 130kph, for example, it accounts for a fuel consumption saving of 1.2 litres/100km inwards comparing with the benchmark vehicle.
This exceptional aerodynamic efficiency was achieved yesteryear combining several factors:
NOTE: the stair out of a vehicle’s overall aerodynamic efficiency is its CdA, i.e. the vehicle’s frontal subdivision (A) expressed inwards foursquare metres multiplied yesteryear its drag coefficient (Cd). The CdA of the Clio IV, for example, is 0.670m², which is a goodness average for its segment. However, CdA gains should non live achieved to the detriment of blueprint considerations or other characteristics, such as cabin space.
Variable ride height
EOLAB’s ride tiptop is variable thank you lot to the usage of active air suspension. The 4 dampers tin live raised or lowered yesteryear 25mm inwards relation to the default setting. When the automobile is parked, the suspension switches to its highest topographic point inwards social club to facilitate entry. As the vehicle begins to move, the suspension resumes its default setting (i.e. it lowers yesteryear 25mm) at speeds of betwixt 5 together with 70kph inwards social club to bound the amount of air that passes underneath it. For the same reason, the ride tiptop is lowered yesteryear a farther 25mm at speeds inwards excess of 70kph.
Active spoiler
At the same time, the aerodynamicists focused on a diverseness of technological solutions together with innovations. EOLAB’s forepart bumper, for example, is equipped with an active spoiler that lowers yesteryear 10cm at speeds inwards excess of 70kph inwards social club to restrain airflow beneath the car. Even when a vehicle is designed with a apartment underbody, at that topographic point are still a number of asperities that tin detract from aerodynamic efficiency.
Aerodynamic flaps
Another mobile characteristic of EOLAB’s aerodynamic bundle is the 40cm x 10cm vertically-positioned flaps that are visible on the raise bumper, rearward of the raise wheels. At speeds inwards excess of 70kph, these flaps opened upward yesteryear 6cm inwards social club to ensure that as much of the airflow as possible stays attached to the vehicle as it moves forward. Without this solution, passing air has a vogue to go detached from the vehicle’s sides also early on after passing the raise wheels together with this has a negative effect on drag. In the opened upward position, airflow remains attached to the automobile as far rearward as possible, correct to the trailing border of the bumper. “These flaps tauten the airflow together with foreclose turbulence which otherwise acts as a form of aerodynamic brake,” explains William Becamel, the aerodynamics practiced who worked on the project.
Active wheels
The teams that worked on EOLAB took a unopen facial expression at its wheels, too. In a perfect aerodynamic world, the rims would live covered together with smooth. This is rarely the case, however, essentially for design- together with brake cooling-related reasons. An ingenious scheme was consequently designed whereby the rims are covered whenever the brakes make non demand to live cooled, thereby reconciling blueprint together with aerodynamic efficiency considerations. The scheme is controlled yesteryear a temperature sensor built into the rims.
Tyres that piece through air
To farther perfect EOLAB’s aerodynamic performance, it is fitted with especially narrow, 145mm-wide tyres. That’s 40mm narrower than the smallest tyres available for the Clio IV. Michelin together with Renault’s designers worked on the tread pattern to give a visual impression of width, patch the sidewalls were designed to exude an impression of low-cal weight. At the same time, tyre supplier Michelin optimised the casing together with tread to minimise rolling resistance patch maintaining splendid levels of security together with performance. The tyres’ rolling resistance is fifteen percentage lower than those of the Clio IV which itself is quite strong inwards this area. These tyres are also lighter, together with their profile has been honed to minimise drag. Meanwhile, Renault has changed the engineering used for the cycle bearings inwards favour of a to a greater extent than efficient solution that has achieved a CO2 emissions saving of 1g/km.
(For farther information, regard appendix at the terminate of this document)
2. THE VIRTUOUS CIRCLE OF SAVING WEIGHT
EOLAB tips the scales at 955kg. That’s to a greater extent than than xx percentage lighter than the benchmark vehicle. Total weight savings amounted to no less than 400kg thank you lot to the teams’ holistic approach. This ambitious programme called for extensive piece of work together with outside-of-the-box thinking from the unlike specialists involved.
Total weight = 955kg
The virtuous circle of shedding weight
While delivering the same aeroplane of performance, lighter vehicles require less unloosen energy to displace forward. One of the primary focuses inwards the instance of the EOLAB projection consequently consisted inwards reducing the vehicle’s overall weight. This inwards plough meant that the vehicle’s regulation assemblies (powertrain, brakes, running gear, cooling system, fuel tank, etc.) could also live lighter, together with these additional savings compounded the initial groundwork.
“The savings achieved yesteryear taking a fresh facial expression at the size of the unlike mechanical assemblies enabled us to encompass the cost of using to a greater extent than expensive materials together with technologies elsewhere without losing sight of the aim non to add together to the overall cost.” Laurent Taupin (EOLAB Project Leader).
Because it is lighter together with to a greater extent than streamlined, EOLAB needs less unloosen energy to live moved forward. It was hence possible to revise the amount of powerfulness necessary to drive it inwards social club to acquire inwards at a final result that ensures running costs comparable with those of a electrical current vehicle, without scrimping on acceleration performance. Equipped with a battery of exactly 6.7kWh (total energy), EOLAB permits null emissions motoring* for a distance of 60km** at speeds of upward to 120kph, a scenario which covers the bulk of everyday needs.
* No CO2 or other regulated polluting emissions during route use.
** Consumption, emissions together with arrive at information homologated inwards accordance with appropriate legislation.
The correct cloth for a given job
To trim down a car’s weight, a well-trod path is to supervene upon steel with lighter materials. All-aluminium together with aluminium/carbon solutions already be but, inwards add-on to the high cost associated with such materials, they ofttimes require an in-depth review of assembly together with production processes, together with at that topographic point is a cost to pay for that.
True to its philosophy, Renault chose to steer clear of radical solutions. “You tin ever salve weight if you’re prepared to pay the price, but that would live opposite to Renault’s philosophy. Our strategy is to trim down weight inwards a way that benefits everybody. That way finding economically feasible solutions that our customers tin afford. Our approach tin live summed upward yesteryear the phrase: ‘the correct cloth for a given job’,” underlines the EOLAB Project Leader Laurent Taupin.
This labor to contain costs went hand-in-hand with a pregnant constraint, however, together with that was to topographic point weight-saving solutions that are compatible with today’s production processes.
A lightweight multi-material torso shell
Employing the correct cloth for a given chore involved conceiving an innovative torso rhythm out that combined unlike materials selected as a component subdivision of their weight, cost together with necessary production processes. EOLAB’s torso rhythm out consequently combines steel, aluminium, magnesium together with plastic composites, whereas the bulk of today’s cars are made of a unmarried type of material. 1. Steel: extensive usage of Very Very High Elastic Limit steels (VVHEL) Over together with inwards a higher house changes to a car’s basic architecture, the exclusively way to lighten steel components is to usage thinner metal. However, since detracting from a given part’s functional properties was out of the question, it was necessary to upgrade the mechanical properties of the steels employed at the same time. Renault consequently turned to Very Very High Elastic Limit steels which have got a yield strength of betwixt 1,200 MPa together with 1,500 MPa, an improvement of betwixt 200 MPa together with 500 MPa over the VHEL steels used for electrical current Renault models. With a tensile strength of upward to 150kg/mm2, these grades were employed wherever their usage served a existent purpose, notably for the forepart component subdivision of the cabin. Their usage requires a procedure known as hot stamping which Renault already uses for its production cars.
2. Aluminium
EOLAB’s highly innovative rhythm out features a pregnant proportion of aluminium inwards different, readily available forms such as sheeting, castings together with profiles. Like steel, upgrading the mechanical properties enables thinner grades to live used with no detriment to a part’s component subdivision but with an additional weight saving over conventional aluminium. Here again, these grades were selected inwards cases where it was possible to optimise the trade-off betwixt function, mass, cost together with the required manufacturing processes. Some of them necessitated a novel warm stamping procedure (approximately 250/300°C, compared with hot stamping which is closer to 900°C) but this was compatible with existing postage stamp store facilities.
All-aluminium circumferential chassis member
H5N1 combination of castings, sail metallic together with profiles was chosen for EOLAB’s all-aluminium raise circumferential chassis fellow member . Their usage represented a goodness compromise betwixt mass together with torso rigidity. Moreover, using the same cloth for this component subdivision of the rhythm out was an attractive suggestion inwards terms of thermal expansion. Indeed, torso shells are exposed to temperatures of upward to 180°C inwards the pigment store curing ovens together with for certain multi-material assemblies tin have got a negative impact on torso shell’s geometry. Advantage was also taken of the usage of cast parts of varying strength to encompass multiple functions, that is to state the usage of large, one-piece components to supervene upon a number of smaller parts. This made it possible to compensate for the technology’s additional cost compared with conventional stamping.
3. H5N1 magnesium roof weighing exactly 4.5kg
While using steel together with aluminium for a automobile torso is itself non usual, Renault went farther downwards this path inwards the instance of EOLAB yesteryear making usage of magnesium, too. This metallic is reputed for its low-cal weight (density: 1.7), but it is also prone to corrosion which is why it has exclusively been used for interior components until now. Some cars already characteristic magnesium but exclusively for moulded parts made from magnesium pulverization (e.g. the bulk of the market’s steering cycle armatures).
EOLAB breaks novel dry soil inwards the automobile manufacture yesteryear using magnesium sheeting. Developed thank you lot to the expertise of the specialist supplier POSCO, this conception permitted the production of bulky items such as the roof, cowl panel together with parts of the topographic point frames. The payoff is obvious, since EOLAB’s roof tips the scales at exactly 4.5kg, compared with 10kg for an equivalent steel roof. (For farther information, regard appendix at the terminate of this document)
“Magnesium sheeting cannot live used for as broad a arrive at of parts as steel, or fifty-fifty aluminium. However, where the compromise betwixt function, mass, cost together with manufacturing processes allows, at that topographic point are spectacular savings to live achieved, especially as the manufacturing procedure is the same as it is for for certain novel grades of aluminium, i.e. warm stamping,” points out Vincent Desmalades, Deputy Project Leader inwards accuse of Processes.
4. The contribution of polymers
In social club to encompass as many realistic solutions as possible to minimise EOLAB’s weight, the projection squad also took a facial expression at polymers which have got long been reputed for their benefits inwards this area.
From thermoset to thermoplastic resins
Assisted yesteryear academy laboratories together with specialist suppliers, the squad behind EOLAB worked on a novel household unit of measurement of thermoplastic resins which are easier than thermoset resins to recover at the terminate of the vehicle’s life cycle together with consequently recycle.
The demonstration car’s front, raise together with cardinal flooring pans, B pillars together with lower cross fellow member are all made from hot-stamped composite thermoplastic, patch the skins of the one-piece wings/bonnet assembly together with doors are made from injection moulded thermoplastic. The type together with proportion of the drinking glass fibres mixed with these polymers vary as a component subdivision of the properties required for each end-use (e.g. longer fibres for structural components).
Reducing the weight of main assemblies
After attending to the torso shell, EOLAB’s designers turned their focus to the car’s main assemblies which were all scrutinised with a sentiment to saving weight. The brakes, steering, suspension, cycle together with tyres were all looked at carefully to shave off kilogrammes without penalising their performance.
1. Lighter running gear
H5N1 vehicle’s running gear lone accounts for almost xx percentage of its weight (e.g. the Clio IV = 225kg). The most efficient solution involved replacing steel with aluminium for a pregnant number of heavy parts, such as the subframe, which has shed 5.3kg compared to that of the Clio IV (14kg), suspension arms (1.8kg saved), hub carriers (5kg saved) together with raise arms (9kg saved). Substantial savings were achieved inwards this way, but EOLAB’s designers didn’t hesitate to explore other, to a greater extent than complex solutions. For example, they took a totally unlike approach to the architecture’s resistance to head-on impacts patch maintaining the same overall aeroplane of security performance. Normally, programmed chassis deformations affects iii areas inwards an impact: the upper component subdivision of the chassis, the side members together with the lower component subdivision of the chassis). In the instance of EOLAB, the latter’s ‘add-ons’ were eliminated but this was compensated for yesteryear relocating together with strengthening the side members. The resulting saving was betwixt 7 together with 8 kilos. “We also looked at making the springs from a drinking glass fibre/thermoset plastic composite, which would have got produced a saving of iii kilograms. Using a unlike composite for the raise beam would have got saved some other iii kilos or so, too,” notes Laurent Taupin.
2. Revised brake system
One powerfulness live forgiven for thinking that brake systems cannot create whatsoever form of contribution to curbing CO2 emissions, yet they can. Indeed, reasonably large weight savings are to live made inwards this area. “EOLAB’s innovative brake scheme was developed inwards conjunction with Continental together with points to the route downwards which Renault intends to go for its electrical together with hybrid vehicles inwards years to come,” says Laurent Taupin. For the same stopping performance, piece of work on the brake scheme yielded a total saving of 14.5kg.
No fewer than iii advanced innovations were developed inwards association with Continental. The most visible contribution was to suppress disc rub, whereby the brake pads remain inwards contact with the discs fifty-fifty when at that topographic point is no force per unit of measurement area on the pedal. This constant rubbing adds slightly to fuel consumption. In the instance of EOLAB, the pads make non touching the discs whenever the driver’s human foot is off the pedal. In add-on to beingness beneficial to fuel consumption, this also extends pad life. To maintain the same speed of response, together with fifty-fifty amend it, EOLAB’s scheme eliminates slack yesteryear moving the pads closer to the discs the instant the scheme detects that the driver intends to apply the brakes.
Furthermore, the system’s novel brake command unit of measurement has replaced the command units of several previously distinct functions (ABS, ESP, emergency brake assist) patch allowing decoupled braking which is indispensable when it comes to recovering braking unloosen energy to trim down unloosen energy consumption. Meanwhile, the forepart brake discs have got been lightened yesteryear combining steel together with aluminium. The component subdivision of the discs inwards contact with the pads is made of steel, patch the cardinal component subdivision is made of aluminium. Also, since the torso rhythm out is lighter, it was possible to trim down the diameter of the discs for a total saving of 4.7kg.
H5N1 similar solution was employed for the raise drum brakes. The friction zone is still made of cast steel but the ease of the drum is made of aluminium. The lighter raise brakes are to a greater extent than compact together with equipped with to a greater extent than efficient bearings for a saving of 8.5kg.
Also inwards partnership with Continental, Renault took payoff of this organisation to create the automatic parking brake human activeness on the raise drums. This is to a greater extent than economical than the market’s existing system. Suppressing the manual machinery (lever, cables, etc.) adds some other 1.3kg to the total weight saving.
Shedding weight inside, too
1. Lighter glass
The EOLAB squad also secured appreciable savings yesteryear reviewing the car’s glazing. Work to trim down the glass’s weight led to collaboration with Saint Gobain Sekurit with the aim of saving betwixt thirty together with 50% compared with present-day standards.
The thickness of EOLAB’s windows was reduced to 3mm (1.5mm less than the electrical current norm), equivalent to the thickness of a pencil line. The sparse windscreen, the shape of which is especially aerodynamic, is an automobile manufacture first. The side windows usage laminated drinking glass (instead of tempered glass), patch for certain non-moving windows create usage of polymers which have got go a widespread cloth for optical glass, but are still rarely seen inwards the automobile industry.
Lastly, the raise hide uses polymères vernis (instead of tempered glass). This engineering made it possible to create a one-piece polymère verni hide that also incorporates the raise lights. This solution serves as an eloquent instance of how unlike functions tin live grouped together to non exclusively salve weight but also heighten aerodynamic performance.
Combined, these solutions brought the total weight of EOLAB’s windows downwards to 21kg, a 25% saving over a Clio (28kg). (For farther information, regard appendix at the terminate of this document).
“We could have got settled for existing processes or recipes for EOLAB, but that wouldn’t have got been inwards the spirit of the projection which has allowed us to extend our expertise. It has also focused the attending of the whole companionship on the number of minimising weight without losing sight of production-related realties,” explains Laurent Taupin.
2. Thinner, lighter seats
EOLAB’s seats also came nether the scrutiny of the car’s designers who non exclusively endeavoured to create these mostly heavy items lighter but also sought to create them slimmer to gratuitous upward extra room for raise passengers.
To attain these 2 objectives, Renault called on the expertise of the topographic point specialist Faurecia:
3. Using chemical scientific discipline for lighter fittings
Close attending was paid to EOLAB’s smaller plastic fittings, such as the B-pillar trim. “These parts may exclusively weigh a few hundred grams each, but they add together upward to nigh 10kg inwards the instance of a production automobile if you lot include the kick lining,” points out Laurent Taupin. With input from suppliers, Renault’s specialists looked at alternative ways to create these plastic parts. One thought was to supervene upon solid parts less than 2.5mm thick with parts comprising an ultra-thin peel (1.8mm) together with injected with foam which is lighter because it contains air bubbles. Thanks to the incorporation of ribbing, they boast the same structural strength. Until now, this technique has been restricted to large visible parts or parts that customers cannot see. In the instance of EOLAB, the challenge was to discover a procedure that would live appropriate for smaller visible parts.
Meanwhile, for EOLAB’s kick trim, Renault used some other experimental technique which over again uses a sandwich construction comprising a foam insert betwixt the 2 outer surfaces. This sandwich is obtained yesteryear slightly opening the mould during production to allow the foam to spread. Use of thinner fittings achieved a weight saving of betwixt xx together with thirty percent.
4. Lighter than air
Meanwhile, plastics specialists took a unopen involvement inwards the air intake ducts which are mostly made of compact polypropylene together with tip the scales at around 3kg. “Three kilos to channel airflow is also much,” believes Laurent Taupin.
The thought was hence to supervene upon this cloth with expanded polypropylene which is much lighter since its density is 0.06 compared with 0.96 inwards the instance of compact polypropylene. However, if it had exactly been a instance of swapping i for the other, the switch would have got been made a long fourth dimension ago. In reality, it calls for duct walls that are 5 times thicker together with that inwards plough way taking a fresh facial expression at the car’s architecture. This is effectively what happened inwards the instance of EOLAB together with its ultra-light air ducts have got been patented. They weigh exactly 700g, which is a spectacular saving of 2.3kg!
3. Z.E HYBRID: HYBRID TECHNOLOGY FOR ALL
In add-on to beingness lightweight together with aerodynamically efficient, the EOLAB demonstration automobile goes fifty-fifty farther inwards its bid to attain ultra-low fuel consumption thank you lot to its 100%-Renault hybrid powertrain which is covered yesteryear to a greater extent than than thirty patents. This engineering consists inwards combining a petrol internal combustion engine (ICE) with a compact electrical motor. This solution permits 60km** of null emission* motoring plus extended arrive at thank you lot to the internal combustion engine. Importantly, it tin live carried over to entry-level vehicles which are yesteryear Definition a to a greater extent than affordable reality for a higher number of motorists. This engineering volition live incorporated inwards the arrive at yesteryear 2020.
* No CO2 or other regulated polluting emissions during route use.
** Consumption, emissions together with arrive at information homologated inwards accordance with appropriate legislation.
A motor within the clutch housing
In the instance of the EOLAB prototype, the ICE component subdivision of the powertrain takes the shape of a small-scale three-cylinder 999cc petrol engine with a powerfulness output of 57kW (75hp) together with peak torque of 95Nm. It is mated to a highly innovative clutch-less transmission based on a compact together with economical three-speed gearbox which is sufficient to encompass the vehicle’s speed range. This is a notable payoff compared with the bulk of the market’s hybrid technologies which create usage of CVT- or DCT-type transmissions (Continuous Variable Transmission, or Dual Clutch Transmission). These tend to live bulky, heavy together with costly, together with consequently ill-suited to small-scale cars.
The primary characteristic of the concept lies inwards the clutch casing which houses a permanent magnet electrical motor (axial flux discoid motor inwards the instance of the prototype). This motor is compact together with economical together with covers the demand for the availability of extra torque since it is capable of immediately delivering peak powerfulness of 50kW together with 200Nm of torque.
Fed yesteryear a 6.7kWh battery, it is sufficiently large to powerfulness the automobile nether electrical power. Here again, the state of war waged on the weight of the torso rhythm out made a cracking bargain of feel inasmuch as a lighter automobile needs less unloosen energy to live moved forward. As a consequence, the battery tin live both smaller together with less expensive.
Gearshifts for electrical together with ICE modes
It is of import to banker's bill that the commencement 2 ratios of the three-speed gearbox are mated to the electrical motor, patch the tertiary ratio is linked to the ICE. These iii ratios permit ix unlike combinations for the electrical together with hybrid modes combined. One of the concept’s major innovations is the fact that gearshifts make non require the usage of a clutch thank you lot to a specific command unit of measurement designed yesteryear Renault’s engineers.
A battery suited to hybrid use
EOLAB’s axial flux permanent magnet electrical motor is powered yesteryear a 6.7kWh lithium-ion battery which differs from the batteries that equip Renault’s Z.E. arrive at of electrical vehicles. While electrical vehicles are designed to store a high amount of unloosen energy because of the fundamental demand to maximise the vehicle’s range, hybrid vehicles similar EOLAB demand to encompass the same powerfulness requirement with a limited quantity of electrical energy. This entails using a unlike type of battery jail cellular telephone with a higher power/energy ratio.
The resulting battery pack is the fruit of active cooperation betwixt the teams at Renault together with the CEA who rose to the challenge of finding smart solutions to come upward up with a battery pack that is capable of storing a high amount of unloosen energy inwards a smaller volume, patch at the same fourth dimension minimising weight.
Z.E. Hybrid… One mode for weekday use, some other for weekends
H5N1 pick of 2 modes.
This is a major concept that shows a way forrard for hybridisation. “Today, most of the market’s hybrid vehicles are higher segment cars with a cost tag of to a greater extent than than €40,000. The solutions showcased yesteryear EOLAB are much to a greater extent than economical together with enable hybrid engineering to live used for smaller cars together with on a much bigger scale. Our objective is to create a automobile with 2 powerfulness sources for the cost of one,” underlines Jean-Pierre Fouquet, Z.E. Hybrid Innovation Project Leader.
** Consumption, emissions together with arrive at information homologated inwards accordance with appropriate legislation.
* No CO2 or other regulated polluting emissions during route use.
4. REAL-TIME INFORMATION CONTRIBUTING TO ULTRA-LOW FUEL CONSUMPTION
HMIs inwards favour of depression fuel consumption together with motoring enjoyment
Although Renault’s commencement hybrid vehicle – EOLAB – is packed with technologies together with innovations, it is still aimed at the brand’s centre customers, so had to remain slowly to usage together with intuitive. It was also developed inwards keeping with Renault’s Driving eco² philosophy. At the same time, its Human Machine Interfaces (HMI) go fifty-fifty farther downwards the route of providing information inwards existent fourth dimension with a sentiment to helping drivers to make goodness from ultra-low fuel consumption.
Its evolution was guided yesteryear iii factors:
When engineering takes centre stage
Given that on-board active systems are non visible from within the vehicle together with are exclusively triggered at speeds or to a greater extent than than 70kph, the driver may experience a for certain grade of frustration. Renault has endeavoured to avoid this number yesteryear incorporating a specific component subdivision into the multimedia tablet which enables all of these systems to live activated together with displayed whilst the automobile is at a standstill. “When an EOLAB-derived production automobile sees the low-cal of day, it volition non exclusively live purchased out of economical motivation. Customers volition also live attracted yesteryear its environmental together with technological benefits. They volition hence desire a ‘quantifiable return’, together with this type of component subdivision volition run across that requirement. Renault is keen to demonstrate that it is possible to drive an ultra-economical automobile whilst at the same fourth dimension enjoying the experience,” underlines Rémi Bastien.
Instrument panel together with multimedia display
In practice, the Human Machine Interfaces (HMIs) have got been divided betwixt 2 principal areas: the musical instrument panel together with a touching hide multimedia display situated inwards a cardinal topographic point on the dashboard.
The commencement original aspect is that this is non fixed. Courtesy of a mechanical arm, it moves inwards accordance with the tiptop of the steering cycle that has been selected yesteryear the driver, inwards social club to ensure optimum visibility.
Its content is spread across 2 digital displays the size of a smartphone: the i on the left provides all the technical information (speed, levels, conventional warnings), patch right-hand side display is dedicated to the GPS. The upper component subdivision is utilised to display the ikon generated yesteryear the cardinal rear-view camera. The lower component subdivision covers all of the multimedia system’s controls (radio, climate control, etc.).
All of the other functions are to live found on the touching hide display, allowing for the dashboard layout to live simplified, in-keeping with the spirit of EOLAB’s uncluttered design. The hide of this 11-inch tablet is divided into 2 parts. For the commencement fourth dimension inwards the automotive world, the tablet tin live fitted either horizontally or vertically, with distinct display graphics for each position. “In the vertical position, the accent is placed upon the sharing of information, which is easily visible to the other passengers. In its horizontal position, the hide is brought closer to the driver, generating a ‘cockpit’ effect, whilst the display graphics becomes warmer together with to a greater extent than colourful,” explains Patrick Lecharpy. This unprecedented horizontal together with vertical duality required specific studies together with inquiry to ensure that the 2 positions were compatible with the vehicle’s security features, most notably its airbags.
Another noteworthy point: “With EOLAB beingness a hybrid vehicle, the drive mode is visible inwards an informative together with educational way on the tablet yesteryear way of cloud-shaped symbols that are bluish when EOLAB is powered yesteryear its electrical motor together with plough cherry-red when the internal combustion engine takes over. What’s more, the size of these clouds varies according to the quantity of unloosen energy available inwards each mode,” reveals Patrick Lecharpy, the project’s blueprint manager.
Putting drivers inwards accuse of their unloosen energy consumption
Generally speaking, with unloosen energy consumption beingness at the really pump of the EOLAB concept, pregnant attending was paid to the presentation of related data. “As this is Renault’s commencement hybrid vehicle together with an ultra-economical car, nosotros genuinely wanted the Human Machine Interfaces to permit a comprehensive agreement of the parameters that influence consumption, inwards social club to assist drivers as they larn how to drive to a greater extent than economically,” indicates Laurent Taupin.
As a result, when the automobile is moving, the cardinal tablet displays a ‘radar-style’ graphic whose 5 branches correspond the 5 principal factors affecting the vehicle’s consumption:
This graphic alters inwards existent fourth dimension according to the status of these 5 key parameters, thereby providing the driver with indications nigh how consumption may live improved inwards existent time. “Today, after a fashion, the bulk of the systems available inwards the marketplace give drivers exactly raw information (current consumption, average consumption, etc.) that don’t genuinely enable them to create whatsoever progress. Courtesy of this graphic, drivers at nowadays have got at their disposal the necessary tools to select accuse of their ain consumption,” continues Jean-Pierre Fouquet, Z.E. Hybrid Innovations Project Leader.
INNOVATIONS FOR ALL
Towards a vehicle with ultra-low fuel consumption that is readily affordable
1. PERFORMANCE AND OWNERSHIP COSTS SIMILAR TO THOSE OF H5N1 CLIO-TYPE VEHICLE
Weight reduction, aerodynamic efficiency together with hybridisation were iii key themes that were explored with a mutual objective – that of developing realistic solutions that are transferable to mass-production cars. “Beyond the prototype, nosotros demand to create advances across the entire range,” affirms Project Leader Laurent Taupin. Similarly of import to banker's bill is the fact that the lower fuel consumption figures have got been achieved without impacting the vehicle’s performance inwards whatsoever way: “However efficient together with economical it is, the vehicle must also remain competitive inwards every surface area if it is to attract buyers. This includes comfort, route holding, cabin space, perceived character together with design.”
In add-on to the fact that it is based on a B-segment saloon, EOLAB was developed using a realistic technological together with economical approach with a twofold objective:
Keeping costs nether control!
When it comes to reducing weight, at that topographic point is ever the alternative of resorting to lightweight materials such as titanium, carbon-fibre or other composites, but inwards sentiment of their expense, their wide-scale usage would inevitably elevate the cost of the car. Such a scenario would live opposite to Renault’s really ethos, which is to create its cars available to the highest possible number of customers. What’s more, a really lightweight together with expensive vehicle would remain something of a niche inwards commercial terms and, as such, would non generate whatsoever existent benefits for the environment. EOLAB was developed with the target of producing a aeroplane of performance together with cost tag representative of a B-segment vehicle. The EOLAB projection squad thus paid careful attending to the key parameter of cost.
2. AROUND 100 TECHNOLOGICAL ADVANCES FOR FUTURE RENAULT MODELS
EOLAB packs around 100 technological advances, all developed through a mind-set of technological together with economical realism. It consequently represents a ground for the blueprint of hereafter Renault vehicles.
Manufacturers have got produced a number of projects to attain ultra-low consumption over the class of the lastly iii decades, but without the solutions found ever finding themselves applied to the vehicles they genuinely market. The argue for this is that they would have got been also expensive and, therefore, non economically realistic.
With EOLAB, however, the procedure was different. All of EOLAB’s technological solutions were evaluated non exclusively inwards terms of their capacity to trim down fuel consumption together with CO2 emissions, but as inwards a context of constraints relating to the existent world inwards relation to production processes, engineering together with costs.
“We worked straight with the teams that develop Renault’s production cars, together with they suggested novel solutions to us inwards our shout out for for ultra-low fuel consumption. Not exclusively did they advise these novel solutions, but they also helped us to envisage what their implementation would signify on a larger scale. This project’s procedure of conception is hence already in-place for hereafter vehicles inwards the Renault range,” observes Laurent Taupin.
A key criterion: compatibility with production facilities
At the pump of the EOLAB projection is the prospect that all of the technological innovations developed as component subdivision of the procedure volition live able to live transferred across to mass-production cars yesteryear 2020. This focus upon realism does not, however, signify that Renault is shirking away from envisioning to a greater extent than futuristic or avant-garde solutions. Quite simply, these were non (yet) necessary for this project, the aim of which was to trim down the CO2emissions of the brand’s arrive at inwards either the curt or medium-term. This pragmatic approach went hand-in-hand with a number of weather of entry for the centre technologies that are potential inclusions inwards EOLAB. Cost together with feasibility are of import considerations, but the primary occupation organisation is their compatibility with existing production facilities with limited investment.
The correct balance betwixt criterion practices together with conception
Particularly unopen attending was paid to the enquiry of manufacturing realism together with the enquiry came nether the auspices of Vincent Desmalades, EOLAB’s Assistant Project Leader inwards this area. He explains that “the priority was to strike the correct balance betwixt 2 extremes: i the i hand, to refuse everything that deviated from accepted standards, at the remove a chance of no longer innovating, together with on the other manus to openly give gratuitous rein to imagination together with the unpredictable fiscal consequences that powerfulness entail”.
It was a balancing human activeness that was non necessarily unproblematic to attain since i of EOLAB’s overriding guidelines was to blueprint an extremely innovative multi-material body, combining steel, aluminium, magnesium, composites together with injected thermoplastics – something that had never earlier been done inwards mass production. In social club to constitute the correct positioning, the EOLAB squad integrated production compatibility into the project’s mind-set from the really start.
That is firstly evident inwards the pick of materials together with processes employed. The usage of magnesium is a especially eloquent example. It combines low-cal weight with splendid production compatibility (hot stamping using existing facilities).
Next, it tin live seen inwards the administration of multiple materials. Even if welding is still widely practised, the multi-material torso calls for new, complementary assembly processes. By dint of its strong multi-material compatibility together with ease of implementation, bonding is the leading candidate amongst the modes of assembly that are currently nether development.
Last but non least, it is perceptible inwards the surface area of industrial feasibility, which is vital to overall performance. This entails non exclusively the feasibility of the centre technologies involved together with the availability of associated assembly processes, but also the co-existence of these technologies within the manufacturing plants. This criterion is key inwards the shout out for to discover the ideal compromise betwixt the functions, weight, costs together with necessary processes associated with the diverse technologies.
EOLAB CONCEPT : H5N1 CONCEPT CAR TO FIRE THE IMAGINATION
Design together with Technology, Seduction together with Efficiency
1. STYLING OF FLOWING, SENSUAL LINES
Alongside the EOLAB prototype, Renault is presenting EOLAB Concept, a minute select on an ultra-low consumption vehicle, inwards the shape of a concept car. Showing that efficiency tin go manus inwards manus with appeal, this concept places particular emphasis on design, slotting into Renault’s blueprint strategy with simple, warm together with sensual lines conveying a strong feel of emotion. It belongs on the 6th petal of the life cycle daisy, representing Wisdom (understanding, an opened upward mind, serenity). Some of the blueprint features of EOLAB Concept prefigure trends that could discover their way onto production models.
Design together with aerodynamics on a par
Aerodynamic together with appealing, compact but spacious, high-tech but non utopian, EOLAB Concept expresses together with embodies the qualities seen on EOLAB prototype, taking them to novel heights. Like a haute couture version placed amongst an off-the-peg model.
EOLAB Concept was inspired yesteryear the paradigm but it takes the blueprint to a novel level. All the fundamentals of the paradigm are maintained inwards terms of aerodynamics, proportions together with interior space, with the features expected of a B segment car. EOLAB Concept is a realistic vehicle, shown inwards its best light. This is because, inwards social club to fully limited the concepts of aerodynamics together with lightweight construction, designers exactly took the car’s ideal lines together with attending to particular a niggling further. Even when it is dependent land to strict blueprint constraints, inwards pursuit of really depression consumption, concept cars must still capture the imagination.
Patrick Lecharpy, Vice-President, LCI (see insert) together with Alliance Synergies, tells us how the duo came about: “A engineering demonstrator is rarely attractive. And a concept automobile is rarely realistic. That’s why nosotros decided to develop 2 vehicles as component subdivision of this project. The concept automobile emphasizes the visual aspects of the demonstrator together with seeks to select blueprint solutions a fight farther nether the lastly ascendancy of the blueprint department, patch the paradigm blueprint came nether the ascendancy of the applied scientific discipline department. The aim was for engineering together with desirability to go manus inwards hand, to avoid a final result that would live high-tech but cold.”
EOLAB Concept is hence a unifying symbol, expressing high-tech conception at Renault patch fully reflecting the brand’s blueprint strategy.
LCI, a start-up within the company, bringing together engineers together with designers
The Cooperative Innovation Laboratory (LCI) is an independent construction operating within Renault. The aim of create administration was to laid upward a creative entity with a collaborative function, grouping engineering, production together with blueprint staff inwards the same working space. This original organisation has spawned a dynamic together with creative entity, able to reply to needs quickly. H5N1 existent wellspring of novel ideas. Made upward of around xl people, “LCI is a fight similar a start-up within a major company. Conditions are ideal for developing innovations together with breakthrough concepts,” explains Patrick Lecharpy.
Each projection has 4 key ingredients: design, technology, economical constraints together with client surveys. LCI develops a broad arrive at of projects together with enjoys considerable leeway inwards its work: one-third of projects are the final result of discussions with external players such as parts suppliers together with specialist schools, the aim beingness to stair exterior the framework of conventional programs together with create a fertile dry soil for completely original ideas. To give exactly i highly eloquent example: Renault Twizy was based on the piece of work of LCI.
With its flexible, dynamic organization, LCI is able to displace chop-chop from conceptual ideas to physical reality (design mock-ups, prototypes, etc.). This enables fast decision-making on a practical basis. H5N1 strength for the company, this entity also highlights the nature of conception at Renault.