Automotive MQB Platform Fact Pack

Frost & Sullivan Market Insight Published: 23 Aug 20

30 Per Cent Reduction in Vehicle Platforms by 2020: OEMs to Ride on Platform

Standardization and Modular Strategy

Date Published: 23 Aug 2011

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2012 – The Year of VW MQB

MQB chassis of the upcoming Golf MK7

The VW Group is a large automotive empire encompassing 10 brands, 240 models produced across 94 sites in 153

markets, totaling over 8.3 million vehicles made each year. The sheer scale of its operations across so many different

countries meant that variability of its products is very high. If manufacturing engineers have their way, all plants will only

produce the same single model, with the same specifications in the same colour. Henry Ford was famously quoted

saying "You can have the car (Model T) in any colour as long as it is black." To offer more variants / choices adds

complexity not only to production control, but also logistics, warehousing and documentation.

To combat this increasing complexity and the associated inefficiency of having so many models, starting this year, VW

will start adopting its new modular toolkit strategy. Central to this strategy are four modular platforms and a new

'Modular Production System (MPB, Modularer Produktionsbaukasten). The four modular platforms are two mainstream

platforms Modular Transverse Matrix or MQB (Modularer Querbaukasten) for small cars like the Golf and Polo, Modular

Longitudinal Matrix or MLB (Modularer Längsbaukasten) for larger cars like Audi sedans, and lower volume Modular

Standard System (MSB) shared with Porsche and the New Small Family (NSF) platform that underpins minicars like the

VW Up! and Skoda Citigo.

2012 – The Year of VW MQB http://www.cbt.com.my/2012/03/12/2012-the-year-of-vw-mqb/

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The modular toolkit strategy allows VW to shave about 20 percent off the unit cost of each vehicle, 20 percent reduction

in one-off model expenditure and 30 percent reduction in engineering hours. But VW's modular toolkit is not just about

lowering cost to pad up the company's profit margins. On the contrary, the first VW brand models based on the MQB

platform, the upcoming all-new Golf, will feature numerous active safety features previously only available in the premium

segment. Expect to see greater democratization of advanced active safety features in upcoming VW Group new models.

The for example, already features active braking, a feature

that was previously only available in more premium cars like the Volvo S60.

tiny Up!

With the anticipated launch of the next generation Golf later this year, the focus is now on the MQB platform. Combined

with VW's modular production system, 30 MQB cars of the same model can be assembled in one hour. This flexible

arrangement can be scaled further up to include multiple models like a Golf, Tiguan or Passat, producing up to 60

different vehicles in an hour.


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With MQB, body welding points and engine mounting is standardised. In earlier VW models, like the current generation

Golf, the exhaust side of the engine (coloured section) is at the front, while in other models it is at the back of the

engine. MQB series engines will all have their exhaust positioned at the bulkhead, and is now tilted towards the back

rather than the front. The uniform mounting position for petrol and diesel engines also make standardisation ome parts

like exhaust and drive shafts easier. Ancillary components such as water pump and alternator are now screwed directly

into the engine or the oil sump. The new arrangement now takes up 50 mm less space than before, freeing more space

for the cabin.

MQB engines also consume about 10 percent to 20 percent less fuel than before. Numerous measures like use of

lightweight construction material and active cylinder management technology, as seen already in the

.

Polo BlueGT

With active cylinder management technology, only two out of the four cylinders will operate under low load. VW says

active cylinder management save about 20 percent of fuel in the new petrol engines. Even without it, they consume eight

to ten percent less fuel, compared to their predecessor engines.


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Usually, every successive generation model is slightly

heavier than its predecessor. All MQB models will weigh

40kg to 60 kg less than the previous model. VW says

the next generation Golf Mk7 is not only lighter but

similar in weight to the Golf Mk4. A large portion of the

reduction is contributed by a 22 kg lighter engine (16

kg contributed by an aluminium crankcase), 18 kg

lighter floor structure (now made with light but strong

hot formed steel), 10 kg lighter interior components and

optimization of materials used throughout the car.


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VWVortex.com

MISCELLANEOUS FEATURES BETA

VWvortex Feature - A First Look at the New Golf 7 MQB ArchitectureBy by: Jamie Vondruska

Feb 16, 2012, 16:25

Last week we had a unique opportunity to go to Wolfsburg, Germany to learn a little bit about Volkswagen Group's new MQB component architecture.

Volkswagen Group brands (Volkswagen, Audi, Lamborghini, Seat, Skoda, Bentley, Bugatti, Porsche and more) comprise more than 200 individual

models of cars. The complexity involved in trying to reduce costs and the number of components, meeting exceedingly strict emission and safety

standards all the while reducing waste and consumption is obviously quite huge. MQB not only represents a new car specific part platform, but also an

all-new modular engine program and modular production program. With MQB VW can build any vehicle from Polo to Mid-size SUV utilizing the same

assembly line. Likewise, if a factory supports MQB, then producing an Audi, Seat or Skoda product at the same facility is also a possibility. This gives

VW Group brands the ultimate flexibility to build market specific trim variations and response to regional needs far quicker while reducing the overall

complexity involved in supporting so many products.

The chart below shows the matrix of new modular "kits" as Volkswagen refers to them:

New Small Family (NSF) represents the new generation of small "city" cars like the Up!. MQB represents an all-new component platform designed to

span a range of vehicles from the A0-class (Polo), A-class (Golf, A3, Altea) and B-class (Passat, third-row mid-size SUV and CC) utilizing a transverse

engine configuration. Volkswagen has been tasked with the development of the MQB architecture. MLB represents the new longitudinal engine

component architecture and stretches from the B-class (Audi A4), C-class (Audi A6) and D-class (Audi A8, Phaeton, Bentley Continental, etc., etc.). Audi

is responsible for MLB. Lastly, Porsche is responsible for the MSB (modular standard) matrix largely comprising the sports cars in the group brands.

The Transition

In the past, the "traditional" way to build a car and utilize some form of component sharing was called platform sharing. We saw a lot of this in the early

80's with a number of cars sharing a common chassis with different (and sometimes not so different) sheet metal. The chart below shows the

progression of component sharing at Volkswagen over the last twenty years.

VWvortex Feature - A First Look at the New Golf 7 MQB Architecture http://www.vwvortex.com/artman/publish/vortex_news/printer_3038.shtml

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In the past, sharing of various components was limited more strictly to the engines, transmissions, suspensions and a handful of electrical, HVAC and

other sub-systems. Since the Golf V, Volkswagen has been in a transition and restructuring mode, working towards full integration of MQB. The new

Audi A3 which will be introduced at the Geneva Auto Show this March, will be the first official MQB component vehicle introduced. We will see the Golf 7

follow this September at the Paris Auto Show. Wolfsburg has been tooling up for Golf 7/MQB for over a year now and some parts of the factory have

been off-limits to the public during this ramp-up phase to keep any details on the Golf 7 under wraps.

As part of the program, Volkswagen teased us with a Golf 7 chassis as shown in the photos below:

MQB Golf 7 chassis front (above) and rear (below)


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While not much is given away looking at a raw chassis, we *can* see that the wheelbase has grown a bit while front and rear overhangs are shorter

(particularly the front). MQB allows for a tremendous amount of flexibility. Essentially the only fixed part of the vehicle is the pedal box area (and only in

length front to rear). Otherwise every other part of the chassis can be stretched in length and/or width as seen in this graphic:

The blue area above is the fixed dimension (again only front to back - width is flexible) with the rest of the areas all permitting a wide variety of sizes and

configurations. To put it in to perspective, the MQB platform can support everything from a mid-size three-row SUV to a mid-engine RWD sports car

using the same overall modular components.

Trimming the Fat

Volkswagen engineers are quite proud of the fact that they were able to reduce overall weight of the MQB platform vehicle by 40 kg - 60 kg (88 lbs. -

132 lbs.). The chart below shows where the various weight savings came from:


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MQB also allows the flexibility for material substitution in various key components to further reduce weight. For example aluminum stampings can be

used instead of steel units depending on the needs of a given product. Volkswagen says nearly 25% of the fuel economy savings comes from weight

reduction. In conjunction with the next generation of engines and transmissions for this platform, MQB should yield even better fuel economy benefits.

Luxury Features

MQB has the ability to support a wide variety of electronics features more often found on more expensive luxury models. How many of these make to the

U.S. market remain to be seen both for cost and legal/compliancy regulation issues. That said, MQB can support them all, so the features could be

added at any time. Look for most of these to make their first appearance in the all-new Audi A3.

Infotainment Systems

Because MQB must straddle a wider number of transverse engine models, meeting the needs of the different brands presents challenges. In the case of

in-car entertainment systems for example, Audi utilizes MMI with a rotary knob adjustment system. Volkswagen instead is going to feature a touch screen

system. In both examples the main ECU controlling the system has to be prepared to deal with both interface systems. In the more specific case of

Volkswagen, expect to see three different main head units pictured below:


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All radios feature touch screen controls. The two higher-end units feature touch controls and proximity sensors that detect when a hand is coming close

to the screen and start to react and change the displayed information based on which part of the screen you are about to touch. Combined with a new

high-resolution 8" screen, this feature works extremely well and looks fantastic. Basic touch-gestures like swiping will also be supported as well. Expect

better BlueTooth integration, better map integration and updating, 3D navigation and even the future possibility to control apps from your phone via the

touch screen.

MQB Engines

Final details have yet to be released on the specific lineup of future engines for the U.S. market, but we can start to piece together a pretty solid road

map.

Volkswagen is currently building an all-new engine plant in northern Mexico that will produce the new EA888 direct injection 1.8l turbo-charged

4-cylinder. Already introduced in the European Audi A4, the new 1.8TSI is a modular engine that shares components with a new version of the EA888

2.0TSI. Since both engines share common components, it will be possible to also produce the 2.0TFSI at the new plant in Mexico.


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The new 1.8TFSI will replace the 2.5l inline-5 cylinder across the existing VW lineup as the new base engine. This new engine has some interesting

design characteristics like an exhaust manifold integrated fully into the head with liquid cooling. We expect horsepower to range between 150hp to

180hp depending on the application. We also expect fuel economy to be significantly better as well. The 1.8TSI is currently available in the European

Audi A4 where it gets 42mpg highway cycle. Combine that with the torque characteristics of the turbocharged engine and VW should have a winner on

its hands.

The 2.0TSI will continue to be available, but our understanding is that Volkswagen is looking to consolidate the 2.0TSI into one model that can range

from 200hp to 280hp (as opposed to the current multiple versions available). Most rumors seem to indicate that the next GTI will have around 230hp.

We've driven the GTI 35 in Europe which also has 230hp and found the engine to be very strong, pulling hard out of corners, yet devoid of torque steer

or other idiosyncrasies common with front wheel drive high-horsepower cars. MQB will have an additional trick up its sleeve with the addition of a new

locking differential for the front wheels (more on that in a moment).

On the TDI front, VW has an all-new EA288 series available in 1.6l and 2.0l turbocharged four-cylinder diesel unit. The 1.6l TDI is good for 88hp and will

be utilized mostly in European markets. The 2.0TDI will have 188hp and torque upwards of 280 lb. ft. The new EA288 modular diesel family has a

number of shared components, giving VW the flexibility to adapt to a variety of models and market specific requirements. For example there are three

standard exhaust gas recirculation (EGR) depending on emission requirements in a specific market. The intercooler is now a water unit that is integrated

into the intake manifold with a reduced volume of air. All of these things add up to improved emissions and economy benefits.

As for the V6 engine strategy, our take is that Volkswagen is still exploring different potential solutions. We have confirmed that the existing VR6 engine

can fit in MQB. However, we had discussions with Dr. Hackenburg (VW Board Member responsible for development) at the Detroit Auto Show and he

offered some insight into where they are headed with a V6 strategy. He mentioned that most of the competitors in the market are moving towards forced

induction (super or turbocharging) in their V6 engines. Volkswagen has been exploring this (rumors we've heard include a 2.8l VR6 Turbo) and the

group obviously includes the 3.0l supercharged V6 used by Audi in longitudinal applications. However Dr. Hackenburg also mentioned that they are

looking at using the 2.5l inline-5 turbo *instead* of a six-cylinder. This would offer all the power of a V6 and more (280hp to 350hp) but with better fuel

economy. Volkswagen is also under pressure to try and localize production as much as possible here in North America (to save costs) and with the

existing normally-aspirated 2.5 inline-5 being produced in Mexico, that line could be converted over to produce the turbocharged version. At the point

this was written, a final decision has not been made yet.

Finally, there will be hybrid and full-electric engine options for MQB as well. We'll see the first Hybrid utilizing the 1.4lTSI in the current Jetta later this

year. Overall MQB has been designed to accept a wide variety of engine options to meet the demands of all the different models and markets. The

engines themselves have adopted a modular strategy to further reduce costs and simplify production.


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For the performance enthusiasts - a locking differential

Volkswagen has been working with Haldex for a number of years to develop an electronically controlled mechanical locking differential which

Volkswagen refers to as VAQ. Similar in concept to the Haldex coupling used in Volkswagen's 4motion AWD models, VAQ utilizes a multi plate coupler

that electronically modulates power to either the left or right front wheels as needed. This torque vectoring effect results in power going to the wheel that

needs it most. In dry situations, for example, at extreme cornering attitude where the inside front wheel has lost traction, power is diverted to the outside

wheel instead (as long as the inside wheel is still slipping). Engineers that have driven this system extensively say that you can literally feel the front end

pulling itself around the curve.

Volkswagen has spent a number of years fine tuning this system and has used it on their Scirocco 24hr of Nurburgring race cars. The chart above

shows the 8.5 second improvement of the natural gas powered Scirocco around the Nurburgring Nordschleife with the VAQ system. You can also see

that exit speeds out of corners is substantially better and that drivers more often maintain 100% full throttle mid-corner instead of having to modulate

power because of traction issues. Volkswagen isn't saying what the price tag will be for such a system and they confirmed it will be optional on the

European Golf 7 GTI. As always, we'll be lobbying Volkswagen of America hard to offer the system here as well.

Modular Manufacturing


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The modular kit strategy also carries over to manufacturing as well. Factories that support MQB, can support building nearly any MQB vehicle on the

same line. This means that there is flexibility to build a Golf followed by a Passat all on the same assembly line. The modular strategy has also carried

through into even the smallest details. As you can see in the chart below showing the Kaluga Russian plant, there were four different dash mount

brackets being used in existing models. With MQB there will be only one reducing the number of parts needed, simplifying engineering and reducing the

training time and tools necessary to install the dash.

Overall, the Volkswagen Group modular kit strategy is a huge step forward on nearly every level of production and flexibility. MQB will be supported fully

in the North American market which means Volkswagen (and Audi) could build any transverse model from Polo to A3 to Golf to Passat to Mid-Size SUV.

The first full MQB vehicle to be launched worldwide will be the Audi A3 at the Geneva Auto Show next month, followed by the Golf 7 at the Paris Auto

Show this September.

© Copyright 2003 by VWVortex.com


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