!NEW! All-New Opel Astra in the Acoustic Lab

• Dynamic, smooth, comfortable: New engines for pleasant sound
• No din: “Dummy heads” as sensitive as the human hearing

In the acoustic lab: New Opel Astra is positioned in the center of the room and is surrounded by numerous microphones.

Silence. It is so quiet in the unusual looking room that you could literally hear a pin drop. The new Opel Astra is positioned in the center of the room and is surrounded by numerous microphones. Is the engine sound of the new compact class star being recorded for the next advertising campaign? Not quite. When the Opel Astra arrives in the acoustic lab, it is still in the final phase of being made ready for series production. The engineers around Bernd Justen are partly responsible for making sure that the new Astra really is a quantum leap. They ensure that the compact class car meets the demanding noise requirements and test the Astra thoroughly in the Opel acoustic lab in Rüsselsheim. Apart from being tested on the comfort and noise evaluation track at the Opel Test Center in Rodgau-Dudenhofen, all new models developed by the carmaker have to come here for final testing.

Meets all noise requirements: All-New Opel Astra in the acoustic lab in Rüsselsheim. 

Noise & vibration: All good under the Opel Astra hood

The dynamic sound of the vehicle while simultaneously delivering excellent running smoothness was always high on the list of specifications of the new Opel Astra. Primarily, the turbo-charged gasoline and diesel engines of the latest generation that power the Opel Astra and make its athletic appearance audible ensure this. “That is only one aspect we check in the acoustic lab,” explains Bernd Justen, Vehicle Performance Manager for compact class cars. Moreover, the Astra is put through an extensive and precisely defined requirements list. “Apart from the appropriate sound of the engine or rolling noise, this includes the sound made by closing a door or the clicking of the indicator. We initially check the simulation-based basic settings. Based on this we keep on working until the Astra meets our noise requirements.”

On the roller test bench: The engines offer a pleasant and dynamic sound experience – and reduces noise levels in the cabin.

The walls and the ceiling of the lab are completely soundproof thanks to noise absorbing materials. During testing, the Opel Astra is driven on large floor rollers, which produce the same resistance the car would experience on the road from wind and rolling friction. “This enables driving with road-like loads. It does not depend on the weather and we can test various scenarios under consistent conditions,” said Justen. These tests include idle behavior, the Start/Stop function and driving under part or full engine load for example. The highly sensitive microphones record all noises so they can be analyzed afterwards.

Meets all noise requirements: All-New Opel Astra in the acoustic lab in Rüsselsheim.

A typical procedure on the roller test bench is ‘full-load, rev-up’ in third gear – a demanding test that the all-new 1.4 ECOTEC Direct Injection Turbo, a four-cylinder Opel unit from the same engine family as the innovative one-liter, three-cylinder engine, passes with flying colors while always remaining within the pre-defined tolerance curve for cabin noise. Just like the three-cylinder engine, the 92 kW/125 hp or 110 kW/150 hp unit was developed with setting new standards in noise and vibration characteristics in mind (fuel consumption combined: 5.5-4.9 l/100 km, CO2 emissions combined: 128-114 g/km). The outstanding refinement was achieved through the noise-optimized engine block design. The implemented measures to reduce the noise level included splitting the oil pan, noise protecting the integration of the cylinder head into the exhaust manifold, designing a sound-absorbing cam cover, decoupling the high-pressure injection valves and trimming the timing chain for quiet concentricity. The test bench quickly reveals that the engineers did an outstanding job: The engines offer a pleasant and dynamic sound experience – and reduces noise levels in the cabin.

“Dummy head” tested: Pleasant sound in the Opel Astra cabin

“Our dummy heads confirm the exemplary noise level,” explains Justen, referring to the weird looking figures in the Opel Astra cabin that are reminiscent of mannequins. Plastic effigies of the human head and shoulder area that possess a perfect replica of all acoustically relevant elements of the human outer ear adorn the seats. “There are highly sensitive microphones fitted in the ears of dummy heads too. They allow us to record and replay noises in the same way that a ‘real’ human would perceive them.” This enables stereo recording and replaying, as well as differentiation between the upward and downward direction of noise, making the dummy’s hearing virtually three-dimensional.

Dummy head: Plastic effigies of the human head and shoulder area that possess a perfect replica of all acoustically relevant elements of the human outer ear are used in the acoustic la

To achieve the desired vehicle sound that is pleasant for occupants, a binaural transfer path analysis and synthesis is conducted using so-called binaural measurements. This enables a distinction between airborne and structure-borne noise source paths. “This allows us to identify and analyze the different sound sources,” explains Justen. Using a noise transfer path model, engineers can identify, for example, which screw needs to be turned to achieve the agreed target value – first virtually and then in reality. If both cases produce satisfactory results, the Astra has taken its next hurdle on the way to production readiness.

!NEW! Light, Lighter – New Opel Astra

• Consistent lightweight design: Five-door model up to 200 kilograms lighter
• Engineered from white sheet of paper: Every component trimmed to highest efficiency
• Compact: All-aluminum engines and interior concept save more weight
• Intelligent architecture: More space in slimmer shell

Consistent lightweight design: New Opel Astra is up to 200 kilograms lighter than its predecessor

Lighter, more frugal and compact while offering more generous interior space – everything about the new Opel Astra follows the maxim of highest efficiency. All components and design features are aligned to this touchstone, resulting in intelligent packaging à la Astra. The next generation of the compact bestseller that makes its premiere at the IAA in Frankfurt (September 17 – 27) is based on an all-new lightweight architecture, its body is noticeably slimmer and it is driven by powerful, weight- and CO2-optimized all-aluminum engines. All told, the new Astra is up to 200 kilograms lighter than its predecessor.

Consistent lightweight design: The new vehicle architecture

The visionary Monza Concept presented at the 2013 IAA was the role model for Opel’s eleventh compact class generation. Every component of the study reflects the efficiency maxim. The new Opel Astra already consistently realizes this vision: depending on the model and trim level, it is up to 200 – but in any case at least 120 – kilograms lighter than its predecessor. The new, thoroughly slimmed down vehicle architecture plays a decisive role in this weight loss: the bodyshell (body-in-white) and structure alone are over 20 percent lighter, down from 357 to 280 kilograms. Another 50 kilograms were saved in the design of chassis components: high-strength and ultra-high-strength lightweight steels, more compact subframes as well as modification to the front and rear suspensions all contributed to this end result. In addition, engineers decided against full underbody paneling to further optimize the aerodynamics of chassis and drivetrain elements, resulting in a double advantage: lower weight and reduced production costs that enable more attractive price structures for customers.

Bodyshell weight alone was reduced by 20% from 357 to 280 kilograms

Further size- and mass-optimization measures include shorter front and rear overhangs, as well as the up to 25 percent lighter exhaust system which saves around 4.5 kilograms on this part alone. The smaller wheels and tires weigh up to 11.5 kilograms less. The same is true for the brakes: as the system has less mass to decelerate, a more compact design weighing 10 kilograms less was possible – while delivering even better braking performance.

Lose the weight: Engines make their contribution

Another plus on the efficiency side is the new-generation engines. They distinguish themselves with their compact and ultra-efficient design: for instance the new 1.4 ECOTEC Direct Injection Turbo engine making its premiere in the Astra weighs much less than current comparable units. Its aluminum engine block alone is ten kilograms lighter than the cast-iron block of its predecessor. Thanks to their compact design, the newest-generation, ultra-modern transmissions save just as much weight.

All-aluminum: New 1.4 ECOTEC Direct Injection Turbo with central direct fuel injection will be available in the new Opel Astra in two outputs, 92 kW/125 hp and 110 kW/150 hp.

Reduced weight also leads to noticeably higher agility. The new Astra is more fun to drive than ever before – while saving fuel and CO2 emissions. The newcomer with the 1.0 Turbo and Easytronic 3.0 combination is one of the most economical and cleanest gasoline models in its segment. The 77 kW/105 hp three-cylinder unit reduces consumption in the combined cycle to 4.2 liters per 100 kilometers and CO2 emissions to an exemplary 96 g/km.

Lose the weight: Light all-aluminum engines like the highly efficient 1.0 Turbo make their important contribution to it.

The interior was also put through a fitness program. Take, for instance, the seats: after five years of detailed work, the development team presented compact class seats that are more functional and comfortable, while featuring more of a space- and weight-saving design than ever before. State-of-the-art packaging calculation methods enable this, as do lighter polyurethane foams and ultra-high-strength steels that are built in under the robust seat upholstery. So the new Opel Astra seats in front and rear are a total of around ten kilograms lighter than in the previous model.

Intelligent packaging: Lighter, more compact yet more spacious

Intelligent packaging: New Opel Astra is lighter, more compact yet more spacious than its predecessor.

The new Astra generation not only looks more sophisticated and athletic, it is also more compact. With a total length of 4.37 meters, the five-door hatchback is almost five centimeters shorter than its predecessor, its height of 1.48 meters is 2.5 centimeters smaller and its width has been reduced by 0.5 centimeters to 1.81 meters. These dimensions also have a positive effect on the vehicle’s weight. At the same time, interior space is more generous. Together with the newly designed, lighter and more compact seats, rear-seat passengers now benefit from 35 millimeters more legroom than before. This puts the five-door model in first place ahead of all the competition. Distance between the first and second rows has been increased by 1.5 centimeters, greatly enhancing traveling comfort and sense of space. The same is true for upper-body freedom of movement for passengers in both front and rear seats. Especially in terms of headroom, the new Opel Astra sets standards in its class: the driver has 2.2 centimeters more headroom than in the predecessor. So the new Opel Astra successfully squares the circle: it is lighter and more compact while offering more space and comfort than before.

!NEW! The Reliable Opel: Zafira MPV Cruises to 500,000 km

• Zafira A MPV clocks 500,000 km in front of the Adam Opel Haus
• Opel Group CEO Dr. Karl-Thomas Neumann welcomes owner

Tough call: Opel Zafira driver Andreas Schild (right) and Opel CEO Dr. Karl-Thomas Neumann (left) debate whether he should swap his trusty red Opel Zafira for a New Opel Zafira Tourer.

The timing was perfect, the last stretch planned in every detail: When reaching the forecourt of the Adam Opel Haus the speedometer of the Zafira turned over to 500,000 km. After 12 years of loyal service to its owner Andreas Schild from Frankfurt, both the car and the driver received their just reward. Opel Group CEO Dr. Karl-Thomas Neumann welcomed Schild and his Zafira in front of the Adam Opel Haus.

Perfect timing: Opel Zafira owner Andreas Schild timed his visit to the Adam Opel Haus to perfection, reaching 500,000 km in front of the Opel HQ in Rüsselsheim.

Schild’s Zafira is a 2.2 liter DTi built in 2002 with 125 hp with Selection Executive trim. What makes the car special is that despite reaching half a million kilometers only very few parts, apart from the usual wear parts such as brake disks or brake pads, have been have been changed: the rear muffler, two suspension struts (without the shock absorbers) along with the power steering pump. All other parts are still the originals.

Polished appearance: Andreas Schild had the Opel Zafira washed and polished to ensure that it would truly shine on its big day.

“Apart from being used as business vehicle on a daily basis, the flexible van is also frequently seen on trips to southern Europe to buy wines and Mediterranean delicacies,” said Schild. “Once I loaded 495 wine bottles and I never had the feeling that I was asking too much of the car.”

“Mr. Schild’s Opel Zafira is an example of the core values of our brand: German engineering and precision combined with high user value are essential components of our brand DNA. Current studies such as the J.D. Power Study Germany 2014, in which our Meriva had the highest customer satisfaction in its sector, underline this,” said the Opel CEO. “The idea behind the excellent Flex7 seating system swung my decision when I bought the car. This system is a real piece of engineering ingenuity,” added Schild.

“When did you buy it?”: Opel CEO Dr. Karl-Thomas Neumann (right) finds is pleasantly surprised by the fact that Andreas Schild (left) has been using his Opel Zafira on a daily basis for twelve years and has amassed 500,000 km.

The owner of a Frankfurt-based event agency has always been a huge fan of the traditional brand. His first car was a 1965 Record 1900 L that his uncle bought him after he passed his driving test in 1978. He also had other Opels such as a Kadett, an Omega and a further Zafira.

Schild is especially amused by the reaction of his friends and family when he continues to roll up in his flexible seven-seater. They always ask the same question. What ? That car still works ?