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.
Opel Test Center hosts final presentation of German research project Ko-HAF
Opel Insignia prototype at the Opel Test Center
Rodgau-Dudenhofen.
Opel has successfully demonstrated a future that
promises fewer traffic accidents and freedom for the driver to read,
write or relax instead of continuously monitoring the car. The automaker
is part of Ko-HAF – “Kooperatives hochautomatisiertes Fahren”
– a German project researching cooperative highly automated driving,
which began in June 2015. The Opel Insignia prototype displayed the
functions of cooperative highly automated driving during the
presentation of Ko-HAF’s final results at the Opel Test Center
Rodgau-Dudenhofen.
What is highly automated driving ? Driver does not have to monitor
the journey constantly, but must be able to take the wheel with time to
spare if required.
Cooperative highly automated driving systems do not need to be
supervised by the driver all the time. Drivers can perform other tasks,
but when prompted by the system they must be able to take control of the
vehicle within a certain time period. The vehicle must therefore be
able to “see” further ahead than possible with its own sensors. In
Ko-HAF, vehicles send information about their current road environment,
such as construction sites, traffic jams and accidents, to a Safety
Server. The information is collected and processed by the Safety Server,
so that a precise map is available to vehicles when they request it –
like an artificial horizon that delivers a highly detailed preview of
the road ahead.
Test vehicle, an Insignia Sports Tourer, is armed with an array of
cameras and sensors. In the trunk a battery of computers handles
communications, records the vehicle’s location, and calculates driving
maneuvers in real time.
Opel’s role in Ko-HAF focused on the computerized maps and the
process of disengaging the car from the automated driving condition,
thus returning control to the driver. The engineers from Rüsselsheim
designed the architecture, interfaces and protocols of the Safety
Server, which were evaluated in the project.
An additional core-task was the development of a self-localization
method for the vehicle. Opel designed algorithms for visual mapping and
localization which are merged with information from back-end and onboard
maps, onboard sensors and the Global Navigation Satellite System
(GNSS). The localization method was validated on the Opel Insignia test
car at the Opel Test Center and on the Ko-HAF test route on the
motorways around Frankfurt am Main.
Opel’s second area of focus concerned the driver’s actions, so-called
non-driving tasks. The company’s engineers developed software and a
system of sensors to detect and classify the driver’s actions while the
car is driving automatically.
Tough going: Testing cars in Dudenhofen since 1966
Taking a break: Opel celebrates anniversary and reopening on September 10
Way ahead: Extensive renovation for test center of the future
Tales from Dudenhofen: Fat trees, wild horses and driver training
On the “torture track” at the Opel Test Center, suspension and chassis components are subjected to the highest stress
Opel “proving ground” in Dudenhofen, as it was known at the time, opened 50 years ago. Ever since, countless Opel cars had to face the toughest tests on their way to production. Right from the start, the proving ground was continuously extended and modernized. In the meantime, it has become the largest and most important Opel test center in Europe. Opel will celebrate Dudenhofen’s half-century with an open day on September 10. Fans and employees will get an exclusive “behind the scenes” look at the way the test center operates. In addition, Opel will present the expended attendance of around 20,000 – including many famous faces from the world of politics, sport and economy – with a colorful show around the models and the brand’s motorsports commitment.
No mercy, right from the start
Opel proving ground near Rodgau-Dudenhofen in Germany was opened in 1966. In the meantime it has become Opel’s most important test center in Europe. The durability of millions of Opel cars has been proven here
At the beginning, in April 1966, the 2.6 square kilometer proving ground has a combination of various streets and roads with a total length of 33 kilometers. Then as now, engineers show no mercy when it comes to testing new developments.For example, on the five-kilometer long, 33-degree banked, high-speed circuit that encloses the proving ground. Alternatively, they take to the “skid pad”, a concreted area with a diameter of 100 meters. It is used to determine the steering behavior or to measure the swerving of the vehicle in corners precisely. In the 1980s, a 4.4-kilometer long “sound and comfort track” is added. In 1992, the entire high-speed circuit is renewed in 24 weeks due to the heavy use. Ever since, the circuit, sound and comfort track, skid pad, hill, handling and torture tracks enable extensive vehicle test and development work on engines, brakes, steering or chassis.
Taking the corner at 250 km/h – with no hands on the steering wheel
The area is extended successively. In 2004, an oval track with watering and drainage system for slingshot tests and slalom drives is added. An all-wheel drive test bench follows in 2006 along with a modern industrial gasoline station with 32 pumps for 16 different types of fuel. Since the second circuit renewal in 2012, test drivers can take the steep curve at 250 km/h without the influence of any lateral force – they can even theoretically take their hands of the steering wheel. This is how the previously calculated target values for example for the top speed look in reality. The internal weather station delivers data on humidity, wind speed and direction. This is complemented by the highly sensitive sensors embedded in the road surface – they permanently deliver data on the temperature and dampness of the surface so that these can be considered in the test result. And obviously the tracks need to be prepared for the test according to the weather conditions.
When new vehicles such as the current Opel Astra are put through their paces in Dudenhofen it means them facing around 40,000 kilometers of extreme stress on the proving ground. The distance is equivalent to over 200,000 kilometers or 15 years on “real roads”. Added to that are countless kilometers on other proving grounds and public roads all over the world. The latest Opel compact underwent strains that are equivalent to those of an entire lifecycle in only 24 weeks.
One of the many decisive tests that the Opel Astra was subjected to is the “endurance test”. The endurance track offers various different road surfaces such as asphalt and cobblestone, bumps and numerous corners. Here the engineers check whether the performance and quality of the prototypes that they determined and validated made it into regular production.
Investments for vehicle development of the future
Opel started the largest expansion and modernization project in Dudenhofen to date in 2013. The company will invest a high two-digit figure in the area located to the southeast of Frankfurt with almost 65 kilometers of test tracks by 2020. Currently, the new access road that leads to the reception building and the parking area has already been completed. Furthermore, the new chassis workshop with a large tire storage area for up to 8,000 wheel / tires along with three new engine test benches could be inaugurated. The “long straight” – a two-kilometer long straight with a multilane return loop and angled corners – is also already in use. The angle of these aforementioned corners has been determined so that all four wheel carry the same load when passing. This allows for brake tests at the end of course delivering results as if the car had also been driving straight on.
A new 300-meter-diameter skid pad is under construction here, which will enable testing of automated driving. The straight will have then the shape of a funnel that widens from 30 meters to 300 meters.“A Boeing 737 could easily land there,” says Dr. Matthias Schollmaier, Director of the Opel Test Center. The “long straight” is the first element to actually been outside the original area and runs parallel to the adjacent main road. For this reason, additional land had to be purchased from the city.
Opel is also increasing the capacities for testing of driver assistance systems in Rodgau-Dudenhofen with the creation of a new track for Automated Emergency Braking. “We have big plans”, says Schollmaier. “Amongst others, we are looking at a warehouse for emergency vehicles and servicing material, additional offices, two multi-storey car parks and a new canteen to cater for the growing number of employees.” In addition, the overall length of the test tracks will be increased to 90 kilometers in the next few years. Furthermore, powertrain test benches, track extensions and new routes will be added to meet various demands. The number of employees in the ultra-modern Dudenhofen Test and Development Center will then increase from 150 to 700.
Tales from Dudenhofen:
“Fat pine“ and Przewalski’s horses
Environmental protection is not only important during testing – it plays an important role for the proving ground area itself. The on-site gasoline station now has over 16 different types of fuel and charging stations for electric cars are also available. 90 percent of the water needed for the car wash is taken from the groundwater and recycled after use. “The entire lighting systems will be switched to LED shorty so that we become even more efficient,” said Schollmaier. The use of an internal thermal power station is also a topic for the future. During the planning period of the area the people responsible already tried to maintain as much of the tree population as possible – not only because it provides valuable protection from prototype hunters. The oldest pine in Hesse can still be found on the middle of the area – the tree, nicknamed “dicke Tanne” (fat pine) is around 275 years old.
Furthermore, rare Przewalski’s horses can be seen grazing in the neighborhood of the Opel Test Center. The animals are part of a nature conservation project near Babenhausen that Opel has supported since 2009. Opel AG financed the project with €900,000 and is cooperating with the Federal Forest Department Schwarzenborn and the Federal Agency for Public Property. The expansion of the Rodgau-Dudenhofen Test Center are compensated by the intensive support for the nature reserve.
How it all began
The ultra-modern Opel Test Center owes its existence to a fortunate coincidence. Dudenhofen’s former mayor Ludwig Kratz received a thick envelope addressed to the “Mayor of Dudenhofen” in 1963. The postcode was missing. Kratz read in the letter from the estate agent that an international automotive company had been negotiating with the community of Dudenhofen in the Palatinate region for some time as they were looking to create a new proving ground. The clever mayor took the initiative and offed an area in the forest belonging to his town – Rodgau-Dudenhofen – as an alternative. Opel agreed to the deal after all the uncertainties had been clarified. The sales contract was signed on October 15, 1964. The success story of the Test Center began and along with it the excellent and close cooperation with the city of Rodgau.
Testing
The employees of the Opel Test Center work in three shifts seven days a week. Every day all the test drivers together rack up a total of around 40,000 kilometers. They go through up to 500 tires per month.
Events
No matter whether it is car presentations, driver or OPC performance training, the Opel Test Center is no longer strictly closed to the public but instead offers the ideal setting for all sorts of events hosted by partners, customers and guests of Opel.
Dynamic, smooth, comfortable: New engines for pleasant sound
No din: “Dummy heads” as sensitive as the human hearing
In the acoustic lab: New Opel Astra is positioned in the center of the room and is surrounded by numerous microphones.
Silence. It is so quiet in the unusual looking room that you could literally hear a pin drop. The new Opel Astra is positioned in the center of the room and is surrounded by numerous microphones. Is the engine sound of the new compact class star being recorded for the next advertising campaign? Not quite. When the Opel Astra arrives in the acoustic lab, it is still in the final phase of being made ready for series production. The engineers around Bernd Justen are partly responsible for making sure that the new Astra really is a quantum leap. They ensure that the compact class car meets the demanding noise requirements and test the Astra thoroughly in the Opel acoustic lab in Rüsselsheim. Apart from being tested on the comfort and noise evaluation track at the Opel Test Center in Rodgau-Dudenhofen, all new models developed by the carmaker have to come here for final testing.
Meets all noise requirements: All-New Opel Astra in the acoustic lab in Rüsselsheim.
Noise & vibration: All good under the Opel Astra hood
The dynamic sound of the vehicle while simultaneously delivering excellent running smoothness was always high on the list of specifications of the new Opel Astra. Primarily, the turbo-charged gasoline and diesel engines of the latest generation that power the Opel Astra and make its athletic appearance audible ensure this. “That is only one aspect we check in the acoustic lab,” explains Bernd Justen, Vehicle Performance Manager for compact class cars. Moreover, the Astra is put through an extensive and precisely defined requirements list. “Apart from the appropriate sound of the engine or rolling noise, this includes the sound made by closing a door or the clicking of the indicator. We initially check the simulation-based basic settings. Based on this we keep on working until the Astra meets our noise requirements.”
On the roller test bench: The engines offer a pleasant and dynamic sound experience – and reduces noise levels in the cabin.
The walls and the ceiling of the lab are completely soundproof thanks to noise absorbing materials. During testing, the Opel Astra is driven on large floor rollers, which produce the same resistance the car would experience on the road from wind and rolling friction. “This enables driving with road-like loads. It does not depend on the weather and we can test various scenarios under consistent conditions,” said Justen. These tests include idle behavior, the Start/Stop function and driving under part or full engine load for example. The highly sensitive microphones record all noises so they can be analyzed afterwards.
Meets all noise requirements: All-New Opel Astra in the acoustic lab in Rüsselsheim.
A typical procedure on the roller test bench is ‘full-load, rev-up’ in third gear – a demanding test that the all-new 1.4 ECOTEC Direct Injection Turbo, a four-cylinder Opel unit from the same engine family as the innovative one-liter, three-cylinder engine, passes with flying colors while always remaining within the pre-defined tolerance curve for cabin noise. Just like the three-cylinder engine, the 92 kW/125 hp or 110 kW/150 hp unit was developed with setting new standards in noise and vibration characteristics in mind (fuel consumption combined: 5.5-4.9 l/100 km, CO2 emissions combined: 128-114 g/km). The outstanding refinement was achieved through the noise-optimized engine block design. The implemented measures to reduce the noise level included splitting the oil pan, noise protecting the integration of the cylinder head into the exhaust manifold, designing a sound-absorbing cam cover, decoupling the high-pressure injection valves and trimming the timing chain for quiet concentricity. The test bench quickly reveals that the engineers did an outstanding job: The engines offer a pleasant and dynamic sound experience – and reduces noise levels in the cabin.
“Dummy head” tested: Pleasant sound in the Opel Astra cabin
“Our dummy heads confirm the exemplary noise level,” explains Justen, referring to the weird looking figures in the Opel Astra cabin that are reminiscent of mannequins. Plastic effigies of the human head and shoulder area that possess a perfect replica of all acoustically relevant elements of the human outer ear adorn the seats. “There are highly sensitive microphones fitted in the ears of dummy heads too. They allow us to record and replay noises in the same way that a ‘real’ human would perceive them.” This enables stereo recording and replaying, as well as differentiation between the upward and downward direction of noise, making the dummy’s hearing virtually three-dimensional.
Dummy head: Plastic effigies of the human head and shoulder area that possess a perfect replica of all acoustically relevant elements of the human outer ear are used in the acoustic la
To achieve the desired vehicle sound that is pleasant for occupants, a binaural transfer path analysis and synthesis is conducted using so-called binaural measurements. This enables a distinction between airborne and structure-borne noise source paths. “This allows us to identify and analyze the different sound sources,” explains Justen. Using a noise transfer path model, engineers can identify, for example, which screw needs to be turned to achieve the agreed target value – first virtually and then in reality. If both cases produce satisfactory results, the Astra has taken its next hurdle on the way to production readiness.
• Newly designed chassis provides more comfort, pleasure and safety • New steering with precise feel for the road, City Mode for maneuvers • From test track to road: Fifth generation Corsa passes toughest tests
Chassis engineers in charge of developing the fifth generation Opel Corsa have set to themselves the objective of delighting future customers with a driving experience comparable to the one provided by larger, more expensive cars in terms of comfort and precision. They have lowered the center of gravity of the new Corsa by 5 millimeters and completely redesigned its chassis and steering systems.
“The chassis of the new generation Corsa does not inherit a single component from the previous model. We turned every conceivable setscrew to achieve a better drive experience with new levels of comfort, precision and pleasure. At the same time, we concentrated on finding the optimal balance between enjoyable dynamics and predictable, safest road-handling,” said Michael Ableson, Vice-President Vehicle Engineering Europe.
New Opel Corsa chassis raises the bar for comfort, fun and safety
In addition to its 5 millimeter lower center of gravity, the Corsa receives a new, stiffer, redesigned chassis. The front MacPherson suspension has a new geometry with new front knuckles which improve the vehicle’s roll behavior, steering response and understeer behavior. A new, reinforced sub-frame increases torsional rigidity, while dual strut mounts provide improved responsiveness on uneven surfaces. Furthermore, the new spring rates and damper characteristics in the front reduce the pitching moment during sharp braking maneuvers. This results in the Corsa remaining controllable in case of emergency braking, even for inexperienced drivers. The rear axle torsion bar has been redesigned too, and an enhanced stabilizer has been added to reduce tilting for a better cornering compliance and stability.
Corsa customers can choose between two chassis set-ups, the standard ‘Comfort’ and the more active and direct ‘Sport’. The Comfort chassis is featured with 14 to 16 inch wheels. The Sport chassis has stiffer springs and shock absorbers as well as a specific steering geometry and calibration for a more direct response. It is optional with 16-inch wheels and comes standard on Corsa models equipped with 17-inch wheels.
New steering system with numerous innovations
In order to improve directional stability, the Opel engineers changed the mounting points of the rack-and-pinion steering shaft and optimized its geometry. A newly constructed mounting for the steering column saves space which is filled with additional padding material and increases driver safety in case of a collision. Furthermore, the steering column possesses special impact absorbers.
The development of a completely new electrical architecture for the fifth generation Corsa enables a more sophisticated level of interaction between its various systems. An optimized software for the electrical and speed-dependent power steering adds additional possibilities. For instance, all new Corsa are equipped with a new standard ‘City’ steering mode that allows reducing steering effort at low speeds for easing maneuvers. The City mode is activated at the press of a button located on the center console.
Furthermore, the active cornering component of the Corsa’s steering aids the driver in crosswinds and on convex roads. Amongst others, the software is fed with the data from the ninth generation Electronic Stability Program (ESPPlus). This system contains no less than eleven different functions, including, for example, the new Hill Start Assist (HSA).
Elsewhere, the fifth generation of the Opel bestseller can be fitted with an Advanced Parking Assistant (€580 including VAT). This system recognizes parallel and perpendicular parking spaces and takes over the steering, meaning that the driver only has to control the pedals.
Well-rounded: Brakes and wheels
The base new Corsa comes with 14-inch steel rims and 185/70 tires. In combination with a turbocharged engine (1.0 Turbo, 1.4 Turbo and 1.3 CDTI), the new Corsa is always fitted with 15-inch or bigger wheels. However, the Opel bestseller can optionally be ordered with 17-inch rims and 215-wide tires. The standard Tire Pressure Monitoring System (TMPS) display warns the driver in the event of excessive pressure loss in one of the tires.
The braking system consists of ventilated front and solid rear discs which can easily cope with high stress. The pedal feel is distinguished by the exactly defined pressure point and excellent controllability. The braking systems is assisted by electronic aids that permanently receive information for the ABS/ESP sensors. For example, the systems recognizes if the braking maneuver is being performed while cornering and distributes the braking force to all four wheels depending on the load.
A car’s life in high speed: Fifth generation Opel Corsa at the test center
The engineers in Opel’s Test Center in Dudenhofen have tested the new generation Corsa extensively over thousands of kilometers before allowing it to be presented to the customers. The Opel Development Team pushed the new Corsa to its limits during the tests: the development prototypes had to master 40,000 kilometers on the torture track, the high speed circuit and in hilly terrain, equivalent to 160,000 kilometer on “normal” demanding roads. Within only 24 weeks, these development prototypes are put through burdens that a production car would normally only encounter during its entire life cycle.
The new Corsa was asked to prove its resilience time and time again on the torture track. The track delivers exactly what its name promises: more than 900 meters of potholes, humps, the “washboard“, a cobbled section and a pavé track. It’s a really tough test for the chassis, which will most probably never go through such torture in real life – but the Corsa mastered it comfortably. To put the steering, transmission and brakes to the test, the new Corsa also successfully completed the hill track many thousand times.
On Dudenhofen’s 40-degree banking circuit without lateral forces engineers can test the stability at high speed. Another circuit that is used during the testing procedure has rising and falling gradients, ranging from eight to 30 percent, with different road surfaces and a serpentine section including hairpin turns – similar to conditions found in alpine mountains.
The endurance test, which all new Opel models are put through, was decisive for the new generation Corsa. The longest track at the test center offers many different road surfaces including asphalt and cobblestones, bumps and numerous curves. Here engineers test if the performance and quality they fine-tuned and approved in the development vehicles have been successfully transferred to the production vehicles. This final quality control ensures that any minute disturbances or doubts are erased, thus guaranteeing that the new Corsa reaches the customers perfectly aligned with the stringent performance and quality targets set at the beginning of its development.
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.”
Over hill and down dale: Urban mini-crossover rocks through the torture track
In fast motion: 24-week test in Dudenhofen as tough as a whole car life
Attractive entry-level price: ADAM ROCKS for 15,990 euros soon available to order
Only flying is better: ADAM ROCKS shows how fast it can go on the newly-expanded high-speed circuit at the Opel Test Center Dudenhofen
Recently it captivated visitors to the Auto Mobil International (AMI) show in Leipzig, and now in just a few days it will be available to order: the Opel ADAM ROCKS is ready to roll! Open-air driving fun is an essential part of the ADAM ROCKS repertoire with a Swing Top canvas roof fitted as standard, all for 15,990 euros (RRP incl. VAT in Germany). But before customers can enjoy this stylish mini-crossover in the city and beyond, Opel engineers have once again put it through its paces at the Opel Test Center in Dudenhofen.
With its muscular proportions, encapsulated by bold side-sill plates and distinctive body cladding, the ROCKS likes to show what it can do beyond the urban landscape. Key to its purposeful stance is a 15 mm increase in body ride height, giving greater ground clearance and a wide, robust appearance. Numerous components have been modified or re-tuned to guarantee (almost) limitless driving fun. These include dampers, springs, the front and rear suspension geometry, steering and the electronic stability control program (ESC).
Opel ADAM ROCKS at the Opel Test Center Dudenhofen
To prove the effectiveness of all these changes, it was time to ‘hit the track’, of course with expert guidance. The Opel engineering team took the ADAM ROCKS to its limits at the Test Center. Be it on the torture track, the high-speed circuit or the hill track – the ADAM ROCKS had to cover around 40,000 km at Dudenhofen. This tough test is equivalent to covering 160,000 km on particularly demanding real roads. Vehicles at the Opel Test Center are exposed to levels of stress and strain in just 24 weeks that correspond to an entire vehicle life experience under normal road conditions.
Alpine mountain-like conditions: to put the steering, transmission and brakes to the test, the all-new Opel ADAM ROCKS also successfully completes the hill track with rising and falling gradients ranging from eight to 30 percent
For example the torture track: here the auto industry’s first urban three-door mini-crossover proved its durability. That’s because the track delivers exactly what its name promises: more than 900 meters of potholes, humps, the “washboard“, a cobbled section and a pavé track. It’s a really tough test for the chassis, which will most probably never go through such torture in real life. But it was not a problem for the ROCKS. After all, the small Opel ADAM ROCKS’ design and durability were inspired by the exploits of agile ‘Parkour’ athletes, who use the city landscape as their playground and easily overcome every obstacle.
Over hill and down dale: the urban mini-crossover Opel ADAM ROCKS rocks through the torture track at the Opel Test Center in Dudenhofen
On the newly-expanded high-speed circuit, the saying is: “Only flying is better”. Thanks to its 40 degree banking, speeds of up to 250 km/h can be achieved without lateral forces. This enables Opel engineers to test their calculated target values, such as top speed, while being able to relax and release the steering wheel once in a while. To put the steering, transmission and brakes to the test, Opel ADAM ROCKS also successfully completed the hill track. This undulating, man-made circuit has rising and falling gradients, ranging from eight to 30 percent, with different road surfaces and a serpentine section including hairpin turns – similar to conditions found in alpine mountains. It was another stage that the newest Opel family member effortlessly rocked through. Opel’s agile urban athlete really showed off its strengths, particularly in curves. The newly-tuned steering underpins ADAM ROCKS’ agility, impressing with its direct responsiveness and sporty driving style.
Quality assurance right before start of sales
On Dudenhofen’s comfort and noise measurement track across various road surfaces, engineers tested their development work to ensure it is transferred to real-life experience. As a result, Opel ADAM ROCKS meets the requirements of the ECE-R51.02 pass-by noise type approval regulations. The main factors affecting pass-by sound are powertrain noise emissions, especially those from the exhaust system. The test track used for the Opel ADAM ROCKS was exactly 23.74 meters long. In accordance with the standard procedure, engineers drive onto the track in second and third gear, both at 50 km/h, and then accelerate under full throttle. To the left and right of the track, directional microphones are posted which capture the pass-by noise. The average limit value for pass-by noise in second and third gear is 74 dB(A) – and the small crossover mastered this without a problem.
But that’s not all. A decisive test which the series production version of the Opel ADAM ROCKS had to undergo was the endurance track. The longest track at the test center offers many different road surfaces including asphalt and cobblestones, bumps and numerous curves. Here engineers test if the performance and quality they fine-tuned and approved in the development vehicles has been successfully transferred to the volume production vehicles. “This gives us another possibility for additional quality assurance right up to the start of sales,” says Rainer Bachen, Lead Development Engineer at Opel. “For example, if we determine in Dudenhofen that the steering feels different, or bothersome noises can be heard inside the vehicle, we can immediately take appropriate measures and get the quality back on track before delivery to our customers.”
During the development phase of Opel ADAM ROCKS, everything for the prototype making in the development center is carried out by hand. In contrast, speed and volume count in series production, so that series production quality also has to undergo final testing. That is why the team brings the Opel ADAM ROCKS into the workshop after the various test runs and examines the vehicle and its individual components. “We want to be absolutely sure that our series production cars drive exactly like we tuned our prototypes during development. In the process, safety, quality and endurance are top priority for us,” says Bachen. So when the endurance test is completed, engineers again check all the fastening elements which were bolted together by series equipment, disassembling the ROCKS down to its single components to assess every single part. After this careful inspection, the result was an unqualified “Thumbs up!”. So there is nothing standing in the way of having pure driving fun at the wheel of the Opel ADAM ROCKS – even over hill and dale – from September.
Engineering vice president, Mike Ableson opens new high-speed circuit
Investments secure Opel Test Center’s worldwide leadership
Dr. Matthias Schollmaier, head of Dudenhofen test center, Opel Vice President Engineering, Michael F.
Ableson, Permanent Under Secretary of Economic Affairs, Steffen Saebisch
and mayor of town of Rodgau, Jürgen Hoffmann.
Opel today opened the completely renewed high-speed
circuit at its Dudenhofen Test Center. The modernization of the test track is
part of an investment totaling 28.5 million euros. At ten million euros the
renewal of the high-speed circuit, the centerpiece of the Opel Test Center, and
the installation of world class test and sensor technologies, represent the
single largest investment.
“The opening of the high-speed circuit is a milestone
for our Test Center”, said Mike Ableson, Opel vice president of Engineering,
during the opening ceremony. “This is a clear sign of our commitment to the
long term future of our development facilities in Germany. The extensions are a
significant contribution to further increasing the quality of our products, and
bringing affordable innovations to our customers fast”.
2003 Opel Eco Speedster
In a symbolic lap of the high-speed circuit with
Steffen Saebisch, Secretary of State at the Ministry of Economy, Transport and
Development in the state of Hesse, Ableson handed over the operation of one of
the most versatile and modern test tracks in the world to the engineers and
technicians in Dudenhofen. The parade lap of the high-speed circuit was led by
the world record breaking Eco Speedster, which set 17 international records at
Dudenhofen in 2003, and an Opel Rekord from 1966, the year the test center was
opened.
1966 Opel Rekord driven by the soccer coach legend Sepp
Herberger and the Opel Panorama bus took part in the first lap on the
track under sunny sky.
In his speech
Secretary of State Saebisch stated: “It is up to the car companies themselves
to secure the industry’s ability to innovate and compete. Opel and GM have
accepted the challenge. With their investments in the extension of the
Dudenhofen Test Center they have made a clear commitment to the future. It is
the duty of politics to create the framework businesses need to overcome their
challenges. This is why education, the reduction of bureaucracy, and the
promotion of innovation are central themes for theHesse government. Hesse needs a strong and dynamic
industry to secure its prosperity, also in the future.”
The investments will enable the test center to
replicate nearly every driving profile imaginable. Mike Ableson: “We are
cementing Dudenhofen’s reputation as one of the leading proving grounds in the
world, and we are extending its business opportunities for development,
component testing and brand communication. Our numerous long-standing external
clients, including many development partners, will also benefit.”
Opening lap of the new track: The record breaking Opel Eco Speedster
and the original 1966 Opel Rekord that belonged to the soccer coach
legend Sepp Herberger which was also the year the proving grounds first
opened.
Vehicle testing at highest
safety levels
The management of test programs at the Opel Test
Center has always met the highest demands for quality, precision and safety. New
sensors in the surface of the high-speed circuit, and the full electrification
of the control and measurement technology will take these standards to an even
higher level in future.
In
the interest of customers, it is highly important that prototypes of future
models are tested down to the last nut and bolt. That means driving the test
cars at their limit under strictly controlled conditions. Thanks to the
increase in the angle of the banking from 37.5 degrees to 40 degrees cars can
now drive safely at250 kilometers per hour
on the high speed circuit, without lateral forces.
Work on the additional extensions has already begun. During
the remainder of 2012 Opel will build new tracks for testing pass by noise and
calibrating new engines.
Additional highlights include an all-new traffic
control system for the whole proving ground; new tracks for testing
transmissions and driving dynamics at Formula 1 levels; and the near identical
copy of a public street, including a city driving route.
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