Volkswagen’s XL1 The Car Of The Future Los Angeles Local News FOX 11 LA KTTV — Volkswagen XL1

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Volkswagen XL1

Volkswagen’s XL1 — The Car Of The Future

Volkswagen executive Christian is in town from Germany ready for the LA Auto Show, but he stopped by Good Day LA to show off the fuel efficient car in the world, the XL1 .

The car can go 260 miles using only one of gas using a combination of an electric and a diesel-fuel engine, or as Lisa says, It goes both

What also adds to the efficiency is the ultra-light weight made from carbon

The car costs about $145 dollars. However, there are of this car that will be in other lines that produces. This means future cars we are familiar like to VS Golf will more fuel effecient in the years.

One cool aspect of highly aero-dynamic car is the rear monitors. One thing that wind drag in most are the rear-view mirrors. The XL1 uses camereas and TV monitors inside the car to see happening behind the car.

You can get a look at the car starting this at the LA Auto Show .

Or follow LA Show on Twitter: @LAAutoShow

Volkswagen sent us LOTS of on the car including specs, manufacturing and the philosophy behind the vehicle:

Germany — The XL1 is the most production car in the world, with a combined fuel consumption of 261 mpg and CO2 emissions of 21 g/km. Thanks to its hybrid system, this can also cover up to 31 miles as a electric vehicle.

The XL1 is an automotive that follows pure design principles: lightweight pounds), exceptional aerodynamics (a of drag of just 0.19), and a low of gravity. Thanks to this this super-efficient Volkswagen can at a constant 62 mph while using 8.3 horsepower. In all-electric mode, the XL1 less than 0.1 kWh to cover than 0.6 miles (one

The XL1’s plug-in hybrid consists of a 48-hp two-cylinder Clean Diesel engine, a electric motor, a seven-speed dual-clutch automatic transmission, and a battery. The 261 mpg fuel consumption is a record for a production car, that Volkswagen is in the automotive technical vanguard. The XL1 also has a top of 99 mph and can accelerate from 0 to 62 mph in 12.7

Conceptually, the XL1 represents the third stage of Volkswagen’s 1-liter car At the start of this current Prof. Dr. Ferdinand Piëch-currently of the Supervisory Board of Volkswagen the visionary goal of producing a car that had a combined fuel of one liter per 100 km (235 mpg). In the XL1, this vision has reality.

Despite the tremendous of the XL1, the engineers and designers came up with a body that delivers more utility than the two previous In the L1, the 1-liter car that was shown in and 2009, the driver and passenger sat each other for optimal in the XL1, the two occupants sit slightly side by side, almost a conventional vehicle.

The XL1 is 153.1 long, 65.6 in wide, and 45.4 in tall. By comparison, a Polo is slightly longer in) and wider (66.2 in), but is taller (57.6 in). a purebred sports car like Porsche Boxster is 5.1 inches Just 250 XL1s will be at the Volkswagen factory in Osnabrück,

Carbonfiber structure

As well as the pioneering technology in the the XL1 also utilizes lightweight and strong carbonfiber reinforced (CFRP) construction for the monocoque, all body parts, and components as the anti-roll bars. Produced the Resin Transfer Molding (RTM), the density/specific gravity of the is around 20 percent of a comparable exterior structure’s. The CFRP are as strong as comparable steel or parts, yet the exterior skin of the XL1 is 0.05 inches thick.

A at the scales shows why CFRP is the material for the XL1’s body. The weighs just 1753 composed of: 501 lb for the drive unit battery; 337 lb for the running gear; 176 lb for the 232 lb for the electrical system; and 507 lb for the body, crash structure and windshield. A of 21.3 percent of the new XL1, or 373 lb, of CFRP. In addition, Volkswagen lightweight metals for 22.5 of all the parts (395 lb), just 23.2 percent lb) of the car being constructed from and iron. An example of the attention to saving can be seen with the they are made from and weigh 25.6 lb each, or half the mass of a normal car

Thanks to the use of CFRP, the XL1 is not only but very safe. In a collision, the strong CFRP monocoque an impressive survival cell for the and passenger. This is achieved by design of load paths, the use of sandwich structures in the monocoque, the front and rear aluminum structures absorb a large of energy in frontal and rear The CFRP doors have impact beams to absorb energy and the door frame minimizes intrusions into the cell. A great deal of was also paid to extricating in the event of a rollover collision: separating screws are used to opening of the doors, which open upwards.

Compared to CFRP in a pre-preg process, the RTM is more economical-with lower at higher volumes-because it can be automated. The RTM are produced in multi-shell heated and molds. This involves liquid resin at high into the tool which the semi-finished carbon material. The is then cured in the mold.

hybrid concept

The XL1 is a plug-in hybrid, using fuel-efficient TDI Diesel common-rail turbodiesel and the DSG dual-clutch automatic transmission. The TDI 48 horsepower and 89 pound-feet of torque just 830 cc. The entire hybrid is housed between the driven wheels. The hybrid module, incorporates the electric motor and the is positioned between the TDI engine and the DSG transmission.

The 5.5kWh lithium-ion in the front section of the XL1-supplies the motor with 220 volts of energy. The battery weighs 150 and consists of 60 cells, with a case. The power electronics manages the flow of high energy to and from the battery or motor and converts direct to alternating current. The XL1’s electrical system is supplied via a converter and a small auxiliary

The lithium-ion battery can be charged a conventional household electric Naturally, battery regeneration is employed to recover energy to the when the car is slowing down, at point the electric motor as a generator. The electric motor, generates 103 pound-feet of torque a standstill, works as a booster to the TDI engine when full power is required. Together, the TDI and electric motor deliver torque of 103 lb-ft along 68 hp in boosting mode.

As well as the TDI engine under hard the electric motor can also the XL1 on its own for a distance of up to 31 miles. In this the TDI engine is decoupled from the by disengaging a clutch, and is shut Meanwhile, the clutch on the gearbox remains closed, so the DSG is fully with the electric motor. The can choose to drive the XL1 in pure mode, provided that the is sufficiently charged, by pressing a on the instrument panel is pressed.

Restarting the TDI engine is a very process. While driving, the motor’s rotor is sped up and is quickly coupled to the clutch in a known as pulse starting. accelerates the diesel engine to the speed and starts it, so the driver notices the transition. In certain conditions, the load of the TDI engine can be so that it operates at its most efficiency level. The gears in the DSG are also always selected the aim of minimizing energy usage.

The two-cylinder TDI engine was derived a 1.6-liter four-cylinder Clean powerplant, so it shares the 88-mm spacing and a bore and stroke of mm x 80.5 mm. The XL1’s engine shares key internal modifications for emissions, which include formed piston recesses for injection and individual orientation of the jets. The common-rail diesel’s running properties were to the two-cylinder engine, aided by a shaft that is driven by and at the same speed as the crankshaft.

The aluminum crankcase is constructed extremely low tolerances, which in leads to very low frictional Exhaust gas recirculation, an oxidation converter, and a diesel particulate are used in order to minimize the XL1’s engine is already with the Euro-6 emissions

The vehicle’s cooling system is designed to maximize efficiency. The water pump actively the engine only when conditions require it. The system automatically controlled air intakes at the of the vehicle to reduce drag. A electric water pump, only when needed, a separate lower temperature to cool the starter generator and the electronics. This thermal strategy also contributes reduced fuel consumption.

Low New Form

The XL1 uses scissor that are reminiscent of a high-end car’s. Because they are low on the A-pillars and just above the in the roof frame, they upwards and slightly forwards as The doors also extend far the roof. When they are they create an exceptionally amount of entry and exit

The XL1’s lines are very to the 2009 L1’s, but the car has a more appearance thanks to its greater The body design was uncompromisingly to follow the laws of aerodynamics, from front to rear to aerodynamic drag. Viewed above, the XL1’s shape a dolphin’s.

In profile, the roofline an arc from the A-pillar back to the The rear wheels are fully to prevent turbulence, while around the wheelarches is optimized by spoilers in front of and behind the There are no door mirrors: are replaced by small cameras as e-mirrors (digital outside that send images to two inside the vehicle. Polycarbonate windows weigh about a less than conventional a pane of glass on XL1 would 16.5 pounds, whereas the ones scale just lb each.

The front of the XL1 no longer a classical radiator grille, but still identifiably a Volkswagen, to the predominance of horizontal lines is part of the Volkswagen Design Specifically, a black cross-stripe with the energy-efficient dual LED to form a continuous band. The air intake for cooling the TDI engine, and interior is located in the lower section and has electrically controlled The narrow turn signals use LED technology; these L shaped follow a horizontal line the headlights and a vertical line the wheelarches. Even though the end is completely different to any other products, it can immediately be recognized as a design by its clean lines.

The design takes an entirely new at the rear, but the brand values of and quality are clearly evident. characteristics stand out: there is the dolphin body that narrows towards the with highly defined edges, for optimal aerodynamics. there is the coupe-shaped roofline doesn’t have a rear Merging into the roofline is the rear trunklid/hood that the drive unit and4.2 feet of luggage space. the strip of red LEDs frames the section at the top and on the sides and incorporates the lights, taillights, rear and brake lights. Fourth, a diffuser exhibits a near transition to the full underbody.

running gear

The running marries lightweight construction maximum safety. The front is by upper and lower control with semi-trailing arms at the The suspension is very compact and a high level of driving In key areas, the running gear mount directly to the CFRP

The weight of the running gear is by the use of many lightweight components. is used for parts such as the arms, brake calipers, and steering gear housing; the bars are made from the brake discs are ceramic; the are case in magnesium alloy; and the wheel body is plastic.

The car is designed to reducing rolling with friction-optimized wheel and driveshafts, as well as ultra-low resistance Michelin tires, 115/80 up front and 145/55 R16 at the But all this efficiency isn’t at the of safety: the XL1 has an anti-lock braking (ABS) and a stability control (ESC).


In Northern Europe’s largest carmaker has set up a new line for the XL1, handcrafting the largely from carbonfiber polymer (CFRP). The XL1 is manufactured by Osnabrück GmbH. In what was the Karmann factory, around employees produce cars as the Golf Cabriolet and the new Porsche

The production processes implemented in are highly innovative and unique, there were no previous of the individual production steps in the world. Over the long other Volkswagen Group will also benefit these numerous innovations.

In Detail

Stage I: Bodyshell

Production of the XL1 begins with of the CFRP monocoque, which is by a supplier in Austria using the RTM The manufacturing process itself was over several years in cooperation with Volkswagen. In the monocoque is mounted to an assembly plate, where the body is without doors or opening This first body stage is referred to as the bodyshell At this station, all parts are to their prescribed design by special fixtures in order to the tight manufacturing tolerances.

The various interior and exterior are pretreated in advance to attain gaps and smooth surfaces, is particularly important because the wanted the high-tech CFRP to be The individual CFRP components are to one another in the bodyshell frame by them together.

Over the course of production stage I, the area is aligned with the channel, then glued and with screws. In addition, all and exterior panels (rear and the front and rear side are positioned and screwed via a sled Employees check and document the tolerances of the entire assembly as the step of every production Each individual part of the XL1 is documented with a serial and its production history.

Stage 2: Door assembly

In with production stage I, the two doors are produced separately. developed its own tool for this, is used to fit the doors to adjoining parts with millimetric before they are fitted to the This is the only way to ensure the defined joint seam and uniform transitions between the are met when they are installed. sheetmetal, carbon parts be reshaped afterwards.

Stage 3: assembly

At the third production the bodyshell frame is placed on a new Here, all body parts-scissor hood, engine cover, and bumper-are assembled to achieve the gaps and flush mounting. of the doors is a special challenge, they require a precise fit to the and side body surfaces.

4: Paint

The paint process was specially formulated for the XL1, a really thin covering to the weight of the vehicle. To meet the A paint quality standard, a fleece layer or resin is added to the parts as a cover in the RTM process. Compared to conventional paints used in the industry, yields a weight reduction of than 50 percent. This CFRP painting process was the of intensive research by the Volkswagen Development Centre in Wolfsburg and by experts at the Osnabrück plant.

The itself consists of three The filler/primer is followed by the base (the solid color) and the layer of clearcoat, which a high level of scratch and UV In the interior, either decorative pearl gray paint is or a matt clear coat on CFRP parts such as the

Stage 5: Front section

painting, all components are transported to assembly. The first step is to join the front body to the prefabricated floorpan. The floorpan consists of components such as the arm front suspension, anti-roll a small 12-volt battery for the electrical system, and the ceramic brakes. Also integrated in the of the car is the high-voltage battery for the plug-in system.

The air conditioning unit is mounted in the vehicle’s cabin, but isn’t possible in the XL1 for packaging Therefore, it’s installed in a insulated capsule in the car’s section. Automatic testing of the electrical system and preliminary of all electronic components are also at the ITC (Startup and Test Centre) in stage.

Stage 6: Rear and interior

Merging the drive with the body occurs front-end assembly. The two-cylinder TDI electric motor, and the seven-speed DSG are installed in the rear section of the The rear suspension and driveshafts are at the same time.

In parallel, the is installed at this station. Due to the production volumes, no provisions made for preassembling the XL1 cockpit: all the individual parts are mounted the vehicle superstructure. The dashboard is made of a 1.4-mm-thick molded that is produced in a special process.

Stage 7: Windshield, and wheels

The XL1 now takes on more of its shape. After assembly of the unit, the laminated glass which is only 3.2 mm thick, is The doors are re-fitted and the engine is also re-mounted on the car. but not least, the XL1 gets its magnesium and low-rolling resistance tires.

Stage 8: Final assembly of the

The scissor doors are the most add-on components of the XL1 body. installing the painted door and the window mechanisms, special are used to glue the polymer windows into place. The part of the windows is permanently to the exterior door skin for reasons, while a segment of the area of the side windows can be Finally, the reversing cameras are in their housings, and the e-mirrors are to the door.

Stage 9: Startup

the entire high-voltage system is For this purpose, simulated faults are introduced to test the emergency shutoff functionality. The step is to start up the TDI engine; all the and sensors are checked. In parallel, adjust the camera-based e-mirrors a special computer program. all systems have been up, a check is made of all electrical according to a precisely observed

Volkswagen XL1


Body Carbonfiber polymer monocoque and panels

x width x height 153.1 in x in x 45.4 in

Wheelbase 87.6 in

system Plug-in diesel rear-wheel drive

Engine TDI Diesel, two cylinder

Capacity 830 cc

48 hp, 89 lb-ft

Electric motor 27 hp, 103

System output 68 hp, 103 lb-ft

Seven-speed DSG automatic

Battery 5.5 kWh lithium-ion

Weight 1753 lb


Max speed 99 mph (electronically

European fuel consumption 261 mpg

C02 21 g/km

EV range 31 miles

range More than 310 (10 liter fuel tank)

Information on Think Blue and Environmental Initiatives.

Sustainable Volkswagen has a multi-faceted approach.

The TDI lineup of the Passat, Jetta, and Touareg offer exceptional efficiency without sacrifice.

into hybrids and e-mobility the already launched Touareg Jetta turbo hybrid and to be launched electric Golf.

Our vehicle strategy is on schedule 2013 is the key year for electric First, the brand starts the age of pure electric driving by the all-electric Up! and as shown in Frankfurt, the which will be based on the generation (A7) Golf MQB

Volkswagen is constantly evaluating new powertrains and clean, efficient strategies including our diesel We felt it was more important to do right than to rush to market.


Volkswagen to be globally leading brand in terms of ecology by Think Blue. sustainability sets itself apart by approach

Herndon, VA — of the environment is one of the most vital of our time. Volkswagen faces up to its as a carmaker. Its attitude on ecological is embodied in the Think Blue. — with the goal of the ecologically leading car brand by 2018. Among other Volkswagen focuses on the question of how and ecologically minded behavior can be

The Think Blue. sustainability differs from similar in its holistic approach: It reaches far products and technologies, is inspiring and for both customers and the interested to participate in it and encompasses multi-faceted projects with a broad of environmental organizations. Naturally, as an automaker puts the focus on environmentally friendly products and solutions. These include, for our BlueMotion models — low-emission or electrically driven — yet also new mobility such as the Quicar car-sharing

With the Think Blue. program, Volkswagen has also set goals for itself in terms of Production in all Volkswagen plants is to up to 25% more environmentally friendly by i.e. the values for energy generated waste, air-borne and water consumption are to be reduced by figure. Volkswagen already sets new benchmarks with Blue. Factory. on an international The Chattanooga plant in the U.S. for is the first car plant in the world has been given the renowned Platinum Award for outstanding efficiency in 2011.

Think also pursues the goal of the awareness of the greater public for behavior and achieving a change in the of thinking in a joint effort. So our is straightforward: Environmental protection is fun and is without sacrifice — can make a contribution in his or her everyday Thus we raise the awareness for a driving style in a playful With Think Blue., will also enter the discourse on sustainable mobility in the with ideas contests, youth workshops and other

Think Blue. also numerous cooperative projects environmental associations. We place value on addressing the most challenges in terms of ecological in each country individually. In and Spain, prevention of soil has priority; the protection of biodiversity precedence in South Africa; our cooperation with Naturschutzbund was given the International Sponsoring as a successful example for credible and cooperation in environmental protection. Blue. has been the umbrella for the long-standing activities of Volkswagen in of ecological sustainability since 2010; it is designed for the long and has been established in 35 countries.

The of Think Blue. Is based on the 1960s slogan Think which referred to the democratization of through the Volkswagen Beetle. In the way, Volkswagen wants to a pioneering role in the challenges of the and make possible efficient and mobility for everybody.

Sustainable is therefore not just a technologicalchallenge. It is becoming an increasingly important and social factor. For these among others, we at Volkswagen committed ourselves to the most ecological restructuring process in our history: We plan to make new vehicle generation on average 10 to 15 per more efficient. We are promoting friendly technologies all over the — especially in China, and Brazil. We are also restructuring our to make them 25 per cent environmentally friendly by 2018. means: Reducing energy and consumption, waste, and emissions per produced by 25 per cent. We are fully to achieving these objectives, in difficult economic times. as Europe’s largest car manufacturer, we to set new standards. That is why we are working to achieve our goal of reducing the CO2 of our European fleet of new vehicles to 95 by 2020.

Volkswagen XL1
Volkswagen XL1
Volkswagen XL1
Volkswagen XL1

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