Volkswagen’s XL1 The Car Of The Future Boston News Weather Sports …

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Volkswagen’s XL1 — The Car Of The Future

Volkswagen executive Christian is in town from Germany ready for the LA Auto Show, but he stopped by Good Day LA to show off the fuel efficient car in the world, the XL1 .

The car can go 260 miles using only one of gas using a combination of an electric and a diesel-fuel engine, or as Lisa says, It goes both

What also adds to the efficiency is the ultra-light weight made from carbon

The car costs about $145 dollars. However, there are of this car that will be in other lines that produces. This means future cars we are familiar like to VS Golf will more fuel effecient in the years.

One cool aspect of highly aero-dynamic car is the rear monitors. One thing that wind drag in most are the rear-view mirrors. The XL1 uses camereas and TV monitors inside the car to see s happening behind the car.

You can get a look at the car starting this at the LA Auto Show .

Or follow LA Show on Twitter: @LAAutoShow

Volkswagen sent us LOTS of on the car including specs, manufacturing and the philosophy behind the vehicle:

Germany — The XL1 is the most production car in the world, with a combined fuel consumption of 261 mpg and CO2 emissions of 21 g/km. Thanks to its hybrid system, this can also cover up to 31 miles as a electric vehicle.

The XL1 is an automotive that follows pure design principles: lightweight pounds), exceptional aerodynamics (a of drag of just 0.19), and a low of gravity. Thanks to this this super-efficient Volkswagen can at a constant 62 mph while using 8.3 horsepower. In all-electric mode, the XL1 less than 0.1 kWh to cover than 0.6 miles (one

The XL1 s plug-in hybrid system of a 48-hp two-cylinder TDI® Diesel engine, a 27-hp motor, a seven-speed DSG® automatic transmission, and a lithium-ion The 261 mpg fuel consumption figure is a for a production car, showing Volkswagen is in the automotive industry s vanguard. The XL1 also has a top speed of 99 mph and can from 0 to 62 mph in 12.7 seconds.

the XL1 represents the third evolutionary of Volkswagen s 1-liter car strategy. At the of this current millennium, Dr.

Ferdinand Piëch-currently Chairman of the Board of Volkswagen AG-formulated the goal of producing a practical car had a combined fuel consumption of one per 100 km (235 mpg). In the two-seat this vision has become

Despite the tremendous efficiency of the the engineers and designers successfully up with a body design delivers more everyday than the two previous prototypes. In the L1, the car that was shown in 2002 and the driver and passenger sat behind other for optimal aerodynamics; in the the two occupants sit slightly offset, by side, almost like a vehicle.

The XL1 is 153.1 inches 65.6 in wide, and just in tall. By comparison, a Volkswagen is slightly longer (156.3 in) and (66.2 in), but is significantly (57.6 in). Even a sports car like today s Boxster is 5.1 inches taller.

250 XL1s will be produced at the factory in Osnabrück, Germany.

structure

As well as the pioneering in the drivetrain, the XL1 also utilizes and extremely strong carbonfiber polymer (CFRP) construction for the all exterior body parts, and such as the anti-roll bars. using the Resin Transfer process (RTM), the density/specific of the CFRP is around 20 percent of a steel exterior structure s. The parts are as strong as comparable or aluminum parts, yet the exterior of the XL1 is just 0.05 inches

A look at the scales shows why is the ideal material for the XL1 s body. The weighs just 1753 composed of: 501 lb for the drive unit battery; 337 lb for the running gear; 176 lb for the 232 lb for the electrical system; and 507 lb for the body, crash structure and windshield. A of 21.3 percent of the new XL1, or 373 lb, of CFRP.

In addition, Volkswagen lightweight metals for 22.5 of all the parts (395 lb), just 23.2 percent lb) of the car being constructed from and iron. An example of the attention to saving can be seen with the they are made from and weigh 25.6 lb each, or half the mass of a normal car

Thanks to the use of CFRP, the XL1 is not only but very safe. In a collision, the strong CFRP monocoque an impressive survival cell for the and passenger. This is achieved by design of load paths, the use of sandwich structures in the monocoque, the front and rear aluminum structures absorb a large of energy in frontal and rear

The CFRP doors have impact beams to absorb energy and the door frame minimizes intrusions into the cell. A great deal of was also paid to extricating in the event of a rollover collision: separating screws are used to opening of the doors, which open upwards.

Compared to CFRP in a pre-preg process, the RTM is more economical-with lower at higher volumes-because it can be automated. The RTM are produced in multi-shell heated and molds. This involves liquid resin at high into the tool which the semi-finished carbon material.

The is then cured in the mold.

hybrid concept

The XL1 is a plug-in hybrid, using fuel-efficient TDI Diesel common-rail turbodiesel and the DSG dual-clutch automatic transmission. The TDI 48 horsepower and 89 pound-feet of torque just 830 cc. The entire hybrid is housed between the driven wheels.

The hybrid module, incorporates the electric motor and the is positioned between the TDI engine and the DSG transmission.

The 5.5kWh lithium-ion in the front section of the XL1-supplies the motor with 220 volts of energy. The battery weighs 150 and consists of 60 cells, with a case. The power electronics manages the flow of high energy to and from the battery or motor and converts direct to alternating current.

The XL1 s 12-volt system is supplied via a DC/DC and a small auxiliary battery.

The battery can be charged from a household electric outlet. battery regeneration is also to recover energy to the battery the car is slowing down, at which the electric motor acts as a The electric motor, which 103 pound-feet of torque from a works as a booster to support the TDI when full system is required.

Together, the TDI engine and motor deliver maximum of 103 lb-ft along with 68 hp in mode.

As well as boosting the TDI under hard acceleration, the motor can also power the XL1 on its own for a of up to 31 miles. In this mode, the TDI is decoupled from the drivetrain by a clutch, and is shut down. the clutch on the gearbox side closed, so the DSG is fully engaged the electric motor.

The driver can choose to drive the XL1 in electric mode, provided the battery is sufficiently charged, by a button on the instrument panel is

Restarting the TDI engine is a very process. While driving, the motor s rotor is sped up and is quickly coupled to the clutch in a known as pulse starting. accelerates the diesel engine to the speed and starts it, so the driver notices the transition.

In certain conditions, the load of the TDI engine can be so that it operates at its most efficiency level. The gears in the DSG are also always selected the aim of minimizing energy usage.

The two-cylinder TDI engine was derived a 1.6-liter four-cylinder Clean powerplant, so it shares the 88-mm spacing and a bore and stroke of mm x 80.5 mm. The XL1 s engine also key internal modifications for reducing which include specially piston recesses for multiple and individual orientation of the injection The common-rail diesel s smooth properties were transferred to the engine, aided by a balancer that is driven by and turns at the speed as the crankshaft.

The TDI s aluminum is constructed with extremely low which in turn leads to low frictional losses. Exhaust gas an oxidation catalytic converter, and a particulate filter are used in to minimize emissions: the XL1 s engine is compliant with the Euro-6 standard.

The vehicle s cooling is also designed to maximize The mechanical water pump cools the engine only operating conditions require it. The includes automatically controlled air at the front of the vehicle to reduce A second electric water used only when circulates a separate lower loop to cool the starter and the power electronics.

This management strategy also towards reduced fuel

Low Drag, New Form

The XL1 uses doors that are reminiscent of a sports car s. Because they are low on the A-pillars and just above the in the roof frame, they upwards and slightly forwards as The doors also extend far the roof.

When they are they create an exceptionally amount of entry and exit

The XL1 s lines are very similar to the L1 s, but the car has a more aggressive appearance to its greater width. The body was uncompromisingly designed to follow the of aerodynamics, narrowing from to rear to reduce aerodynamic Viewed from above, the XL1 s resembles a dolphin s.

In profile, the traces an arc from the A-pillar to the rear. The rear wheels are covered to prevent turbulence, airflow around the wheelarches is by small spoilers in front of and the wheels. There are no door these are replaced by small known as e-mirrors (digital mirrors) that send to two displays inside the vehicle.

side windows weigh a third less than windows: a pane of glass on XL1 weigh 16.5 pounds, the polycarbonate ones scale 11.5 lb each.

The front of the XL1 no sports a classical radiator but it s still identifiably a Volkswagen, to the predominance of horizontal lines is part of the Volkswagen Design Specifically, a black cross-stripe with the energy-efficient dual LED to form a continuous band. The air intake for cooling the TDI engine, and interior is located in the lower section and has electrically controlled The narrow turn signals use LED technology; these L shaped follow a horizontal line the headlights and a vertical line the wheelarches.

Even though the front end is different to any other Volkswagen it can immediately be recognized as a Volkswagen by its clean lines.

The design an entirely new path at the rear, but the values of precision and quality are evident. Four characteristics out: First, there is the body form that towards the rear with defined trailing edges, for aerodynamics. Second, there is the roofline that doesn t a rear windshield.

Merging the roofline is the large rear that covers the drive and4.2 cubic feet of space. Third, the strip of red frames the rear section at the top and on the and incorporates the reversing lights, rear foglamps and brake Fourth, a black diffuser a near seamless transition to the underbody.

High-tech running

The running gear marries construction with maximum The front suspension is by upper and control arms, with arms at the back. The suspension is compact and offers a high of driving comfort.

In key areas, the gear components mount to the CFRP monocoque.

The weight of the gear is reduced by the use of many components. Aluminum is used for such as the suspension arms, calipers, dampers, and steering housing; the anti-roll bars are from CFRP; the brake are ceramic; the wheels are case in alloy; and the steering wheel is plastic.


The car is also designed to rolling resistance, with wheel bearings and driveshafts, as as ultra-low rolling resistance tires, sized 115/80 up and 145/55 R16 at the back. But all this isn t at the expense of safety: the XL1 has an anti-lock system (ABS) and a stability program (ESC).

Manufacturing

In Germany, Europe s largest has set up a completely new line for the XL1, the cars largely from reinforced polymer (CFRP). The XL1 is by Volkswagen Osnabrück GmbH. In was once the Karmann factory, 1800 employees produce such as the Golf Cabriolet and the new Boxster.

The production processes in Osnabrück are highly innovative and because there were no examples of the individual production anywhere in the world. Over the term, other Volkswagen brands will also from these numerous

Production In Detail

Stage I: frame

Production of the XL1 begins delivery of the CFRP monocoque, is produced by a supplier in Austria the RTM process. The manufacturing process was developed over several in close cooperation with In Osnabrück, the monocoque is mounted to an support plate, where the is built without doors or panels. This first production stage is referred to as the frame.

At this station, all are moved to their prescribed positions by special fixtures in to maintain the tight manufacturing

The monocoque s various interior and surfaces are pretreated in advance to tight gaps and smooth which is particularly important the designers wanted the high-tech to be visible. The individual CFRP are joined to one another in the bodyshell by gluing them together.

Over the further course of stage I, the trunk area is with the water channel, glued and fastened with In addition, all structural and exterior (rear cross-members and the front and side panels) are positioned and via a sled fixture. Employees and document the dimensional tolerances of the assembly as the final step of production stage.

Each part of the XL1 is also documented a serial number and its production

Stage 2: Door assembly

In with production stage I, the two doors are produced separately. developed its own tool for this, is used to fit the doors to adjoining parts with millimetric before they are fitted to the This is the only way to ensure the defined joint seam and uniform transitions between the are met when they are installed.

sheetmetal, carbon parts be reshaped afterwards.

Stage 3: assembly

At the third production the bodyshell frame is placed on a new Here, all body parts-scissor hood, engine cover, and bumper-are assembled to achieve the gaps and flush mounting. of the doors is a special challenge, they require a precise fit to the and side body surfaces.

4: Paint

The paint process was specially formulated for the XL1, a really thin covering to the weight of the vehicle. To meet the A paint quality standard, a fleece layer or resin is added to the parts as a cover in the RTM process. Compared to conventional paints used in the industry, yields a weight reduction of than 50 percent.

This CFRP painting process was the of intensive research by the Volkswagen Development Centre in Wolfsburg and by experts at the Osnabrück plant.

The itself consists of three The filler/primer is followed by the base (the solid color) and the layer of clearcoat, which a high level of scratch and UV In the interior, either decorative pearl gray paint is or a matt clear coat on CFRP parts such as the

Stage 5: Front section

painting, all components are transported to assembly. The first step is to join the front body to the prefabricated floorpan. The floorpan consists of components such as the arm front suspension, anti-roll a small 12-volt battery for the s electrical system, and the ceramic brakes.

Also integrated in the of the car is the high-voltage battery for the plug-in system.

The air conditioning unit is mounted in the vehicle s cabin, but isn t possible in the XL1 for packaging reasons. it s installed in a special insulated in the car s front section. Automatic of the vehicle s electrical system and startup of all electronic components are performed at the ITC (Startup and Test in this stage.

Stage 6: section and interior

Merging the unit with the body after front-end assembly. The TDI engine, electric motor, and the DSG transmission are installed in the rear of the XL1. The rear suspension and are installed at the same time.

In the cockpit is installed at this Due to the small production volumes, no were made for preassembling the XL1 instead, all the individual parts are inside the vehicle superstructure. The itself is made of a 1.4-mm-thick woodfiber that is produced in a pressing process.

Stage 7: doors, and wheels

The XL1 now takes on more of its final After assembly of the drive the laminated glass windscreen, is only 3.2 mm thick, is installed. The are re-fitted and the engine cover is re-mounted on the car.

Last but not the XL1 gets its magnesium wheels and resistance tires.

Stage 8: assembly of the doors

The scissor are the most complex add-on of the XL1 body. After installing the door and integrating the window special fixtures are used to the polymer side windows place. The largest part of the is permanently joined to the exterior skin for packaging reasons, a segment of the lower area of the windows can be opened.

Finally, the cameras are placed in their and the e-mirrors are mounted to the door.

9: Startup

First, the entire system is checked. For this simulated isolation faults are to test the system s emergency functionality. The next step is to up the TDI engine; all the actuators and sensors are In parallel, employees adjust the e-mirrors using a special program.

After all systems been started up, a check is of all electrical equipment, according to a observed list.

XL1 SPECIFICATIONS

Carbonfiber reinforced polymer and panels

Length x width x 153.1 in x 65.6 in x 45.4 in

87.6 in

Drive system diesel hybrid, rear-wheel

Engine TDI Clean Diesel, two

Capacity 830 cc

Output 48 hp, 89 lb-ft

motor 27 hp, 103 lb-ft

System 68 hp, 103 lb-ft

Transmission Seven-speed DSG

Battery type 5.5 kWh lithium-ion

1753 lb

Performance/fuel economy

Max 99 mph (electronically limited)

European consumption 261 mpg

C02 emissions 21 g/km

EV 31 miles

EV/TDI range than 310 miles (10 liter tank)

More Information on Blue and Volkswagen s Environmental

Sustainable mobility: Volkswagen has a approach.

The Volkswagen TDI lineup of the Jetta, Golf and Touareg exceptional fuel efficiency sacrifice.

Moving into and e-mobility with the already Touareg hybrid, Jetta hybrid and soon to be launched Golf.

Our electric vehicle is on schedule globally. 2013 is the key for electric mobility. First, the starts into the age of pure driving by introducing the all-electric Up! and as in Frankfurt, the e-Golf, which be based on the next generation Golf MQB platform.

Volkswagen is evaluating new technologies, powertrains and efficient fuel strategies our diesel technology. We felt it was important to do this right to rush something to market.

S THINK BLUE. INITIATIVE FOR ENVIRONMENTAL LEADERSHIP

Volkswagen to be leading automotive brand in of ecology by 2018 Think sustainability strategy sets apart by holistic approach

VA — Protection of the environment is one of the vital topics of our time. faces up to its responsibility as a carmaker. Its on ecological sustainability is embodied in the Blue. initiative — the goal of becoming the ecologically car brand worldwide by 2018.

other things, Volkswagen on the question of how mobility and ecologically behavior can be reconciled.

The Think sustainability strategy differs similar projects in its holistic It reaches far beyond products and is inspiring and motivating for both and the interested public to participate in it and multi-faceted collaborative projects a broad range of environmental Naturally, Volkswagen as an automaker the focus on innovative, environmentally products and technical solutions. include, for instance, our BlueMotion — particularly low-emission or driven vehicles — yet new mobility ideas such as the car-sharing project.

With the Think Blue. program, Volkswagen has also set goals for itself in terms of Production in all Volkswagen plants is to up to 25% more environmentally friendly by i.e. the values for energy generated waste, air-borne and water consumption are to be reduced by figure. Volkswagen already sets new benchmarks with Blue.

Factory. on an international The Chattanooga plant in the U.S. for is the first car plant in the world has been given the renowned Platinum Award for outstanding efficiency in 2011.

Think also pursues the goal of the awareness of the greater public for behavior and achieving a change in the of thinking in a joint effort. So our is straightforward: Environmental protection is fun and is without sacrifice — can make a contribution in his or her everyday Thus we raise the awareness for a driving style in a playful

With Think Blue., will also enter the discourse on sustainable mobility in the with ideas contests, youth workshops and other

Think Blue. also numerous cooperative projects environmental associations. We place value on addressing the most challenges in terms of ecological in each country individually. In and Spain, prevention of soil has priority; the protection of biodiversity precedence in South Africa; our cooperation with Naturschutzbund was given the International Sponsoring as a successful example for credible and cooperation in environmental protection.

Blue. has been the umbrella for the long-standing activities of Volkswagen in of ecological sustainability since 2010; it is designed for the long and has been established in 35 countries.

The of Think Blue. Is based on the 1960s slogan Think which referred to the democratization of through the Volkswagen Beetle. In the way, Volkswagen wants to a pioneering role in the challenges of the and make possible efficient and mobility for everybody.

Sustainable is therefore not just a technologicalchallenge. It is becoming an increasingly important and social factor. For these among others, we at Volkswagen committed ourselves to the most ecological restructuring process in our s history: We plan to make new vehicle generation on average 10 to 15 per more efficient. We are promoting friendly technologies all over the — especially in China, and Brazil. We are also restructuring our to make them 25 per cent environmentally friendly by 2018.

means: Reducing energy and consumption, waste, and emissions per produced by 25 per cent. We are fully to achieving these objectives, in difficult economic times. as Europe s largest car manufacturer, we to set new standards.

That is why we are working to achieve our goal of reducing the CO2 of our European fleet of new vehicles to 95 by 2020.

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