Saving Lives: 50 years of Seat Belts in all Opel Vehicles

• Ahead of the times: In 1973, Opel introduced seat belts as standard across range, three years before they became mandatory
• Start 1968: Opel Kadett, Admiral and Diplomat already available with front seat belts
• Comfortable: Opel Omega 1986 - first car with height-adjustable belts as standard
• Fine-tuned: New Opel Astra Electric with further developed “belt anti-lock braking system”

Newly developed electric motor, class-leading IntelliLux LED Pixel Light with a total of 168 LED elements, head-up display or natural voice recognition "Hey Opel" – first electrified Opel Astra is full of technical highlights. But the engineers have also further developed compact class bestseller in less visible areas. One safety specific feature now makes new Opel Astra Electric even safer: adaptive belt force limiter. It controls the belt force, which acts on the body during an impact, even more precisely in order to reduce injuries as far as possible and at the same time protect the driver as much as possible.

Adaptively controlled restraint system uses sensors to recognize severity of accident and optimally adapts belt force to course of crash. A plus in safety that can make all difference. Despite all airbags and assistance systems: “Seat belt is still the most important lifesaver in the car,” says Peter Schüßler, Manager of Passive Restraint Systems at Opel in Rüsselsheim. And the most important of all safety features is celebrating an even-number anniversary this summer: 50 years ago, in 1973, Opel began to install three-point belt systems with practical one-hand operation as standard in all models – and that three years prior to wearing seat belts became compulsory in Germany. A lot has happened in 50 years: an average of 15 metres of seat belts are installed in every Opel model. In total, after five decades, this results in around 750 million metres of seat belt webbing. This corresponds to 18 circumnavigations of equator.

Safety comes first at Opel: Seat belt as a lifesaver

As early as the 1960s, Opel engineers were testing seat belts as a life-saving restraint system in cars. As early as April 1968, Opel Kadett, Admiral and Diplomat, among others, could be ordered with front seat belts. Classic Opel Manta A coupé followed in October 1970. Opel lifesaver was also available as standard in sporty models – for example in Opel Kadett B Rallye from 1967 and in Opel Commodore A GS a year later.

At same time, Opel actively campaigned for acceptance of seat belts early on and thus assumed a pioneering role. In 1969, Opel engineers demonstrated results of their accident research programme to representatives of media at Dudenhofen Test Centre. 

Most important message: more than half of all accident victims could still be alive if they had worn seat belts. At the beginning of 1972, Opel’s management sent a letter to all employees, asking them to wear their seat belts – and offered all employees discounted belts for retrofitting. Offer proved hugely popular with 12,000 sets being provided within a very short time.

Significance recognised early on

General public were somewhat more reluctant to accept seat belt as an indispensable part of vehicle safety. Millions of people initially refused to “buckle up” when it became compulsory to wear seat belts as of January 1, 1976. At that time, many considered it to be too cumbersome to wear a seat belt. Especially when car was used by different family members and the seat belt had to be adjusted in each case. This problem was soon solved by the automatic seat belt retractor. For a long time, however, there seemed to be no cure for various prejudices such as: Belt curtails personal freedom, and its safety effect is questionable. But the concerns were silenced when the number of road fatalities began to fall.

Simultaneously, the safety specialists were constantly improving the systems. In 1986, Opel Omega was first car in world to offer height-adjustable seat belts at front and rear seats as standard. In 1991, Opel presented belt tensioner in Opel Astra F, followed by full-size airbag and active safety systems such as Anti-lock Braking System (ABS) and Electronic Stability Program (ESP).

Airbags, in particular, further reduce risk of injury significantly – assuming that driver and passengers are actually buckled up. One system restrains body in event of a collision, other cushions impact. Seat belt absorbs around two-thirds of energy of an impact. First belt force limiters were used from 2000s to avoid peak loads. Other improvements increase comfort, such as electric seat belt feeder in convertibles.

Crucial millimetres: Collapsible steering column

Opel engineers identified another key factor for more safety back in 1960s: safety steering column. Preventing steering wheel and column from penetrating passenger compartment is still one of starting points of safety strategy. In event of an impact, steering column collapses slightly. In this way, system, in combination with seat belt and airbag, enables a dynamic crushable distance of up to 100 millimetres – crucial millimetres that minimise the risk of injury.

Adaptive belt force limiter now installed in Opel Astra Electric has an even more refined “anti-lock braking system” for belt. “Belt force is electronically controlled during the course of the impact,” the specialists explain. “In order to measure biomechanical load acting on the chest, four sensors are installed in THOR crash test dummy.” In earlier versions, only single measurements were possible. This increase in sensitivity was made possible by the latest generation of crash test dummies, which have been in use since 2020.

Sensors galore: New dummies provide crucial insights

Development of the safety belt is inextricably linked to the further development of the intelligent high-tech dummies that are used in tests to simulate the effects of an impact on the human body before a safety system is approved for series production. Youngest generation is known as THOR.  Abbreviation stands for “Test device for Human Occupant Restraint”. Equipped with over 120 sensors, THOR electronically senses and communicates what happens to it in event of an impact. With this dummy’s help, adaptive belt force limiter was developed, which was first used in Opel Mokka and now in Opel  Astra. It is another milestone in decades-long development of passive safety features. And possibilities are far from exhausted.

New challenges posed by automated driving

From 2026, for example, consumer protection tests are to evaluate injury values that consider the more fragile bone structure of senior citizens. Team in Rüsselsheim also has its sights firmly set on more distant future: Automated driving will alter a lot completely. Above all, because vehicle occupants will no longer necessarily sit facing forwards, but may face each other. And some could even be lying down. Seat belts could be fully integrated into seats. “We are already working intensively on what this means in detail for the restraint systems,” explains Peter Schüßler. With automated driving, the success story of seat belts, which has lasted for five decades, will then enter a new era of saving lives.

Opel makes campus in Rüsselsheim electric

• 500 charging points at company headquarters already completed
• Another 540 charging points will be implemented in public parking lots near Opel as part of the “Electric City Rüsselsheim” project
• Battery container shows possible second life application of disused vehicle batteries
• Opel is going electric: Nine electrified models on the market this year, with more to follow

Opel campus in Rüsselsheim already has over 500 charging points for the company's steadily growing electric fleet

Opel is pushing ahead with the expansion of the infrastructure at its home location, which is so important for electromobility. Opel campus in Rüsselsheim already has over 500 charging points for the company's steadily growing electric fleet. Another 540 publicly accessible charging points are currently being installed by the city of Rüsselsheim am Main in the parking lots around the company headquarters.

New Opel Corsa-e

Since all new Opel are designed and developed in Rüsselsheim, the expansion of the charging infrastructure at the company headquarters was of particular importance. Announced construction of around 500 internal charging points for company cars and development vehicles has now been completed, so that a steadily growing part of the company fleet can be driven electrically.

New Opel Mokka-e

Initiative is linked to two funding projects. One - E-Mobility Lab Hessen - is a partner for around 120 charging points in the engineering sector in Rüsselsheim and Dudenhofen, which can be used for development vehicles. E-Mobility Lab Hessen is doing research together with Opel, and the development center will become “a real laboratory for electromobility, power supply, intelligent charging stations and intelligent load management”.

New Opel Grandland Hybrid4

As part of the second funding project, Electric City Rüsselsheim, more than 380 charging points for company and company cars have been created on the Opel campus. Another 540 public charging stations will follow in the parking lots around the plant, which the City of Rüsselsheim will implement in a further step by Electric City.

New Opel Combo-e Life

Electric City is a joint project of several partners, to which the city of Rüsselsheim am Main, Opel, the RheinMain University, the municipal housing company gewobau and the mobility consultancy Urban Mobility Innovations (formerly B2M) belong. Together, the partners want to massively advance the expansion of the charging infrastructure for electric vehicles. Funded by the Federal Ministry of Economics, around 1,200 charging points are being built, more than 800 of which will be publicly accessible within the entire city area. Opel has already implemented its part, and urban activities are currently following in all city districts and residential areas, on the campus of the RheinMain University of Applied Sciences, in gewobau residential complexes and in parking lots at shopping centers.

New Opel Zafira-e Life

Another aspect on the way to e-mobility: modular battery storage system, which was developed entirely in-house at Opel as part of the E-Mobility Lab Hessen, has gone into operation in Dudenhofen. Battery storage system uses used vehicle batteries from the Opel Ampera to temporarily store electricity. This stationary battery use in so-called Second Life serves to balance consumption peaks and thus stabilize the power grid. A total of 18 vehicle batteries are reused in the battery storage system, with the storage capacity of which eight electric vehicles can be charged at the same time. Alternatively, a four-person household could be supplied with electricity for a month.

Opel battery storage system in Dudenhofen.

Basis for the successful implementation of the extensive electric strategy lies in the models, of course - and a lot has happened here at Opel in recent years. From Corsa-e to Zafira-e, from Combo-e to Movano-e, from passenger cars to light commercial vehicles - Opel offers its customers a diverse portfolio of electrified vehicles and already covers the most important segments. But this is only the beginning. An electrified version of the Opel Astra will follow this year, and by 2024 there will be an electrified version of every Opel.

New Opel Astra Hybrid

Opel's electric offensive is part of the overall strategy of the Stellantis Group, which was presented during EV Day. Company aims to become the market leader in Low-Emission Vehicles (LEV). By 2030, Stellantis' LEV mix for cars in Europe is expected to grow steadily to over 70 percent - 10 percentage points above the current industry forecasts for the overall market mix. Stellantis is also working on innovative charging solutions.

Test Marathon: New Generation Opel Astra Enters Finishing Straight

• Arctic Circle: Testing dynamics and warm-up behaviour at -30° C in Swedish Lapland
• Dudenhofen Test Centre: Chassis development for safety and comfort in Germany
• EMC lab in Rüsselsheim: Resistance to electro-magnetic waves

All-New Opel Astra: Dudenhofen Test Centre

Development of the all-new Opel Astra is fully on target, the premiere of the 11th generation of the brand’s best-selling compact model is now just weeks away. Initially created – like all modern automobiles – with the assistance of computer-aided design, since last winter the new model has been undergoing final testing, fine tuning and validation in real life conditions. Now Opel Astra is entering the finishing straight of a true test marathon.

Opel engineers took prototypes and development vehicles far north to test the new model on the icy roads and in the deep frozen air of Swedish Lapland. Closer to home, they have been pounding around the test tracks at the Dudenhofen Test Centre and most recently, carrying out validation drives on public roads in the Rhine-Main region, accompanied by senior management. At the same time, the all-new Astra was taking its final tests in the Rüsselsheim EMC laboratory (Electro-Magnetic Compatibility) before receiving type approval for commercialisation.

“Demanding test programme of the all-new Opel Astra is going exceptionally well”, says Astra Chief Engineer, Mariella Vogler. “Development team – which, by the way, comprises more female engineers than ever before – has created an uncompromisingly cool new generation of Opel Astra that will thrill our customers.”

With the all-new Astra, Opel is demonstrating German precision in every detail and taking direct aim at the sweet spot of the compact market sector. Pure and bold design, top technologies and exciting powertrain line-up – including plug-in hybrid electric drive – will make it a benchmark in its class.

Winter testing: High comfort and safety under all conditions

Winter 2020/2021 in Sweden. As usual at this time of year, Lapland is a frequent travel destination for Opel engineers. On this occasion, they brought the next generation Astra with them. At temperatures as low as -30° C, chassis experts turned lap after lap on the slippery surfaces of the specially prepared tracks, continuously optimising the electronically controlled systems for stability, traction and anti-lock braking. Objective: the new Astra must always handle safely and consistently, regardless of the surface – be it ice, snow, slush or wet or dry asphalt. Or in other words, it has to behave like an Opel – under all conditions.

All-New Opel Astra: Winter testing

“During development we made sure that the new generation Astra will once again offer drivers and passengers a lot of driving fun and comfort”, says Opel’s head of vehicle dynamics, Andreas Holl. “On the one hand, our sophisticated and dynamic design ensures that occupants will always feel safe, even at high speeds on the motorway. On the other, it offers plenty of comfort – even on poor road surfaces – for a relaxed driving experience.”

All-New Opel Astra: Winter testing

During their stay in Lapland this year, Opel’s chassis specialists were joined by their colleagues from “HVAC” (heating, ventilation and air conditioning). One of HVAC’s goals is to make sure that the passenger compartment warms up quickly. So they monitored the new Astra’s engine heat rejection, coolant flow, heater core performance and blower airflow, as well as the heated steering wheel and the heating of the front and rear seats.

But warm-up testing is not only done so that customers feel warm and comfy on cold winter mornings. Warm-up performance is also precisely defined by regulation and even more stringent in-house safety standards, which state that the frozen windshield and side windows of an Opel must be clear of ice and fog in the shortest time to ensure safe driver visibility.

All-New Opel Astra: interior

Furthermore, as the next generation Astra as plug-in hybrid will play an important role in continuing the electrification of Opel’s product portfolio, the engineers also kept a close watch on the warm-up times of the lithium-ion battery, to make sure that the performance of the cells meets the standards for electric driving experience even in cold weather.

Dudenhofen Test Centre: Torture, on and off the test tracks

Performance of a different kind is evaluated at the Dudenhofen Test Centre in Germany. Engineers from the competence centre for “ADAS” (Automated Driver Assistance Systems) in Rüsselsheim used the proving ground’s high speed oval and long straight to calibrate the new Astra’s advanced technologies – from Adaptive Cruise Control and Emergency Braking, to Forward Collision Alert and Rear Cross Traffic Assist.

Pre-production cars used for these tests also had to meet high standards on Dudenhofen’s long straight. Here, like every Opel, the next generation Astra had to demonstrate it is “Autobahn-proofness”, meaning that it must remain controllable at speeds well above 140 km/h and stable under hard braking. While driving at high speeds on the oval, Opel engineers also took opportunity to evaluate components such as the bonnet and windscreen wipers. Nothing is allowed to flutter, vibrate or cause irritating noises.

All-New Opel Astra: Validation drives

After working up a sweat in the high-speed driving tests, the new Opel Astra cooled down in the drive-through water trough, at various depths of a minimum 25 centimetres. Despite pushing a big wave of water in front of itself, the test car is not allowed to “inhale” or “swallow” any water – the powertrain, the electrical system and every part under the bonnet must stay protected from water.

There was no respite for the all-new Opel Astra even after it left the test tracks. Despite the tortures meted out on the high-speed oval, the handling circuit or in the water trough, the Opel engineers also took the test vehicles into the Dudenhofen climatic chamber. This environmental test facility is for evaluating the operability of vehicles, subsystems and components in extreme conditions. For the next generation Opel Astra, the climatic chamber was set up to test the car’s sealing against dust and sand.

In addition to the climatic chamber, Opel put test cars into a climatic wind tunnel to validate the new Astra’s performance under a variety of operating conditions. For example, the climatic wind tunnel simulated driving in traffic jams, uphill and down, in order to test the cooling of the brakes. The engineers were even able to find out if swirling snow in front of the vehicle could block the air intakes.

On the boss’s agenda: Validation drives around Opel’s hometown

All-New Opel Astra: Validation drives

Climatic conditions conducive to dust, sand or snow were not expected during the current phase of testing. Validation drives take place with prototypes and engineering cars at several stages throughout the development of a new model. They are for verifying systems and subsystems and validating their overall integration in the vehicle. As development approaches the final stages, the cross-functional team of engineers and technicians is joined by members of senior management, including the boss himself – Opel CEO, Michael Lohscheller.

All-New Opel Astra: Validation drives

Most recent validation drives of the still-camouflaged new Opel Astra took place in June on public roads in the Rhine-Main region around Opel’s hometown – and the car’s “homeplant” – of Rüsselsheim. Engineers and managers were occasionally joined by journalists from the press.

All-New Opel Astra: Validation drives

Electro-magnetic immunity: Prerequisite for type approval

While development prototypes and pre-production vehicles are driving in the far north, in Dudenhofen and on public road in and outside Germany, others also undergo intensive testing on test rigs and in laboratories in Rüsselsheim. Electro-magnetic compatibility (EMC), for example, is tested throughout development. Furthermore, no car can be sold in Europe without passing EMC tests during the type approval process. EMC testing ensures that a car’s electronic systems do not suffer from interference.

Opel team tested the new Astra’s immunity to electro-magnetic emissions in the purpose-built EMC lab in Rüsselsheim. While the test car is exposed to emissions radiated across a wide range of frequencies, special absorbers on the walls “soak up” the transmitted emissions so that they do not reflect back into the chamber. Engineers thus obtain clean, reliable data. New model only gets the “green light” – and finally receives type approval – when all its systems have demonstrated their immunity to electro-magnetic emissions.

First Opel Corsa-e Rally Cars Delivered to Customers

• Delivery of first 10 Opel Corsa-e Rally cars in Dudenhofen
• Teams received car, equipment and information
• Teams from six nations to take part in ADAC Opel e-Rally Cup

Delivery of first 10 Opel Corsa-e Rally cars in Dudenhofen

ADAC Opel e-Rally Cup is ready for its debut season. The first ten Opel Corsa-e Rally cars have already been delivered to customers. At the Test Centre in Dudenhofen, rally teams received not only the vehicle but also their equipment, including stylish team tents and racing overalls for drivers and co-drivers.

Opel Corsa-e Rally

During the vehicle delivery, the teams received a comprehensive briefing on the new e-technology. This was followed by extensive functional tests with the 100 kW (136 hp) electric cars. In addition, the customers were able to convince themselves of the high potential of the Opel Corsa-e Rally in the “hot seat” next to Opel racing legend, Volker Strycek, on the spectacular endurance track of the test centre.

Opel racing legend Volker Strycek in the Opel Corsa-e Rally

“Vehicle delivery was an important step for us, the teams and the project,” says Opel Motorsport Director, Jörg Schrott. “It is a clear signal that things are finally about to get underway. Anticipation and excitement for the start of the season could be felt by everyone. Remaining cars will now be delivered successively.”

After the cancellation of the ADAC ACTRONICS Rally Sulingen due to Corona, the season opener of the ADAC Opel e-Rally Cup will now take place on June 11/12 at the ADAC Rally Stemweder Berg. In preparation, the teams of the ADAC Opel e-Rally Cup will contest a test event beforehand to familiarise themselves with the vehicle and charging infrastructure. In addition, the teams will receive high-voltage training, which will be conducted and certified by TÜV Thüringen.

Teams from Germany, France, Austria, Belgium, the United Kingdom and the Netherlands have registered for the ADAC Opel e-Rally Cup 2021. Further details on the field of participants will be announced at a later date.

Testing: All-New Opel Mokka on the Road to Production Readiness

• Opel engineers put the finishing touches to next-generation Mokka
• New Opel Mokka up to 120 kilogrammes lighter than previous model
• Chassis and assistance systems set up during winter tests in the Arctic
• All-electric Opel Mokka-e offers engaging drive
• Suspension tuning currently underway at Test Center Rodgau-Dudenhofen
• New Opel Mokka in dealer showrooms in early 2021

All-New Opel Mokka at the Test Center Rodgau-Dudenhofen in Germany

Dynamic, efficient and high quality: these are just a few of the development objectives of the all-new Opel Mokka. With typical precision, German engineers have been putting the finishing touches to the next-generation bestseller. At the Test Center Rodgau-Dudenhofen in Germany, they are currently setting up the new Mokka for optimum acoustic comfort in the interior, excellent driving safety at high speeds and Opel-typical steering and pedal feel. Since February, the Opel experts for chassis, powertrain, electronics and lighting have been using the Arctic winter for the tuning of chassis and assistance systems on frozen lakes and narrow country roads in Swedish Lapland.

Next Opel Mokka generation is a completely new design based on the company's highly efficient CMP multi-energy platform (Common Modular Platform). This modular kit offers maximum flexibility in vehicle development. CMP also allows the use of purely battery-electric drive as well as internal combustion engines. Customer has the choice. Thanks to the use of high-strength steels, the vehicle weight is low and the body stability is high. New Opel Mokka weighs up to 120 kilograms less than the previous model – with almost the same wheelbase and tyre sizes. With the electric Opel Mokka-e, batteries are installed deep in the vehicle floor, which lowers the centre of gravity and at the same time increases torsional rigidity by a further 30 % – excellent prerequisites for dynamic driving. Customers can look forward to a very agile second-generation Opel Mokka, which will be available in dealerships from early 2021. Until then, the testing continues at full speed.

Phase 1: Testing and fine-tuning at Arctic Circle

Opel engineer Gunnar Nees never tires of turning lap after lap on ice. He regularly stops for a few minutes. Reaches for the laptop, reads out measured values, logs every kilometre covered. In the vast Arctic wilderness, it is still freezing cold in March. Exactly the right conditions for orchestrating the harmony between ABS, ESP, assistance systems and the rest of the new Opel Mokka’s chassis.

Eevelopment cars are still hiding behind a green and black camouflage, with 3D-like graphics that blur the vehicle’s contours. Engineer behind the steering wheel has come to the far north to set up the chassis. Like every Opel, new Mokka must respond precisely to steering inputs and give good feedback, be comfortable and at the same time have a firm enough ride. An Opel must not display uncontrolled body movements, for example, when the vehicle is driving over a large bump at medium speed. Opel philosophy calls for safe and relaxing driving on the autobahn. An Opel must remain easily controllable in all situations and be fun to drive at the same time.

These characteristics must be present under all weather conditions everywhere – at the icy Arctic Circle as well as in high summer at the Mediterranean. However, nothing should change in terms of precise handling and consistently good-natured driving behaviour. Parts, components and systems are continuously fine-tuned by the Opel engineers: dampers, springs, steering. In addition, the control software is adapted: for ideal pedal feel when accelerating and braking, for the right amount of steering power assistance and for the interaction between all assistance systems.

Phase 2: High-speed driving on German test tracks

Back in Germany: same test engineer pilots Opel Mokka prototype on home ground at the Rodgau-Dudenhofen Test Center. Karsten Bohle, project coordinator for the second-generation Opel Mokka, joins Gunnar Nees.

“We are all looking forward to seeing New Opel Mokka on the road in customer hands. Test drives are running like clockwork, also because our new baby, with its low weight and compact external dimensions, reacts well to adjustments. Handling and comfort are super. New Opel Mokka is a joy to drive,” said Bohle, “the development work has been great fun.”

Karsten Bohle, project coordinator for the second-generation Opel Mokka

New Opel Mokka is ready to take its final exams at the Test Center. While shaken, ride comfort and interior acoustics must remain unstirred – not even by the torture track. Here, not far from the Opel headquarters in Rüsselsheim, the tracks are replicas of the trickiest road surfaces in Europe. Opel engineers have tested here for decades and built up a huge wealth of experience. Engineers repeatedly adjust springs and dampers, the balance between responsiveness and sporty precision continuously improved. New Opel Mokka features particularly low road noise for optimum acoustic comfort, which the high-quality materials in the interior further increase. Squeaks and rattles are taboo.

Steering and suspension get their Opel “feel” on the Dudenhofen handling course. Two tie rods at the McPherson strut turrets are standard equipment; they provide further stiffness at the front end, adding a touch more precision and agility. New Opel Mokka turns into corners eagerly, is easy to handle at the limit and the assistance systems function perfectly. Then comes the ultimate discipline – the high-speed oval with its steep banking, followed by the long straight. This test demands rock-solid stability at all speeds. In real life, it also results in a huge safety benefit when taking avoidance manoeuvres at lower speeds. Opel engineers only award their seal of approval for the autobahn when they return satisfied from the high-speed oval. New Opel Mokka has already passed this test with flying colours. However, testing, testing and yet more testing will continue until the summer. When New Opel Mokka has achieved production readiness, cars will start rolling off the assembly line at the end of the year.

Holzer Motorsport and Michelin New Partners for ADAC Opel e-Rally Cup

• Holzer Motorsport is service provider for new brand cup
• Michelin supplies tyres for world’s first brand cup for electric rally cars
• Opel Corsa-e Rally test programme enters second phase

New Opel Corsa-e Rally 

Opel Motorsport has extended the long-standing cooperation with Holzer Motorsport. The race and rally specialists from Augsburg will provide the technical support and the on-event parts service for all teams competing in the ADAC Opel e-Rally Cup. Tyres for the first electric rally brand cup in the world will be supplied by Michelin.

Development of the Opel Corsa-e Rally for the ADAC Opel e-Rally Cup continues at a fast pace. Two development vehicles of the 100 kW (136 hp) electric car have been undergoing durability testing since the end of last year at the Dudenhofen Test Center. The next step will be performance tests on rally stages.

“This is good news for our teams”, says Opel Motorsport Director, Jörg Schrott. “The continuation of our 20-year-long cooperation with Holzer Motorsport further enhances the status of the ADAC Opel e-Rally Cup. Günther Holzer and his crew have been skilled and reliable partners for all teams in the ADAC Opel Rally Cup since 2013. The same goes for Michelin. After the successful cooperation in the ADAC Opel Rally Cup, Michelin will now equip all the Opel Corsa-e Rally cars.”

New all-electric brand cup featuring Opel Corsa-e Rally will begin on August 21-22 with the ADAC Saarland-Pfalz Rally.

Development of Opel Corsa-e Rally Underway

• Opel develops the first battery-electric rally car
• Two development vehicles undergoing durability testing at Dudenhofen Test Centre
• Opel Corsa-e Rally features three drive modes for competition
• Entries for ADAC Opel e-Rally Cup 2020/2021 open on December 15, 2019

Opel Corsa-e Rally 

Comprehensive development programme of the Opel Corsa-e Rally for the ADAC Opel e-Rally Cup is proceeding at full speed. Two examples of the battery-electric rally car are currently undergoing durability testing at the Dudenhofen Test Centre. “We have two objectives”, said Opel Motorsport Director, Jörg Schrott. “Both cars are covering as many kilometres as possible, in order to gather the maximum amount of data at an early stage. There is no experience of an electric rally car that we could turn to, so initially we had to rely on calculations and simulations. These are being gradually replaced with real data. Other focuses are on loads and temperature management of the battery under rally conditions, as well as adapting the software. I am pleased to report that our programme is going smoothly.”

While the power output is almost the same, 260 Nm of torque is much higher than the Opel ADAM Cup’s.

Engineers at Opel Motorsport will turn to the speed of the 100 kW (136 hp) electric rally car in the second phase of development. “With a brand cup car, it is important that the performance remains constant and accessible under all conditions. The equipment should guarantee equal opportunity for all participants”, said Jörg Schrott. “We also decided that the Corsa-e Rally should match and exceed the high standards of its petrol-engine predecessor, Opel ADAM Cup. We are on the right road here too. While the power output is almost the same, 260 Nm of torque is much higher than the Opel ADAM Cup’s. Centre of gravity is low, thanks to the underfloor-mounted battery, and the weight distribution is also very good, which is extremely important for an agile competition car. Now we need to find the most balanced chassis setup, so in January we will start simulating some real rally stages.”

Engineers at Opel Motorsport will turn to the speed of the 100 kW (136 hp) electric rally car in the second phase of development. 

As soon as development of the Opel Corsa-e Rally has been completed, a reference car will be built that will also serve as the template for customer vehicles. Around 20 examples are expected to be built for the 2020/21 season, up to 15 will be delivered to customer teams in the summer – in time for the first test event in July.

Ideal setup: drive modes for rally stages and road sections

Opel Corsa-e Rally has the same battery as the production car. 50 kWh energy storage capacity enables a range of 337 km according to WLTP. In order to optimise the range for rallying, the battery offers three modes: in “competition mode”, full power and maximum torque are available. Electric cars have especially high torque, so the “rain mode” gives a torque curve adapted to slippery surfaces. Teams will use the energy-saving “eco mode” between stages and for driving to service.

Orders for the Opel Corsa-e Rally can be placed now, entries for the 2020/21 ADAC Opel e-Rally Cup open on December 15, 2019. 

ADAC Opel e-Rally Cup Presented at Essen Motor Show

• Tests with the battery-electric Opel Corsa-e Rally proceeding according to plan
• ADAC and Opel announce further details about the new rally entry platform
• Super Season" 2020/2021 starts in August; highlight is German World Cup round

New Opel Corsa-e Rally

Preparations for the world's first electric one-make rally cup are in full swing. ADAC Opel e-Rally Cup and the Opel Corsa-e Rally car will be presented to sports enthusiasts at the Essen Motor Show from November 29 to December 8 (ADAC stand, Hall 3). At the same time, two purely battery-electric Opel Corsa-e Rally cars will complete an extensive development programme. 136hp electric cars are currently undergoing endurance and component testing at the Test Center in Dudenhofen.

New Opel Corsa-e Rally: 136hp electric cars are currently undergoing endurance and component testing at the Test Center in Dudenhofen

“The demanding development programme is going according to plan, but is far from completed yet,” said Jörg Schrott, Director Opel Motorsport. “The aim is to supply our customer teams with a fully reliable, easy to handle and powerful rally car that will enable the ADAC Opel e-Rally Cup to seamlessly continue the success of its predecessor, the ADAC Opel Rally Cup.”

New Opel Corsa-e Rally: Interior with safety roll cage

2020/2021 calendar with ten qualifying rounds

In the meantime, the two partners Opel and ADAC have announced further key information for the new electric one-make rally cup. Before the start of the ADAC Opel e Rally Cup season as part of the ADAC Saarland-Pfalz Rally (August 21/22, 2020), the customer teams will have the opportunity to prepare their new equipment at two test events. The first test event will be organised by ADAC and Opel will start by organising a test event – the venue and date of this e-Rally Experience Day will be announced at a later date. The second opportunity for testing will take place under competitive conditions. The teams can take part in the ADAC Rallye Oberehe (August 8), a so-called R70 event over 70 kilometres of special stages in Rhineland-Palatinate.

The official start of the season in Saarland will be followed by three more rounds at two events in the 2020 calendar year - the ADAC Rallye Südbayern (September 26/27) and the ADAC Rallye Deutschland from October 15 to 18. The ADAC Opel e-Rally Cup will be holding a double-header at the German World Rally Championship qualifyier. Six further events of the first "Super Season" will be held in 2021 and will be announced at a later date.

Test sessions 2020

Test 1                       e-RALLY Experience Day                                                         Tbn

Test 2                       ADAC Rallye Oberehe                                                      August 8

Qualifying rounds 2020

Event 1                     ADAC Saarland-Pfalz Rallye                                     August 21/22

Event 2                     ADAC Südbayern Rallye                                     September 26/27

Event 3                     ADAC Rallye Deutschland – National 1                   October 15/16

Event 4                     ADAC Rallye Deutschland – National 2                   October 17/18

 Entries open before Christmas

Registration for the ADAC Opel e-Rally Cup starts on December 15, 2019 and teams can register at reduced conditions until January 31, 2020. The fee of €5,900 (plus VAT) includes a comprehensive service package:

• Entry fee for two test sessions and all qualifying rounds of the ADAC Opel e-Rally Cup 2020/2021
• Two ADAC Opel e-Rally Cup overalls
• Team clothing for driver and co-driver
• Service tent with floor tarpaulin and service advertising banner
• Hospitality access for four persons at all rally events
• Free charging on-site
• Electro-technical training for driver/co-driver

The fee for registrations received after February 1, 2020 is €7,500 (plus VAT). The scope of services remains unchanged.

The sporting regulations of the ADAC Opel e-Rally Cup are also taking shape. “In the design of the regulations, we are very much guided by that of the ADAC Opel Rally Cup. This had proven its worth over many years,”" says Thomas Voss, Head of Motorsport at the ADAC. After approval by the German motorsport authority DMSB, the sporting and technical regulations of the ADAC Opel e-Rally Cup will be available for all participants and interested parties to download.

Additional information is available at www.opel-motorsport.com and via email to customer@opel-motorsport.com

Testing, Testing, Testing: Next generation Opel Corsa gets ready

• Development plan’s targets: Sales start this summer, first deliveries in fall
• Polar circle Test Centre, Sweden: Man and machine deep frozen at -30° C
• Dudenhofen Test Centre, Germany: Chassis development for balanced handling and comfort
• Rüsselsheim EMC lab: Resistance to electro-magnetic waves

Opel engineers have been testing the next-generation Corsa for several months in Swedish Lapland, around 40 kilometres south of the Arctic Circle.

Sixth-generation Opel Corsa is getting ready for its launch this fall. While the new model has been created with the help of the newest, fastest and most efficient virtual development methods, Opel engineers now take it on their usual playgrounds to test, refine and validate it in real-life conditions. Since January chassis, powertrain, electronics, lighting and other Opel engineering experts have been using the long polar winter in Swedish Lapland for intensive testing in ultra-low temperatures on frozen lakes and snow-covered roads. Elsewhere, pre-production cars are currently lapping the test tracks at the Dudenhofen Test Centre while laboratory testing such as electro-magnetic compatibility also takes place at the Russelsheim facilities.

“During the development of the next-generation Opel Corsa, we placed special importance on increasing efficiency,” said Thomas Wanke, Global Lead Development Engineer, Vehicle Performance, who is working on a new generation of the Corsa for the fourth time in his career. “The new model is significantly lighter, which lowers fuel consumption and also increases the fun factor. As with the previous generations I worked on, the chassis we are currently refining was developed on all kinds of European roads including the high-speed German autobahn. Our aim is clearly to offer the customer top chassis execution with an optimum balance between safety, comfort and fun.”

Customers can look forward to a very fun and efficient Opel Corsa. Thanks to lightweight engineering, the new generation of the bestseller – more than 13.6 million units sold so far, with five generations since 1982 – is ten percent lighter than the previous model. Chassis delivers the typical Opel balance of sportiness and comfort, even though the new model is perceptibly more dynamic than its predecessor. Opel will also offer the Corsa for the first time as a Battery Electric Vehicle (BEV), right from the start of sales early this summer.

Winter testing: High comfort and safety under all conditions

As they have done for decades now, the Opel engineers have been testing the next-generation Corsa for several months in Swedish Lapland, around 40 kilometres south of the Arctic Circle. Among others, experts from the chassis controls department have been setting up the electronically controlled systems for stability, traction and anti-lock braking on low-grip surfaces, at temperatures as low as -30° C. The purpose of these extreme tests: regardless of ice, snow, slush or asphalt, and differing levels of grip on either side of the car, the control systems must always function reliably. As for delivering high levels of safety, comfort and driving dynamics, Opel engineers are refining the calibration of the chassis systems down to the smallest detail: where does “fun-to-drive” stop and stability control begin? At the Arctic Circle, the conditions for such fine tuning are more suitable than anywhere else. The engineers therefore repeatedly lap the specially prepared handling course, oval and surfaces, continuously optimising the control systems.

Testing with heavily camouflaged cars in Lapland began shortly after Christmas on public roads. From January through March, the ice on the frozen lakes was around one metre thick, so that the test cars, snow-ploughs and water sprinkler trucks could drive on them. The long polar nights also enabled extensive testing of the Adaptive IntelliLux LED technology which, after having premiered in their respective segments with the Astra and Insignia, will also be available for the first time in the Corsa class. The climate and environment in Northern Sweden made it possible to precisely evaluate and optimise the automatic glare-free matrix headlights which continuously adapt to the prevailing traffic situation and surroundings and simply “cut out” approaching traffic and preceding vehicles from the illuminated area. Making this system, which minimises glare while constantly providing drivers with optimum visibility, available in a popular, small car such as the Corsa is another demonstration of the democratisation of technology from Opel.

High-speed testing: Around the banked oval at Dudenhofen Test Centre

During their night-time test drives on the oval, handling circuit and comfort track at the Dudenhofen Test Centre, the Opel engineers also appreciate the high output of the new Corsa’s headlights. The long straights were used to prepare the new generation for driving on the autobahn, where Opel sets especially high standards for the steering and suspension.

“We place the highest importance on body control,” said Wanke. “For example, every Opel must deliver a firm, precise ride over undulating surfaces at autobahn speeds. The car must never feel too soft. The new Corsa impresses in this regard.”

The speed-dependent steering has been tuned for optimum precision, a progressive build-up of steering force and good feedback. The shock absorbers are designed to react immediately to the slightest ripple in the road surface or change in direction. The pre-production cars used for conducting all these tests also had to meet high standards for lane-changing and stability under braking. The new Corsa must remain controllable even at speeds higher than 140 km/h; brake-oversteer is forbidden. The bodywork is also tested while the car is driving at high speed on the oval – no part is allowed to flutter or vibrate, or cause annoying noises.

After completing all its tests for the autobahn, the new Opel Corsa can take a bath – in the drive-through water trough, at various depths from a minimum of 25cm. Although the car pushes a big wave ahead of itself, water is not allowed to enter the vehicle; the engine must not “inhale” any water, the electrical system and every part must remain protected from the wave. The lower engine cover in particular, although under high pressure from the water, must not malfunction.

Electronic testing: Around the clock in the Rüsselsheim EMC

While development prototypes and pre-production vehicles drive in the far north, in Dudenhofen and at various secret places in and outside of Germany, others also undergo severe testing in Rüsselsheim’s test rigs and laboratories. Electro-magnetic compatibility, (EMC) tests, for instance, take place throughout development. They ensure there is no susceptibility of the various electronic systems to disturbances. In the past it was only necessary to prevent the crackling on the radio that was caused by the alternator, the ignition, the windscreen wipers or similar systems. Nowadays the task is much more complex – after all, the new Opel Corsa is full of highly advanced electronic equipment. These include safety devices such as ESP, numerous assistance systems like matrix headlights, as well as the whole infotainment system.

In a purpose-built chamber at the EMC lab in Rüsselsheim, the Opel team tests the immunity of the car’s electronic systems against electro-magnetic emissions. These can be conducted along cables in the wiring harness or over the air. The test car is exposed to emissions radiated across a wide range of frequencies. The special absorbers on the walls “soak up” the transmitted emissions so that they do not reflect uncontrollably back into the chamber. The engineers thus obtain clean, reliable data. The car receives the green light only when all its systems have demonstrated their immunity against electro-magnetic emissions. New Opel Corsa has already passed its test; the electronics are optimally protected from disturbances.