GM Daewoo targets growth
South Korea’s third-largest OEM, General we are getting more of GM’s engineering
Motors Daewoo Auto & Technology to Asia.” Yu is also Vice President in
(GM DAT), represents the Korean produc- charge of GM Daewoo’s Technical Center.
tion base for General Motors and is Noting the possibility that the number
helping its new parent supply the grow- of GM engineers in the U.S. would decline
ing automotive market in not only South gradually, Yu said GM and its Asian units
Korea but also Asia. And after its recent including GM Daewoo are expected to
acquisition, GM DAT is beginning to work trade more engineering work in the future
more autonomously for its parent and is as the two continents develop cars for
becoming a hub of automotive develop- both regions under GM’s “global architect
ment in the region. To that effect, the development program.”
automaker said it is benchmarking Yu said he would take part more
Hyundai and Kia. strongly in GM’s Shanghai engineering
“GM Daewoo is working to meet all operation of the Pan-Asia Technical
requirements such as product develop- Automotive Center, or PATAC, which is a
ment, marketing, manufacturing and pro- 50-50 joint venture of GM and Shanghai
duction, and external customer satisfac- Automotive Industry Corp.
tion in South Korea on its own,” said Yu Because of lower wages in Asian coun-
Ki-Joon, who coordinates GM’s engineer- tries such as South Korea, China, and
ing operations in Asia. “In other words, India, Yu said GM’s Asian companies
would take more responsibilities in some
parts such as brackets and heater pipes,
although such important parts as cam-
shafts and pistons still are designed and
released in the U.S. by GM. Along with
Asian engineers taking more corporate
responsibilities, they and North American
engineers are communicating more often
through conference calls and frequent
visits to each other’s operations, Yu said.
Yu said GM Daewoo is taking part in
GM’s development of the redesigned
Saturn Vue, which will be produced in
North America in 2007. GM and Suzuki
Statesman features engineers developed the current Vue for
a lightweight, all- North America. Engineers at GM Daewoo
aluminum V6 engine are speciﬁcally developing an SUV based
with double overhead
camshafts and four
on GM’s Theta platform, a concept of
valves per cylinder. which was shown at the Seoul Motor
Show, for sale in South Korea in 2006.
GM Daewoo ofﬁcials said the auto-
maker would take more responsibility for
the design of the next-generation Theta
platform under GM’s strategy to give more
engineering responsibility to its Asian units
including GM India, which is producing
GM Daewoo’s Lacetti compact based on
kits from GM Daewoo.
Showing signs that there will be more
engineering cooperation between GM’s
units in Asia, and aided by a fast and
convenient computer communication
system, GM Daewoo is also importing the
8 AUGUST 2005 aei aei-online.org
have given me complete conﬁdence that wheelbase gives it a slim, limousine-style
we made the correct choice in making proﬁle and a spacious cabin. In addition
vehicles here in Korea by GM Daewoo,” to prestige model cues such as the bright
John G. Middlebrook, GM’s Vice President chrome accents, GM Daewoo said best-
of Global Sales, Service and Marketing in-class rear legroom of 1099 mm (43.3
operations, said in Seoul in March. “GM in) is indicative of the Statesman’s sense
Daewoo’s lineup of affordable, high-qual- of space.
ity cars gives us a tremendous opportunity Among the Statesman upgrades for
to grow our business around the world, Korea are heated front and rear seats for
particularly in the Asia-Paciﬁc region.” the harshest winter conditions, GM
“Adding the Statesman to our portfo- Daewoo said. Other amenities are a fuel
lio completes the GM Daewoo passenger information (range, economy) display,
car lineup,” said GM Daewoo President and dual DVD screens in the backs of the
and CEO Nick Reilly. “Our product offer- Statesman’s front headrests can show
ings now range from mini-cars to large videos in conjunction with individual
luxury sedans. The Statesman provides us headphones or the sedan’s 12-speaker
Yu Ki-Joon, GM’s Asia-Paciﬁc
Engineering Coordinator, is
an entry into one of the fastest-growing sound system.
in charge of overseeing and segments of the Korean car market.” The The Statesman’s 3.6-L Alloytec V6 en-
consolidating the regional introduction of the Statesman “is an ex- gine produces 254 hp (189 kW) at 6500
engineering of GM units in Asia. cellent demonstration of how GM rpm and 340 N·m (251 lb·ft) at 2800
Daewoo is leveraging the global resources rpm, making it the most powerful engine
upgraded Statesman of Holden Ltd., of GM to bring new products to the mar- in its segment in the Korean market. The
GM’s Australian unit, and expects to pro- ket much faster than we could on our Statesman will also be offered with a
duce a localized version of that model in own,” Reilly added. 2.8-L version of the engine.
coming years. Unlike some of its recently launched The global V6 family was developed
“GM Daewoo’s manufacturing and competitors, the Statesman is a true large for worldwide application in premium
design facilities, products, and employees car, Reilly said. A segment-leading long and high-performance vehicles. The
Your partner in powertrain performance
lightweight, all-aluminum, 60° V6 engine normal mode is supplemented by an ac- ence of weight from the rear to front axle
features double overhead camshafts and tive select function that enables the driver due to braking.
four valves per cylinder. The Alloytec’s to change gears by a paddle on the steer- During its three years of development,
cam phasers are continuously variable, an ing wheel. GM Daewoo said the model underwent
electronically controlled, hydraulically ac- Like most renowned luxury cars, GM cold-weather testing in Sweden, hot-
tuated system enabling the camshafts to Daewoo’s new ﬂagship is rear-wheel weather testing in the deserts of
rotate relative to the crankshaft. The vary- drive. This ensures better handling and a Australia, and altitude testing at Pikes
ing of intake valve timing improves en- smoother driving experience, along with Peak in the Colorado. In all, 1.6 million
gine smoothness at idle and optimizes steering that is freer of any traction inﬂu- km (1 million mi) of durability testing and
inlet ﬂow dynamics for maximum perfor- ences than standard front-wheel drive. a variety of crash tests were carried out to
mance. By closing exhaust valves later With an automatic leveling suspension, ensure the Statesman met the highest
than typically the case, the system forces the Statesman maintains a balanced levels of quality for safe, trouble-free driv-
the desired amount of exhaust gas back height regardless of load for an even bet- ing. In addition, 143 experimental en-
into the combustion chamber for more ter ride. gines were put through 60 speciﬁc tests
complete burning in the next combustion The Statesman comes with the latest- and more than 200,000 h of testing, ac-
cycle. In conjunction with its variable in- generation Bosch ABS, and its ESP stabil- cording to GM Daewoo.
take manifold, electronic throttle control ity control features corner brake control Plans call for the Statesman to offer
(ETC), which eliminates the mechanical (CBC), which helps maintain optimum the most extensive VIP warranty and af-
connection between accelerator pedal vehicle stability through curves and cor- ter-sales package in the Korean market
and engine, further improves fuel efﬁ- ners. CBC senses different wheel rotation among both domestically built and im-
ciency and reduces emissions as well speeds and coordinates the brakes as ported cars. Service will be available
as engine vibration and noise. The result they are applied to the individual wheels. through GM Daewoo’s nationwide net-
is said to be the best fuel economy Electronic brake-force distribution (EBD), work of service centers. The price of the
(8.6 km/L) in the Statesman’s segment. which also comes standard with ESP, Statesman will be between KRW 40 mil-
The Statesman features GM’s latest transfers brake torque between axles, lion and 50 million, depending on the
ﬁve-speed automatic transmission, also providing optimized control of rear brake engine and trim level.
used in Cadillac products. A fuel-efﬁcient pressure when there is a natural transfer- Peter Chang
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Sonata raises the bar
The mid-size Sonata, the best-selling se-
dan in the Hyundai product line, is now
rolling off the production line at
Hyundai’s all-new manufacturing plant in
Montgomery, AL, in all-new 2006 pro-
duction form. The new car was designed
speciﬁcally to meet the needs of the
American consumer and is the product of
three years of intensive collaborative de-
velopment at Hyundai’s global R&D op-
erations, including those in Michigan and
California. Before the engineers started The Sonata comes with six standard airbags: dual front, front seat-mounted side-impact, and
working on this Sonata, Hyundai began front and rear passenger side-curtain airbags.
by surveying U.S. consumers in “concept
clinics” held in San Diego, CA, four years “We are proud of the value equation The new Sonata comes with six stan-
ago. More than 200 people rated the we’ve engineered into the all-new dard airbags (dual front, front-seat-
then-new Sonata against rivals such as Sonata,” said Bob Cosmai, President and mounted side-impact, and front and rear
the Toyota Camry, Honda Accord, and CEO of Hyundai Motor America. The base passenger side-curtain airbags), standard
Ford Taurus. From that input, the 2006 price for the four-cylinder version starts at active front head restraints, standard ABS,
Sonata began to take shape. $17,895, with the V6 GLS starting at and for the ﬁrst time in the midsize sedan
“We try to make cars from a custom- $20,895. The top-of-the-range LX version segment, standard electronic stability
er’s point of view, not from an engi- has a sticker price of $22,895, and the control (ESC) with traction control.
neer’s,” said Oh Sung Hwan, Deputy only option is a higher-power audio pack- Hyundai Mobis supplies the ESC tech-
General Manager for Production Control age. The 2.4-L four-cylinder model with nology in cooperation with Bosch.
at Hyundai. Benchmarking was conduct- manual transmission is expected to “The beneﬁt of electronic stability
ed with the Audi A6 for craftsmanship achieve 24/34 mpg city/highway. V6 auto- control in reducing single-vehicle SUV
and the Lexus ES 330 for NVH perfor- matic models (manuals are not available) accidents is clear, but our own research
mance. are rated at 20/30 mpg city/highway. and that done by NHTSA (National
The new 2006
designed to meet
the needs of the
and is the product
of three years
The new 2.4-L G4KC Theta inline four-cylinder engine, standard on the
“We are proud of the value equation we’ve Sonata GL and GLS, is manufactured in Korea (shown with Korean-
engineered into the all-new Sonata,” said market engine cover).
Bob Cosmai, President and CEO of Hyundai
12 AUGUST 2005 aei aei-online.org
The mid-size Sonata’s cabin has 121.7 ft3 (3.45 m3) of total volume, which places it in the government’s “large car” category. The car’s trunk has
16.3 ft3 (0.46 m3) capacity.
Highway Trafﬁc Safety Administration) Both engines feature electronic multi- bar. LX models get 17-in wheels that de-
and IIHS (Insurance Institute for port fuel injection, four-jet fuel injectors, liver a sportier ride character without
Highway Safety) indicate there is also a and an in-tank fuel pump. Emissions are changing the suspension tuning.
compelling case for equipping passenger kept low—all models achieve the ULEV The 2006 Sonata is larger than the
cars with this technology,” said John standard—by a three-way catalyst with previous version, gaining 2 in (50 mm) in
Krafcik, Vice President of Product exhaust gas recirculation. length, 2 in (50 mm) in height, and 1 in
Development and Strategic Planning at A ﬁve-speed M5GF2 manual transmis- (25 mm) in wheelbase. The new car’s
Hyundai Motor America. Recent NHTSA sion is standard on Sonata GL models cabin has 121.7 ft3 (3.45 m3) of total inte-
studies show passenger cars equipped equipped with the new 2.4-L engine, and rior volume—a level of spaciousness that
with ESC experience 35% fewer single- an automatic four-speed F4A42 Shiftronic places it in the government’s “large car”
vehicle crashes and 30% fewer single- transmission is optional. V6 Sonata mod- category. Compared to the previous
vehicle fatalities. els are ﬁtted with Hyundai’s all-new ﬁve- Sonata, the new car offers increases in all
The all-new 2.4-L G4KC Theta inline speed A5HF1 Shiftronic automatic trans- categories of legroom, headroom, and
four-cylinder engine, standard on Sonata mission, which features an overdrive lock- shoulder room.
GL and Sonata GLS four-cylinder models, up torque converter to improve fuel To improve overall ergonomics, seating
has dual overhead camshafts (DOHC) and economy at highway speeds. comfort, and entry/egress, Sonata’s seat-
is rated at 162 hp (121 kW) and 164 lb·ft Sonata provides occupants a smooth ing position height (H-point) has been
(222 N·m). This all-aluminum engine fea- ride combined with ﬁrm handling thanks increased by 1 in (25 mm). Accessibility
tures a balance shaft for smooth opera- to four-wheel independent suspension. and ergonomics are further improved
tion, continuously variable valve timing The front suspension uses a double wish- with increased distance between the driv-
(CVVT), durable stainless-steel exhaust bone design with coil springs and twin- er and the A-pillar, and more room be-
manifold, and hydraulic motor mounts. tube gas-ﬁlled hydraulic dampers. A front tween the seat cushion and the headliner.
All four-cylinder engines for the Sonata antiroll bar on four-cylinder models is Sonata’s trunk volume has increased
will initially be made in Korea. 0.98 in (25 mm) in diameter, while on the 16% to 16.3 ft3 (0.46 m3). The design is
Standard on the Sonata GLS V6 and V6 models it is increased to 1.02 in highlighted by an articulating four-bar-
Sonata LX models is a new 3.3-L V6 en- (26 mm). The L-shaped lower arm design link hinge mechanism augmented with
gine producing 235 hp (175 kW) and is said to reduce vibration while increas- two assist struts to maximize trunk access
226 lb·ft (306 N·m). This G6DB engine is ing handling precision. Bushing size has and ensure that items put in the trunk are
the ﬁrst member of Hyundai’s new been increased to better isolate road im- not damaged by the trunk-closing hard-
Lambda engine family and has an alumi- pact and wheel vibration. ware.
num cylinder block and cylinder heads, The ﬁve-link rear suspension features a Some of the many suppliers on the
DOHC, four valves per cylinder, CVVT, trailing link, two longitudinal links, and program are Michelin (tires), Johnson
and a variable intake system. It is ﬁtted to an upper A-arm. The upper arm has been Controls (ﬂoor consoles and interior
the Sonata front subframe with hydraulic moved to the lower crossmember to iso- trim), Lear (seats), PPG Industries
engine mounts for good NVH characteris- late wheel vibration for improved ride (glass), and Mando America (brakes,
tics. V6 engines for the North American quality. The rear suspension also features steering, and suspension components).
market will be built at Hyundai’s new twin-tube gas-ﬁlled hydraulic dampers David Alexander
manufacturing plant in Montgomery, AL. and a 0.67-in (17-mm) diameter antiroll
14 AUGUST 2005 aei aei-online.org
The Mercedes-Benz bionic car is a con- The specialists in Stuttgart took the and low mass. Transferred to the external
cept vehicle based on a prime example of boxﬁsh shape and developed it into a paneling of a car door, this natural con-
engineering in nature. The structure and wind tunnel model of a realistic car with struction principle produces a honeycomb
overall shape of the vehicle are based on a Cd of 0.095, despite ﬂouting some im- pattern with 40% more rigidity than a
the boxﬁsh, a species that has evolved to portant principles in automotive aerody- traditional door design. Conﬁguring the
meet the demands of living in a coral namics such as scalloping of the sides and entire body using the SKO method results
reef. The boxﬁsh is streamlined—al- having a blunt rear end. The driveable in a mass reduction of about 30% com-
though it may not seem that way at ﬁrst concept car that resulted has a Cd of pared to a typical body, while meeting
look—and agile, with a body that is stiff 0.19, helped by features such as plastic- stiffness and safety performance targets.
and low in mass. The basic shape is also shrouded rear wheels, ﬂush-ﬁtting door The bionic car’s drivetrain features a
well suited to automobile packaging. handles, and the use of cameras instead four-cylinder turbocharged diesel mated
Researchers at DaimlerChrysler ex- of exterior mirrors. to the Autotronic continuously variable
amined the shape of the boxﬁsh in wind In consultation with bionics experts, transmission. The 2.0-L engine produces
tunnels and water channels to better un- DaimlerChrysler researchers developed a 103 kW (138 hp) and 300 N·m
(221 lb·ft). A particulate ﬁlter and selec-
tive catalytic reduction (SCR) technology
keep emissions low.
The SCR system being tested in the
bionic concept car bionic car beneﬁts from DaimlerChrysler‘s
is driven by a four- experience with commercial vehicles. It
cylinder turbocharged uses an aqueous urea solution called
diesel engine mated
to the Autotronic AdBlue that is sprayed into the exhaust
continuously variable system in precisely metered quantities to
transmission. A convert nitrous oxides into harmless nitro-
particulate ﬁlter and
gen and water. The AdBlue reservoir is
reduction technology located in the spare wheel well and is
keep emissions low. sufﬁcient for distances corresponding to
DaimlerChrysler engineers used the boxﬁsh
as a basis for the external shape of their new
concept vehicle. The ﬁsh evolved to have
self-correcting hydrodynamic stability in the
turbulent currents around coral reefs.
Based on the “soft kill option” method, the body structure of the Mercedes-Benz bionic car is
derstand its properties. The standard conﬁgured so that material under low loading can be eliminated, while highly stressed areas
“water drop” shape considered the ideal are reinforced. It is the same principle that governs the growth of bones.
aerodynamic form has a Cd of 0.04 when
exposed to an open ﬂow. An accurate computer-assisted process for applying the service interval for a current Mercedes
model of the boxﬁsh shape delivered a the growth principle used by nature to diesel car.
Cd of 0.06, with the added revelation automobile engineering. Based on the The Mercedes-Benz bionic car has a
that tiny vortices form along the edges on SKO (soft kill option) method, body and top speed of 118 mph (190 km/h), with a
the upper and lower parts of the body suspension components are conﬁgured 0-60 mph (0-97 km/h) time of 7.9 s.
that help to stabilize the ﬁsh even in ar- so that material under low loading can be Using U.S. Federal Test Procedure FTP-75,
eas of high turbulence. The shape eliminated, while highly stressed areas are fuel consumption is approximately
evolved to have self-correcting hydrody- reinforced. It is the same principle that 70 mpg.
namic stability in the turbulent currents governs the growth of bones and tree David Alexander
around coral reefs. Under oblique ﬂow, branches.
the aerodynamic side force is only about The hexagonal scales of the boxﬁsh
35% of the value of an average car. have also evolved to deliver high strength
16 AUGUST 2005 aei aei-online.org