Mercedes-Benz utilises PEMFC fuel cells (Polymer Electrolyte Membrane Fuel Cell) for the F‑CELL vehicles. An assessment of various fuel cell designs showed them to be the best option for motor vehicles. The key advantage when it comes to vehicle drive systems is their operating temperature of up to around 80 degrees Celsius.
A fuel cell is a voltaic cell that converts the reaction energy of an added fuel (e.g. hydrogen) and an oxidising agent (e.g. airborne oxygen) into electrical energy. A fuel cell is not an energy storage device like a rechargeable battery, but an energy converter.
The drive system on a fuel cell vehicle is twice as efficient as a vehicle with a combustion engine, essentially the result of converting the fuel’s (hydrogen) chemical energy directly into electrical energy. At the heart of the PEM fuel cell is the proton exchange membrane (PEM), a plastic film that conducts protons, and which separates the reaction agents: oxygen and hydrogen. The plastic film measuring just a few tenths of a millimetre is coated with a thin layer of platinum on both sides. This platinum layer acts as a catalyst for the chemical reaction that breaks down the hydrogen into protons and electrons. While the protons flow through the membrane to the oxygen, the electrons are prevented from getting through. The hydrogen reacts with the oxygen to create water, which is dissipated into the atmosphere. The excess electrons on the hydrogen side and the lack of electrons on the oxygen side induce an electrical voltage. If the two poles are connected, an electric current flows, which drives the electric motor in the F‑CELL vehicle. Apart from electrical energy, the reaction in the fuel cell also generates heat that can be used to heat the vehicle, for instance.
To achieve sufficient electrical power for fuel cell vehicles, individual fuel cells are electrically connected in series to create stacks. A control unit ensures the stack is supplied with the right amounts of hydrogen, and oxygen from the air. The hydrogen is fed into the stack via the anode module, while the air is added via the cathode module. A humidifier module keeps the stack moist to achieve optimum operating conditions within the stack. A cooling system always maintains the fuel cell at its optimum operating temperature of around 80 degrees Celsius.
System partner for the zero-emission drive system
The Automotive Fuel Cell Cooperation headquartered in Vancouver developed the fuel cell stack for the B‑Class F‑CELL. The company was founded in 2007 with Daimler as the majority shareholder (50.1 percent). Other partners include the Ford Motor Company (30 percent) and Ballard Power Systems (19.9 percent).
NuCellSys GmbH developed the ancillary units to operate the fuel cell stack and integrate the stack into the fuel cell system. The wholly owned subsidiary of Daimler AG is responsible for system engineering and design, component and software development as well as system validation.
Mercedes-Benz is launching its first series-produced electric car with a fuel cell on the road: the new B‑Class F‑CELL. The small-scale production of the environmentally friendly electric car is already underway. The first of around 200 vehicles will be delivered to customers in Europe and the USA in spring next year. At the heart of the B‑Class F‑CELL is the new-generation electric drive system powered by a fuel cell, which is compact, powerful, safe and fully suited for everyday use. The fuel cell generates the electrical power on board, while producing little more than pure water and zero emissions. The key drive components are located in the sandwich floor, where they are protected and do not take up much space, leaving the vehicle’s interior and boot fully usable. Thanks to its long range of around 400 kilometres and short refuelling times, the B‑Class F‑CELL combines local zero-emission mobility with long-distance comfort and compelling performance. Driving pleasure and performance on a par with a 2.0-litre petrol car come courtesy of the 100-kW/136-hp electric motor, which develops effortlessly superior torque of 290 Nm. The B‑Class F‑CELL consumes the equivalent of 3.3 litres of diesel per 100 kilometres in the New European Driving Cycle (NEDC).
The technology for the B‑Class F‑CELL drive system is based on the optimised latest-generation fuel cell system. It is some 40 percent smaller than the system in the A-Class F‑CELL from 2004, but develops 30 percent more power while consuming 30 percent less fuel. The main drive system components include:
Cold-start capability down to minus 25 degrees Celsius
The fuel cell module in the B‑Class F‑CELL, the stack, boasts outstanding cold-start capability down to minus 25 degrees Celsius. The system features a new humidification system consisting of hollow fibres that ensures, unlike with the first-generation fuel cell, that water no longer freezes in the stack, a characteristic that used to impair cold-start capability. Even at minus 15 degrees Celsius the B‑Class F‑CELL starts just as quickly as the very latest diesel engine. A dedicated operating strategy helps ensure the fuel cell stack reaches its optimum operating temperature of around 80 degrees Celsius as quickly as possible each time the vehicle is started. Thanks to the powerful cooling system and intelligent temperature management, this ‘pleasant temperature’ is maintained constant under all operating conditions.
Range of around 400 kilometres with the tanks full
The hydrogen used to run the fuel cell is stored in three tanks at a pressure of 700 bar. Each tank holds just under 4 kilograms of the gaseous fuel. The tanks are hermetically sealed from the outside world, preventing the loss of hydrogen into the atmosphere even if the vehicle is left to stand for long periods.
Thanks to the high compression ratio, the B‑Class F‑CELL can cover long ranges of up to 400 kilometres with the tanks full, over twice as far as the A-Class F‑CELL. If the tanks are empty, they can be filled simply and quickly in less than three minutes, thanks to a standardised refuelling system.
Equivalent of just 3.3 litres of diesel per 100 kilometres
The electric motor – a permanently excited synchronous motor – develops a peak output of 100 kW/136 hp and a maximum torque of 290 Nm – typical of the high torque generated by an electric motor –, which is available from the instant the engine starts to turn. It ensures that the B‑Class F‑CELL, whose impressive dynamic handling properties are in some cases far better than those of a two-litre petrol car, gets off to an excellent start. Nonetheless, the local zero-emission electric drive with fuel cells consumes the equivalent of just 3.3 litres of diesel per 100 kilometres (NEDC).
Compact lithium-ion battery with large storage capacity
A powerful high-voltage lithium-ion battery is used to store the power. It boasts an energy capacity of 1.4 kWh and is cooled via the air-conditioning system circuit. When it came to the battery for the B‑Class F‑CELL, Mercedes‑Benz drew on the experience garnered during the development of the lithium-ion technology for the S 400 HYBRID. Advantages of the lithium-ion battery include its compact dimensions and much superior performance compared with nickel metal hydride batteries (NiMH). The energy density is 30 percent higher than with NiMH technology; the power density 50 percent higher by comparison. Furthermore, high recharge efficiency and a long service life make the technology even more compelling.
Intelligent drive system management for superb efficiency
Mercedes-Benz has further enhanced the operating strategy of the electric drive with fuel cells for the B‑Class F‑CELL. As the outside temperatre plummets, the electric motor receives its electrical energy during a cold start both from the lithium-ion battery and from the fuel cell system as it “powers up”. Battery power is sufficient as the outside temperature warms up; the fuel cell then comes on line later – depending on the power requirements. In drive mode, the energy management system constantly maintains the F‑CELL system in the optimum operating range. The lithium-ion battery dynamically smoothes out variations with regard to the electrical power required in the current driving situation.
Whenever the driver brakes or as soon as they take their foot off the accelerator, the electric motor converts kinetic energy into electrical energy, which is then stored in the battery, using a process known as recuperation. While manoeuvring or on short journeys, the electric drive motor uses battery power. If the battery capacity is not sufficient, the fuel cell automatically kicks in. In a bid to ensure optimum efficiency and customer benefits, the intelligent drive management system decides whether the electrical energy is used from the lithium-ion battery, the fuel cell, or a combination of the two systems.
Full everyday practicality thanks to sandwich floor
Four fully fledged seats and a boot capacity of 416 litres make the B‑Class F‑CELL fully suitable for day-to-day and family use. The F‑CELL concept has been realised on the basis of the unique sandwich floor architecture, which Mercedes-Benz introduced 10 years ago in order to integrate alternative drive systems with the first-generation A-Class, and which has been honed consistently since then. The key components for the electric drive with fuel cells are optimally protected in the vehicle underbody, thanks to a space-saving design that also promotes a low centre of gravity. Advantages of the design include:
The B‑Class F‑CELL offers consummate driving pleasure and full day-to-day suitability – without local emissions. The innovative electric car also has a great deal to offer when it comes to equipment and appointments, including the bonamite silver special paint finish and exclusive 10-spoke light-alloy wheels. In the interior, leather upholstery, heated seats, automatic climate control and the COMAND system, as well as other features, ensure a high level of comfort. The dynamic energy flow display in the COMAND system display keeps the driver constantly abreast of the battery charge status, operating mode of the fuel cell system, as well as providing information on nearby hydrogen filling stations.
Safety first: uncompromising safety standards
Mercedes-Benz applies the same high safety standards to the B‑Class F‑CELL as to any of its other series-production models. The starting point is the outstanding crash safety of the Mercedes-Benz B‑Class, which received the highest five-star rating in the European NCAP (New Car Assessment Programme). The integrated safety concept of the B‑Class F‑CELL takes the specific characteristics of the innovative drive system into account. The experience garnered over many years by Mercedes-Benz with the electric drive powered by fuel cells from the A-Class F‑CELL and the high-voltage technology involving the lithium-ion battery from the S 400 HYBRID went into honing the concept.
Mercedes engineers have tested the safety of the drive-specific components including the hydrogen tank in the B‑Class F‑CELL in more than 30 crash tests. The hydrogen tanks are installed in the sandwich floor and therefore well protected in the event of an impact. They hold the hydrogen which is pressurised to 700 bar and have been designed to withstand all conceivable loads.
In the event of a crash, safety valves close the hydrogen supply lines to the fuel cell and decouple the tanks from the other system components. Even after a serious accident, the hydrogen poses no risk whatsoever. If a fire leads to excessive heat, a temperature-controlled value vents the tank contents in a controlled manner.
The lithium-ion battery and high-voltage system in the B‑Class F‑CELL feature – based on the experience garnered with hybrid technology in the S 400 HYBRID –an extensive, seven-stage safety concept.
The high level of safety means Mercedes-Benz fuel cell vehicles can use underground car parks, multi-storey car parks or tunnels with no restrictions whatsoever.
F‑CELL – paving the way for the mass-produced fuel cell
With the B-Class F-CELL, Mercedes-Benz has for the first time applied all development and production standards associated with series production to an electric vehicle with fuel cells. All F‑CELL components meet the familiar Mercedes-Benz high standards in terms of quality, reliability and service life, thus putting in place the ideal conditions for mass production of the fuel cell powered electric drive including battery to improve efficiency and reduce costs. From 2012, the company intends to fit its vehicles with lithium-ion batteries produced by its joint venture Deutsche Accumotive GmbH.
Modular system for tomorrow’s electric cars
Along the same strategy adopted for developing the hybrid, the Mercedes engineers have also developed a modular system for electric vehicles with batteries and fuel cells. This enables amongst others the same parts to be shared efficiently across all electric vehicles. All key components of electric vehicles are ideally suited to modularisation: from the electric motor and the transmission, the battery and high-voltage safety concept to the high-voltage wiring, and software modules. Specific components, such as stacks and hydrogen tanks, can be used as standard components for entirely different vehicles in the F‑CELL line-up. For instance, simply by varying the quantity as necessary: for example, the Mercedes-Benz fuel cell bus is powered by two passenger car systems of the same type that is also used in a B‑Class F‑CELL.
The close to series Concept BlueZERO is testimony to just how the company has implemented the modular concept with future electric vehicles featuring a battery and fuel cells. As with the B‑Class F‑CELL, the Concept BlueZERO also houses the key drive components in the sandwich floor in a crash-resistant configuration. Based on a single vehicle architecture, the variable concept paves the way for three variants with different drive system configurations, which can meet all customer requirements for sustainable mobility – also, and in particular as regards the key aspects of safety and range:
As the first European car manufacturers smart and Mercedes-Benz are entering the age of electric mobility with vehicles that are fully suitable for everyday use. The new smart fortwo electric drive has taken on a pioneering role among battery-powered electric vehicles. With a range of up to 135 kilometres the two-seater car is the ideal solution for zero-emission motoring in towns and cities. The Mercedes-Benz B-Class F-CELL is the perfect complement. As an electric vehicle with a fuel cell it combines driving without any local emissions with the advantage of a large range of up to 400 kilometres which makes it suitable for longer trips as well. Both vehicles are now being handed over to customers.
Dr. Dieter Zetsche, Daimler CEO and Head of Mercedes-Benz cars says “As a global supplier of premium cars we want to meet the mobility requirements of our customers all over the world. This is why we are broadly positioned and have developed a modular drive mix to suit different requirements. The smart fortwo electric drive and the Mercedes-Benz B-Class F-CELL are already demonstrating the contribution that electric cars can make to sustainable mobility. Experts are unanimous in their belief that the “coexistence” of different drive technologies will shape the face of road traffic for years to come. This is why Daimler’s approach is to develop vehicle concepts with modular drive technologies which ensure that the focus is always on both customer benefits and environmental compatibility. In addition to the optimisation of vehicles with state-of-the-art combustion engines and further efficiency increases with hybridisation tailored to customer needs, the third central focus of development is on fuel cell and battery-powered vehicles that do not produce any local emissions. Dr. Thomas Weber, Daimler AG board member responsible for Group Research and Development at Mercedes-Benz Cars says “Each of these technologies demonstrates its advantages with regard to optimum consumption and emission figures in specific fields of application. We are the only manufacturer worldwide to offer our customers appropriate solutions for all fields of application – from personal mobility to local public transport and goods transport on the roads.”
Electric cars are now being delivered to customers
With the electric cars from smart and Mercedes-Benz that are fully suitable for everyday use, zero-emission driving is already a reality. The new smart fortwo electric drive is a pioneer among battery electric vehicles which are primarily suited to use in urban areas. The second generation is already being built and now boasts a highly efficient lithium-ion battery which enables a range of 135 kilometres and impressive performance. Following the start of series production in Hambach, France in mid November 2009, the first small series of 1000 vehicles will be handed over to customers in Berlin on 17 December.
The two-seater car will initially be delivered to selected customers in six European countries plus the USA and Canada within the framework of a leasing or rental model. Volume production will start in 2012 and the smart fortwo electric drive will then be available to anyone interested.
Thanks to its range of around 400 kilometres, the Mercedes-Benz B-Class F-CELL is suitable for both zero-emission driving in city traffic and also for travelling longer distances. Small series production of this electric car has also started. Next year the first of approximately 200 vehicles will be delivered to customers in Europe and the USA.
Both electric cars are fully suitable for everyday use. All the main components are housed in a space-saving position between the axles where they are optimally protected, and this means that the interior space is not compromised in the electric versions of the standard cars. Furthermore, the smart – the ultimate city car – has an extremely comfortable range for city driving and it can be charged at any household socket. The B-Class F-CELL offers a large range and is suitable for travelling longer distances as well. As its hydrogen tanks can be fully refuelled in around three minutes it is also the electric car with the shortest charging time.
Infrastructure is essential
An appropriate refuelling and electricity charging infrastructure is essential for wide customer acceptance and quick widespread use of electric vehicles. This is why Daimler is committed to setting up a comprehensive network of electricity charging stations and hydrogen filling stations. In September 2009 together with the Federal Ministry of Transport and partners from the energy sector the company presented a plan for establishing a hydrogen infrastructure in Germany. At the same time Daimler reached an agreement with other leading car manufacturers to bring several hundred thousand fuel cell cars to the roads from 2015.
Parallel to this, together with various partners in Europe the Stuttgart car manufacturer is advancing the expansion of a public electricity charging infrastructure. This is because although electric vehicles like the smart fortwo electric drive can easily be charged at a domestic garage socket, around 40 percent of European vehicle owners do not have a parking space of their own. Publicly accessible charging stations are therefore needed. To enable this to be realised Europe-wide as far as possible with standardised framework conditions, Daimler is developing corresponding standards together with other car manufacturers and utility companies.
Electric mobility – an affordable alternative?
New technologies generally entail high investments and costs. This means that at the current stage of development electric cars are still more expensive than comparable models with combustion engines. Daimler is applying all available levers to reduce the costs to a level that is economically acceptable and attractive to customers. For example, by industrialising lithium-ion technology with the company Deutsche Accumotive GmbH and the economies of scale resulting from this. Furthermore, in product development Daimler is systematically using a modular E-drive system. This enables synergies to be ideally used between the different vehicle segments.
There are also numerous other factors that make electric mobility attractive for customers. Tax relief and other government subsidies are an important aspect. For example, the state of Monaco offers tax relief of up to €9,000 to electric car owners. Other countries have also set up funding programmes for sustainable mobility. France offers a “super environment incentive” of €5000 for vehicles that emit less than 60 grams of CO2 per kilometre. China and Japan have announced subsidies of €6,500 and €11,000 respectively.
Customers benefit from lower running costs
In addition, owners of electric cars can benefit from lower running costs. For example, in Germany the electricity costs for a distance of 100 kilometres currently stand at between two and three euros. And many experts believe that in the long-term the costs for hydrogen will level out at a price that makes it an inexpensive alternative to fossil fuels.
However, the question of the future taxation of new fuels has not yet been clarified. Dr. Thomas Weber says “It would make sense to find a solution that supports the introduction of new drives during the transitional period – for example with temporary tax exemption for electricity and hydrogen, just as various countries offer tax relief today for natural gas used to power vehicles.”
For example, electric cars like the smart fortwo electric drive are exempted from the city congestion charge in London, enabling their owners to save considerable sums of money.
Dr. Joachim Schmidt, Head of Sales and Marketing at Mercedes-Benz Cars says “All things considered we see good prospects for electric mobility with fuel cells and batteries. Whilst other companies are still presenting electric show cars, we at smart and Mercedes-Benz are already bringing two vehicles that are fully suitable for everyday use to the roads.”
A few weeks after the production of the smart fortwo electric drive started at the plant in Hambach, smart signed an agreement with the Principality of Monaco, in the presence of His Royal Highness Prince Albert II. From next spring, the first electric smarts will be run on the roads of Monaco.
The ten smart fortwo electric drive will be exclusively used by state services (such as postal and telecommunications services) or monacan public service partner companies, which are already very engaged in the field of zero-emission mobility.
“We are very proud that the Principality of Monaco as one pioneer in sustainability projects decided to count on/partner with the pioneer of zero emission mobility – the smart fortwo electric drive,” stated Dr. Joachim Schmidt, Executive Vice President Sales and Marketing Mercedes-Benz Cars. “We need engaged partners like this in order to make emission free driving become reality.”
The partnership between smart and the Principality of Monaco will be part of the worldwide roll-out of the smart fortwo electric drive. The 1,000 vehicles will be on the road for everyday use in major cities of Europe, the United States and Canada.
Mercedes-Benz France Chairman Reinhard Lyhs: “Through this partnership, the smart fortwo electric drive is confirming its pioneering role in electric mobility. For us, the interest shown by the Principality of Monaco – itself a pioneer in zero-emission mobility – in the electric smart, is a powerful argument in favour of the concept and technologies of our electric model.”
Major stages in 2007 and 2008
smart has been fulfilling the role of pioneer in terms of zero-emission mobility since 2007. Since 2007, 100 first generation smart fortwo electric drive cars have been tested in London. The feedback of the customers was very positive and confirmed the concept’s high level of maturity.
In 2009, Daimler AG Group introduced the second generation smart fortwo electric drive equipped with a lithium-ion battery. Compared with other types of battery, lithium-ion technology has several crucial advantages, including higher power, shorter charging times, a longer lifetime and extreme reliability. The smart fortwo electric drive can be recharged using a standard domestic power socket.
From 2012, the smart fortwo electric drive will be produced as an additional model within the smart range at Hambach and will be sold through the smart dealer network.
A tale of success: the smart factory in Hambach
smart’s Hambach production facility opened in 1997. Since 1998, it has been producing the smart fortwo, which has been in its second generation since. In 2008, more than 800 employees within the factory and around 800 other staff from seven suppliers assembled almost 140, 000 smart fortwo vehicles. In September 2008, the company celebrated its tenth birthday at the same time as the millionth smart fortwo left the production line at Hambach.
About smart
Respect for the environment and modern functionality have been in the genes of the smart fortwo since it was launched over ten years ago. Since then, its innovative concept has become widespread, combining new technology, compatibility with eco-thinking and personal mobility. Scarcely more than two and a half meters long, this extremely compact and highly economical car carries its passengers in great comfort and complete safety. Its original design has made it an “icon” among lifestyle vehicles, proving that mobility, environmental responsibility and joie de vivre can be combined in perfect harmony. The smart fortwo has genuinely succeeded in creating a class apart.
Smart is currently distributed in 41 countries worldwide, having just launched in China and Brazil. Smart’s first markets were Germany, Italy and the US.
Daimler AG today announced that it selected the smart plant in Hambach, France, as the location for future series production of the smart fortwo electric drive. As of 2012, the highly innovative electric vehicle, equipped with the most modern lithium-ion-battery, will roll off the assembly line in large-scale production and will be offered to customers through the smart sales network. The announcement was made on the occasion of an official visit of French President Nicolas Sarkozy at the Hambach plant.
Dr. Dieter Zetsche, Chairman of the Board of Management of Daimler AG and Head of Mercedes-Benz Cars: „The smart fortwo electric drive proves that emission-free driving in an urban environment is already feasible today. The initial series production will begin now with 1,000 vehicles, the first of which will be delivered to customers by the end of this year. As of 2012, the smart fortwo electric drive will then be part of the regular product program of the smart brand. With our decision to locate production here at the parent plant in Hambach, we are setting the course both for series production of electric vehicles and for the future of this highly innovative assembly plant“.
Daimler will invest a double-digit million euro amount at the Hambach plant for production of the next generation of the smart fortwo electric drive with lithium-ion-battery. During his visit, President Sarkozy announced that the French government will support the project through its PAT (Prime d’aménagement du territoire) program. Further support is to be extended by the Region Lorraine and the Département de la Moselle. Both these measures will comprise a total of 15 percent of the investment. The president was visiting the plant today to – amongst others – get a first-hand impression of environmentally compatible powertrains of the future.
In November 2009, the plant will start to produce a small series of about 1,000 units of the smart fortwo electric drive. In a first step, these vehicles will be provided to customers participating in various mobility projects in major cities in Europe and the U.S., in order to generate additional feedback from the use under everyday conditions.
As of 2012, the smart fortwo electric drive will be produced in significantly larger volumes as a regular part of the smart product portfolio and will be sold through the smart sales network. smart thus emphazises its pioneering role on the way to individual mobility with local zero-emissions in cities and urban areas.
First Milestones in 2007 and 2008
Since 2007, the smart brand has taken a pioneering role in the electrification of drive systems. Back then, smart started emission-free driving under tough everyday conditions of city traffic in London. 100 smart fortwo electric drives of the first generation have been in practical customer operation. The feedback from this project has been very positive and confirmed the high degree of maturity of this vehicle concept.
Just one year later, the company introduced the second generation with an even more advanced electric drive and an innovative, highly efficient lithium-ion battery. Lithium-ion technology has decisive advantages over other types of batteries including higher performance, shorter charging times, a long life and high reliability. In addition, a smart fortwo electric drive can be charged at a regular household power outlet.
A story of success: The smart Plant in Hambach
The smart plant in Hambach was inaugurated in 1997. Since 1998, it has produced the smart fortwo, since 2007 in its current generation. In 2008, more than 800 employees of the plant and some further 800 people employed by seven system partners produced about 140,000 units of the smart fortwo. In September 2008, the brand celebrated its tenth anniversary along with the 1-millionth smart fortwo produced at the Hambach plant.
The Hambach plant has represented an innovative production concept since its beginning: The assembly line in the shape of a plus sign has been designed to optimally meet the demands of assembly and logistics and ensures highly efficient production processes. This principle enables the system partners to supply modules directly to the assembly line, which reduces transport and logistics efforts to a minimum and hereby also provides an advantage regarding ecological aspects. In addition, the environmentally friendly and cost effective paint shop, an energy concept with numerous savings opportunities and the construction principle of the vehicles ensure that the ecological product responsibility of the smart brand is translated into the production.
About smart
Environmental friendliness and contemporary functionality have been defining features of the smart fortwo ever since it was launched more than ten years ago. Since then its innovative concept has combined sustainable, forward-looking technologies with individual urban mobility. With a length of just over two and a half meters, the extremely compact and fuel-efficient vehicle brings its occupants to their destination comfortably and safely. Its distintive design made smart an automotive lifestyle icon which shows that mobility, responsibility to the environment and joie de vivre are compatible with one another. The smart fortwo has established a class of its own.
Today, smart is present in 41 markets around the globe, with most recent market launches in China and Brazil. Germany, Italy, and the U.S. are key markets.
The near-series Mercedes-Benz Concept BlueZERO E-CELL PLUS electric car combines environment-friendly electric mobility in the city with unrestricted suitability for long-distance driving. This is made possible by the combination of the battery-electric drive with a combustion engine. The range extender gives the BlueZERO E-CELL PLUS a total range of up to 600 kilometres, with 100 kilometres thereof solely under electric power and thus free of local emissions.
The BlueZERO E-CELL PLUS is part of a family of modularly constructed electric cars, which will enable Mercedes-Benz to meet all customer requirements for sustainable mobility in the future. In this variant of the concept vehicle, the electric motor of the purely battery-powered BlueZERO E-CELL is combined with an additional three-cylinder, turbocharged petrol engine. Putting out 50 kW, the compact combustion engine is installed in the area of the rear axle and can charge the battery while the car is being driven. The CO2 bonus for the battery-electric driving mode reduces the vehicle’s emissions to only 32 grams of CO2 per kilometre. The range extender enables the BlueZERO E-CELL PLUS to drive for up to 600 km, of which up to 100 km can be driven in electric mode with zero local emissions. The long combined range makes the BlueZERO E-CELL PLUS fully suitable for everyday use and assures that the customer will reach his or her destination even with a depleted battery. After all, the car can be refuelled quickly and easily at any normal filling station.
Battery with superior lithium-ion technology
During rapid charging with a charging capacity of 20 kW, the high-performance, 18 kWh lithium-ion battery of the BlueZERO E-CELL PLUS can store enough power within around 30 minutes for a 50 kilometre cruising range. The complete electric range of 100 kilometres requires a charging time of somewhat more than an hour. Charging time with a standard charge cycle at a conventional household outlet with 3,3 kW is approximately 6 hours. Special on-board electronics support the intelligent charging stations and billing systems used by electric fuelling stations. Advantages of lithium-ion batteries compared to other battery technologies include their compact dimensions, high output and energy density, high charge efficiency and long service life.
Concept BlueZERO – the triad of electric mobility
Mercedes-Benz is showing the way to environmentally compatible electric mobility with the near-series Concept BlueZERO. The vehicle’s intelligent modular concept enables a single vehicle architecture to be used to create three models with different drive system configurations.
All three BlueZERO models feature front-wheel drive, which is typical for this class of car. The drive components have been modularly organised by the Mercedes engineers and can be combined as needed. These include state-of-the-art liquid-cooled lithium-ion batteries with up to 35 kWh capacity, and a compact electric motor with a maximum output of 100 kW (sustained output: 70 kW). The maximum torque of 320 Nm is available from the electric motor’s first revolution, and it surpasses the value attained by today’s V6 petrol engines at 2,500 rpm. Like its two sister models, the BlueZERO E-CELL and the BlueZERO F-CELL, the BlueZERO E-CELL PLUS can accelerate from 0 to 100 km/h in less than eleven seconds. To ensure optimum range and energy efficiency, the top speed is electronically limited to 150 km/h.
“The Concept BlueZERO offers a triple demonstration of the technical maturity of alternative drive systems from Mercedes-Benz. Electric vehicles with battery electric or fuel cell drive systems will not truly be on an equal footing with today’s combustion engine drive systems until the customers are confident that there is a sufficient infrastructure of electricity and hydrogen refuelling stations,” says Prof. Herbert Kohler, Head of E-Drive and Future Mobility and also Chief Environmental Officer at Daimler.
Concept BlueZERO: Modular architecture for flexibility and efficiency
The three BlueZERO variants were developed on the basis of the unique sandwich-floor architecture known from the A-Class and B-Class. The advantage of the enhanced design is that the key drive components are installed in the vehicle’s underbody in such a way that they take up little space, ensure a good centre of gravity, and are maximally protected. The BlueZERO models therefore differ considerably from conventionally designed electric cars, which have heavy and voluminous storage batteries installed in the boot, for example, or in the area of the backseat. All three BlueZERO variants share key technological components and have identical designs and vehicle dimensions. Even though they have compact exterior dimensions, the 4.22-meter-long BlueZERO models have a spacious and versatile interior and cargo space. The vehicles’ five full-size seats, approximately 450 kilograms of payload, and more than 500 litres of cargo capacity make them suitable family cars.
“Our modular system permits different drive configurations for each customer requirement,” says Dr. Thomas Weber, the Daimler Board of Management Member responsible for Group Research and Mercedes-Benz Cars Development. “The improved sandwich floor platform serves as the perfect basis for a diverse range of vehicles with electric drives. We are currently developing an additional platform for future compact models that have drive systems using optimized internal combustion engines. The smart linking of both architectures will allow us to expand our product range in an extremely flexible and efficient manner. Beginning in 2009, we will manufacture the first small batch of Mercedes fuel cell cars. In 2010, they will be followed by a small batch of Mercedes-Benz vehicles that run solely on electric power supplied by a battery. Thanks to these measures, we are excellently positioned for the future.”
Electric powered vehicles are fun to drive
Mercedes-Benz vehicles will continue to combine environmental awareness and driving fun in future. One way in which the Mercedes-Benz designers have emphasised this aspiration is by introducing paint finishes in three new ALU-BEAM colours. Each of the three variants makes its individual mark: Confident ALU-BEAM Copper was chosen for the BlueZERO E-CELL PLUS. The BlueZERO E-CELL is painted a fresh ALU-BEAM yellow; the BlueZERO F-CELL appears in ALU-BEAM green.
Mercedes-Benz feels it won’t be just one technology that paves the way to sustainable mobility in the future, however. Instead the company is responding with solutions that are every bit as varied as the demands. The individual technologies are being used in specific applications where they can provide the greatest advantage with respect to optimal consumption and emission values. Mercedes-Benz views the development of electric cars with battery and fuel cell drives for local zero-emission driving as a means of supplementing the extremely clean and economical BlueEFFICIENCY and hybrid vehicles already available today. However, the unrestricted and convenient operation of electric cars still faces a series of challenges, including high system costs, insufficient infrastructure and short cruising ranges. Advanced diesel and petrol engines will remain the driving force for automobiles for a long time to come – not only for individual mobility in passenger cars (especially over long distances), but, more importantly, for freight transport in trucks. Despite all the progress that Mercedes-Benz has once again so emphatically documented with the Concept BlueZERO, electric cars will not be replacing vehicles with combustion engines any time soon. The electrification of modern, high-tech engines will, however, play an increasingly important role in the drive system mix of the future.
Mercedes-Benz today has again detailed one member of their modularly constructed electric car family– the Mercedes BlueZERO E-CELL PLUS. Based on the BlueZERO E-CELL (one of the models unveiled late last year that’s driven only by a battery-powered electric drive), the BlueZERO E-CELL PLUS features the same battery powered electric motor but adds a compact 50kW three-cylinder turbocharged petrol engine. As a result, the BlueZERO E-CELL PLUS boasts an operating range of up to 600 km, whereas the BlueZERO E-CELL notes an operating range of 200 km.
In terms of operation, the BlueZERO E-CELL PLUS features a rapid charging option with a capacity of 20 kW, enough power to allow for a 50 km cruising range in about 30 minutes. To achieve full electric charge, a little over an hour is needed, which will then allow the BlueZERO E-CELL PLUS to achieve its maximum range of 100 km (using the electric drive only). Charging time with a standard charge cycle at a conventional household outlet with 3,3 kW is approximately 6 hours.
Speaking briefly about the new concept, Prof. Herbert Kohler, Head of E-Drive and Future Mobility and also Chief Environmental Officer at Daimler, notes: "The Concept BlueZERO offers a triple demonstration of the technical maturity of alternative drive systems from Mercedes-Benz. Electric vehicles with battery electric or fuel cell drive systems will not truly be on an equal footing with today’s combustion engine drive systems until the customers are confident that there is a sufficient infrastructure of electricity and hydrogen refueling stations."
Mercedes-Benz is launching its first series-produced fuel cell car on the road: the new B‑Class F-CELL. The environmentally friendly electric car has better a performance similar to than a 2,0-litre petrol car and is fully suited for everyday driving. The zero-emission drive system consumes the equivalent of 3.3 litres of diesel per 100 kilometres in the NEDC (New European Driving Cycle). Production of the B‑Class F-CELL will commence in late 2009 with a small lot. The first of around 200 vehicles will be delivered to customers in Europe and the USA at the beginning of next year.
The new fuel cell vehicle offers everything that people expect from a Mercedes-Benz: High comfort and safety as well as no reduction in interior space and boot capacity. Customers will not have to sacrifice any driving pleasure either, because the electric motor has a peak performance of 100 kW/136 hp and a maximum torque of 290 Nm, which is available from the first rotation. It ensures that the B‑Class F-CELL, whose impressive dynamic handling properties are in some cases far better than those of a two-litre petrol car, gets off to an excellent start. Despite these qualities, the zero-emission fuel cell drive consumes the equivalent of only 3.3 litres of diesel fuel per 100 kilometres (NEDC). Thanks to its great range of about 400 kilometres and short refuelling times of around three minutes, the B‑Class F-CELL ensures local zero-emission mobility even for long stretches.
“2009 is the year in which we are establishing further milestones where sustainable mobility is concerned. The B-Class F-CELL is taking on a pioneering role as the world’s first fuel cell powered automobile to be produced under series production conditions”, says Dr. Thomas Weber, Member of the Board of Management of Daimler AG, responsible for Group Research and Development for Mercedes-Benz Cars.
The vehicle’s technological heart is the new generation of the compact, high-performance fuel cell system, in which gaseous hydrogen reacts with atmospheric oxygen at 700 bar to generate a current for the electric motor. The fuel cell system of the B‑Class F-CELL has a very good cold-start capability even at temperatures as low as minus 25 degrees Celsius. The drive system was completely newly developed versus the F-CELL A-Class presented in 2004, with Mercedes-Benz engineers achieving considerable improvements in output, torque, operating range, reliability, starting characteristics and comfort. The B-Class F-CELL now offers driving pleasure and day-to-day suitability at Mercedes level – without local emissions.
As in hybrids with combustion engines, the fuel-cell car uses a lithium-ion battery with an output of 35 kW and a capacity of 1.4 kWh to boost power and recover braking energy. Lithium-ion technology offers several advantages over conventional batteries, including compact dimensions, high performance, great recharge efficiency and a long service life.
The B‑Class F-CELL employs the unique sandwich floor architecture that is well-known from the A- and B-Class. The advantage of this design is that the drive components are located in the sandwich floor, where they are protected and don’t take up much space so that the vehicle’s interior remains fully usable and a boot capacity of 416 litres is available.
The B-Class F-CELL does not need to fear comparison where equipment is concerned either. Eye-catching features include a bonamite silver paint finish and exclusive light-alloy wheels in a 10-spoke design. In the interior, leather upholstery, seat heating, automatic climate control and the COMAND-system, as well as other features, continue to ensure a high level of comfort.
Same level of safety as in other Mercedes cars
No matter what the conditions, the operational reliability of the B‑Class F-CELL is of the same high level as in Mercedes vehicles with conventional combustion engines. The B‑Class F-CELL’s integrated safety concept takes the specific characteristics of the innovative drive system into account. The concept incorporates the expertise from the many years of experience Mercedes-Benz has had with fuel cell drives and high-voltage applications. Mercedes engineers have tested and optimised the drive-specific components’ safety in more than 30 additional crash tests.
Network of filling stations required for car’s widespread use
With more than 100 test vehicles and a combined total of over 4.5 million kilometres of trial testing, Daimler and Mercedes-Benz have the most extensive experience with fuel cell vehicles of any manufacturer worldwide. The B‑Class F-CELL is further testimony of this technology’s high level of development for automotive use. However, a comprehensive network of hydrogen filling stations still has to be set up before locally zero-emission driving can become a widespread reality. To make this possible, Daimler is cooperating with government authorities, energy utilities and oil companies in joint projects in places such as Hamburg, Stuttgart and California.
Mercedes-Benz views the development of electric cars with battery and fuel cell drives for local zero-emission driving as a means of supplementing vehicles with high-tech internal combustion engines. Advanced diesel and petrol engines will remain important for automotive applications for a long time to come – not only for individual mobility in passenger cars – especially over long distances – but, more importantly, for freight transport in trucks. Electric vehicles, on the other hand, will increasingly be used in urban transport.
A couple days ago we told you about Mercedes’ potential plans to bring an electric-drive variant of the forthcoming Mercedes-Benz SLS AMG, and today, the company has confirmed exactly that. According to Mercedes, they are “developing an exciting super sports car with zero-emission high-tech drive,” one that “sees Mercedes-Benz and AMG displaying their expertise in the development of alternative drive solutions for high-performance super sports cars.”
If you viewed our prior story on the SLS eDrive, you already know most of the details: four electric motors (one positioned near each wheel) provide a combined peak output of 392kW and a maximum torque of 880 Nm, with one transmission per axle transmitting power. According to Mercedes, “this intelligent all-wheel-drive system allows dynamically optimized power transmission without any losses by means of Torque Vectoring – in other words, the specifically targeted acceleration of individual wheels.”
Powering the Mercedes SLS electric drive at present is a liquid-cooled 400-volt lithium-ion battery of modular design with an energy content of 48 kWh and a capacity of 40 Ah – one that is charged by means of targeted recuperation during braking whilst the car is being driven.
All of this translates into an electric SLS capable of accelerating from 0-62mph in around 4 seconds.
According to Volker Mornhinweg, Chief Executive Officer of Mercedes-AMG GmbH: “With the SLS AMG with electric drive, we wanted to redefine the super sports car. For us, it is not just about responsibility. We attach just as much importance to excitement and classic AMG performance.”
New details have emerged today of the forthcoming Mercedes-Benz SLS Gullwing: according to AMG boss Volker Mornhinweg, the company is currently developing a plug-in electric version of the model. The Mercedes SLS eDrive, as its being called, is expected to be offered with the same lightweight aluminum body as the standard SLS (a model that will see it debut in Frankfurt this September), along with an interior that again remains largely unchanged from the non-electric Gullwing.
According to Mornhinweg: “The great thing is we haven’t had to alter the styling in any way,” who added “it’s completely original in appearance.” Volker then went on to note that “The very nature of the SLS, with its sizeable engine bay, sturdy torque tube running back along the backbone of the car and the mounting point for fuel tank, lends itself perfectly to adaptation for electrification.”
In total, it’s being said the Mercedes SLS eDrive will boast 392kW and 649 lb-ft of torque – this compared to the standard SLS Gullwing’s 571 hp and 470 lb-ft. While performance figures haven’t been finalized, the company is aiming for a 0-62mph time of less than 4 seconds (standard SLS: 3.8 seconds) and a top speed of 120mph (standard SLS: 196mph). Range is between 93 and 112 miles, depending on the load placed on the battery, and the recharging time sits around five hours on high-density charge or eight hours on conventional power.
As for hardware changes, Mercedes engineers have taken the route of replacing the standard SLS’ double-wishbone suspension up front with a new pushrod front suspension – one that features coil-over dampers mounted horizontally – thus freeing up space around the front axle. It is here that Mercedes will place two 98-kilowatt motors (there’s also two 98-kilowatt motors on the rear axle), making the SLS eDrive a four wheel drive vehicle. Energy for these motors will be supplied via a lithium-ion battery, mounted in the space usually filled by the standard SLS’ torque tube.
Unfortunately, there is one caveat of the new Mercedes-Benz SLS eDrive: if you’ve got your checkbook handy ready to be first in line to procure one, you’ve got a while to wait. The SLS eDrive is tentatively set for production in 2015, so if you’re looking to fill an immediate need for an electric supercar, you’ll have to look elsewhere. On a side note, there are rumors Audi could be debuting and electric R8 in Frankfurt…
We will of course keep you posted as new details of the Mercedes SLS eDrive become available.
As you may remember, about a month ago we brought you the details of a special concept vehicle known simply as the F-Cell Roadster. Inspired by the legendary Benz patent motor car and featuring design traits of modern F1 race cars, the F-Cell’s 1.2 kW hybrid drive allows the model to reach a top speed of 15 mph and achieve an operating range of 217 miles.
Over the weekend, the F-Cell Roadster took to the road, completing a portion of the historic route once traveled by Bertha Benz – a journey that has since been recognized as the first long distance journey in an automobile. Specifically, the F-Cell Roadster started in Manheim, where it was then driven via Ladenburg and Heidelberg before passing its symbolic finish line at the chemist’s shop in Wiesloch – the location where Bertha Benz stopped to refuel in 1888.
Commenting on the F-Cell Roadster’s journey, Dr. Thomas Weber, the member of the Daimler AG Executive Board responsible for corporate research and development at Mercedes-Benz Cars, notes: “This trip by the F-CELL Roadster is symbolic of the current change taking place in automobile engineering. At that time Bertha Benz was not yet able to purchase the petrol she needed at a filling station, and for emission-free mobility we are also dependent on the widespread distribution of fuels for the future – electric power and hydrogen. But just as Bertha Benz refused to be discouraged by inconveniences in her day, we are just as determined to help ensure that these technologies achieve their breakthrough.”
To see photos from the Mercedes F-Cell’s trip, keep scrolling for the full photo gallery highlighting the event (click any picture to enlarge). You can also read more about the F-Cell Roadster as well as Bertha Benz’ historic route in the official press release, also included below.
Up until now, much of I’ve written about the smart fortwo has been relatively objective, due to the fact that I personally haven’t been in the market for one of the little models. Today that changes, however, as a family member is considering the purchase of a new fortwo, and it’s with rather mixed emotions that I write this article.
A few days ago at the start of the Detroit Auto Show, Daimler announced that at the end of 2009 the company will begin production of an electric smart fortwo, and they are “exploring” opportunities for the United States market. They then took the opportunity to detail at length the various projects currently underway in which electric fortwo models are in operation, such as the previously detailed “e-mobility Berlin.” But going back to what I said originally, with a family member considering a new fortwo, American consumers have to ask: what the hell is taking so long?
Daimler is “exploring opportunities for the United States market?” What specifically does that mean? Does that mean we’ll get an electric smart fortwo by 2010, or does it mean we’ll get some scaled back project where 100 or so fortwo ed’s will be tested on U.S. soil? To be honest, I don’t really care what it means. What I do care about is why the current U.S. smart fortwo lineup consists of one engine variant that averages 40 mpg. An electric smart fortwo? How about a diesel smart fortwo that averages 60-70 mpg. That’s what we really want. And yet, a single smart fortwo in the U.S. is what exists, while the Toyota Prius – a model that’s both larger and more practical – outperforms the smart by roughly 10 mpg.
Do I want an elecric fortwo in the United States? Absolutely. But Daimler, quit stringing us along offering us small glimpses of what the future may hold; bring a diesel smart to the U.S. in the interim; and please, give us some incentive not to buy a Prius, because right now, you’re not doing so great.
But enough of my views on the subject. To read more of Daimler’s plans for the electric smart fortwo, keep reading for the official press release.
Mercedes-Benz is showing the way ahead in environmentally responsible electromobility by presenting its near-series Concept BlueZERO at the North American International Auto Show in Detroit. Based on a single vehicle architecture, this intelligent, modular concept allows three models with different drive configurations, all of which are able to meet customer requirements in terms of sustainable mobility:
The three BlueZERO variants are based on the unique sandwich-floor architecture which Mercedes-Benz introduced some ten years ago, initially for the A-Class and then for the B-Class, one of the aims being to integrate alternative drive systems. Advantages of the modified construction include the positive effect of the major drive components on the centre of gravity, their space-saving design, and the fact that they are extremely well protected within the vehicle underbody. The five-seater BlueZERO concept cars also set standards in terms of lightweight design, interior layout, and body form.
“The flexible BlueZERO concept allows electromobility for every requirement and highlights the fact that Mercedes-Benz is the world’s only car manufacturer to already have in place all the key technologies for electric cars offering full everyday practicality”, says Dr. Dieter Zetsche, Chairman of the Board of Management of Daimler AG and Head of Mercedes-Benz Cars.
The BlueZERO principle: flexible design, compact exterior, and generously sized interior
All three BlueZERO variants share the same key technical components, while the design and vehicle dimensions are identical. Measuring just 4.22 meters in length, the BlueZERO models combine compact exterior dimensions with a generously proportioned and variable interior and luggage compartment. Five fully-fledged seats, a payload of around 450 kilograms, and a luggage compartment capacity of over 500 liters make for outstanding everyday practicality. Thanks to their sandwich construction with a raised sitting position, the cars also offer an exceptionally high level of crash safety for the passengers and the technology, not to mention excellent all-round visibility.
Compared to electric cars based on conventional vehicle platforms and originally only designed for use in combination with internal combustion engines, Concept BlueZERO offers the following conclusive advantages:
Interior space is retained in full. As the energy accumulators/generators are integrated into the spacious sandwich floor, no compromises are necessary with respect to passenger space, luggage capacity, or variability.
The powertrain technology built into the sandwich floor ensures a low centre of gravity and, consequently, extremely reliable and agile handling.
Crash safety is of the extremely high standard associated with Mercedes thanks to the sandwich concept and the housing of major powertrain components between the axles.
As a result, the BlueZERO models are very different to conventionally constructed electric cars, which have the heavy and voluminous storage battery housed in the boot or in the rear-seat area, for example.
Modular design assures flexibility and efficiency
“Our modular system allows different drive configurations for every customer requirement”, says Dr Thomas Weber, the member of the Daimler AG Board of Management responsible for corporate research and development at Mercedes-Benz Cars. “The modified sandwich-floor platform provides the perfect basis for a wide model range with electric drive systems. We are also developing a new, additional platform for future compact models with power units based on optimized internal combustion engines. The intelligent networking of both architectures enables us to develop our product portfolio extremely flexibly and efficiently. From 2009, we will be producing the first Mercedes fuel-cell cars on a small scale. Small-scale production of Mercedes-Benz cars with battery-electric drive alone will then commence in 2010. This means we are extremely well equipped for the future.”
All three BlueZERO models feature front-wheel drive, which is typical for this class of car. The Mercedes engineers have put together a modular system comprising several flexibly combinable drive components. These include state-of-the-art liquid-cooled lithium-ion batteries with a storage capacity of up to 35 kWh and the compact electric motor with a maximum output of 100 kW (continuous output 70 kW), which develops a peak torque of 320 Nm. All three variants accelerate from 0 to 100 km/h in less than 11 seconds. Their top speed is electronically limited to 150 km/h in the interests of optimal range and energy efficiency.
Electric drive systems with a range of 100, 200, and well over 400 kilometers
With a charging capacity of 15 kW, the powerful lithium-ion batteries in the BlueZERO E-CELL and the BlueZERO E-CELL PLUS can store enough energy for a range of 50 kilometers within 30 minutes. In terms of purely electrical drive, one or two hours of charging time is needed for a range of 100 and 200 kilometers respectively. The charging times are doubled if the charging capacity is 7 kW, as would be the case in a normal household. Both of these BlueZERO vehicles incorporate an electronic control unit that supports intelligent charging stations and billing systems.
At the rear, the BlueZERO E-CELL PLUShas the same 1.0-litre turbocharged gasoline engine as the smart fortwo as an additional range extender. This compact three-cylinder powerplant has an output of 50 kW at a constant 3500 rpm. If required, it can recharge the 17.5-kWh lithium-ion battery by means of a similarly rated alternator. A range of up to 600 kilometers is possible on a single tank. The purely electrical, locally emission-free range is up to 100 kilometers. The BlueZERO F-CELLwith fuel-cell drive achieves a range of well over 400 kilometers with zero emissions (as per NEDC).
BlueZERO design: both elegant and functional
Leading-edge technology is uniformly and attractively packaged in all three BlueZERO variants. The unique and distinctive Mercedes design idiom displayed by the body highlights the progressive nature of Concept BlueZERO at first glance.
The powerfully elegant front end is dominated by the radiator grille with its centrally located star. The excellent aerodynamics of the BlueZERO are partly due to the closed front apron, whose design means that cooling air intakes are not required. The 20-inch wheels have also been aerodynamically optimized, while low-friction tires are fitted to reduce rolling resistance.
The striking character lines along the flanks lend the BlueZERO an extremely dynamic side line and accentuate its bionic structure inspired by nature. This characteristic feature of the Mercedes-Benz bionic car was adapted and modified for the BlueZERO models. These elements lend the body its dramatic power.
New-quality light production
The compact rear end of the Concept BlueZERO is characterized by tail lights in the shape of a curved “L”. In addition, the Mercedes designers have achieved a new-quality light production: transparent lenses produce a red light curtain which tapers smoothly towards the sides, creating a lightly diffused effect. This effect is repeated, albeit in white this time, by the front headlamps. What’s more, the front lights feature new lens technology and a plexiglass edge to produce “C” shaped daytime driving lights with the help of state-of-the-art LED technology.
Intelligent technology made visible
Translucent surfaces make the normally concealed technology visible. The light-gray tailgate is made completely from lightweight but highly robust Lexan, allowing a view of the aluminum structure that makes up the rigidifying frame, for example. At the same time, this transparent tailgate provides a view of the vehicle interior, making the advantages of the sandwich-floor platform obvious at a glance: for maximum customer benefit, the luggage compartment and passenger area remain fully usable, since there are no technical components that need to be accommodated here.
“It was very important for us to ensure that the guiding Mercedes-Benz principle of ‘Fascination and Responsibility’ was clearly reflected in the design of the Concept BlueZERO”, says Mercedes-Benz design chief Gorden Wagener. “This is yet another clear statement that environmental awareness and driving pleasure will continue to go together in our vehicles in the future. We want people to realize at first sight that the Concept BlueZERO is definitively not a lesser option.”
The Mercedes-Benz designers have emphasized this aspiration by introducing paint finishes in three new ALU-BEAM colors. Each of the three variants makes its individual mark: the BlueZERO E-CELL is painted in fresh ALU-BEAM yellow, while the BlueZERO F-CELL has ALU-BEAM green paintwork. Confidence-oozing ALU-BEAM orange was chosen for the BlueZERO E-CELL PLUS.
Extended version
Mercedes-Benz Concept BlueZERO: three-fold proof of the everyday practicality of zero-emission vehicles
Current challenges such as growing worldwide mobility requirements, declining crude oil reserves, and increasingly stringent exhaust emission regulations are making the electric car more and more a focus of public attention. Thanks above all to major advances in battery technology, electric drive is seen as a promising answer to the question of how individual mobility can be made sustainable.
Battery-electric drive systems offer a wealth of advantages in this respect: they provide a high level of torque, are compact and quiet, run extremely efficiently and with zero local emissions, and they operate without the need for fossil fuels. However, it is not currently possible to fulfill all mobility requirements with a single electric vehicle concept. Those who drive predominantly or even exclusively in urban areas do not place as much emphasis on vehicle range but very much like the idea of lower noise levels and emissions. For such customers, a battery-electric vehicle is an attractive solution.
Those who also wish to cover long distances on country roads and motorways combined with low noise levels, no local emissions, and short refueling times have a viable alternative in the shape of the fuel-cell electric vehicle. This technology clearly shows the way ahead in terms of sustainable mobility after the “crude oil age” but requires a hydrogen-fuel-supply infrastructure. The beneficial combination of maximum range, fast energy storage on board from an existing infrastructure, and noiseless and locally emission-free mobility in urban areas is offered by a battery vehicle with range extender.
Concept BlueZERO: modularity assures optimal everyday practicality
The sandwich-floor architecture and the modular design allow three different drive configurations that are able to meet an extremely wide range of different requirements. Measuring 4.22 meters in length, 1.89 meters in width and 1.59 meters in height, the extremely compact BlueZERO concept offers decisive design advantages over electric cars based on conventional vehicle platforms and designed only for use in combination with internal combustion engines.
Interior space is retained in full. As the energy accumulators/generators are integrated into the spacious sandwich floor, no compromises are necessary with respect to passenger space, luggage capacity, or variability.
The powertrain technology located in the sandwich floor and integrated directly at the front axle assures a low centre of gravity and, consequently, extremely reliable and agile handling.
Crash safety is of the extremely high standard associated with Mercedes thanks partly to the housing of the powertrain components between the axles.
Furthermore, all three BlueZERO electric cars are highly suitable for electromobility in urban areas on account of their compact dimensions, easy entry and exit, raised sitting position, and optimal all-round visibility. All of which makes Mercedes-Benz the first and, to date, only car manufacturer in the world to offer three optimal solutions that meet all customer electromobility requirements.
Intelligent sandwich platform assures the highest possible level of safety
Featuring a modified version of the sandwich-floor platform, the BlueZERO concept sets standards for the electric car sector in all areas relevant to day-to-day motoring. The best possible crash safety is assured, since almost all of the drive components are housed within the sandwich floor, that is to say in the protected area between the axles.
Typically for this class of car, all three versions of the Concept BlueZERO are front-wheel drive models with an electric motor at the front axle. The batteries are located in the center of the vehicle floor behind this, in a position which protects against intrusion in the event of a frontal or rear impact, since the energy accumulators are located outside of the body’s impact and deformation zones. Furthermore, the extremely robust construction of the sandwich floor can offer a high level of protection for both the battery and the occupants, even in the event of a side collision. This advantage is also of economic benefit, since the battery is the largest cost factor in electric drive systems. Consequently, if the battery remains undamaged in an accident, the follow-up costs are reduced considerably. By virtue of its proven nutshell effect, the sandwich floor is the safest place for housing the still relatively expensive energy accumulators.
Room for five occupants and luggage thanks to highly efficient use of space
This clever sandwich construction also has obvious advantages where packaging is concerned: locating the drive modules in an underfloor position makes it possible to retain all of the passenger and luggage space in this 4.22-meter long five-seater, with no restrictions whatsoever. In the purely battery-powered BlueZERO E-CELL, for example, up to two of the lithium-ion battery packs developed by Mercedes-Benz can be accommodated in the sandwich floor.
In addition to exemplary safety and unrestricted everyday practicality, the BlueZERO models have further strengths that are by no means the norm for electric cars, namely agility and driving enjoyment. This is in large measure due to the low centre of gravity, another benefit of the low installed position within the sandwich floor, and the front axle suspension. In combination with uncompromising attention to centered masses, this results in outstanding roadholding and handling agility.
Modular drive concept for individually configured electric vehicles
Mercedes-Benz will present two BlueZERO variants at the 2009 NAIAS show in Detroit: the BlueZERO E-CELL as a purely battery-powered vehicle and the fuel-cell version, the BlueZERO F-CELL – both of which are emission-free in local operation. Mercedes-Benz development engineers are also working on a third version with a range extender, the BlueZERO E-CELL PLUS. This is additionally equipped with a compact internal combustion engine as a generator that produces power during a journey.
All these models feature battery packs based on the latest lithium-ion technology. This new battery technology has decisive advantages over conventional battery types, among them very compact dimensions, significantly higher performance, excellent reliability, and a long operating life. The identical components used in the modular system also include the compact, permanent-magnet synchronous electric motor, which operates at a maximum of 13,280 rpm. It develops a peak output of 100 kW and a continuous output of 70 kW. Its peak torque is 320 Nm, while the continuous torque is 180 Nm. The maximum torque is available from the first revolution of the electric motor and exceeds the figure achieved by a current V6 gasoline engine at 2500 rpm.
BlueZERO E-CELL: agile, quiet and locally emission-free
The BlueZERO E-CELL is equipped with a lithium-ion battery with a capacity of 35 kilowatt hours (kWh). The liquid-cooled high-voltage cells have an operating voltage of 240 to 426 V. With this battery, the BlueZERO E-CELL has an operating range of up to 200 kilometers. Recharging the empty battery takes three to four hours. The BlueZERO E-CELL accelerates from zero to 100 km/h in less than eleven seconds and, in the interests of optimal range and energy efficiency, has an electronically limited top speed of 150 km/h.
BlueZERO F-CELL: emission-free driving on long journeys with the fuel cell
The new-generation fuel cell used in the BlueZERO F-CELL is more compact and – with a maximum output of 90 kW (continuous output 80 kW) – also more powerful than its predecessor. It can be cold-started at temperatures down to minus 25 degrees Celsius and also has the benefit of short refueling times.
On the road, the BlueZERO F-CELL assures a high standard of dynamic handling, yet this family-friendly compact car consumes just 2.9 liters of fuel (diesel equivalent) per 100 kilometers. According to the NEDC, the BlueZERO F-CELL is able to cover well over 400 kilometers on one tank of hydrogen.
In the fuel cell version of the BlueZERO, the electric motor, high-voltage battery, and hydrogen tank are likewise positioned beneath the passenger cell to save space. The system uses the most efficient energy source for the current driving situation. When parking or maneuvering at slow speed, for example, the electric motor uses only battery power. When accelerating, energy is provided by both the fuel cell and the battery. When braking, the electric motor acts as a generator and charges the battery. This efficient system therefore makes use of the energy that would be converted into heat during conventional braking and stores it in the powerful lithium-ion battery.
For longer journeys too, Mercedes-Benz sees the fuel cell as one of the key technologies for zero-emission driving. Providing a suitable network of hydrogen filling stations is in place, this technology offers ideal possibilities for sustainable mobility well into the future. The hydrogen-powered fuel cell combines zero emissions with a long operating range, since electrical power is generated on board during the journey. There are no exhaust emissions whatever, and no CO2 is emitted either. The BlueZERO F-CELL emits nothing more than steam. Moreover, a fuel cell drive system is almost twice as efficient as an internal combustion engine.
BlueZERO with range extender: flexible solution with a long range
In the third version, the BlueZERO E-CELL PLUS, the Mercedes engineers combine the electric drive system from the purely battery driven BlueZERO E‑CELL with an additional internal combustion engine that serves as a range extender. The compact 50-kW three-cylinder turbocharged gasoline engine from the smart fortwo charges the battery whilst the car is being driven.
Advantage of the range extender: as with conventionally powered cars equipped with a gasoline or diesel engine, the customer benefits from a significantly longer range (up to 600 km), especially as the BlueZERO E-CELL PLUS can also be quickly and easily refueled at any normal filling station. The customer can therefore be sure that the car is available for use anywhere and at any time. And when an urban area is reached after an overland journey, the driver can continue on their way under electric power alone.
The BlueZERO E-CELL PLUS therefore allows electric mobility at the touch of a button, a particular benefit in densely populated urban areas with environmental zones, toll charges, and other access restrictions affecting cars with internal combustion engines.
The BlueZERO E-CELL PLUS with the range extender clearly highlights the advantages of the sandwich-floor platform: here too, the key drive components are integrated in the underfloor area to save space. The internal combustion engine is installed near the rear axle, in the spare wheel well. Thanks to the range extender, the BlueZERO E-CELL PLUS has a range of up to 600 kilometers, of which 100 kilometers are in locally emission-free electric mode, with no drop in performance. The NEDC fuel consumption is 4.5 liters per 100 kilometers. In conjunction with a plug-in battery and the resulting CO2 bonus, the car emits just 32 grams of CO2 per kilometer.
In addition, the highly efficient modular concept allows further variants to be individually configured. If the system is designed appropriately, the internal combustion engine used as a range extender can also be employed temporarily as a direct drive unit – when driving on country roads, for example. This setup leaves the full battery capacity available for driving in town. Other conceivable variants might be to use the fuel cell as a range extender, or a combination of the fuel cell and plug-in batteries. Thanks to this versatility, the Mercedes-Benz modular electric drive concept is able to cover every conceivable option for electric driving.
Instead of a fuel filler cap, the car features plug-in connectors to EU and US standards for rapid recharging with electrical power. One contact is intended for conventional power cables that fit any household power socket. The second is suitable for connection to public recharging stations.
BlueZERO design: both elegant and functional
Cutting-edge technology is very attractively packaged in all the BlueZERO variants. The future-oriented yet unmistakable Mercedes-style body contours accentuate the progressive nature of the Concept BlueZERO at first glance.
The Mercedes-Benz designers have emphasized this aspiration by introducing paint finishes in three new ALU-BEAM colors. Each of the three variants makes its individual mark: the BlueZERO E-CELL is painted in fresh ALU-BEAM yellow, while the BlueZERO F-CELL has ALU-BEAM green paintwork. Confidence-oozing ALU-BEAM orange was chosen for the BlueZERO E-CELL PLUS.
Striking design idiom with bionic structures
The striking character lines along the flanks give this compact concept car a very dynamic side line and accentuate its bionic structure. This characteristic feature of the Mercedes-Benz bionic car was adapted and modified for the Concept BlueZERO. These elements lend the body design its dramatic power.
The lower line emerges from the flank in the front doors at the height of the wheel hub, then rises gently to turn steeply upwards and harmoniously continue the body line to the tail lights. This has the effect of stretching the body in visual terms, while suggesting dynamic forward movement despite the comfortable vehicle height. The precisely placed edges break the light to striking effect and lend the BlueZERO a masculine character that is a hallmark of the new Mercedes-Benz design idiom.
Translucent surfaces make the normally concealed technology visible. The light-gray tailgate is made completely from lightweight but highly robust Lexan, allowing a view of the aluminum structure that makes up the rigidifying frame, for example. At the same time, this transparent tailgate provides a view of the vehicle interior, making the advantages of the sandwich-floor platform obvious at a glance: the luggage compartment and passenger area remain fully usable, since there are no technical components that need to be accommodated here.
Key features at the distinctive rear end of the BlueZERO models include tail lights in the form of a curved “L”, whose flame-like shape add a futuristic touch. In addition, the Mercedes designers have achieved a new-quality light production: four transparent lenses produce a red light curtain which tapers smoothly towards the sides, creating a lightly diffused effect.
This effect is repeated, albeit in white this time, by the front headlamps. What’s more, the front lights feature new lens technology and a plexiglass edge to produce “C” shaped daytime driving lights with the help of state-of-the-art LED technology. The extremely energy-efficient LED technology offers the same brightness but requires ninety percent less power than conventional lights.
The lenses are held by supports which also serve as direction indicators.
Aerodynamic design with eye-catching effects
The radiator grille with its centrally located star and even more pronounced V‑shape is a striking reinterpretation of the world-famous Mercedes-Benz radiator grille. The excellent aerodynamics of the BlueZERO are partly due to the closed front apron, whose design dispenses with any cooling air intakes. The 20-inch wheels are also aerodynamically optimized. Low-friction tires are fitted to reduce rolling resistance.
Like many other design features, the wheel covers are transparent and allow a view of wheel spokes, which are visually enhanced with three-dimensional light effects. All BlueZERO variants are also equipped with a semi-transparent, lightweight panoramic roof into which solar panels have been integrated. The thin-layer cells used here allow 20 percent of the light into the interior. Given enough sunlight, they generate sufficient electric power to charge cell phones or mobile MP3-players, for example.
Progressive interior design
The interior features an all-new, progressive design idiom: the lines are curved and blend in subtly with the organic surfaces. The Concept BlueZERO is a logical continuation of the bionic design line and is similar to the Mercedes-Benz bionic car. A wealth of structures inspired by nature and modeled based on organic growth can be found in several of the paneling components: in the door stowage areas, the cockpit, the centre console, the load compartment, and the load sill guard.
The array of colored transparent surfaces lends the interior a feeling of lightness. This is enhanced by semi-transparent surfaces whose edges form striking light breaks. This interplay between transparency and edge emphasis contrasts extremely well with the soft design idiom. The suggested fluorescent conductor paths in the center console represent the advent of a future drive technology.
The sporty front seats feature seemingly inserted upholstery and dynamically shaped backrests. The overall impression is one of lightness and litheness, all
of which makes the vehicle interior feel much more open. As a five-seater, the Concept BlueZERO offers the flexibility and functionality of a modern-day compact car.
The material concept is largely based on a tone-in-tone composition enriched by touches of color. By way of example, the belt color and the seam thread in the paneling components establish a link with the car’s exterior, while the leather strip in the seats creates a visual link with the high-quality steering wheel.
Thanks to their surface quality, the materials are highly resistant. The material mix of textiles and plastics combines a high level of value with high-tech appeal.
Concept BlueZERO: a blueprint for efficient electromobility
With the BlueZERO concept studies, Mercedes-Benz provides a very specific outlook on the immediate future of electric motoring. Major components of this modular drive concept will shortly be used in standard-production cars made by Mercedes-Benz. These include the fuel cell drive system, which will enter small-scale production in 2009. In 2010, the first Mercedes-Benz electric car will also be introduced into small-scale production.
Modular design as a strategic guideline
With this intelligently conceived modular system, Mercedes-Benz will also be able to realize tailor-made drive configurations for individual requirements in the electric car sector. For the brand’s clients, this means a wide choice of purpose-made, efficient, and affordable solutions.
The product implementation presented by Mercedes-Benz on its “Road to the Future” is uncompromisingly wedded to the modular design principle: modular drive technologies that can be used individually or in combination depending on vehicle class, operating profile, and customer requirements are a key factor in this.
Modular drive concept also for hybrid vehicles
This particularly applies to hybrid models such as the S 400 BlueHYBRID, which is due to be launched in 2009 as the most economical gasoline-powered luxury saloon and CO2 champion in its class. For its hybrid models with gasoline and diesel engines, Mercedes-Benz has developed a modular system which can be expanded with respect to performance and range of applications.
In the S 400 BlueHYBRID, the hybrid module with its start-stop function, recuperation and boost effect already makes considerable savings possible.
With a suitable configuration, it is also possible to drive under electric power alone with this hybrid module, while the operating range in electric mode depends on the battery capacity.
The plug-in hybrid represents a further step, where the battery can also be charged from the mains in order to increase the electric operating range.
Intelligent drive mix for sustainable mobility
In the view of Mercedes-Benz, there will be no single technology as the ideal solution for sustainable mobility in the future. Instead the company is responding to the varied requirements with equally versatile solutions. The respective advantages of the individual technologies in terms of optimal fuel consumption and emission values are applied in specific application areas. Mercedes-Benz is basing its strategic planning for the future of individual mobility on the following mix of drive systems:
For long-distance operations, sophisticated internal combustion engines with or without a hybrid module will be used, as well as fuel cell powered vehicles.
For rural operations, plug-in hybrids will increasingly be added to the mix.
For urban operations, locally emission-free vehicle concepts with battery and fuel-cell drive systems are considered to be the most suitable.
The electric drive configuration presented in the Concept BlueZERO does full justice to this requirement profile. Mercedes-Benz has conducted intensive research in the field of fuel cell technology since as early as 1991 and, therefore, has enormous experience with electro- mobility. The brand has the world’s largest fleet of fuel cell powered vehicles undergoing client trials, for example.
And in the field of battery-powered vehicles, the company has also gained unrivalled experience from fleet trials involving 100 smart electric drive cars in London. The Concept BlueZERO impressively reflects this in-depth know-how.