Daimler started production at its new passenger car plant in Kecskemét today. Passenger cars are now rolling off the assembly line in Hungary less than four years after the location decision was made in summer 2008. Dr. Dieter Zetsche, Chairman of the Board of Management of Daimler AG and Head of Mercedes-Benz Cars, Plant Manager Frank Klein and Hungarian Prime Minister Viktor Orbán welcomed around 600 Hungarian and German guests at the opening ceremony. At the press conference, Dr. Dieter Zetsche stressed the importance of the new location: “With the start of production in Kecskemét, the Mercedes-Benz offensive in the premium compact segment is shifting up a gear. With the production network of the Rastatt and Kecskemét plants, we now have the capacity to meet the demand from many existing – and new – customers in the premium compact segment.”
In this respect, Zetsche announced that another model series would also be coming to the new location – the 4-door coupé of the new generation of Mercedes-Benz compact cars. As part of the ongoing plant development, headcount is to be increased from around 2,500 to more than 3,000 by the end of this year.
Zetsche expressed his special thanks to Daimler’s Hungarian partners in the political, administrative and social areas: “They welcomed us like a friend and actively supported us through every stage of the plant development. Their tireless commitment was one of the main reasons for the positive outcome of this project, and will continue to be a key factor in the success of the Mercedes-Benz Kecskemét plant.”
Zetsche also praised the outstanding work of the Hungarian, German and international employees in developing the new plant: “This team has provided the perfect example of how we will expand our passenger car production capacity in the years ahead. We are thus laying the foundations for implementing our Mercedes-Benz 2020 growth strategy.”
Frank Klein, Managing Director of Mercedes-Benz Manufacturing Hungary Kft., said: “We are making history today: less than four years after the location decision was made, ‘Mercedes-Benz Made in Hungary’ has become a reality. From now on, we can show that we are a key pillar of the Mercedes-Benz production network. Our intensive preparations have enabled us to produce the established Mercedes-Benz quality right from the very first vehicle.”
The first vehicle from the plant is to be auctioned off. The proceeds will be donated to the Hungarian aid organization Nemzetközi Gyermekment ő Szolgálat (International Children’s Safety Service).
Additional capacity for B-Class production
The first product in the new generation of Mercedes-Benz compact cars, the B-Class is now built at the new plant. It went into production at the plant in Rastatt, Germany back in September 2011. With this increased production capacity, it is now possible to fully address the overwhelming customer response: Mercedes-Benz has already received more than 100,000 orders for the B-Class since its launch in November 2011.
Efficient production in the Rastatt-Kecskemét network
In total, Daimler has invested €1.4 billion in production of the new generation of Mercedes-Benz cars: €800 million for construction of the Kecskemét plant and €600 million for expansion of the Rastatt plant.
The joint production of the B-Class in Rastatt and in Kecskemét enables flexible and optimum management of both plants’ capacity utilization. This volume flexibility is a key factor of the economic efficiency of the production network. In addition, the joint architecture of the new generation of compact cars ensures complete type flexibility in production: in principle, all models at the location can be produced on the same assembly line, in all variants of the product range and in any sequence.
The production network also includes the efficient logistical link between the two plants, which are part of the Daimler Rail Net network. The recently opened east-west rail link supplements the existing north-south links between the powertrain and vehicle plants in Germany. In particular, body parts, engines, transmission systems and other components are delivered from the German locations to Kecskemét by rail. From 2013, most of the completed vehicles will also be transported by rail in the opposite direction. Overall, when completed, this will save up to 60,000 tons of CO2 per year.
Perfect planning and green production from the outset
The plant in Kecskemét was the first passenger car production plant in the Group to be entirely digitally planned and to receive three-dimensional backup. This was an essential requirement for the perfectly-timed workflows and adherence to all deadlines and cost targets.
State-of-the-art, environmentally sound technology is used at the plant. For instance, the paint shop is one of the most modern and resource-friendly facilities of its kind with its innovative dry separation method. The overall energy concept is particularly geared towards efficiency, e.g. the ventilation system of the production shops with heat recovery, the use of highly efficient strip-lighting systems for illumination and the use of two district heating plants to supply electricity and heat.
The most attractive employer in the region
The plant is the most attractive employer in the region, especially since employee training is a top priority. All new employees undergo intensive training programs, which are available at the in-house training center in Kecskemét and at the German locations, particularly at the Rastatt plant. This thorough, high-grade training is the key success factor in producing top-quality vehicles to Mercedes-Benz standards at the location from the outset.
Innovative dual training in Hungary, strategic partnerships in the area of education
The Mercedes-Benz Kecskemét plant is also covering future requirements for qualified staff through strategic partnerships in the area of education. In particular, the plant is breaking new ground by offering high-grade dual vocational training based on the German model, which is being delivered in conjunction with Kecskemét City Council and the Chamber of Industry and Commerce of the county of Bács-Kiskun. The first 34 trainees started their courses in 2011, and the next intake of 36 trainees will start their training in September 2012.
In the tertiary education sector, the Mercedes-Benz plant and Kecskemét University of Applied Sciences have joined forces to enable practically-oriented, dual university education. The first students in this new training format will commence their studies in September 2012. With this offering, the partners are aiming to make the University for Applied Sciences the number one centre in Hungary for training of extremely well-qualified specialists for the automobile industry.
Hungarian companies benefit from the project
The Hungarian economy has benefited significantly from the choice of location. For instance, over 90% of the order volume for construction of the plant was placed with Hungarian companies. Operation of the plant also provides wide-ranging opportunities for Hungarian partners, for example service providers and craftsmen. Regarding the production materials for the new generation of Mercedes-Benz compact cars, 17 Hungary-based suppliers have been awarded a substantial order volume worth running into nine figures of euros.
Credits: Daimler AGCopyright © 2012, Mercedes-Benz-Blog. All rights reserved.
Daimler Buses achieved its second-best sales result ever in 2011, selling a total of 39,740 vehicles or 2% more than in the previous year. The division achieved this result despite difficult sales conditions for complete buses. The only time that sales were even higher was in 2008, when almost 40,600 units were delivered. As a result, Daimler Buses continues to be the world’s leading supplier of buses weighing more than 8 tons GVW.
311,000 buses were sold worldwide, an increase of 2% compared to the previous year. Whereas business was booming particularly in Latin America, the bus market in Western Europe remained in a slump because of the financial and debt crisis. Market development was similarly negative in North America, which, like its Western European counterparts, suffered from public sector budget constraints and therefore from substantially fewer calls for bids.
Strong sales increase in growth markets
The main reason for the rise in sales at Daimler Buses was the increased demand in Latin America, where the division boosted sales of Mercedes-Benz brand chassis by 8% to 25,000 units. Sales were also buoyed by purchases made earlier than planned due to the introduction of the Euro V emissions standard in Brazil in 2012. The market share of Daimler Buses in Latin America remained at a high level of around 43% in 2011. Substantial increases were posted in Mexico as well. Business was also good in Turkey, where sales rose by 55% to the record figure of 1,100 buses.
By contrast, Daimler Buses was unable to buck the downward trend in Western Europe and North America. As a result, sales dropped in Western Europe by 17% to 5,900 vehicles and chassis. Sales of city buses once again declined steeply, as the public sector continued to be negatively influenced by budget restraints. The division sold 600 buses in North America, or almost one third less than in 2010. Budgetary constraints were also the defining factor in this market.
“In 2011 we kept pace with the global market as a whole,” says Hartmut Schick, Head of Daimler Buses. “We captured an impressive 12% of the global market, which makes us the world’s Number One bus supplier. More specifically, we clearly maintained our leading position in the core markets.”
Daimler Buses’ revenues and earnings both declined in 2011. At €4.4 billion (2010: €4.6 billion), revenues were slightly lower than in the prior year. These figures are the result of two contrary developments. Whereas the demand for chassis rose substantially, it dropped considerably for complete buses, which generate significantly more revenue per bus. This development therefore had an even bigger impact on earnings than on revenues, and EBIT declined from €215 million to €162 million. “2011 was clearly a chassis year, while the business with complete buses was very sluggish, particularly in Europe,” comments Schick.
"We've got the right strategy"
Even though Daimler Buses’ return on sales dropped to 3.7% in 2011 (2010: 4.7%), the division’s target for 2013 remains at 6%. “We have the right strategy, and we will systematically pursue it,” says Schick. A key element of this strategy is the GLOBE 2013 growth and efficiency offensive. This “fitness program” will be rolled out at all locations and along the entire value chain. “We will leave no stone unturned and make sure that nothing is omitted,” states Schick.
One of the aims of this strategy is to more strongly interlink the European production network, which has locations in Germany, Turkey, and the Czech Republic. The two German bus plants in Mannheim and Neu-Ulm will remain an integral part of this network, which is why the division invested extensively there in recent years as well as in Hosdere, Turkey.
“GLOBE 2013 will further increase the competitiveness of the German locations. We are making Mannheim and Neu-Ulm sustainably fit for the future. Daimler Buses is the only major bus manufacturer to remain faithful to Germany as a production location,” says Schick.
As part of GLOBE 2013, Daimler Buses will exploit existing growth potential in its traditional markets and further expand its business operations into new ones. In response to the introduction of the Euro VI emissions standard, the division is launching a product offensive in the city bus segment as well as in the coach market. Daimler Buses’ Travego Edition 1 is the first Euro VI-compliant coach. “Our products precisely meet our customers’ wishes, and we will systematically exploit growth potential,” says Schick.
City buses in India — chassis in China
Big growth opportunities are also offered by new markets such as India and China. After having introduced two travel coach models in India since 2008, Daimler Buses is now launching the first Mercedes-Benz city bus there. India is the world’s second-largest bus market, with a current volume of about 46,000 buses per year. Experts predict that this volume will grow to around 80,000 units in 2020.
By then, the bus market in China is expected to increase from its current level of more than 100,000 units to around 150,000 units. Daimler Buses is taking a multi-track approach in order to exploit the opportunities in China. The division will begin selling chassis in the country this year. In addition, Daimler Buses will talk with the Chinese company Foton about joint projects. Foton and Daimler are already cooperating in the truck sector. The two companies are partners in the joint venture company Beijing Foton Daimler Automotive Co., Ltd., which produces Auman brand medium-duty and heavy-duty trucks in China.
Daimler Buses expects sales to be negatively affected by the introduction of the Euro V emissions standard in Brazil this year, whereas business will probably improve slightly in Western Europe.
Credits: Daimler AG
Copyright © 2012, Mercedes-Benz-Blog. All rights reserved.
“The A-Class makes a clear statement on the new dynamism of Mercedes-Benz”, said Dr. Dieter Zetsche, CEO of Daimler AG and Head of Mercedes-Benz Cars. “Together with the successful new B-Class and three further model variants based on this vehicle architecture, it will be an important driver in our ‘Mercedes-Benz 2020’ growth strategy. We are expecting a conquest rate of more than 50 percent for the A-Class. And that’s why we say that ‘A’ now stands for attack.”
Representatives of the international press were able to gain a first impression of the new A-Class on the eve of the Geneva Motor Show. Dr. Dieter Zetsche unveiled the Mercedes athlete in the compact segment as part of an exclusive presentation. The “first pulse of a new generation” was experienced live by an audience that included Germany’s national soccer coach Joachim Löw and team manager Oliver Bierhoff, as well as national players Benedikt Höwedes and Mario Götze.
The new A-Class exudes dynamism from the very first glance – its sits lower to the ground than its predecessor by up to 18 centimetres. The radical design language that was introduced with the “Concept A-CLASS” to an enthusiastic reception worldwide has been systematically carried over into series production. With a reinterpretation of the classic two-box design, Mercedes-Benz designers created an emotional exterior with an extremely sporty character. And with a cd figure starting from 0.26, the A-Class sets a new benchmark in its class.
Premium interior and full iPhone® integration
The sporty appearance continues into the interior. Added to that is a premium feel that is unique in this vehicle segment. The operating concept also sets benchmarks with a fully integrated smartphone. The driver now has access to the main content of his iPhone® with the “Drive Kit Plus for the iPhone®” and an app concept developed in-house by Daimler that brings “Digital DriveStyle” into the vehicle. This enables the full range of smartphone capabilities to be used safely and conveniently inside the car, too, for the first time.
All functions of the iPhone® integration can be used with the Audio 20 entry device, and will also be available for a wide range of other Mercedes-Benz models as of this summer. Furthermore, Mercedes-Benz will shortly be enabling the in-car use of smartphones with other operating systems.
New petrol and diesel engines with exemplary efficiency
A wide range of spark-ignition and diesel engines fulfils every performance desire and, at the same time, marks the current state-of-the-art in efficiency – for the first time, a Mercedes-Benz with an internal combustion engine will emit just 99 g CO2 per kilometre. The output spectrum ranges from 80 kW (109 hp) for the entry-level diesel through to 155 kW (211 hp) for the new 2.0-litre petrol version. Mercedes-Benz is introducing an innovation in the 1.6-litre petrol engine in the shape of CAMTRONIC – by adjusting valve lift on the inlet side, the volume of fresh air is restricted under partial load and fuel consumption reduced. All six engines are equipped as standard with direct injection and the ECO start/stop function. As an option, they can be combined with the 7G-DCT dual-clutch automatic.
The new A-Class – exemplary in dynamics and safety
At the same time, the A-Class provides impressive proof that safety is not a question of price at Mercedes-Benz – the radar-based COLLISION PREVENTION ASSIST system and ATTENTION ASSIST are part of the standard equipment. Well-known safety features from the larger Mercedes model ranges are also available for the A-Class for the first time, including PRE-SAFE® and DISTRONIC PLUS, as well as the blind spot, lane keeping and speed limit assistants. The sophisticated chassis design chassis design guarantees high active safety and previously unheard-of handling characteristics. The most dynamic version in the lineup is the A-Class Sport engineered by AMG, on which the visual relationship to the Concept A-CLASS is particularly evident thanks to the new diamond grille.
E 300 BlueTEC HYBRID – the world’s most fuel efficient full-size car
With the E-Class diesel hybrid, Mercedes-Benz is starting a new chapter in the brand’s core segment and setting benchmarks for full-size business vehicles along the way. The S 300 BlueTEC HYBRID, which is available as both a saloon and estate, sets new records in efficiency. The world’s most fuel-efficient full-size model sets the pace with outstanding efficiency figures (4.2 l/100 km) combined with high power output. The four-cylinder diesel in the E 300 BlueTEC HYBRID generates 150 kW (204 hp) and 500 Nm of torque. The electric motor delivers 20 kW and 250 Nm.
“Our modular hybrid drive reduces consumption and increases driving fun and comfort at the same time,” said Prof. Dr. Thomas Weber, Daimler Board Member for Group Research and Head of Mercedes-Benz Cars Development. “Plus, the system is so compact that is fits entirely into the engine compartment, complete with the battery. This means that there are no reductions in available space, neither in the interior nor the boot.” Mercedes-Benz is the only premium manufacturer to offer an estate with hybrid drive – the load-master among hybrids.
World premiere for a top-class athlete – the new SL 63 AMG
With a power output ranging from 395 kW (537 hp) to 415 kW (564 hp), the new Mercedes-Benz SL 63 AMG offers the perfect pre-requisites for unparalleled dynamics and a uniquely refined driving experience. Systematic lightweight design sets the new generation of the high-performance roadster – and the entire new SL line-up – apart. Thanks to an all-aluminium body-in-white and carbon-fibre rear lid, the weight of the SL 63 AMG is down by 125 kilograms. A performance boost is delivered by the combination of a further refined AMG sports suspension based on Active Body Control, new AMG speed-sensitive sports steering, AMG high-performance composite
brake system and AMG SPEEDSHIFT MCT 7-speed sports transmission.
“Typically for AMG, we have once again loaded the top version of the SL with a few more horses, forming the basis for its supreme dynamics,” said Dr. Joachim Schmidt, Executive Vice President Mercedes-Benz Cars, Sales and Marketing. “At the same time, the performance specialists in Affalterbach have also achieved an impressive improvement in efficiency. The new SL 63 AMG boasts average fuel consumption of just 9.9 litres per 100 kilometres, 4.2 litres less than its predecessor.” This means that the reduction in fuel consumption for the AMG version matches that of the series-production model at around 30 percent.
Efficient driving fun as standard – more new models for the C and E-Class
Alongside the E 300 BlueTEC HYBRID, Mercedes-Benz is adding two more efficiency champions to its C and E-Class lineup. Among the most fuel-efficient cars in its class is the E 220 CDI BlueEFFICIENCY Edition, which will reach dealers in March. Thanks to the Aerodynamics package, electric power steering (EPS) and a longer rear axle ratio, the 125 kW (170 hp) full-size model consumes just 4.5 litres of diesel per 100 km. This equates to CO2 emissions of 119 g/km – ten grammes or almost 8 percent less than before. Arriving on the market in parallel is the C 180 BlueEFFICIENCY as the new entry-level petrol C-Class. The 115 kW (156 hp) 1.6-litre turbocharged four-cylinder consumes just 5.8 l/100 km. The CO2 figure of 136 g/km marks an improvement of up to 21 g/km (ca. -1.0 l/100 km) compared with the previous C 180 with similar equipment.
C-Class Sport – the C-Class has never been so dynamic
With the new Coupe models “sport – engineered by AMG”, as well as the AMG Plus sports package, the selection of sporty C-Class versions is greater than it has ever been. The new coupe models C 250 Sport and C 250 CDI Sport are exceptionally dynamic, with specialists from AMG involved in their development. Both models offer the visually upgraded AMG Plus sports package, the more direct speed-sensitive steering and sporty transmission settings in S and M mode (in combination with 7-speed automatic). The new models will be available on the market starting June 2012.
Credits: Daimler AG
Copyright © 2012, Mercedes-Benz-Blog. All rights reserved.
Following on from the unusual "A-Class QR Trophy" campaign, Mercedes-Benz is now kicking off the second phase of the digital communication offensive for the new A-Class. To tie in with the world premiere in Geneva on 5 March 2012, the Stuttgart-based automobile brand is launching a central, interactive online platform which will pool all communications activities worldwide for the new A-Class. In the launch phase the online hub is offering a special at www.mercedes-benz.com/a-class which not only enables users to discover the highlights of the new compact model in interactive mode but will also showcase the appearance at the motor show live. The online platform is also optimised for smartphones and tablets.
"Apart from chiming in with the needs and expectations of younger target groups, the digital offensive for the new A-Class is a demonstration of Mercedes-Benz's sustained commitment to providing the user with innovative multimedia experiences on any device of their choice, in keeping with our brand claim, 'The best or nothing', says Anders Sundt Jensen, Vice President Brand Communications Mercedes-Benz Cars.
Apart from following the press conference at the world premiere in Geneva from home via a live stream, during the appearance at the fair from 9 to 14 March users will also be able to view the new A-Class from different perspectives by interactive means and to share their first impressions with friends and visitors to the motor show. Their comments will be posted directly on an LED screen at the exhibition stand and on the internet platform. Up to five cameras will broadcast live images of the new Mercedes compact model non-stop via the internet. On tablet PCs, visitors to the motor show who obstruct the view of the A-Class can simply be "wiped away" via a so-called “private mode” function.
So-called "A Guides", presenters on the booth, will broaden the scope of visual functions available to online visitors. With iPads which incorporate an integrated camera they will offer individual close-ups of the new A Class's exterior or interior and enter into dialogue with internet users. The visitors at the exhibition stand will be interviewed by the "A Guides" and their statements will be posted on the internet. A camera crew will accompany the "A Guide" team, also streaming live on www.mercedes-benz.com/a-class.
The international online platform is the core element of the launch campaign and will successively incorporate additional information and campaigns up to the market launch of the new A-Class in September 2012. Parallel to the Geneva launch users can also experience the product highlights and equipment of the new A-class in a new manner.
Jung von Matt/Alster and Jung von Matt/next are responsible for developing and implementing the international market launch campaign, including the digital measures. Scholz & Volkmer is attending to digital realisation of the live coverage from the exhibition stand.
Credits: Daimler AG
Copyright © 2012, Mercedes-Benz-Blog. All rights reserved.
Mercedes-Benz launches hybrid offensive: The world's most economical luxury-class model
Mercedes-Benz is opening a new chapter in its brand's core segment and at the same time setting new standards for luxury-class business vehicles: the E 300 BlueTEC HYBRID, available as a Saloon and Estate, impresses with new record values when it comes to efficiency. It boasts exemplary consumption levels (4.2 l/100 km[1]) as well as impressive performance: the 4-cylinder diesel engine of the E 300 BlueTEC HYBRID has 150 kW (204 hp) and 500 Nm. Combined with an electric motor producing 20 kW and 250 Nm, this results in a coherent overall concept. The E 300 BlueTEC HYBRID is the most economical luxury-class vehicle in the world.
The V6 petrol engine in the E 400 HYBRID produces 225 kW (306 hp) and 370 Nm, and is also supplemented by a further 20 kW and 250 Nm from the electric motor. The consumption figures based on the American CAFE standard are: City 24 mpg, Highway 31 mpg, Combined 27 mpg.
"With these two E-Class models we are now continuing our comprehensive hybrid offensive. The modular technology opens up a quick way for us to complement other model series with hybrid models", explains Professor Dr. Thomas Weber, Daimler Board Member for Group Research and Head of Mercedes-Benz Cars Development. "With a clear focus on the different requirements of the global markets, we are able to offer precisely the models which our customers want. The E-Class hybrids provide a clear reduction in consumption as well as a very impressive driving experience: they represent hybrid motoring at the premium level."
The new models do not require their passengers to have to compromise when it comes to space, however, whether in terms of the interior or the luggage compartment. And there are also additional benefits to the intelligent modular hybrid concept, which represents a comprehensive enhancement of the Mercedes-Benz S 400 HYBRID which has advanced to the position of clear market leader since 2009: no changes to the vehicle body are required, the hybrid module is both flexible and modular, thus allowing its use in other model series, and in addition to diesel and petrol variants there will also be right-hand drive variants. Meanwhile, the extra cost involved here is only moderate. The new hybrid models will be celebrating their world premiere at the Detroit Motor Show (14 to 22 January 2012) and will appear on the market over the course of the year. The E 300 BlueTEC HYBRID is initially planned to be launched on the European market, while the E 400 HYBRID will be made available on the American market first, followed by other countries such as Japan and China later.
The philosophy: increase efficiency without compromising comfort or use
The new hybrid models from Mercedes-Benz are part of the company's intelligent downsizing strategy which aims to make conventional models perform significantly more efficiently than ever before – without compromising when it comes to driveability or comfort. As part of this move, rather than focusing primarily on regular consumption, the engineers at the company have been examining exemplary consumption levels in everyday traffic. The notorious safety philosophy known as "Real Life Safety", which similarly highlights gains in safety under practical conditions rather than standard crash test results, is now being paired with "Real Life Efficiency".
Take the E 300 BlueTEC HYBRID by way of example: the hybrid model is based on the notoriously economical E 250 CDI, but exceeds it in terms of performance and undercuts in terms of fuel consumption by around 15 percent. The details are as follows:
- E 250 CDI: output of 150 kW, max. torque of 500 Nm, top speed of 242 km/h, acceleration from 0 to 100 km/h in 7.5 seconds, consumption of 4.9 litres of diesel/100 km, CO2 emissions of 129 g/km
- E 350 BlueTEC: output of 155 kW, max. torque of 540 Nm, top speed of 239 km/h, acceleration from 0 to 100 km/h in 7.8 seconds, consumption of 6.8 litres of diesel/100 km, CO2 emissions of 180 g/km
- E 300 BlueTEC HYBRID: output of 150 kW + 20 kW electric motor, max. torque of 500 Nm + 250 Nm, top speed of 242 km/h, acceleration from 0 to 100 km/h in 7.5 seconds, consumption of 4.2 litres of diesel/100 km, CO2 emissions of 109 g/km (values for Saloon)
As a result, the E 300 BlueTEC HYBRID is on a par with the E 300 CDI (170 kW/540 Nm) in practical use. However, it undercuts this model in terms of consumption and CO2 emissions by around 35 percent. The E 300 BlueTEC HYBRID also matches the E 300 CDI when it comes to vehicle weight too.
At the same time, hybridisation also represents an increase in ride comfort: starting up and moving off are practically silent, and the hybrid module also dampens any vibrations from the combustion engine. Furthermore, the vehicle's full range of climate control functions remain available even in start/stop mode.
The E 300 BlueTEC HYBRID and E 400 HYBRID at a glance:
Motoring: sailing along the motorway
The hybrid technology from Mercedes-Benz provides a whole host of additional functions which enhance comfort and efficiency at the same time, while making an overall contribution to creating a special driving experience with a sense of refined sportiness:
- Stationary vehicle/ECO start/stop function: the combustion engine can already be switched into deceleration mode at speeds below 160 km/h, since ancillary components such as the steering, brakes and air conditioning compressor operate electrically. The combustion engine is restarted quickly, conveniently and almost silently. A special Mercedes feature is the way in which the practical HOLD function interacts with the start/stop system: as soon the HOLD function is enabled (by fully depressing the brake pedal when stationary), the combustion engine also remains switched off when the driver then takes their foot off the brake pedal. Alternatively, when waiting for longer periods, the gear selector lever can be put into position "P" or the parking brake enabled, thus allowing the driver to remove their foot from the brake pedal.
Manoeuvring: parking or turning are for the most part carried out in electric mode
Accelerating: moving off and driving at low loads are carried out in purely electric mode. Accelerating from a standstill is particularly powerful, since the full torque of up to 250 Nm is available from the electric motor
Boost function: the electric motor supports the combustion engine when accelerating, such as when executing an overtaking manoeuvre, by providing additional drive torque
Cruising: at constant speeds, the engine control unit shifts the operating range towards lower specific fuel consumption levels
- "Sailing": the so-called "sailing" function can be used at speeds below 160 km/h. With this function, the combustion engine switches off and the desired speed is maintained primarily by using the electric motor, until the batteries need to be recharged
- Recuperation of kinetic energy (regenerative braking)in deceleration mode or when braking: during deceleration (reduction in speed by snapping off the throttle), the electric motor works as a generator and stores the converted kinetic energy back in the high-voltage battery. If the brake pedal is pressed, the generator output is initially increased proportionally for greater deceleration. Only when increased brake pressure is applied are the wheel brakes additionally called upon. To implement these functions, the new hybrid models have brakes which have been specially adapted for recuperation ("energy recuperation")
Comprehensive road tests using different test subjects have shown that it only takes a relatively short time for additional savings to be achieved as drivers learn to make increasingly deliberate and effective use of such functions. They are supported in their use of the features by the display concept of the hybrid models. The central display provides information on the current energy flow and the charge status of the batteries, as well as a top view of the vehicle, depicting the drivetrain and coloured energy flow. The driver is able to monitor fuel consumption via energy/time graphs.
Consumption: benefits in actual traffic, not just on paper
In urban traffic, with its frequent stationary, deceleration and short acceleration phases, the hybrid drive is able to play to its strengths in particular. This is thanks, on the one hand, to the frequent regenerative braking phases when decelerating and, on the other, to the capability to offer purely electric motoring when approaching traffic lights. The purely electric driving mode can also be used in stop-and-go traffic up to a speed of around 35 km/h and on journeys of up to a kilometre. When stationary, the combustion engine is switched off in most cases.
When it comes to inter-urban motoring, the boost, "sailing" and regenerative braking phases alternate in conjunction with an intelligent displacement of the combustion engine's load point. The actual effect depends on both the route profile as well as the behaviour of the driver.
On the motorway, the boost function takes a back seat in the higher engine speed range. Savings are achieved by the "sailing" function at speeds up to 160 km/h, for example on slight downhill gradients, by displacement of the combustion engine's operating point, electric operation of accessories, and regenerative braking when decelerating.
Extensive road tests on a wide variety of different routes have shown that compared with the notoriously economical E 250 CDI, it is possible to achieve additional significant increases in efficiency with the E 300 BlueTEC HYBRID.
The increased fuel efficiency is even more pronounced when the E 300 CDI is used as the comparison vehicle.
The hybrid module: compact, intelligently integrated powerhouse
The hybrid drive unit is an enhancement of the module used in the S 400 HYBRID and is based on the 7G-TRONIC PLUS automatic transmission.
A new element is the lack of hydraulic torque converter. Instead a wet clutch has been added, as also found in a number of powerful AMG models. As a result, the electric motor can be integrated into the transmission unit in such a way that it only requires marginally more installation space than the 7G-TRONIC (+65 mm). The lack of converter allows for a purely electric driving mode as well as the "sailing" function, and also therefore significantly increases the potential for reducing consumption.
The compact electric motor, which is installed in the clutch housing between the engine and the transmission to save space, is a 3-phase AC internal rotor magneto motor, which develops a peak output of 20 kW and a peak torque of 250 Nm at an operating voltage of 120 Volts.
The components: perfectly integrated into the vehicle
The electric energy of the hybrid drive comes courtesy of the high-voltage lithium-ion battery which has been specially developed for automotive use. Its characteristics include an output of 19 kW and an energy content of 0.8 kWh, enabling the E-Class to achieve a speed of up to 35 km/h and a range of up to one kilometre in purely electric mode.
Major advantages over conventional nickel/metal hydride batteries include a higher energy density and better electrical efficiency, together with more compact dimensions and a lower weight. Thanks to space-saving installation in the engine compartment, where it replaces the conventional starter battery, the generous interior space and boot capacity remain unchanged. The lithium-ion battery not only stores energy for the electric motor, but is also connected to the 12-Volt onboard network via the DC transformer to supply power to other standard consumers such as the headlamps and comfort features. The battery system consists of the cell block with its lithium-ion cells and the cell monitoring system, the battery management function, the high-strength housing, the cooling gel, the cooling plate, the coolant feed and the high-voltage connector.
To support cold starting and act as a buffer store for the on-board electrical system, a regular 12 Volt battery is located beneath the luggage compartment, and an additional small backup battery prevents unpleasant flickering of the vehicle lighting and dropouts in the infotainment system in start/stop mode.
By using sophisticated packaging it has been possible to integrate numerous hybrid-specific components, such as the high-power electronics, directly into the engine compartment along with the combustion engine, thus perfectly rounding off the modular principle: the hybrid models can be produced together with the regular versions on the same assembly line, without any specific issues. Another plus point of the overall concept is the scalability and compatibility with other vehicles and engines.
Safety: on a par with previous models
The intelligent integration of hybrid systems without having to make any changes to the vehicle body not only has the practical benefit of enabling full use of the available space. At the same time it also helps to ensure that the same high level of safety can be offered as in their counterparts fitted with combustion engines – something which is particularly important to Mercedes-Benz. The crash behaviour of the vehicles has also been safeguarded accordingly by means of crash simulations and tests.
When it came to the hybrid-specific properties which were relevant to aspects of safety, the development engineers were able to call on the extensive experience gained with the S 400 HYBRID introduced in 2009. The challenge in this area lay in ensuring the greatest possible safety for the electrical components. This safety system already applies in production, includes workshop personnel during servicing and maintenance, and also takes the emergency services into account when passengers need to be recovered following an accident.
Accordingly the hybrid technology of Mercedes-Benz is equipped with an extensive 7-stage safety concept.
1. In the first stage, all of the high-voltage wiring is colour-coded to eliminate confusion, and marked with safety instructions. This prevents assembly errors in production, and makes the regular quality checks easier to carry out.
2. The second stage comprises comprehensive contact protection for the entire system by means of generous insulation and newly-developed, dedicated connectors.
3. As part of the third stage, the lithium-ion battery has been given a whole package of carefully coordinated safety measures. This innovative battery is accommodated in a high-strength steel housing, and also secured in place. Bedding the battery cells in a special gel effectively dampens any jolts and knocks. There is also a blow-off vent with a rupture disc and a separate cooling circuit. An internal electronic controller continuously monitors the safety requirements and immediately signals any malfunctions.
4. The fourth stage of the safety concept includes separation of the battery terminals, individual safety wiring for all high-voltage components and continuous monitoring by multiple interlock switches. This means that all high-voltage components are connected by an electric loop. In the event of a malfunction, the high-voltage system is automatically switched off.
5. Active discharging of the high-voltage system as soon as the ignition is switched to "Off", or in the event of a malfunction, is part of the fifth stage.
6. During an accident, the high-voltage system is completely switched off within fractions of a second (stage six).
7. As the seventh and last stage, the system is continuously monitored for short circuits.
[1] All consumption and performance figures are preliminary figures based on the Saloon model, as at December 2011
Credits: Daimler AG
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