Charged with Electric Vehicle News and Views
The electric RAV4 has sold poorly, despite low-cost lease and loan offers Toyota introduced last year to promote sales. Due to the high demand for carbon fiber in automotive production, BMW and SGL Automotive Carbon Fibers is going to triple the capacity of the carbon fiber plant in Moses Lake, WA (USA).
The expansion will be funded by an investment of 200 million US dollars, in addition to the previously invested 100 million US dollars. The site expansion, scheduled to be completed by early 2015, will make the plant in Moses Lake the world’s largest carbon fiber plant. With the anticipated creation of 120 new jobs, the headcount at the joint venture in Moses Lake is going to rise from currently 80 to about 200 people. Due to the automated production processes, the expansion of the site in Moses Lake will make it possible for the BMW Group to apply carbon fiber material also in other model series in the future, at competitive costs and in large quantities.
At present, the Moses Lake plant operates two production lines, exclusively for BMW i, with an annual output of approx. 3,000 tons of carbon fiber. Already this summer, SGL Automotive Carbon Fibers will commission a third and fourth production line in Moses Lake, which are currently being built, thus doubling the plant’s capacity to 6,000 tons per year. Today’s groundbreaking ceremony for a fifth and sixth production line has been the first step toward tripling capacities to 9,000 tons annually in the medium term. The energy needed for the carbon fiber production is fully generated from hydropower.
“With its highly automated carbon fiber production and stringent quality standards, Moses Lake is setting new standards in the industry. At present, the site is the world’s fastest growing carbon fiber producer. Together with the BMW Group, we are doing pioneering work to establish CFRP as a material in large-series automotive production. In a mix of materials, CFRP offers new opportunities in lightweight construction for an eco-friendly mobility,” explained Dr. Jürgen Köhler, CEO of SGL Group.
Dr. Klaus Draeger, Board Member Purchasing and Supplier Network at BMW AG: “CFRP is a key material for the automotive industry of the 21st century. In our endeavor to identify increasingly lightweight materials in order to reduce a vehicle’s weight and thus its fuel consumption and carbon emissions, this material plays a crucial role. As part of an intelligent mix of materials, we will apply carbon also beyond our BMW i and BMW M models in the future. Thanks to the pooling of the SGL Group’s expertise and our knowledge in large-series production of CFRP components, we will be able to produce the ultra-lightweight high-tech material also for other model series, at competitive costs and in large quantities.”
The carbon fiber plant in Moses Lake is a key element in the strategy pursued by the two companies, which anticipates the industrialized large-series production of carbon fiber reinforced plastics (CFRP) for the application in future vehicle concepts. Up to now, carbon fiber produced in Moses Lake is exclusively used for the BMW i models. Since the start of the year, the Leipzig plant has built over 5,000 BMW i3 vehicles. At present, the production output stands at 100 units a day. Furthermore, the BMW Group has been applying the ultra-lightweight high-tech material also in its BMW M models for the past ten years.
Andreas Wüllner, CEO of SGL Automotive Carbon Fibers: “In the course of only four years, SGL Automotive Carbon Fibers has managed to become the world’s largest carbon fiber production site. The automotive industry will increasingly turn to CFRP because it is a material of the future.”
Availability of renewable energy crucial in the decision for the location in Moses Lake
As part of their joint venture agreement, the BMW Group and the SGL Group invested an initial 100 million dollars at their Moses Lake site by 2013, creating 80 new jobs. Jay Inslee, Governor of Washington State: “Congratulations to the BMW Group and the SGL Group on the groundbreaking of their fifth and sixth production line at the Moses Lake Plant. Washington State is proud to partner with BMW. The game-changing technology of carbon fiber is driving a surge in U.S. manufacturing, and with this production plant Washington State is at the forefront of that surge.”
The production of carbon fiber requires a great amount of energy. Accordingly, decisive factors for the set up of the carbon fiber plant in Moses Lake included the availability of renewable hydropower as well as competitive energy costs in Washington State. The availability of skilled workers also had an influence on the decision in favor of the location, which was taken in April 2010. The groundbreaking ceremony for the plant was in July 2010, the opening of the production site in September 2011. Dr. Jörg Pohlman, CEO of SGL Automotive Carbon Fibers: “We received great support from the regional authorities in Grant County and Moses Lake, a decisive element in making this rapid development of the past few years possible. With the site expansion, we are reaching an important milestone in safeguarding the site’s future.”
Production of carbon fiber composites
The production of carbon fiber composites for automotive manufacturing requires several process steps: The necessary precursor, which is based on polyacrylnitrile fiber, is made by a joint venture between SGL Group and the Japanese company Mitsubishi Rayon in Otake, Japan. In a next step, polyacrylnitrile fiber is turned into the actual carbon fiber in Moses Lake. This material is then processed at the second joint venture site in Wackersdorf, Germany, and turned into textile carbon fiber layers, the starting point for the production of CFRP body parts at the BMW plants in Landshut and Leipzig. In the BMW i models, CFRP already holds a significant share in the mix of materials, a first at this scope and in series production. The joint venture gives the BMW Group access to this innovative key material in the long term. The SGL Group provides their expertise in high-performance materials and their experience with carbon fiber-based materials.
For the first time, Mercedes brings a fully electric car to the U.S
The B-Class ED is the product of a technology-sharing alliance between Tesla and Daimler that goes back to Mercedes’ 2009 investment.
Rather than rely on in-house R&D, Mercedes essentially contracted with Tesla—the Silicon Valley car maker and acknowledged leader in electric automobiles—to provide the EV architecture (motor, transmission, battery, power electronics) for its electron-fired B-Class.
Tesla will make the B-Class battery pack, power management system etc at the factory in Fremont, Calif., and ship them to Germany for final vehicle assembly.
The B-Class Electric Drive, which is built on the same production line as the gasoline-powered version, is going to go on sale in Europe around the end of the year and will also come in a right-hand drive version for other markets in 2015.
One of these days, one of these compliance cars is going to break out, sales-wise. The B-Class ED, which will sell in all 50 states, could be the one. While it might have emerged out of a compliance effort, the B-ED just shines, a premium family electric that braids Tesla’s and Mercedes’ DNA so convincingly the car might as well be called the Model B.
Many people who own the Chevrolet Volt try to outwit the car’s computer so they seldom burn a drop of gas. 
The 2014 Cadillac ELR is unique, beautiful, efficient, serenely comfortable and electronically avant-garde, but at $76,000, it’s also bracingly expensive. 
The turbocharger, the engine component that uses the exhaust’s hot air to increase horsepower, is performing new tricks. It is now also producing electrical power for hybrid systems. 
The i8 is BMW’s sci-fi, ultralight showpiece, a plug-in hybrid that has a range of about 20 miles in E.V. mode. But good luck squeezing into the front seat. Nobuhiro Tajima and his APEV Monster Sport team are preparing for their third year at the Pikes Peak International Hillclimb with Battery power.
Nine-time Unlimited division champion Nobuhiro “Monster” Tajima will be gunning for outright course record again after he was the first to break the 10 minute barrier with an electric vehicle at Pikes Peak in 2013, even surpassing the 9:51.278 he turned in during the 2011 race in a 900 hp Suzuki SX4, when he was the first driver ever to crack the Peak’s elusive ten-minute barrier.
The outright hill record goal posts have been moved significantly this year by nine time World Rally Champion Sébastien Loeb setting a time of 8:13.878 in a 900 hp 900 kg Peugeot 208 T16 Pikes Peak Special.
When asked after the 2013 event about beating the new gasoline record, Tajima responded: “We are able to do that very soon, it depends on the battery. With a high quality and high density battery, I can beat that record for sure.”
