Rumor: Mercedes secretly preparing a micro-car to rival the BMW´s Project-i


SKY

Kraftwagen König
Hey guys. I know an engeneer who works here in Spain, and whose company has been contracted by MB for the extensive experiense in carbon fiber manufacturing. He claims the objetive of the deal is to create a car to rival the new BMW city car.

I don´t see it as a breaking rumor, but I´ve found interesting to see a PM in my inbox of this guys telling me this info.
 
Here's an update on recent going-ons. :t-drive:


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Daimler to Build Carbon Fiber Plant


Daimler CFRP plant to be built in Germany
The carmaker partnered with Toray in April
Mass production of CFRP vehicles planned for 2013

The race in the field of the so called carbon fibre reinforced plastic (CFRP) industry is on between German manufacturers Daimler and BMW. After the latter already announced the construction of a CFRP factory in the US in collaboration with the SGL Group, Daimler is now following its lead.

Back in April this year the German manufacturer partnered with Toray Industries for the production of the material and to use it in the 2013 Mercedes Benz SL-Klasse. Now the carmaker says it will be building its own production facility in Germany.

According to Automobilwoche, citing Daimler’s head of research and pre-development Bharat Balasubramanian, the carmaker is currently working with Toray to find ways to optimize the resin transfer moulding (RTM) process and shorten the production process.

Daimler's entrance in the race is based on the experience the carmaker already has with using the material. So far, carbon fiber bodies can be found in the 2,000 McLaren SLR models sold. The new CFRP plant is supposed to help Daimler produce around 25,000 to 30,000 carbon-fiber bodied cars per year.

“The SLR has brought more vehicles onto the roads in this material than any other producer and thereby also shown that CFRP can very well fulfill the extreme safety requirements for the raw structure,” Balasubramanian told the source.

As for rivals BMW, the first chance to use carbon fiber to build a vehicle will be the ActiveE, followed by the Megacity vehicle in 2013. The Megacity will be built around a carbon fiber and aluminum chassis, with its body panels using composite materials or carbon fiber, in an effort to keep the weight down.

Daimler to Build Carbon Fiber Plant - autoevolution
 
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Picture source: Mercedes-Benz-Blog -- Unmistakable. Unique. Classy. Mercedes-Benz.

Daimler to produce own carbon fiber composites

By David Vink | EUROPEAN PLASTICS NEWS

STUTTGART, GERMANY -- Daimler AG announced at its TecDay innovation day in Stuttgart in October that it will introduce more carbon fiber reinforced plastic (CFRP) composite parts into its vehicles by 2012 by building its own production facility in Germany.

Daimler’s head of research and pre-development, Bharat Balasubramanian, told Plastics News sister magazine Automobilwoche that the company is working with Toray Industries Inc. on optimizing the resin transfer molding (RTM) process used for CFRP in order “to bring down cycle time to several minutes and thereby to reduce costs by a factor of five.”

Balasubramanian reckoned the firm should reach this greater production efficiency within three years and so “enable economic series production for models with 25,000 to 30,000 units per year -- for example in the CL, SLK and CLS”.

Daimler is no newcomer to CFRP parts in its vehicles, as it sold 2,000 of its McLaren SLR car with CFRP body.

Daimler says that with the SLR it “has brought more vehicles onto the roads in this material than any other producer and thereby also shown that CFRP can very well fulfill the extreme safety requirements for the raw structure”.

The company says many welded and riveted sheet steel parts can be replaced with single CFRP parts that are put together with adhesive. This eliminates the need for larges presses and expensive press tools, as well as the need for anti-corrosion treatments.

As CFRP is 50 percent lighter than steel and 30 percent lighter than aluminum, Daimler says that a typical steel bodywork weight of 350 kilograms drops to 175 kg, resulting in greater fuel economy and lower emissions.

However, Balasubramanian says that Daimler will nevertheless use a mixture of materials, partly as “CFRP cannot be beaten back into shape in the event of a crash, but has to be completely replaced”. With the intended increased CFRP use, the company will need new methods and tools for repair and after-sales operations, Daimler points out.

Plastics News - Daimler to produce own carbon fiber composites
 
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Daimler and Toray to Establish Joint Venture for Manufacturing and Marketing of carbon-fiber based automobile parts

OFFICIAL PRESS RELEASE


Targeted mass production of high-tech lightweight components significantly improves fuel economy and reduces CO2 emissions of cars

New production and joining process enables large-scale production

Toray Industries, Inc. (headquarters: Chuo-ku, Tokyo; President: Akihiro Nikkaku; hereinafter referred to as “Toray”) and German automobile manufacturer Daimler AG (headquarters: Stuttgart, Germany), announced that the companies agreed to establish the joint venture (headquarters: Esslingen, Germany), for manufacturing and marketing of Carbon Fiber Reinforced Plastics (CFRP) automobile parts. The companies signed a joint venture contract today.

Under the Joint Development Agreement signed in March last year, Toray, in addition to developing optimal carbon fiber intermediate materials for CFRP, has been working on the design and molding processes, with Daimler taking responsibility for designing parts and developing technologies for joining of the parts. By bringing together their respective strengths, the companies have succeeded in developing an innovative technology for mass-production of CFRP parts with a significantly shorter molding cycle. The partners plan to start supplying the mass-produced CFRP parts utilizing Short Cycle Resin Transfer Molding (RTM), an innovative CFRP molding process technology developed by Toray for Daimler’s Mercedes-Benz passenger vehicles to be launched in 2012.

Daimler and Toray to Establish Joint Venture « The World Of Mercedes-Benz /////AMG

:t-cheers:
 
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Is carbon fiber replacing aluminum as the “cool” material to have?

Speaking to executives at the premium carmakers, you’ll get just that impression. Just look at the incredibly light Lamborghini Sesto Elemento, or listen to BMW gushing about its Megacity Vehicle: better be part of the game, which is driven by marketing almost as much as by technology. Now Mercedes-Benz is about to become a real player, too.

With the SLR McLaren, Mercedes was ahead of the carbon-fiber race for a few years already, but the new halo car, the SLS AMG, is all-aluminum. Now the company is re-focusing on carbon fiber, and significant parts and panels could be used for series production vehicles as early as 2012. Carbon-fiber components will be used for vehicles with production volumes of 20,000 to 40,000 annually—far more than the SLR.

Carbon fiber works perfectly for crash structures and monocoques, but cost is an issue as well, so don’t look for full carbon-fiber bodies at Mercedes, but rather for a creative mix of it with steel and aluminum. To transfer the technology into series production, the carmaker is teaming up with Japan’s Toray Industries. The supplier will handle the entire development and production chain.

The Continental: Daimler Looks to Carbon Fiber - Car and Driver Blog
 
more secrets Mr. Piëch might snap up? ;)


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Mercedes-Benz-Blog TRIVIA


Four cars in one – Mercedes-Benz Vario Research Car

Facts

Vehicle: Mercedes-Benz Vario Research Car
Introduced in: 1995
Where: Geneva Motor Show
Goals: Variable vehicle concepts, ergonomics
Powertrain: Front-wheel drive, continuously variable automatic transmission

Technical highlights

Swap bodies: sedan, station wagon, convertible and pickup on one and the same chassis, exchanged within 15 minutes
Light and sturdy bodies made of carbon-fiber reinforced plastic (CFRP)
Active Body Control (ABC)
Production launch in the Mercedes-Benz CL (1999, C 215 series)
Color display Production launch in the Mercedes-Benz S-Class
(1998, W 220 series)
Central rotary control for the electronic functions
Production launch in the Mercedes-Benz S-Class (2005, W 221 series)
Navigation system
Production launch in the Mercedes-Benz S-Class (1995, W 140 series)
Safety display coupled to traffic sign evaluating function and distance warning radar

One car, four vehicles – variability is the emphasis of the design of the Vario Research Car (VRC) by Mercedes-Benz, which attracted great attention at its premiere at the 1995 Geneva Motor Show. For in just a few minutes, the VRC can be converted into a different car. Whatever trip you plan, you will not need more than one car thanks to the variability of the body of the Vario Research Car. On weekdays it’s a sedan. For longer journeys, the load capacity of a station wagon is available. In the summer the sun invites you to take an open-top ride in a convertible. And for heavy loads, there’s the pickup with its open cargo space.

Mercedes-Benz solved the problem with a compact two-door car. It features a single-piece body consisting of roof, side walls and rear section; the body can be lifted off and exchanged for another variant. Doing it calls for a few simple operations and only about 15 minutes’ time. The Vario Research Car was combined with a vision: customers do not own the bodies themselves but drive up to a rental station. While they drink a cup of coffee, service technicians switch the body. A few minutes later, customers are back on the road again. How long they use a particular body variant is up to them, because the rental system is just as flexible as the car itself.

One car for different activities

Futurology provided the impetus for the Vario Research Car. The prediction is that people will have more leisure time which they will employ for different activities. For these activities, and for everyday use, they would like to choose a vehicle to fit their purpose. But having one’s own little fleet would not be economical. The Vario Research Car from Mercedes-Benz offers the solution.

On top of that, the VRC illustrates clearly that research vehicles demand a dialogue with the public: Mercedes-Benz requests drivers to state their opinions about each new concept. In the case of the Vario Research Car, the response has been particularly extensive and unusually diversified. From this response, Mercedes-Benz obtained numerous valuable suggestions for future production models.

This research car too features a number of forward-looking technical solutions. The body change should be easy to accomplish. Only the interplay of several components can make this possible. The service technicians place the roof structure on the chassis; electric motors pull it into its final position, where special locking mechanisms hold it at eight anchorage points. To release it, it suffices to actuate levers on the door pillars and the upper windshield frame. The rest is again done by the servomotors which undo the locks and slightly raise the body so that it can easily be lifted off.

For the electric connections in the rear, which differ for each body, there is a central terminal which automatically recognizes the type of body. If, for example, a station wagon body is mounted, the rear-screen wiper/washer will be supplied with current. In the sedan, the heated rear screen and trunk lights have to be connected to the electric system. In the convertible, the electric drive for the soft-top requires energy and has to be controlled.

Bodywork made of new materials

The bodies are light and sturdy – a result of the new materials tested by the engineers. They are made of the high-tech material CFRP – carbon-fiber reinforced plastic. Compared to aluminum, CFRP is 25 percent lighter and, what is more, features high strength. The bodies weigh only 30 to 50 kilograms each and, despite their lightweight design, afford a high level of stability and crashworthiness. The Vario Research Car served to further test front-wheel drive in a Mercedes-Benz, which was combined with continuously variable automatic transmission as well as active suspension (Active Body Control, ABC) for improving handling safety and comfort.

The cockpit contains a color display which shows the driver all the required information. On the center console a rotary actuator is installed with which the driver can selectively control the entire menu. It includes not only rev counter, trip computer and trip odometer, but also the route recommendations of the onboard navigation system. A special feature is the safety display in combination with a traffic sign evaluating system. If the driver keeps to the official speed limit, it shows a green circle. If he or she drives faster or does not keep a proper distance from the vehicle ahead, the color and shape of the symbol change – the circle turns into a yellow ellipse or a red triangle depending on how much the driver exceeds the speed limit or falls below the safe distance. For this function, the onboard electronics are coupled with distance radar and traction control.

The upper part of the center console accommodates a second display where, among other things, information on the settings of the air conditioning and navigation system are shown. When the driver stops to refuel, he or she is also told whether the tire pressure, the levels of engine oil, coolant and wash water, and the light system are okay. While on the go, drivers are prevented from choosing additional functions, so as not to distract their attention from traffic, while front passengers have unimpeded access to all secondary information. To tell the difference, the rotary control “senses” whether it is being touched by the left hand (front passenger) or right hand (driver).

First-time use of drive-by-wire for steering and brakes

The Vario Research Car was the first research car from Mercedes-Benz featuring drive-by-wire technology, in which the steering and the brakes, for example, are actuated electrically with no mechanical linkages existing to the steering hands and braking feet. But the testing of this technology was not the main purpose of the VRC – the variability of the body was the principal concern. With the Vario Research Car, Mercedes-Benz underpinned its forte, the holistic design of new vehicles – and its ability to put them on wheels in fully operational condition.

Daimler Global Media Site > Newsroom (Home)

:t-cheers:
 
Autobild update ;)

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Mercedes E super light to start 2015

The carbon material plays a decisive role. According to AutoBild Mercedes is planning a four-door sedan in the E-class format for 2015, which should be extremely light. The E super light weighs only 1.3 tons thanks to a body made of carbon including fuel cells or hybrid drive, thus bringing about 350 pounds less on the scale than a conventionally-powered E-class with a body made of steel.

Carbon has advantages in weight and stiffness

Reason for the increase in carbon plans, is the weight of vehicles. And the weight spiral turns through hybrid and electric drives even further upward, thereby jeopardizing efficiency and safety. Weight can thus become an important discipline in automobile construction. Carbon would also have another advantage. The material can give engineers and designers unprecedented freedom. Thus the E super light thanks to the high stiffness of carbon can do without B-pillar.

Two possible alternatives to the E super light

Senior executives at Daimler with CEO Dieter Zetsche are discussing three carbon models: Besides the E superlight there could be a clever, high-roof vehicle in the B-class format, which could compete with the BMW i3.

Limousine most likely

Moreover, an SCS super sports car is in discussion, which is positioned above the SLS. But AutoBild says the E superlight is the most likely. Production of the E super light could be increased in the first two years to 20,000 vehicles a year.

Space frame made of carbon

Unlike competitors such as BMW Mercedes relies on a holistic carbon structure, which also directly couples the drive and suspension into a carbon fiber space frame. The know-how around the carbon material comes from Toray, a Japanese carbon fiber specialist, founded in 2010 with whom Mercedes has a joint venture.

translated from AUTOBILD article
 
MB already had the perfect platform to build a micro city car, it was called the Smart. It just baffles me as to why MB has neglected that it.
 
Wolfgang, correct me if I am wrong, but are you suggesting MB is divesting the shares they have in the venture because they have now developed sufficient expertise in-house?
 
^ Yes. Translated from the article: :)

Daimler founded the company headquartered in Esslingen near Stuttgart with Toray to manufacture lightweight parts for their own vehicles and also to resell later. The necessary processes are now developed, declared the Daimler spokeswoman.

PS. The new company's name is "euro advanced carbon fiber composites GmbH". www.eacc.de (currently being reworked).
 

Mercedes-Benz

Mercedes-Benz Group AG is headquartered in Stuttgart, Germany. Established in 1926, Mercedes-Benz Group produces consumer luxury vehicles and light commercial vehicles badged as Mercedes-Benz, Mercedes-AMG, and Mercedes-Maybach. Its origin lies in Daimler-Motoren-Gesellschaft's 1901 Mercedes and Carl Benz's 1886 Benz Patent-Motorwagen, which is widely regarded as the first internal combustion engine in a self-propelled automobile. The slogan for the brand is "the best or nothing".
Official website: Mercedes-Benz (Global), Mercedes-Benz (USA)

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