Seven-floor testing and development building for propulsion systems of the future
€210 million investment at Rüsselsheim headquarters
Opel has invested €210 million in the complex of the new Global
Propulsion Systems Center in Rüsselsheim. More than 800 people work
here.
Only two years after the groundbreaking ceremony the new,
ultra-modern Global Propulsion Systems Center at Opel’s Rüsselsheim
headquarters is ready to go into service. Volker Bouffier, Prime
Minister of the federal state of Hesse, who took the opportunity to take
a close look at the impressive building complex, attended the official
inauguration ceremony.
Hesse’s Prime Minister Volker Bouffier presents the “Hessian Lion”
to Opel CEO Dr. Karl-Thomas Neumann on the occasion of the inauguration
of the new Global Propulsion Systems Center in Rüsselsheim.
More than 800 engineers and technicians will develop the propulsion
systems of the future in the complex with a surface area of around
36,000 square meters. The complex not only has a technology center and
office space but also 45 latest generation test dynamometers.
Hessian Prime Minister Volker Bouffier and Opel CEO Dr. Karl-Thomas
Neumann put the first test dynamometer for propulsion systems into
operation.
The €210 million invested in the new Global Propulsion Systems Center
is the biggest single investment in buildings in Rüsselsheim since the
inauguration of the new production plant in 2002.
“The future will quite literally be shaped in the new Global
Propulsion Systems Center. Rüsselsheim is one of the most important
centers of innovation in our state and it has become an internationally
competence center, especially in the mobility sector. Products, concepts
and solutions that are used around the glove are developed here. This
importance is once emphasized by the new center. The investment made by
Opel is a clear commitment to Rüsselsheim and I am happy that the
company will continue to shape the future from here. Opel is a key part
of Hesse and a piece of Hessian identity,” said Prime Minister Volker
Bouffier.
Opel CEO Dr. Karl-Thomas Neumann and Uwe Baum, Deputy Chairman of the
Opel Works Council, welcomed Prime Minister Bouffier. Dan Nicholson, GM
Vice President Global Propulsion Systems was also present to greet the
guests.
“The new development center will make our work even faster and even
more efficient. It not only strengthens Opel but also Rüsselsheim and
the entire GM development network. Opel and its parent company General
Motors want to remain one of the pioneers of clean propulsion systems as
seen with the new groundbreaking Ampera-e electric car,” emphasized Dr.
Karl-Thomas Neumann.
“This new center is a very important strategic investment. We will
develop the propulsion systems of the future here by using ultra-modern
tools and a total of 45 new dynamometers. GM decided to build this
center in Rüsselsheim for good reason. It is a sign of appreciation for
the performance and the know-how of our highly-qualified Opel engineers.
The global network makes GM and Opel especially strong,” said Dan
Nicholson.
Uwe Baum, Deputy Chairman of the Opel Works Council, added: “This
investment is an important step for the future and proof of the growth
and employment opportunities at Opel. The center for propulsion systems
will help us secure work places and competences at the development
center, as already agreed in the ITDC labor contract. Today is a good
day for Opel and for Rüsselsheim.
This new construction is part of the €230 million investment in new
testing and development facilities at the International Technical
Development Center (ITDC) and at the Development Center in
Rodgau-Dudenhofen announced two years ago, with most of the total amount
being invested in Rüsselsheim.
The facility is integrated in the global development system of GM
Global Propulsion Systems. The output can be optimally evaluated and
implemented thanks to the internationally standardized testing
procedures and software.
Robot tested: Outstanding ergonomic AGR seats for Astra, Insignia and Meriva and co.
Second row comfort: Heated rear seats make new Astra debut
Learning curve: From box seat to 18-way adjustable seat with massage function in 117 years
Bernd, Werner, Oliver and Marius are full of enthusiasm for their task – repeatedly they rub over the side bolsters of the seat underneath them before simulating getting in and out while scrubbing across the leather. Somewhat stubborn and relentless but at the same time completely dedicated. Bernd, Werner, Oliver and Marius are inspection robots in the test lab of the Opel International Technical Development Center in Rüsselsheim. To be more precise, they consist of a friction pad covered with a jeans-like material and a foam layer that simulate the human posterior and thighs. “They are more than just robots for us – they are fully qualified members of the team. They perform an important job and therefore they all have names,” explains seat specialist Andrew Leuchtmann, Senior Manager Interiors at General Motors Europe.
The robot team simulates gets into and out of cars 50,000 times a week – equivalent to an entire lifecycle of a car. Both the premium and ergonomic seats targeting the seal of approval from the back specialists of Aktion Gesunder Rücken e.V. (AGR) as well the integrated comfort seats that come as standard are subjected to this ordeal. After the tests, the engineers can recognize whether the seats will be able to withstand future strains just by looking at the fabric structure. “The color has normally faded and the surface is scratched but the most important thing is that the foam underneath is ok and that the surface structure remains stable,” says seating expert Leuchtmann. If this is not the case, the premium and ergonomic seats Opel offers for the driver and front passenger need to be upgraded – after all, there have to last an entire car life, no matter whether it is in the Mokka, Cascada, GTC, Meriva, Zafira Tourer, Astra or Insignia.
“This is where we obviously benefit from our great experience,” says Leuchtmann. After all, the Rüsselsheim-based carmaker can look back on 117 years of seating heritage. The success story of ergonomically valuable sitting began in 2003 with the first AGR seal of approval for the Opel Signum, making Opel the first manufacturer to offer back-friendly seats in the middle class.
The offensive for healthy sitting at affordable prices was rolled out across the model range. Especially long distance and company car drivers are grateful for the system. The numerous settings available allow the AGR certified premium seats in the Opel Insignia to be perfectly adjusted for each driver, ensuring that they are relaxed and symptom-free even after many hours at the wheel. Since 2003, Opel has made democratizing good seats one of its missions and is the leading volume manufacturer in regards to ergonomic seats with the AGR seal of approval.
The new lightness of sitting in the Opel Astra Sports Tourer
Lightweight: AGR seats in the new Opel Astra have shed 10 kilograms in weight thanks to ultra-high-strength steels.
The structure is the most important component of the seat. It ensures the safety of the occupants and keeps them in the right position in case of an impact. However, at the same time is also normally responsible for the considerable weight - not so in the new Opel Astra Sports Tourer. The seats have shed 10 kilograms in weight thanks to ultra-high-strength steels. The engineers know exactly how much weight they can take out safely before even starting on the first prototype thanks to a computer simulation. Darker colors show stress peaks in the material that could lead to a breakage. “We really pushed our limits on the Opel Astra Sports Tourer and experimented a lot,” says Leuchtmann. Amongst others, numerous welding tests were necessary. “You can no longer weld if the material is too thin,” says the engineer.
Comfort guaranteed: The numerous setting possibilities ensure that everybody can find the ideal position.
Once the first prototypes have been built and the fabrics or leather for the covers selected, Werner and colleagues can start their work. But before that, the team calculates to the load level the robots need to apply to the test subject. Furthermore, a team of experts consisting of men and women of different size and build are asked to take a seat with a pressure mat measuring the peak loads, for example where the sit bones make contact. “We test it with prototypes in the real car,” explains Leuchtmann. “Opel Meriva seat for example is higher and you enter differently than you do the new Opel Astra Sports Tourer where the seats are lower.” Testers also sit differently on a premium or ergonomic seat. Because of the especially good lateral guidance, the side bolsters are higher and therefore under more stress. The data obtained results in an average calculation for stress and Werner and co can be programmed accordingly.
Mobile wellness: Massage and ventilation function along with electropneumatically adjustable side bolsters and lumbar support make the AGR seats in the new Opel Astra true all-rounders.
Nine human seating experts are also at work in parallel. They, for example, drive around in a new Opel Astra Sports Tourer – for hours on end and for countless kilometers. They test the four-way electropneumatically adjustable lumbar support, the extendable thigh support or the massage function, complete a comprehensive survey and give a subjective overall grade. Serial production can only start when the last weakness has been eliminated.
Opel Meriva first vehicle to receive AGR certificate for integral ergonomic system
The development of a new seat takes around five years – of those, the team invests two years in the implementation of new concepts. This was also the case for Opel’s flexibility champion, the Meriva. It is the first and to date only vehicle with the AGR seal of approval for its integrated ergonomic system. This includes the ergonomic seats along with the 84-degree opening FlexDoors, the versatile FlexSpace seat concept for the rear seats and the optional FlexFix bicycle carrier. Or take the Astra Sports Tourer for example. Thanks to advance development, which also considers customer feedback along with comments posted in forums and blogs, the optional FlexFold rear seatback that can be split in a 40:20:40 ratio at the touch of a button could be realized. Furthermore, heated outer rear seats are available as an option for the first time. The added level of comfort will ensure that the next major trip with family or friends is more relaxing.
To ensure that Opel maintains its frontrunner position in seating development, the engineers are already working on the next generation of the premium and ergonomic seats behind closed doors. “Maintaining our ‘knowledge head start’ over our competitors and consistently extending our production know-how is vital,” insists Leuchtmann. “That is why we develop as much as possible internally and even have some components delivered by our own plant in Kaiserslautern.” The front seat structures are made entirely at the Kaiserslautern plant. The near vicinity to Rüsselsheim also has logistical advantages. The goal is clearly defined: Seats of the future will be even more ergonomic, even lighter, even more stylish and even safer. “We still have a lot of new ideas on how the contouring can adapt even more individually,” reveals the expert. “And there is still more to come on the massage front.” The fact that further Opel models with premium and ergonomic seats will follow seems to be a matter of course especially as the company looks to democratize good sitting further.
Historical Overview of Opel seat Engineering
1899 – The box seat: The whole Opel Patent Motor Car System Lutzmann including the seats is reminiscent of a carriage. The seats cannot be adjusted.
1929 – Lower position: 30 years later, the Opel 4/20 “Moonlight Roadster” still comes with a firmly fixed bench. However, the position is considerably lower and the passengers can stretch their legs.
1950 – More comfortable: The seats of the Opel Olympia are fixed to a metal frame and the longitudinal position can be adjusted. The backrests of the front seats can be folded forwards to facilitate rear seat passenger ingress/egress.
1956 – Continuous longitudinal adjustment: The continuously adjustable front bench and the adjustable backrests of the Opel Kapitän are a further milestone. The backrests can be set to the optimum position by pulling a lever and simultaneously applying pressure.
1968 – Sporty: The legendary Opel GT gets sporty contoured seats with integrated headrests. Extended cushions and a significantly improved shoulder section show which way development is heading.
1970s – Headrests: Opel optionally fits certain model ranges with headrests – such as the Monza, the Kapitän/Admiral/Diplomat models or the Rekord C and D. The Opel Diplomat B comes with height-adjustable comfort headrests, which can even be tilted forwards.
1978 – First height adjustable seat: Opel Monza drivers can adjust the height of the seat with ease thanks to a telescopic rod.
1994 – Safety with a capital ‘S‘: The seats in the Opel Omega B are comfortable and as an option electrically adjustable. The reinforced rear backrests and the side airbags make an important contribution to passive safety, crash tests with a load are conducted for the first time. In the rear, all three seats come with three-point seat belts and headrests.
2003 – The first AGR seal: The Aktion Gesunder Rücken e.V. (Campaign for healthy back) gives the 18-way electrically adjustable multi-contour driver seat in Opel Vectra/Opel Signum its sought-after seal of approval. Opel is the first carmaker to offer back-friendly seats in the midsize class.
2008 – Comfort seats: The standard comfort seats in the Opel Insignia offer numerous setting possibilities – the height can be adjusted by 65 mm (electric) whereas adjustments of 270 mm are possible in longitudinal direction – outstanding figures. The premium driver seat is AGR certified.
2012 – Ergonomic total concept: FlexDoors with an opening angle of 84 degrees, AGR-certified ergonomic seats and the FlexFix bicycle carrier convince the AGR experts and they award the Meriva with their seal of approval. The first and still only serial production car to receive the certificate for its overall concept.
2015 – Compact class wellness: For the first time the AGR-certified premium ergonomic seats of the new generation Astra are not just 18-way adjustable including side bolster adjustment but are also optionally available with further comfort features such as massage and memory function along with ventilation
Opel’s three-cylinder ecoFLEX engine has been singled out by South African motoring magazine – CAR – as the best of its ilk.
Opel 1.0 ecoFLEX Direct Injection Turbo
In their March issue, which features the editors’ annual Best Buy choices, they selected the turbopetrol one-litre - which does duty in both the Opel ADAM and Corsa ranges - as their Powertrain of the Year. They lauded it for its “gutsy performance and frugal consumption,” and went on to describe it as “a prime example of engine downsizing.”
They also praised it for being refined and characterful.
The 1.0 litre ecoFLEX was introduced to the South African market in the Opel ADAM at the end of 2014 and rapidly went on to become a firm favourite in the marketplace thanks to its exceptional refinement, low-end torque and efficiency. When the fifth-generation Corsa was launched locally early last year, the triple – also in 85 kW/170 Nm guise – became available in Opel’s supermini.
Confirming its status as a benchmark engine is that derivatives from both nameplates, powered by identical ecoFLEX powerplants, were under the bonnets of Opel’s two finalists, the ADAM and Corsa, in the South Africa Guild of Motoring Journalists’ Wesbank Car of the Year competition.
ADAM was the first Opel to receive this new, direct injection engine, developed at the manufacturer’s International Technical Development Centre (ITDC) in Rüsselsheim, Germany.
Opel ADAM with 1.0 ecoFLEX Direct Injection Turbo
Combined cycle fuel consumption is a mere 5.1-litres per 100 kilometres, with CO2 emissions of just 119 g/km. In the Opel Corsa application the headline numbers are 5.0 litres and 117 g/km respectively.
Opel Corsa with 1.0 ecoFLEX Direct Injection Turbo
These outstanding numbers are especially impressive given the generous power output and high torque. Maximum torque is already available at just 1 800 rpm and remains at 170 Nm until 4 500 rpm.
Compact dimensions and low mass are achieved with features that include an all-in-one cylinder head and exhaust manifold, and a tiny, low-inertia turbocharger. It even boasts a switchable water pump, which is disengaged when the engine coolant is cold in order to accelerate warm-up, contributing further to the low fuel consumption. Other efficiency enablers include direct fuel injection, variable valve timing and weight-saving all-aluminium construction.
A host of features have all but eliminated noise, vibration and harshness, with the result that the 1.0 ecoFLEX is not only more refined than other three-cylinder engines, it’s also quieter than many four-cylinder units.
Toughness test: Compact station wagon defies temperatures from -40 to +60 C°
60 degrees Celsius in the winter: New Opel Astra Sports Tourer has to demonstrate that it can withstand extreme heat in the climatic chamber.
Scorching hot desert sand…” – Opel‘s International Technical Development Center (ITDC) reproduces conditions comparable to the Sahara desert. In Rüsselsheim in the middle of winter, the mercury is at 60 degrees Celsius and the sweat is pouring. In the middle of it all, the new Astra Sports Tourer defies the adverse conditions. Calmly and smoothly, it bounces up and down on the heat test bench while the earsplitting racket from the ventilation system fills the 60 square meter room.
One day later, same place, same time, but the observer is confronted with a completely different scenario: the Opel Astra Sports Tourer is all wrapped up in a white outfit that is covered with a thin layer of ice. The compact station wagon’s spacious interior is not visible from the outside, as the windows are completely frozen over. The temperature is -40 degrees, and without warm winter clothing no one can last in here. “We want to see how the materials in the Sports Tourer react to extreme conditions. We also check if its appearance changes and if extreme heat or cold have an effect on, for example, gap width,” explains Otto Hemmelmann, Lead Engineer Test Methods. With his interdisciplinary team from various specialist areas, he is responsible for this foray into scorching and freezing conditions.
Seal of approval: First extreme heat followed by icy condition on the cold test bench the next day – the New Opel Astra Sports Tourer shows that it is perfectly suited for all climatic conditions.
Daily temperature extremes for higher customer satisfaction
The heat and cold test bench – also called thermal cycling testing – is part of the compulsory program in Opel vehicle development, just like the acoustic and electronic lab tests. “After all, our customers around the world drive the Astra in all different climate zones,” says Hemmelmann. In general, every new vehicles is tested during the development phase, here a completely standard Astra Sports Tourer. This ensures that exactly the materials that are later used in customer vehicles are actually put to the test. During the two-week phase, temperatures change daily. “Sealing, bonding, plastic parts and materials, rubber – all this has to work properly, meaning constant elastic constricting and stretching like a rubber band, without bearing any traces of it,” explains the Chief Engineer.
Even direct sunlight can be simulated in the climatic chamber with the help of special radiators. “If the Sports Tourer is parked outside in the summer, interior temperatures can reach 90 degrees,” says Hemmelmann. With the help of the sun simulation, the team tests the interior materials’ stress tolerance. “But we also test how long the air conditioner has to be on until the temperature is bearable again.” In addition, the so-called four-post test bench moves the Sports Tourer up and down under its wheels. This enables testers to ensure that comfort in the car is not compromised even under extreme conditions and that the interior materials make no irritating noises or smells during driving despite high strain and stress.
Intelligent tailgate and FlexFold rear seat back tested
The Astra Sports Tourer is not specially prepared for the heat/cold test bench. It is fitted with commercial tires and belts secure the compact station wagon on the four-post test bench. Nevertheless, the vehicle is thoroughly checked before the test. Because after the hot/cold treatment, the engineers look at the Sports Tourer through the customer’s eyes and identify differences. “We look at what impression the car makes on us and take measurements to determine if anything has become distorted or misaligned,” says Hemmelmann. The team’s systematic examination puts a special focus on the installed plastic parts such as bumpers and side sills. “The gap width is extremely important in these cases, because of course the components must not be protruding.” Employees from the respective specialist areas also check all functions in the interior. For instance, does the glove compartment open smoothly and easily? Can the FlexFold rear seat back be seamlessly adjusted in all situations? And above all, does the sensor-controlled tailgate also open and close at -40 degrees with a simple kicking motion under the bumper? After all, this practical function makes its premiere in the new Astra Sports Tourer. Only when all components, body and add-on parts are tested and cleared has the Astra Sports Tourer passed the thermal cycling test – and then it is ready for its daily job as a comfortable business or multi-functional family car.
Seven-storey testing and engineering building for the powertrains of the future
210 million euro investment in Rüsselsheim running according to plan
GM’s leading powertrain developer Dan Nicholson emphasizes global responsibility
Topping-out ceremony of the new powertrain center in Rüsselsheim: Foreman Sascha Göbel, Opel Group CEO Dr. Karl-Thomas Neumann, GM Vice President Global Powertrain Dan Nicholson, Head of the Works Council Dr. Wolfgang Schäfer-Klug, Vice President GM Powertrain Engineering Europe Christian Müller and the Lord Mayor of Rüsselsheim Patrick Burghardt (from left to right)
Opel is investing in the powertrains of the future. 210 million euro have been allocated to the new, ultra-modern powertrain center currently being built in Rüsselsheim where efficient drive systems will be developed and tested. Construction is going exactly to plan: The topping-out ceremony took place today, the center will be inaugurated in 2017.
Opel Group CEO Dr. Karl-Thomas Neumann and Head of Works Council Dr. Wolfgang Schäfer-Klug were joined at the topping out ceremony by GM’s highest powertrain developer Dan Nicholson, Vice President Global Powertrain. Rüsselsheims lord mayor Patrick Burghardt was also among the guests when Sascha Göbel, the representative of the responsible construction company read out the traditional topping-out address.
The topping-out wreath was pulled to the top of the new Opel powertrain center in Rüsselsheim. Foreman Sascha Göbel (right) read out the topping-out address assisted by his colleague Florian Kunz.
Dr. Karl-Thomas Neumann emphasized the importance of this investment for the future of the brand. “We take our responsibility for the climate and environment seriously and are on track to meeting the CO2 target set for 2020. The new powertrain center will make our work even more efficient. It will not only strengthen Rüsselsheim but also the entire GM development network and it ensures that Opel will remain at the forefront of clean propulsion.”
“The powertrain center is an extremely important strategic company investment. GM decided on building this center in Rüsselsheim for a very good reason – this is where responsibility for small and medium-sized gasoline engines lies. It recognizes the performance and the know-how of our highly qualified Opel engineers,” added Dan Nicholson.
Head of Work Council Dr. Wolfgang Schäfer-Klug added: “The negotiations on the Opel collective agreement were the basis for the decision to invest in the new powertrain center here in Rüsselsheim. It secures and extends employment in the development center. I am therefore particularly happy to be at the topping-out ceremony of the building today.”
“The new powertrain center will further strengthen the outstanding importance of the International Technical Development Center for the Rüsselsheim site and Opel’s considerable research and development competence. But also beyond this, Rüsselsheim is synonymous for innovative technologies and forward-looking concepts,” said Patrick Burghardt, lord mayor of Rüsselsheim.
Apart from the workshop and office building, the new building complex will have three wings with test benches and a technical center. The total building surface area is around 36,000 square meters. Amongst others, the new center will also house 43 newest-generation performance test benches.
The groundbreaking ceremony took place last summer and since then the construction has grown in 180,000 accident-free working hours.
The new complex is part of the investments of 230 million euro investments in new testing and engineering facilities at the International Technical Development Center and at the test center in Rodgau-Dudenhofen. The lion’s share of that, 210 million euro, is being invested in the Rüsselsheim site. The complex will cover an area of around 13,000 square meters south of the railroad tracks and west of Portal 45 in Rüsselsheim, parallel to the Rugbyring. This is the largest building investment in Rüsselsheim since the opening of the new production plant in 2002.
The site is embedded in the global engineering network of the GM Powertrain Organization. Due to internationally synchronized test methods and software, findings can be optimally analyzed and implemented.
Trendsetting: Third generation adaptive lighting already in development
Forward-looking: Eye movements control direction and intensity of headlamp beam
Across all classes: Opel safety lighting system AFL+ from Astra to Insignia
Coming soon: LED Matrix light makes glare-free high beams the standard
Lightning-fast reaction: The camera in Opel’s eye-tracking system scans the driver’s eyes more than 50 times per second to instantaneously adjust the headlamp beam.
Car headlamp beams that are directed by the driver’s eyes? What may still sound like science fiction fantasy in the United Nations’ International Year of Light is not all that far away from reality. Engineers at Opel are already busy developing automotive lighting for the day after tomorrow: with its eye-tracking technology, Opel presents the future of situation-appropriate lighting and once again takes on a pioneering role in lighting technology. This announces a third generation of automotive adaptive lighting, that will be introduced after the current, widely-praised and multi-award-winning AFL+ Bi-Xenon system featuring up to 10 lighting functions available in most Opel models, and Opel’s LED Matrix light that will soon go into series production.
Safety on board: The AFL+ system in the Opel Insignia ensures variable light distribution according to driving situation, road and weather conditions.
Glare-free: Opel’s LED Matrix light deactivates individual LEDs so that oncoming traffic is not dazzled. The rest of the road remains brightly illuminated.
“We’ve been pursuing this concept of controlling the direction and intensity of light based on where the driver is looking for around two years. The more we understand the benefits of this technology, the more intensively we push ahead with our joint project,” says Ingolf Schneider, Director Lighting Technology at Opel, describing the collaboration between Opel’s International Technical Development Center and the Technical University of Darmstadt.
In contrast to high-performance eye-tracking systems requiring five to 10 cameras, a simple webcam was at first used. Focused on the driver’s head, it scanned prominent points, such as the nose and eyes, to detect movement and thereby the driver’s line of sight.
The system then translated the information gathered into data commands for electronically-controlled actuators, which quickly aligned the vehicle’s headlamp projectors. While this technique came very close to achieving eye-control of the headlamps, calculation of data still took too long and the recording rate of the webcam was also too slow to meet the demanding requirements of road traffic conditions.
Fast reaction and intelligent delay
Optimization of the camera’s operating parameters and the adaptation of the eye-tracking algorithm brought the breakthrough. The camera is now equipped with peripheral infra-red sensors and central photo-diodes which together enable it to scan the driver’s eyes more than 50 times per second in dusk and night-time conditions. And with much faster data processing and transmission, the headlamp actuators react instantaneously to make both horizontal and vertical adjustments.
The future of situation-appropriate lighting: Opel engineers are already today working on eye-tracking technology, which will enable drivers to control the car headlamp beams with the direction of their gaze.
Only one problem remained. In practice, a driver’s eyes very naturally and unconsciously jump from one focal point to another. So if the headlamps were allowed to follow this movement precisely, the vehicle’s light cone would jerk around erratically. “To overcome this problem, we have successfully developed a sophisticated delay algorithm which ensures a suitably flowing movement for the light cone,” says Schneider. “Another major benefit is that the eye-tracker doesn’t have to be individually calibrated for a particular driver. The system works perfectly with anyone behind the wheel, no matter what their size.” Even if the driver is momentarily distracted from looking at the road ahead, lighting is always provided in the direction of travel. That’s because the low beam of the headlamps is programmed to ensure sufficient illumination.
Modern safety lighting already widely accessible today: AFL+ from Opel
Even as Opel is developing eye-tracking as the lighting system of the future, it already provides advanced technologies which ensure optimal night vision and highest driving safety on roads today. Opel has brought a break-through in automotive lighting in offering the current generation of AFL+ in a wide range of models, from the Mokka, Cascada and Zafira Tourer to the Astra and Insignia families, thus once again delivering on the company’s ambition of making premium technologies available to a wider audience. In combination with the Opel Eye front camera, it features up to 10 lighting functions, using Bi-Xenon headlamp beams which automatically adapt to a diverse range of driving situations. For different road and weather conditions, variable light distribution is automatically provided as appropriate for pedestrian areas, city driving, country roads, highways and adverse weather. AFL+ also includes functions such as dynamic curve light, cornering light and the use of energy-saving LED daytime running lights. The direction and intensity of the light beam is adjusted according to both steering angle and vehicle speed. In addition, high beam light assistant switches the headlamps to low beam whenever the forward-facing Opel Eye camera, integrated in the interior mirror mounting, detects the proximity of headlamps or tail-lights of other vehicles. A Light and Visibility Pack also includes automatic low beam lighting, together with tunnel recognition. With this array of automatic lighting functions, AFL+ not only improves the visibility of one’s own vehicle but also reduces driver stress and night-time drowsiness.
Bright as day: The LED Matrix light system
Parallel to refining the proven AFL+ and conducting the development of the future eye-tracking lighting generation, engineers at Opel’s International Technical Development Center in Rüsselsheim are currently completing the final validation tests on their next-generation lighting system for upcoming Opel vehicles. LED Matrix light provides glare-free, high beam lighting, which is automatically and constantly adapted for varying traffic situations. In this way, the LED Matrix light functions with the Opel Eye front camera, but its accuracy and adaptive capacity go one step forward. When light sources are detected from oncoming or preceding traffic, individual LEDs in the relevant zone are deactivated, while the rest of the road remains brightly illuminated. This Opel automotive lighting system turns night into day for drivers without dazzling other road users. It will be introduced within the next 18 months.
North American International Auto Show: Buick Cascada makes debut in Detroit
Powerful engine: 200 hp 1.6 ECOTEC Direct Injection Turbo
First Buick convertible in 25 years: Four-seater at US dealers in early 2016
Successful synergies: Both the Buick Cascada (photo) and its Opel sister model were developed in Germany
Impressive presentation at the North American International Auto Show in Detroit (January 12 - 25). Buick revealed its Cascada convertible, an elegant four-seater will go on sale in the USA in the first quarter of 2016.
Successful synergies: Both the Opel Cascada (photo) and its Buick sister model were developed in Germany
This marks another example of the two brands’ successful collaboration, which already includes the jointly-developed Buick Encore and Opel Mokka, the Buick Verano and Opel Astra sedan as well as the Buick Regal and Opel Insignia.
Small SUV twins: The Buick Encore (photo) and the Opel Mokka are closely related to each other
Small SUV twins: The Opel Mokka (photo) and the Buick Encore are closely related to each other
Elegant compact sedans: The Buick Verano (photo) and the Opel Astra share same technical platform
Elegant compact sedans: The Opel Astra (photo) and the Buick Verano share same technical platform
Elegant midsize sedans: The Buick Regal (photo) and the Opel Insignia share same technical platform
Elegant midsize sedans: The Opel Insignia (photo) and the Buick Regal share same technical platform
“The Opel Cascada was developed at our International Technical Development Center in Rüsselsheim, where more than 6,000 engineers work on Opel models, but also on products for other GM brands. So we are constantly searching for synergies, and are delighted that there is now another Cascada for a new market with this Buick. This shows our outstanding engineering expertise while also increasing capacity utilization at our Polish plant in Gliwice,” says Opel Group CEO Dr. Karl-Thomas Neumann. In Europe, the Cascada has won over customers and trade media alike, resulting in numerous awards including the Plus X Award in Germany and the Golden Steering Wheel in Switzerland. In Portugal, Turbo Magazine named it Convertible of the Year in 2014.
The Buick Cascada is powered by the super-efficient 1.6 ECOTEC Direct Injection Turbo with 147 kW/200 hp. The four-cylinder unit delivers maximum torque of 300 Nm. The HiPerStrut (High Performance Strut) front suspension precisely and comfortably transfers power onto the road, ensuring a smooth driving experience. The newest-generation turbo engine in the Buick is mated to a six-speed automatic transmission.
The Cascada’s special feature is its high-quality soft-top that opens in just 17 seconds at the touch of a button, also at driving speeds up to 50 km/h. The US four-seater comes with luxurious equipment such as 20-inch alloy wheels and leather seats that automatically slide forward to offer passengers easy access to the rear seat area. Highlights include the IntelliLink infotainment system with a seven-inch color touchscreen.
With the Cascada, Buick offers American customers an extremely emotional product – it is the brand’s first convertible in 25 years. In the USA, convertible market sales increased by three percent to more than 131,000 units from 2009 to 2013. This segment is distinguished by high customer loyalty: 37 percent of customers remain true to convertibles when they buy a new car. However, a good two-thirds of them change brands, which offers plenty of conquest potential for the Buick Cascada.
“We will continue to work closely with Buick in the coming years wherever it makes sense,” says Dr. Karl-Thomas Neumann. A sound approach, as both brands stand for similar values but do not get in each other’s way on international markets: Buick is sold in North America and China, Opel mainly in Europe. GM has already announced the production of a new Buick model in Rüsselsheim later in the decade. “This enhances capacity utilization at our Rüsselsheim plant, thereby increasing its efficiency,” adds Dr. Neumann.
Buick Enclave SUV
But that’s not all: the Australian brand Holden will also benefit from this global GM strategy. Opel will export vehicles to Australia and New Zealand this year. In addition to the Holden Astra GTC, the especially sporty VXR version and the flagship Insignia, there will also be a Holden Cascada. Dr. Neumann says: “This makes the Cascada a convertible triplet on three continents – a very nice compliment and even more proof of the appeal of our large convertible.”
Holden Astra VXR, Insignia VXR and Cascada convertible
The Opel Group continues to strengthen its top management team. Effective January 1, 2015, Charlie Klein (54) currently Executive Chief Engineer, Vans, Light Commercial Vehicles and Alliance Programs, is appointed Vice President Vehicle Engineering, Europe. Charlie Klein will replace Mike Ableson who is moving back to the US and will become Vice President of Global Product Planning and Program Management at General Motors. Charlie Klein will report to Ken Kelzer, Vice President, Global Vehicle Components and Subsystems and to Dr. Karl-Thomas Neumann, GM Executive Vice President and Head of the Opel Group. He will also replace Mike Ableson as a Member of the Board for Adam Opel AG.
Charlie Klein, Vice President Vehicle Engineering Europe
Dr. Neumann: “We welcome Charlie Klein to the Opel Group top management team. He has been in charge of successful alliance projects with Renault and PSA in recent years, and we believe he is the right person to lead the more than 6,000 engineers at the International Technical Development Center (ITDC) in Rüsselsheim. At the same time, I would like to thank Mike Ableson who put his stamp on the engineering work here in a relatively short time and played a significant role in the ongoing Opel/Vauxhall product offensive.”
To further support Opel’s comeback, effective January 1, 2015, Carsten Wreth (49) will join the company in a newly created position as Vice President, Customer Experience Europe. Wreth comes from Telefonica Global Services and will report to Peter Küspert, Vice President Sales & Aftersales and member of the Board, Opel Group.
Carsten Wreth, Vice President Customer Experience Europe
Küspert: “Carsten brings in 15 years of experience of putting the customer at the heart of everything the company does. He will play a pivotal role in making our organization even more customer focused.”
Carsten Wreth was born in 1965 and has a degree in Business Administration and Mechanical Engineering from the University of Kaiserslautern, Germany.
Trendsetter: Opel ADAM ROCKS enters new market segment
Cool wheels: Robust outdoor looks with canvas roof and new three-cylinder turbo
Well-connected: Advanced IntelliLink infotainment system always up-to-date
Opel ADAM ROCKS, Color Gold Busters
Opel ADAM family is growing: as an adventure-loving open-air car, a stylish trendsetter and an individualization champion, the new Opel ADAM ROCKS plays many roles perfectly. And as a three-door, 3.75-meter long urban pocket-crossover, it also opens up a new market niche. Opel designers have developed new design elements, décors and seating trims all unique to ADAM ROCKS which, together with the Swing Top canvas roof fitted as standard, give it its very own chic charm. The latest member of Opel’s urban lifestyle family is also powered by an all-new 1.0 ECOTEC Direct Injection Turbo engine. This high-tech, pocket powerhouse already complies with tough Euro 6 emissions standards and raises the bar for three-cylinder engine refinement with exceptionally low noise and vibration, as well as superb comfort. Opel’s advanced IntelliLink infotainment system with its fast, user-friendly operation integrates smartphones into ROCKS’ cockpit at a very affordable price. From late September, ADAM ROCKS goes on sale at dealerships from 15,990 euros (RRP incl. VAT in Germany).
“Customers will be thrilled with the ROCKS combination of open-air driving fun, state-of-the-art connectivity and a lively new engine,” says Peter Christian Küspert, Opel Board Member for Sales. “ROCKS also shares the ADAM family’s huge personalization potential, which means almost every example of this urban crossover will be unique. ADAM ROCKS drivers will hardly ever see another model on the road that looks exactly like theirs.”
Stylish interior and affordable IntelliLink system
Opel ADAM ROCKS stands for pure adventure inside and out. Protective, anthracite-colored body cladding enhances its tough, muscular look. Silver skid plates front and rear, and a bold chrome exhaust fitted as standard complete its exterior design highlights. ROCKS also offers new body paints, such as vibrant yellow “Goldbusters”, and a wide range of roof design options. To further individualize the cabin, new colors, door trim options and décor elements unique to Opel’s mini urban trailblazer are available. So in terms of customization potential, Opel ADAM ROCKS is on a par with its stable-mates.
Opel ADAM ROCKS, Swing Top canvas roof
With its Swing Top canvas roof, Opel ADAM ROCKS offers easy access to open-air driving fun whenever and wherever the driver feels like it. The roof folds back neatly on to the C-pillars in just five seconds – and can, of course, be opened or closed while the car is moving (at speeds up to 140 km/h). The entire roof module is acoustically tuned for good noise insulation inside the cabin and the robust, three-layer fabric has a neoprene center sandwich for weatherproofing and durability.
ADAM ROCKS also features Opel‘s award-winning IntelliLink infotainment system with all its multi-media connectivity options and apps. It allows the seamless integration of ANDROID as well as Apple iOS smartphone functionalities inside the car. This ensures drivers never lose contact with what’s going on around them, while allowing them to make phone calls or choose favorite music tracks or, using SIRI EYES FREE voice control, to hear an incoming SMS read aloud or dictate an SMS and emails – all while keeping their hands on the wheel and their eyes on the road. When ADAM ROCKS is stationary, photo galleries or videos can be viewed on the 7-inch high-definition color touch-screen. IntelliLink is not only safe and easy to operate, it is also extremely affordable, making ROCKS the best connected small car on the market, just like its ADAM stable-mates. It’s a talent recently underlined by ADAM winning the “Connected Car Award” from German trade journals Auto Bild and Computer Bild.
Opel ADAM ROCKS, IntelliLink Infotainment
All-new 1.0 ECOTEC Direct Injection Turbo with 90 and 115 hp
The Opel ADAM ROCKS showcases the arrival of an all-new development under its hood. In addition to familiar naturally-aspirated, 1.2 and 1.4 liter gasoline engines delivering 51 kW/70 hp to 74 kW/100 hp, Opel is offering its all-new 1.0 ECOTEC Direct Injection Turbo for the first time. This all-aluminum three-cylinder unit delivers 66 kW/90 hp, while a top-of-the-line version reaches 85 kW/115 hp. The four-cylinder engines are mated to a five-speed transmission and both 1.0 liter Turbo units come with a new compact and lightweight six-speed manual gearbox. This gives ADAM ROCKS a comfortable, superbly smooth and fast shift operation.
New compact and lightweight six-speed manual gearbox (MT6)
Maximum speed is 180 km/h (66 kW/90 hp) and 196 km/h (85 kW/115 hp), and the sprint from zero to 100 km/h takes just 11.9 and 9.9 seconds respectively. Both versions deliver strong, low-end torque of 170 Nm from just 1,800 rpm.
Opel ECOTEC 1.0 Direct Injection Turbo
The all-aluminum engine features state-of-the-art technologies such as high-pressure direct fuel injection, continuously variable valve timing, a switchable water pump, a cylinder-head integrated exhaust manifold and a single scroll turbocharger. Despite its fiery performance, the 1.0 ECOTEC Direct Injection Turbo consumes just 4.5 liters (66 kW/90 hp) and 5.1 liters (85 kW/115 hp) of fuel per 100 km over the combined cycle, not least thanks to Start/Stop fitted as standard (according to Regulation [EC] no. 715/2007).
Opel ADAM ROCKS’ suspension system – McPherson struts on a sub-frame up front and a torsion beam at rear – has been modified to suit its wider range of use. The car’s off-road character is emphasized by a 15-mm increase in ride height compared to ADAM with identical 17-inch wheels, giving Opel’s mini crossover SUV-like ground clearance of around 14 centimeters. Chassis components modified or re-tuned include the dampers, springs, rear suspension geometry and steering. ADAM ROCKS’ rugged good looks are enhanced by wide front and rear tracks (1,472 and 1,464 mm respectively) which, combined with a 2,311 mm long wheelbase, also ensure a high level of driving stability and comfort.
Made in Germany: Opel ADAM ROCKS brings hallmark quality to the road
Opel ADAM ROCKS went from concept car to production readiness in just twelve months. It was born and nurtured at Opel’s International Technical Development Center (ITDC) in Rüsselsheim and, like the rest of the ADAM family, it is built in Germany at Opel’s Eisenach plant. Opel is the only automaker to develop and make a small car like ROCKS in Germany, and the Eisenach plant’s high efficiency has made it possible.
Automaker investing 210 million euros in Rüsselsheim
State-of-the-art facilities to develop and test clean engines
43 modern performance test benches available by 2017
Hesse’s Minister for Economic Affairs Tarek Al-Wazir at groundbreaking ceremony
Opel starts major construction project at its Rüsselsheim headquarters: The company continues its investment offensive, allocating 210 million euros to the construction of a complex of buildings – the tallest seven stories high – on the south-west sector of the International Technical Development Center (ITDC) premises. On a total building surface area of around 36,000 square meters, from 2017 engineers and technicians will develop the powertrains of the future. The new center will also house 43 newest-generation performance test benches.
The groundbreaking ceremony for the major project took place on Monday. Manning the shovels were CEO Dr. Karl-Thomas Neumann, Head of Opel Works Council Dr. Wolfgang Schäfer-Klug, Vice President of the GM Powertrain Division Steven Kiefer, Opel Board Member for Engineering Michael Ableson, and two high-ranking political guests: Hesse’s Minister for Economic Affairs Tarek Al-Wazir and Rüsselsheim’s mayor Patrick Burghardt.
“With this investment we very clearly show: Opel is back. Opel is on the attack,” said Karl-Thomas Neumann. “Our model offensive is in full swing – and engines are a very important part of this offensive.”
The construction project is part of the investment announced last year that earmarks 230 million euros for new testing and engineering facilities at the ITDC and at the Test Center Rodgau-Dudenhofen. The lion’s share of that, 210 million euros, is being invested in the Rüsselsheim site. The complex will cover an area of around 13,000 square meters south of the railroad tracks and west of Portal 45 in Rüsselsheim, parallel to the Rugbyring. This is the largest building investment in Rüsselsheim since the opening of the new production plant in 2002.
The site is embedded in the engineering network of the GM Powertrain Organization. Due to internationally synchronized test methods and software, findings can be optimally analyzed and implemented. Steven Kiefer, Head of GM Powertrain, said, “For us, Rüsselsheim is the center for the development of small and mid-size gasoline engines. We rely on internationally-networked German engineering and with the construction of this new site, we create optimum working conditions for our experts.” Kiefer continued, “Important new engine generations will be created in Rüsselsheim, including their applications for all markets where GM is present. The new facilities meet globally uniform technical standards and increase the flexibility, development speed and efficiency of the entire group.”
A new building as symbol for the engine offensive
The construction project in Rüsselsheim is a visible sign of the Opel engine offensive. To 2018, Opel will introduce 27 new models and 17 new, economical engines to the market. With the refreshed product portfolio, market share in Europe is to be substantially increased to 8 percent by 2022. Board Member for Engineering Michael Ableson, said, “We are looking at the whole diverse variety of future propulsion technologies that are more economical and environmentally friendly. The combustion engine maintains an important role, as it still has a lot of potential. As one of the pioneers of clean propulsion, it is Opel’s goal to not only undercut the future stringent CO2 barriers, but to also ensure driving fun and best performance at the same time.”
Head of Works Council Schäfer-Klug said: “As employee representatives, from the very beginning we advocated investment in, preservation and expansion of engineering jobs. So I am delighted that we are laying this foundation stone today. It is more proof of growth and job security at Opel.”
Hesse’s Minister of Economic Affairs Tarek Al-Wazir praised Opel‘s commitment to the region: “I am sure that fuel consumption and CO2 emissions of engines will always be important to customers. Therefore the new development center for efficient engines is a smart, climate-friendly investment. I am pleased that Opel invests a three-figure million amount in these future technologies here in the Rhine-Main area”.
And Rüsselheim’s mayor Patrick Burghardt also sees the engine building complex as a sign of a new start for the city: “A new site of this size has not been built here in a long time. Rüsselsheim and Opel – this is not only a long, rich tradition, it is also a clear prospect for the future.”
