Title: Metal over Capacitive Sensor (MoC):
More design freedom and interference-free control thanks to innovative sensor technology for opening doors and liftgates
Company: Witte Automotive
Speaker: Reinaldo Mensch, Karsten Steinhaue
Abstract: With the new MoC (Metal over Cap) sensor
technology, environmental influences are reliably filtered out, which
ensures the trouble-free activation of electric side door locks.
The technology also opens up unprecedented design flexibility for vehicle designers: The design of the MoC sensors can be adapted as desired. This enables new installation variants and designs for the handles. This also makes it possible to implement fixed exterior door handles that require virtually no release stroke and low operating forces.
Individual programming creates unique haptic experiences: Should the door be opened with just a light touch? Or does a certain force have to be applied first to activate the sensor? These and other parameters can be individually adapted to the customer's wishes - even after the handle has been completed.
Mode of operation:
The MoC sensor concept adds a safe switch variant to the Kessy system.
The metal above the sensor almost completely shields it from environmental influences.
The MoC sensors are read by the microcontroller, which is also used to evaluate the boiler system. Only minimal mechanical movements are required for actuation. This means that the installation space can also be kept to a minimum.
Title: Economical lightweight door for commercial vehicles
Company: EDAG Engineering GmbH
Speaker: Sebastian Flügel
Abstract: Globalisation, increasing logistics volumes and dwindling resources are necessitating a change. We therefore developed a lightweight door for commercial vehicles to save fuel and to reduce emissions. We created a future-oriented design that includes aerodynamic elements and innovative joining technology. With our concept of steel-intensive hydroformed construction, we were able to implement a cost-effective approach with maximum functional performance.
Title: Affordable aluminium doors for high-volume mid-size SUVs
Company: Alumobility (probably one speaker from Novelis and one from Constellium)
Speaker: Dr. Axel Förderreuther
Abstract: Based on globally available aluminium alloys, Novelis and Constellium, as part of the new Alumobility global ecosystem they co-founded, have developed an affordable aluminium door for the fast-growing segment of high-volume mid-size SUVs. Using a recent steel reference door, an aluminium-oriented manufacturing layout suitable for high volumes has been designed to optimize the Value-In-Use (VIU) in terms of €/kg saved. The aluminium door has been designed to fit the reference door package using formability simulation for critical panels. Results from static and dynamic FE analysis confirm equivalent performance to the steel reference while achieving 45% lightweighting. The design and joining methods are also applicable to other high-volume doors, i.e. from the C-segment.
Title: Scalable vehicle access experience through smart mechatronic systems
Company: Brose Fahrzeugteile
Speaker: Sebastian Hermeling
Abstract: Although mobility can be boiled down to a
problem of overcoming spaces, yet in private transportation it is
undeniable more often an emotional driven decision to buy a certain
vehicle than it was a rational reflection. Though the user experience
becomes more and more important and probably one core elements of a
With regards to this, one must state that the very first interaction with the car begins before even starting the engine. And by the way: In an all-electric vehicle this is probably not as exciting as it used to be. But being both first and last impression of a journey, the vehicle access holds tremendous potential to create unique experiences.
User centricity is key. New, sensor-enhanced products and functions offer car makers the opportunity to create new, exiting features and experiences such as: Gesture controlled, fully automated door opening, or a comfortable servo controlled manual door movement.
The challenge of course: Keep the costs reasonable and handle the complexity. Smart and scalable solutions are required. A combination of standardized component kits, sensor synergies and adaptable, scalable user experiences can be the answer. Brose for instance develops scalable mechatronic systems – combing electronics and control units, various sensor technologies as well as well-engineered mechanical actuators – exactly for this purpose.
This presentation will discuss the impact of changing consumer behavior and expectations and will introduce ideas how smart mechatronic systems help to create more value-add in the context of vehicle access. It will furthermore propose system architectures that might be worth to consider for future field applications.
Title: Battery gives e-locking systems a breakthrough and even opens doors.
Company: Kiekert AG
Speaker: Tobias Klocke
Abstract: In the course of the electrification of the automobile, electromechanics is also advancing at a rapid pace. The proportion of moving components in the vehicle that are moved electromechanically is rising continuously. Electrical locking and unlocking as well as electrical opening of locking systems in the vehicle were milestones in entry and access convenience. The electrical opening of closure systems has become established primarily for liftgates and tailgates. This is because only an electromechanically "released" liftgate can subsequently open by drive. Electromechanically opening side door locking systems with an integrated drive are already installed in a few series-produced vehicles. But they are still a long way from being used on a large scale. So there is potential here. However, since side doors are also escape doors, the question of safety and thus redundancy for opening arises in the event of a drop in on-board voltage. This can be ensured by means of a mechanical internal and external actuation chain. However, in this case, the advantages that make the use of electromechanical opening so attractive, must be foregone. This is because, among other things, the design freedom gained for external and internal handles is marginal and the reduction in individual components is also limited. To enjoy these advantages, therefore, the redundancy must also be electrical and independent of the vehicle electrical system. Capacitors or so-called supercaps can independently supply locking systems with energy in the event of a voltage drop. However, this technology is relatively expensive, not fully developed and also has disadvantages in terms of the space required. The latest generation of e-locking systems from Kiekert specifically relies on the use of batteries as electrical redundancy. This combination is characterized by the following features. 1. Minimum necessary force The force of the redundant energy source must be sufficient to reliably open the lock. Kiekert's specially developed "rolling pawl" ratchet reduces the force required to open the ratchet to a minimum. Sliding friction instead of static friction is the keyword here. 2. Reliability of the energy storage system The redundancy must store energy independent of the on-board power supply for decades at best and keep it available for immediate use. The minimum power to be applied allows the use of a conventional 3 volt battery system. This technology has long been mature and proven. In addition, the lock design provides for easy battery replacement in aftersales, so that the very unlikely event of a failure can be detected and immediately addressed. As a result, this innovative e-locking solution from Kiekert has clear competitive advantages that are protected by patents. However, to really thrill the OEM engineers, Kiekert has equipped its e-locking system with another unique convenience and security feature. The locking system is also able to present the door to the user and even force it open in the event of tension or icing. The so-called "presENTER" is a pin that can be moved out of the lock, attaches to the striker and pushes the door open with a force of up to 500 Newtons. This technology opens up completely new future vehicle access possibilities for OEMs. With this innovative locking system, Kiekert is setting new standards in safety, convenience and design. The presentation elaborates on these in an exciting and visualized way and provides an outlook on future further developments.
Title: Insights on transforming automotive tailgates with thermoplastics
Speaker: Simon Staal
Abstract: The automotive industry is revolutionizing vehicle design and production. Designers and engineers are reimagining everything from the wheels up. This includes the rear of the vehicle and one of its heaviest components: the tailgate. This presentation will consider some of the latest trends in tailgate design and discusses how this part is evolving. The session will review critical factors in the material selection, the engineering and design and the production of the tailgate, in addition to the value of thermoplastics in enabling lightweight, stylish designs and the integration of new functionalities.
Title: Virtual validated door concept for cars without B-pillars
Company: Benteler International AG
Speaker: Dr. Jörn Tölle
Abstract: BENTELER not only makes mobility lighter, safer and more sustainable – but also more convenient: to make vehicle entry easier, the metal processing specialist has developed a new door concept that removes the need for a B-pillar. This production-ready product is even lighter than existing solutions on the market and offers improved safety and material features.