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Modular MatrixDiversity Through Standardisation

More than 4o modelsby Volkswagen Group that are based on

the Modular Transverse Matrix will

enter the market during the next years.

2o12 sees the start of productionaccording to the new modular matrix principle.

Editorial Dr. Ulrich Hackenberg 2This Is MQB Greater Efficiency in Every Way 2Flexible Factory New Production Standards 3Modular Motor More Space and Less Consumption 4Slimmed Down A Basis for Lightweight Standard Production 6

As Standard Assistance Systems for the Golf Class 8Imprint 8

VIAVISIONSHAPING THE FUTURE OF MOBILITYVOLKSWAGEN GROUP

NO 02March2012


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As a global automobile manu-facturer, Volkswagen is con-stantly working on making carsand production processes moreeconomical and efficient. A newbasis for this is the ModularTransverse Matrix. Find out

what stands behind this term

on the following pages.

Happy Reading.

Dr. UlrichHackenberg,Member of theBoard of Man-agement ofVolkswagenBrand with re-sponsibility for

Research andDevelopment.

Editorial

30 vehicles per hour can be produced on one assembly line infactories that work according to the modular matrix principle.When demand rises, this number can be increased to 60 withthe help of additional robots.

40 to 60 kilograms of weight are saved in every car that has beenproduced using the MQB system. This is achieved by using newmeans of construction, downsizing of certain engine parts orthe use of lightweight materials for example.

40Volkswagen Group models that are based

on the MQB will enter the market during thenext few years.

assistance and infotainment systems that have only been available in the luxuryclass so far will be installed in MQB models. The Modular Transverse Matrix standsnot only for improved economy and efficiency but also for enjoyable driving, comfortand new security systems for the majority of car drivers.

20* Volkswagen Group is the source of all information in this edition.

20percent of fuel is saved using the new petrol engines that are part of the MQB. This is madepossible by reduced friction resistance in the engines or through active cylinder managementfor example. Besides the reduction in CO2, the focus for diesel engines is on effective emissioncontrols.

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MODULAR TRANSVERSE MATRIX VIAVISION

This Is MQBGreater Efficiency in Every Way

The business of Volkswagen Group is complex: ten brands, more than220 models, even more different customisations. At the same time, theGroup has made it their business to reduce the consumption of combus-

tion engines, to include natural gas and electric cars in their productline-up and to introduce technical innovations, like assistance systemsfor example, to as many cars as possible. The basis for the realisation ofthese goals will be the Modular Transverse Matrix (MQB)*: a standard-ised vehicle architecture that allows the combination of different carparts, according to the modular matrix principle, time and time again.This increases the diversity of the product line-up and the efficiency ofproduction, engines and material mix.


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Flexible FactoryNew Production Standards

Output with the Modular Production System:(vehicles per hour)

30 cars per hour can be produced on one assembly line using the basic model ofthe Modular Transverse Matrix. The flexible system can be expanded withadditional robots at predefined positions, if one factory is to produce differentmodels, and can produce up to 60 vehicles of different brands and models.

3o

6o

Application examples

The new Audi A3 and the newGolf will be produced using theMQB. Systems for welding carparts will be standardised forexample. A new flexible mobiletechnology is employed here,that allows the system to be

adapted to the differently sizedframes and wheelbases ofdifferent car models. Also,additional robots at predefinedpositions can be quickly addedin order to increase productionfigures if need be.

More than 90 factories in 22 countries are part of the VolkswagenGroup; 8.16 million vehicles were sold in 2011. In order to even betterreact to increasing demand, and to offer a growing line-up of different

models, Volkswagen is also introducing the Modular Production System(MPB) in addition to the MQB. By standardising individual productionsteps and entire factories, production time and production costs arelowered on top of that, different brands and models of the Group canleave the same assembly line, for example, the Golf, Tiguan and Passat.

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02 March 2012 MODULAR TRANSVERSE MATRIX


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Modular MotorMore Space and Less Consumption

Alternatives

Different drive systems will beinstalled in the different models

without difficulty because of theuniform mounting position in theengine compartment besides theconventional combustion engine,alternative drives like electric andnatural gas engines, too.

Plug-In

the EA111 engine seriesin the Golf

e-DRIVE

EcoFuel CNG

Previously, the exhaust side of the engine block (coloured) was sometimes builtinto the front and sometimes into the back but is now uniformly positioned at thebulkhead, between the engine compartment and passenger compartment. The

engine block itself is now tilted towards the back and not the front. The engine conse-quently requires 50 millimetres less space, which benefits the passenger com-partment. To save even more space, numerous ancillary components, such as thewater pump or alternator, are screwed directly into the engine or the oil sump.The new mounting position for petrol and diesel engines will be uniform in orderto make standardisation of some parts, like exhaust lines and drive shafts, easier.

The new position:

all MQB engines

With the new Modular Transverse Matrix, cars get new engines that areall installed at the same angle of inclination. This has numerousadvantages: The new uniform mounting position creates more space

in the passenger compartment and drastically reduces the number ofengine-gearbox combinations that have to be developed individually.Thanks to the identical mounting position in all models, alternativedrive systems can be installed without much effort. Further measureslike active cylinder management, for example, reduce consumptionand emissions.

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ENGINES VIAVISION

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Cylinder managementFriction loss wanted

Internal friction, for example that of the pistons against the cylinder

walls, costs fuel to overcome. Multiple measures reduce this friction innew petrol and diesel engines. The bearings of the overhead camshafts,piston rods and crankshaft for example are designed to significantlyreduce friction.

Thermal management system

A cold engine consumes more fuel because the engine oil is viscouswhen cold and consequently increases friction resistance. In addition acold engine takes longer to heat up the interior. This is why new engines

first heat up stationary water in the cylinder head. The engine warmsup faster, as does the heating. Additionally, the petrol and dieselengines have two separate cooling circuits instead of one large one in the earlier generations of engines, large cooling circuits not onlycooled the overall system but also engine components that are supposedto heat up quickly.

Emissions control

High nitric oxide emissions present a special challenge for diesel

engines. In January 2014, the permitted level of nitric oxide emissionswill be lowered from 180 to 80 milligrams per kilometre. To lower theseemissions, new diesel engines are fitted in addition to the existingcatalytic converters and particle filters with storage catalytic convert-ers in small cars, as well as AdBlue injection in larger cars. Storagecatalytic converters collect the nitric oxide and convert it into non-toxicsubstances. With the AdBlue injection, the exhausts are added toan aqueous urea solution which renders the major part of the nitricoxides harmless.

The bottom line

2o percent of fuel is saved using new petrol engines with activecylinder management. Otherwise they consume eight to tenpercent less fuel, compared to their predecessor engines. 7grams less CO2 per kilo-metre is emitted by the new

generation of diesel engines.

While driving at low load states,

meaning the lower-to-middlerange of engine speed, two ofthe four cylinders in the petrolengine are shut down. Theactivation and deactivation ofthe cylinders takes between13 and 36 milliseconds, whichis unnoticeable to the driver.If the driver presses theaccelerator pedal hard, thetwo cylinders switch back on.

The specified reductions inconsumption apply when driving atconstant speed. Initially, activecylinder management (ACT) isintegrated as standard in the Polo.

Reduced consumption:(per 100 kilometres)

1 literless

0.7 literless

at 70 km/hin 5th gear

at 50 km/hin 3rd/4th gear

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02 March 2012 ENGINES

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Weight reduction in MQB vehicles:(in kilograms)

Floor structure

-18Interior components

-10

Slimmed downA Basis for Lightweight Standard Production

Vehicles have tended to become heavier nowadays because of assistancesystems, climate control and other technological advances. The MQBreverses this trend: Almost all parts are optimised in their construction,

or made from different material compositions, and are thus signifi-cantly lighter. When the new seventh generation Golf rolls off the MQBassembly line this year, it is planned to reach the same weight level asthe Golf IV.

4oto 60kilograms less,is what cars in

the small, compact andmedium class weigh, com-pared to their predecessormodels.

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LIGHTWEIGHT CONSTRUCTION VIAVISION


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Running gear

-6

Electrical system

-3

Engine

-22

The vehicles produced with MQBare becoming lighter in many

places without compromisingsafety or driving comfort.

Powertrains and engines loseweight because of the increased useof aluminium. A large proportion of

the floor structure consists ofhot-formed steels, which are

especially light and have improvedcrash properties. In the interior too,

the front and rear seating systems,the load-bearing structure of the

dashboard and the air conditioningsystem are weight-optimised. The

electrical system components in thevehicle weigh less as well, thanks to

detailed optimisations. Intelligentmaterial selection and improved

construction save additional weightin the chassis area, such as

shock absorbers, suspension andwheel suspension.

Crankcase

Turbocharger

Crankshaft

Connector rods

Control drive

The petrol engine* of 2012 is almost 22kilograms lighter than its predecessor

model of 2008. The lions share is savedin the crankcase: Because, now the

light metal aluminium is employed, it is16 kilograms lighter than before.

*The numbers refer to the petrol engine

VW 370 1.4 l 90 kW TSI.

16

2.5

2.2

0.6

0.6

Weight reduction of engines:(in kilograms)

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02 March 2012 LIGHTWEIGHT CONSTRUCTION


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ASSISTANCE VIAVISION

As StandardAssistance Systems for the Golf Class

Hitherto the latest assistance systems were exclusive to the luxury class.With the Modular Transverse Matrix, 20 different assistance andinfotainment systems like traffic sign detection or multicollision break,

which won the first price in Innovation and Environment 2012 bythe German car association*, are being introduced to vehicles of theGolf class. Two systems are premiering with the MQB: the electronicallycontrolled front-axle transverse differential lock and progressive steering.

Multicollision brakeThis is employed when the vehicleis involved in a collision. Because oftenfurther collisions happen after thefirst impact, the multicollision brake automaticallydecelerates. Still the driver stays in control:Upon acceleration the multicollision breakdeactivates.

))Proactive occupant protection systemThe system detects a potential accidentsituation, triggered by hard breakingor severe oversteering for example.It protects passengers by automatically preten-sioning their belts and closing the windows.Both measures ensure optimal protection.

Progressive steeringProgressive steering utilises a steeringstroke and a steering rack that aretoothed in such a way that the transitionbetween straight line driving and larger steering

wheel turning angles is easier to handle. Not onlydoes this improve control over the car but alsomakes parking more comfortable because thesteering wheel requires a smaller turning angle.

Front-axle transverse differential lockThis is new for front wheel drive pro-duction vehicles: The electronicallycontrolled front-axle transverse differen-tial lock (VAQ) stabilises front wheel carsduring cornering. A special clutch prevents wheelslip on the inside of the curve when turning bends can be taken more stably and moresecurely.

www.viavision.org.uk, www.viavision.org

Edited byVolkswagen Aktiengesellschaft

Konzern KommunikationBrieffach 1972, 38436 Wolfsburg

Phone: +49 (0)5361/9-77604Fax: +49 (0)5361/9-74629

Imprint Published byVerlag Rommerskirchen GmbH & Co. KG

Mainzer Strae 16 -18, Rolandshof,53424 Remagen

Phone: +49 (0)2228/931- 0www.rommerskirchen.com

Printed by

L.N. Schaffrath GmbHMarktweg 42-50, 47608 Geldern

V.i.S.d.P.

(Person responsible according to the German

press law)Stephan Grhsem, Leiter Konzern Kommunikation;

Peter Thul, Leiter Kommunikation Marke & Produkt

Editorial staffSusanne van den Bergh, Stefanie Huland,

Adrienne-Janine Marske, Kathi Preppner, Lena WildeContact: [email protected]

* ADAC, Gelber Engel 2012.

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