IUV: Lightweight e-car to drive 1000 kilometers with hydrogen

E-cars with the lowest power consumption
Dacia Spring (test consumption: 15.8 kWh) |
RRP from EUR 20,490, savings of up to EUR 9,614 |
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Renault Twingo Electric (test consumption: 16.4 kWh) |
RRP from EUR 23,790, savings of up to EUR 11,961 |
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Hyundai Kona EV (test consumption: 18.8 kWh) |
RRP from EUR 35,650, savings of up to EUR 13,689 |
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Fiat 500e (test consumption: 18.8 kWh) |
RRP from EUR 26,790, savings of up to EUR 12,610 |
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Audi Q4 e-tron (test consumption: 21.1 kWh) |
RRP from EUR 41,900, savings of up to EUR 12,895 |
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VW ID.3 Pro S (test consumption: 21.3 kWh) |
RRP from EUR 36,960, savings of up to EUR 10,210 |
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Skoda Enyaq iV 80 (test consumption: 21.9 kWh) |
RRP from EUR 44,750, savings of up to EUR 12,860 |
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VW ID.4 Pro (test consumption: 21.9 kWh) |
RRP from EUR 38,915, savings of up to EUR 10,244 |
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Opel Mokka-e (test consumption: 21.9 kWh) |
RRP from EUR 34,110, savings of up to EUR 15,341 |

The seating concept is designed for five people, who can also sit opposite each other in highly automated driving.
Several lightweight construction approaches combined in the IUV
According to the DLR researchers, the bodyshell of the travel-compatible e-car weighs just 250 kilograms, which consists primarily of fiber-reinforced plastics. This is about a quarter less than is usual in the upper and middle class. One of several lightweight construction principles is the so-called functional integration. For example, the floor structure not only carries all of the vehicle’s superstructure, it also conducts electricity and data. This eliminates the need for additional cables, thereby saving weight. Overall, the IUV has an unladen weight of 1,600 kilos with energy storage.
Battery for around 200 kilometers – then hydrogen

The drive concept consists of a battery (in the rear), a fuel cell (in the front end) and a hydrogen tank (in the underbody).
IUV drives fully automatically to level 4
“The aim of the IUV is to make long-distance traffic sustainable and locally emission-free,” explains project manager Sebastian Vohrer from the DLR Institute for Vehicle Concepts in Stuttgart. In the future, electrification and automation would have an impact on drive technologies, but also on the interior, i.e. on the entire vehicle structure. Yes, automation. The IUV mostly drives itself, according to SAE level 4 (highly automated).
Automated driving in stages
Level 0: Driver only
definition: Driver performs longitudinal and lateral guidance continuously. No intervening vehicle system active. Called: The driver does everything alone. He drives, steers, brakes, accelerates and pays attention to his surroundings. The vehicle does not undertake any interventions or has no technical requirements for this.
Level 1: Assisted
definition: The driver carries out longitudinal OR lateral guidance continuously, the system takes on a different function in each case. Called: With assisted driving, the system supports the driver with certain assistance systems, for example with a blind spot warning, a lane departure warning or hill start assist.
Level 2: Partially automated
definition: Driver must constantly monitor the system. System takes over longitudinal AND lateral guidance in a specific application. Called: With semi-automated driving, the car can take over individual tasks for the driver. Most manufacturers are currently at this stage. Automatic parking or a lane keeping function are among the most common systems. The traffic jam assistant can accelerate, brake and follow the vehicle ahead in a traffic jam without the driver having to intervene.
Level 3: Highly automated
definition: Drivers no longer have to constantly monitor the system. Must potentially be able to take over. System takes over longitudinal and lateral guidance in a specific application. Recognizes system limits and requests drivers to take over with sufficient time reserve. Called: Level three is referred to as highly automated driving. For example, the car independently sets the indicator, changes lanes or adjusts its speed to the flow of traffic. The driver is no longer responsible for the vehicle and can divert his attention from what is happening on the road for a long time. However, the autopilot can always ask the driver to take back the wheel in order to steer the car himself
Level 4: Fully automated
definition: No driver required in specific use case. System can handle all situations automatically in the specific application. Called: Level four defines full automation. The car takes over all the functions and only releases them again when the system cannot cope with a situation.
Tier 5: Driverless
definition: System can automatically deal with all situations throughout the journey. No driver required. (Source in each case: VDA/Federal Office for Roads) Called: In principle, people and the steering wheel will become superfluous. The car and the system only need a destination input and the release to start. The vehicle then drives to the destination independently. Autonomous or driverless driving has been achieved.
Cockpit becomes lounge or office
Clever air conditioning uses pressure difference
Production of the IUV without classic tools
And the production concept is also new. Additive manufacturing lacks classic machines and tools, and each component is built up layer by layer. Newly developed parts can thus be flexibly tested as prototypes.

Three demonstrators: In addition to the IUV (right), the NGC project also includes the Urban Vehicle (UMV/left) and the Safe Light Regional Vehicle (SLRV).