Automotive Design and Production

APR 2017

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www.ADandP.media It comes down to the price to drive. For 25 miles, it is $0.81 for the Ioniq Electric. has an EPA-estimated 58 mpg combined, which is the highest rating of any non-plug-in vehicle on the U.S. market. (The SEL and Limited are 55 mpg combined, so it's not like they're not efficient.) MATERIALS MATTER One of the things that they addressed in developing the Ioniq is to have a car that rides and handles like, well, a car. So the Hybrid and the Plug-in have a multi-link rear suspension system with dual lower control arms. To minimize mass, there are several aluminum suspension components in both the front and rear. In the front, for example, there is a weight save of 13 pounds and a mass reduction of nine pounds in the back. And the aforementioned packaging of the battery pack below the rear seat also has the consequence of lowering the center of gravity, which improves ride and handling. Aluminum is also used, it should be noted, for the hood, which is a weight save of 14.4 pounds compared with steel (mass of the aluminum hood: 16.5 pounds), and for the liftgate, which is a weight save of 13.5 pounds (mass of the aluminum liftgate: 16.5 pounds). And the steel that is used for the body-in-white is both strong and light: 14.6 percent is 150 K; 14.1 percent is 100 K; and 24.8 percent are advanced high-strength steels from 60 K to 80 K. They've also increased the use of structural adhesives. The Ioniq is approximately the same size as an Elantra. That is, the Ioniq and Elantra both have a 106.3-inch wheelbase, though the Elantra is longer, at 179.9 inches compared with the Ioniq at 176 inches. Both of those vehicles are smaller than the Sonata, which has a 110.4-inch wheelbase and which is 191.1 inches long. However, when it comes to the use of structural adhesives, the Sonata has 390.4 inches. The Elantra has 393.7 inches. And the Ioniq has 475.7 inches. The phrase "increased use" doesn't begin to do that justice. And then there is torsional rigidity, which is achieved through a variety of means, including reinforcing the connection structure of the underbody and side body. As measured in 10 4 kg f ·m 2 /rad, the Elantra is 26.8, the Sonata 28.7 and the Ioniq is 29.2. In developing the suite of Ioniq vehicles, they looked at everything. In the hybrids, there is no stand-alone 12-v lead-acid battery to accompany the internal combustion engine; the functionality of that battery is integrated into the hybrid battery pack, for a weight savings of 26 pounds. There is a spring on the brake pads to assure that there is no drag once the pedal is lifted. They're making extensive use of bio materials like sugar cane in the interior of the vehicle—fabrics contain as much as 20 percent and the soft-touch surfaces are TPO with 25 percent sugar cane. A final word about efficiency. It comes down to the price to drive. So they looked at the EPA figures for the overall cost to drive a vehicle 25 miles. In the EV arena, it costs $0.92 for a Bolt and $0.97 for a Leaf. It is $0.81 for the Ioniq Electric. In the hybrid space, the Prius Eco is at $1.04 and the C-Max $1.46. It is $1.00 for the Ioniq Hybrid Blue. That's the efficiency that the aluminum, adhesive, lithium ion polymer and the slipper surface and the rest help deliver. 33 AD&P; ∕ APRIL 2017 HYUNDAI

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