EHV braved the chilly to learn the way Mercedes-Benz’s are using its new VAN.EA platform to place house between luxurious high-end vans for personal use, and people for industrial functions
The remark about “one winter of testing” piques my curiosity when speaking to Mercedes-Benz’s engineers in Arjeplog, Sweden. For so long as I’ve spoken to Mercedes-Benz engineers, spending two winters of testing on a single automobile previous to its manufacturing has been one thing of a ceremony of passage for them. The typically -30 situations right here within the Swedish automobile testing outpost, the place camouflaged pre-production check automobiles and prototypes just about outnumber these of the circa 2,000 native inhabitants, are good for this gruelling testing. Nonetheless, for this testing program – particularly for Mercedes-Benz’s new VAN.EA electrical structure – these engineers received’t be flying again to check the identical automobile subsequent yr. Whereas they’ll be again to briefly swell Arjeplog’s inhabitants once more, they’ll be testing one thing else.
As a result of it’s an accelerated check program that’s being trialled with the brand new VAN.EA platform, an EV-specific platform that can underpin the alternative for Mercedes-Benz’s V-Class passenger and industrial Vito choices. It’s doubly fascinating, too, as not solely is that new platform exploring a brand new improvement timeline, however it’s additionally bringing components from passenger automobile division in addition to that of economic autos.
That shift is a direct results of Mercedes-Benz’s ambition to discover the growth of the tremendous luxurious MPV market, someplace it’s already obtained a foothold in with the V-Class. However there’s recognition that nevertheless many V-Class you see in costly postcodes around the globe, its industrial origins imply it’s unable to claim the true luxurious that patrons are more and more demanding, and Mercedes-Benz needs to supply. Mercedes-Benz admits it’s eager to supply an OEM mannequin to take gross sales away from the quite a few conversion corporations that take base fashions and create luxurious autos, too. Tremendous luxurious raises the concept of the corporate’s Maybach model, and whereas no one’s admitting to that presently, nor are the denials significantly vociferous.
What’s simple is the affect of China, each as a possible market, in addition to for offering competitors – significantly on this mannequin sphere and, notably, on the pace of BEV mannequin introductions. Europe is presently the strongest market for Mercedes-Benz’s present providing with a 60% share and it needs to retain that, and develop, however the firm additionally sees substantial development alternative in each China, US and Canada for luxurious non-public vans.
Dr Andreas Zygan, Head of Improvement at Mercedes-Benz Vans explains the brand new structure, saying: “We’ve got constructed a purpose-built BEV platform with VAN.EA, which permits us to satisfy the necessities of a purely electrical automobile.” Naturally meaning the packaging of the EV battery and motors, however right here in a automobile that might be carrying as many as eight folks, security.
Icing out ICE
The necessities for improved NVH over the present mannequin are paramount, too, not least as a result of there’s no masking sound from an inner combustion engine, but additionally to convincingly fulfil that tremendous luxurious ambition on the higher finish of the mannequin spectrum. Key right here is the development, Zygan admitting that there’s much more give attention to materials combine, with focused light-weight fabrication combining with high-strength steels, with the battery pack itself including to the automobile’s stiffness. A van is difficult too, as a result of, as Benjamin Kaehler, Chief Engineer Vans, Mercedes-Benz, explains: “It’s a field, and then you definitely lower holes in it for the doorways, the tailgate, which impacts on its stiffness.” Countering that’s the focused use of strengthening supplies all through.
“With this new structure there are particular benefits for us as an OEM, “ explains Kaehler. “Firstly, we will notice a whole vary of privately used vans from sensible household bands to unique prime and variants. Secondly, we will design each mid-size and enormous bands from gross automobile weights of three.5 tons to greater than 5 tons. And thirdly, we will supply each electrical autos and people with state-of-the-art combustion engines. Nonetheless, the benefit of our new and structure is that, for the primary time, we will realise a transparent separation between industrial and privately used autos, particularly in design. We’re nonetheless satisfied that the automotive future is absolutely electrical, and it’s our ambition to play an energetic function in shaping that.”
There’s acknowledgement – and a level of frustration – that the pace of the transition to EVs isn’t fairly as speedy as initially anticipated, no less than concerning buyer adoption and acceptance. That means this goal BEV platform has needed to be tailored to just accept combustion engines. Mercedes-Benz is describing this as VAN.CA (Combustion Structure). Kaehler explains: “It’s true that our prospects’ necessities and market situations decide the pace of this transition part, so we will even offer our prospects progressive and extremely engaging combustion engines. However the important thing phrase is bridging.”
In concrete phrases, this implies Mercedes-Benz is coming into a brand new period with two variations of its van structure. “The variance of the van electrical structure, VAN.EA, that are uncompromisingly developed for absolutely electrical driving, shall be launched in 2026,” says Kaehler, “With our second variant of the van structure, the van with combusted structure VAN.CA, ultra-modern combustion choices will comply with.”
In doing this Mercedes-Benz is actively lowering the complexity of its product portfolio, with VAN.EA and VAN.CA platforms that includes round 70% components commonality, each in a position to be produced on the identical manufacturing line, with the apparent advantages for flexibility and economies of scale. That the BEV is the first focus of the event, with the combustion structure being the secondary consideration utterly adjustments the earlier improvement for such autos.
Freezing the info
It’s not simply the main focus onto BEVs that has switched with this structure, however the testing itself. “To realize our bold improvement targets, we make the most of all alternatives supplied by digitization,” says Kaehler. As such all check autos function real-time knowledge logging, which communicates with what the engineers describe because the ‘energy wall’ in a brand new VR studio. The result’s they’ll scale back real-time testing of all options and focus solely on what’s required to drive.
“Doing so has allowed us to shorten and parallelise the electrical drive timeline, and we’re talking right here of a discount of round 20%,” explains Kaehler. “With our so-called mission management centre on the van headquarters, we’re in a position to optimise the info of each check in actual time. This cross-functional cooperation between all departments in addition to the help of mission management is vital. Right here, all knowledge has monitored and evaluated. Points can now be eradicated as shortly as potential and in some instances whereas driving via over the air software program updates.”
Every automobile produces round 2.4 terrabytes of information per day, although there are much less prototypes constructed, they usually’re much less ‘full’. Getting within the VAN.EA check automobile underlines that, with it doing with out a lot of its inside trim, Kaehler saying that they solely check the drive, air flow and heating programs, against the whole automobile: “You don’t must construct up a whole automobile right here, we will do that in parallel, this new testing is creating a brand new mind-set.”
The VAN.EA exams aren’t simply pioneering a brand new potential automobile section then, however quicker, extra environment friendly means of car improvement, which it’s clear the testing crew engineers, and administration are very happy with. The teachings realized will nearly actually be adopted throughout the passenger automobile line, the brand new processes and concepts, and whereas which may solely imply one winter per automobile, the proliferation of fashions, and, presently no less than, the necessity to develop combustion variations off this structure signifies that the inhabitants of Arjeplog isn’t prone to be seeing a discount any time quickly.
VAN.EA Tech
800V know-how, a BEV particular structure, front- or 4MATIC all-wheel drive with the choice of air suspension and rear-wheel steering for manoeuvrability and stability, Mercedes-Benz isn’t holding again with its new VAN.EA platform. Essentially, to penetrate the brand new upmarket section it’s aiming for, however the industrial autos will even profit, in driveability, agility and, because of the suspension design, load house. The engineers are remaining tight-lipped concerning the actual specs however what they do admit is the anticipated WLTP vary shall be round 500km (round 310 miles).
Naturally, some industrial purposes would require much less vary, and can function smaller batteries and single axle motor set-ups, however the scalable, versatile nature of the platform is designed to adapt to the numerous wants of its prospects. Certainly, Mercedes-Benz has acknowledged it’ll produce a CEP-specific model ex-factory for the Courier, Categorical and Parcel providers, with this key market rising at a price of round 8% yearly.
Three modules primarily exist within the platform, the entrance module comprising of the electrical powertrain and entrance axle, this being the identical in all VAN.EA variations as a part of Mercedes-Benz’s optimised commonality technique. The centre part dictates the wheelbase, this primarily a battery service, which might be fitted with differing capability batteries relying on the utilization case. The rear part accommodates the rear axle, which is both unpowered, or positive aspects an electrical motor for 4Matic four-wheel drive fashions.
Just like the combustion autos the VAN.EA shall be supplied in camper van guises alongside the passenger and luxurious fashions, with the passenger autos gaining the choice of air-sprung suspension which can supply adaptive damping and the flexibility to decrease and lift the automobile for relieving ingress/egress. With manufacturing variations as a consequence of arrive in 2026, and this automobile having undertaken its closing, and solely, winter check – in EA guise no less than – Mercedes-Benz will proceed to drip-feed data on the VAN.EA over the approaching months.
CLA and GLC BEVs testing drop-in
Whereas in Arjeplog we had the chance to drop in on the testing of Mercedes-Benz’s CLA and GLC BEVs. The manufacturing model of the CLA shall be unveiled this Spring, with the GLC anticipated to comply with it later within the yr. The CLA is predicated on Mercedes-Benz’s MMA electrical structure, it options 800V electronics with charging potential at a price of as much as 320kW. Both entrance or 4Matic four-wheel drive, the CLA borrows closely from Mercedes-Benz’s record-breaking Imaginative and prescient EQXX, with the manufacturing CLA promising a possible vary for consumption of 12kWh/100 and a WLTP vary of over 750km. That’s with the biggest capability battery, which the engineers admit is 85kWh in capability (a smaller 58KWh battery will even be supplied). The MMA platform is both rear or all-wheel drive, with the rear motor that includes a two-speed transmission to supply one of the best in efficiency and economic system.
That completely synchronous machine compact rear motor is 200kW within the rear-drive fashions, with the 4Matic four-wheel drive variations gaining an 80kW motor on the entrance axle with a DCU disconnect for max effectivity. Key components from that EQXX features a productionised model of its multi-source warmth pump, which Mercedes-Benz claims can produce 3kW of output from simply 1kW of vitality, the system utilizing battery waste warmth and the ambient air for max effectivity. The battery chemistry on the bigger battery additionally differs from that on the smaller one, with the 85kWh pack that includes silicon carbide anodes to enhance vitality density over standard batteries by round 20%.
Aiding that effectivity is a newly developed braking system that may recoup as much as 200kW when braking, Mercedes-Benz engineers having labored tirelessly on a brand new braking system that feels extra pure than most EVs, mixing the regeneration and bodily friction brakes to reduce the vagueness so usually related to EV braking programs, significantly throughout that tough transition from regeneration to friction braking.
That know-how, in addition to the battery chemistry, two pace motor and decoupling entrance motor (on 4Matic) variations is all additionally as a consequence of function on the GLC. This new SUV BEV is a vital one for Mercedes-Benz, because the GLC is the corporate’s best-selling mannequin. On proof of our transient drive of each, and the dedication that the engineers need to them, these new BEVs can have the vary, driving dynamics and charging potential to make them extremely compelling alternate options to the present and future competitors.
