Mercedes-Benz is determined to lead the way the EV (electric vehicle) era, which it says will be defined by range and efficiency. The company’s Vision EQXX concept EV revealed at CES 2022 demonstrates the gains that are possible by rethinking the technology fundamentals.

“The Mercedes-Benz Vision EQXX is how we imagine the future of electric cars,” Ola Källenius, Chairman of the Board of Management of Daimler AG and Mercedes-Benz AG. “…We started this project leading to the most efficient Mercedes-Benz ever built—with an outstanding energy consumption of less than 10 kWh per 100 km. The Vision EQXX is an advanced car in so many dimensions—and it even looks stunning and futuristic. With that, it underlines where our entire company is headed: We will build the world’s most desirable electric cars.”

Rather than just increasing battery size, the “international” development team targeted maximum vehicle range and efficiency by focusing on drivetrain efficiency, energy density, aerodynamics, and lightweight design. Based on internal digital simulations in real-life traffic conditions, the concept will be capable of exceeding 1000 km (620 mi)—an efficiency of more than 6 mi/kWh.

“The technology program behind the Vision EQXX will define and enable future Mercedes-Benz models and features,” said Markus Schäfer, Member of the Board of Management of Daimler AG and Mercedes-Benz AG, Chief Technology Officer responsible for Development and Procurement. “Vision EQXX has seen the best minds from our R&D centers work together with engineers from our Formula 1 and Formula E programs. They are proving that innovations from motorsport—where powertrains are already highly electrified—have immediate relevance for road car development.”

Many of the concepts features and developments are already being integrated into production vehicles, including the next-generation MMA (Mercedes-Benz Modular Architecture) for compact and medium-sized cars. That might account for the great amount of detail provided by the company on the concept’s technology and suppliers.

Key concept technical data include a usable battery energy content of more than 100 kWh, maximum system voltage of greater than 900 V, energy consumption of less than 10 kWh/100 km (more than 6 mi/kWh), an aerodynamic cd of 0.177, a maximum power output of about 150 kW, a wheelbase of 110 in (2790 mm), and gross vehicle weight of about 3858 lb (1750 kg).

 

Pushing efficiency to a new level

The project went from a clean sheet to a completed vehicle in just 18 months.

“With the Vision EQXX, we’re presenting the results of an extraordinary challenge: we pushed efficiency to a totally new level,” said Joerg Bartels, Vice President for Vehicle Engineering and Overall Vehicle Functions. “And we explored new ways to increase the range of an electric car.”

The team set out to create an electric drivetrain with a world-beating combination of efficiency, energy density, and lightweight engineering. The goal was 95% efficiency, compared to just 30% for the most efficient internal combustion engine drivetrain or around 50% from an average human long-distance runner. Mercedes-Benz R&D collaborated with Formula 1 experts at Mercedes-AMG High Performance Powertrains (HPP) in Brixworth, UK, to rethink the drivetrain and slash system losses.

“We worked on every part of the system to reduce energy consumption and losses through system design, material selection, lubrication, and heat management,” explained Eva Greiner, Chief Engineer of the electric drive systems at Mercedes-Benz.

The electric drive unit—consisting of the electric motor, transmission, and power electronics (the last featuring a new generation of silicon carbides)—is based on the unit in the upcoming Mercedes-AMG Project ONE hypercar. Mercedes-Benz and the HPP team developed a new battery pack with a “remarkable” energy density of close to 400 W·h/L, making it possible to fit a battery pack with just under 100 kWh of usable energy into the compact dimensions of the concept.

“In effect, we fitted the energy of the EQS into the vehicle dimensions of a compact car,” said Adam Allsopp, Advanced Technology Director from HPP. “The battery has almost the same amount of energy but is half the size and 30% lighter.”

The substantial increase in energy density comes in part from significant progress made in anode chemistry. The anodes’ higher silicon content and advanced composition mean they can hold considerably more energy than commonly used anodes. Another contributor to energy density is the high level of battery pack integration. The battery development team also decided to experiment with an unusually high voltage of more than 900 V.

The battery pack features active cell balancing, which draws energy evenly from the cells while the car is driving, giving it greater stamina. A lightweight battery enclosure was engineered jointly by Mercedes-AMG HPP and Mercedes-Grand Prix using a sustainable composite material derived from sugar-cane waste, reinforced with carbon fiber, as used in Formula 1. Overall, the battery pack including the OneBox power electronics weighs just around 1091 lb (495 kg).

The exceptional efficiency of the electric drive unit means it generates minimal waste heat, which helped keep the thermal management system extremely small and lightweight. The system combines an innovative air-flow management system and a cooling plate installed on the vehicle floor, allowing the vehicle to gain about 20 km (12 mi) of range in its most aerodynamic mode.

A multi-source heat pump recovers waste heat from the drivetrain and has an external heat exchanger that draws heat from ambient air. The latter is handy for heating up the cabin quickly and is highly effective at lower temperatures. To squeeze out every bit of heat, it uses “evaporator enthalpy” when dehumidifying moist ambient air.

The electric system that powers many of the concept’s ancillaries draws additional energy from 117 solar cells on the roof. The system was developed in collaboration with the Fraunhofer Institute for Solar Energy Systems ISE. Per day and under ideal conditions, it can add up to 25 km (15 mi) of range.

The solar energy is stored in a lightweight lithium-iron-phosphate battery that supplies a climate blower, lights, infotainment system, and other ancillaries. Mercedes-Benz and its partners are working toward using solar power to also charge the high-voltage system.

 

Digital design and aerodynamics

On a regular long-distance drive, a typical EV dedicates almost two-thirds of its battery capacity to push its way through the air, which is why engineers around the world are focused on reducing aerodynamic drag, especially for EVs. So the design/engineering team used digital modeling techniques to reach a compromise that reduces the concept’s drag coefficient to just 0.17 while retaining the Mercedes-Benz “sensual purity” design language and the practicalities of a road car.

“It usually takes around a year to finalize the form,” said Teddy Woll, head of aerodynamics at Mercedes-Benz. “We had less than half of that for the Vision EQXX. Lean, agile processes and mature digital tools make collaborative work far easier, with faster decision-making and more nimble compromises.”

Key aero features include the tapering greenhouse and a rear-end cleanly defined by a tear-off edge accentuated by a gloss-black end trim and rear light clusters. The rear track is 2 in (50 mm) less than the front’s to enable lower body tapering. A retractable lower rear diffuser deploys at higher speeds.

The concept’s frontal area is actually smaller than that of today’s Mercedes CLA. The front bumper air curtain pairs with the wheel covers to reduce air separation at the front wheels. Air pathways guide additional cooling air over the hood, reducing drag around the mirrors and lowering overall drag compared with a conventional outlet into the underbody.

On the design side, a band of light above the gloss-black grille flows into the energy-efficient headlights. Each headlight consists of two star-shaped elements, the larger one housing both the low-beam and high-beam light arrays behind a glossy center lens. The arrangement, paired with the 2D star pattern on the front bumper, is said to preview front-end design detailing of future Mercedes-Benz models.

Mercedes-Benz worked with Bridgestone to adapt the Turanza Eco tire for the concept. It combines light weight with environmentally friendly Enliten and ologic technology for ultra-low rolling resistance. The tire’s aerodynamically optimized sidewalls match the covers mounted on the 20-in, lightweight, forged-magnesium wheels, which have a semi-transparent double-spoke design.

 

Sustainable interior materials

The interior’s new “super-purist” design style is a departure from the conventional company design approach, the layout focusing on a few modules and design simplicity. The interior features extensive use of lightweight, sustainable materials and organic-inspired design detailing—with no animal-derived products.

For example, the door pulls are made from AMSilk‘s Biosteel fiber, a high-strength, biotechnology-based, and certified-vegan silk-like fabric marking its first automotive application.

Mylo is used for details of the seat cushions in the concept. The verified vegan leather alternative from Bolt Threads, Inc. is made from mycelium, the underground rootlike structure of mushrooms. It is certified bio-based, which means it is made predominantly from renewable ingredients found in nature.

Also used is the animal-free leather alternative from Desserto called Deserttex, a sustainable biomaterial—made from cactus fibers combined with a sustainable bio-based polyurethane matrix—that is extremely soft to the touch.

Carpets are made from 100% bamboo fiber, the raw material being fast-growing, renewable, and offering a luxurious look and feel.

The concept also makes use of recycled waste materials. Recycled PET (polyethylene terephthalate) bottles are used in a shimmering textile to enhance the floor area and door trim. The designers used Dinamica made by Miko from 38% recycled PET to link the upper edge of the screen with the doors and headliner. The interior also features a sustainable plastic substitute made from household and municipal landfill waste from startup UBQ Materials.

“Working with these innovative, sustainable materials to design the interior of the Vision EQXX was a hugely liberating and exhilarating experience,” said Gorden Wagener, Chief Design Officer Mercedes-Benz AG. “They open up completely new avenues of creativity.”

 

Bionic body parts

Mercedes-Benz engineers drew inspiration from nature and external expertise for the bionic engineering of key body parts using a digital process called bionic mesh design. The company’s BIONICAST registered trademark is being applied to structural castings engineered according to these principles of nature.

One result is the largest aluminum structural casting at Mercedes-Benz called BIONEQXX. The major structural component for the rear floor was developed in-house using entirely digital techniques and a software approach to package optimum functionality within the compact dimensions of the available space. The resulting one-part casting has a web-like appearance with gaps where there is no need for structural reinforcement.

To keep out water and dirt from the rear floor, Mercedes-Benz engineers turned again to UBQ Materials for a more sustainable plastic substitute made from waste that typically ends up in landfills. The openings in the BIONEQXX rear floor casting were closed using 42 patches produced on a 3D printer and designed using shape optimization to achieve extremely high stiffness and sound-damping qualities.

Principles of bionic engineering were also applied to the damper domes at the front of the car and the bracket carrying the windshield wipers and motor.

The technology has already been transferred to Mercedes-Benz production models, the new EQS flagship EV using it for chassis components to reduce weight but increase stiffness.

 

Advanced bodyshell materials

The Vision EQXX features many advanced materials, several of which are currently being used in the development of future production models.

One of those is MS1500 ultra-high strength martensitic steel, marking a first for a Mercedes-Benz body-in-white application. The material offers strength for excellent occupant crash protection while keeping weight down.

The concept’s body-in-white is one of the first Mercedes-Benz applications of low-CO2 flat steel produced with 100% scrap using an electric-arc furnace technique. These low-CO2 steel grades have been introduced recently in company production vehicles in conjunction with Salzgitter Flachstahl GmbH.

The concept’s doors are made from a hybrid of carbon- and glass-fiber-reinforced plastic components with aluminum reinforcements. A polyamide foam reinforces the lower edge of the door and optimizes energy absorption in a side-on collision.

Aluminum brake discs reduce mass significantly compared with cast steel discs. In addition to being corrosion-free, an innovative coating reduces brake dust emissions by up to 90%. New advanced glass-fiber-reinforced plastic springs developed in partnership with Rheinmetall Automotive remove further weight compared with conventional coil springs.

 

Neuromorphic computing and leading-edge UX

The concept also takes its cue from nature in the way it thinks, using a form of information processing called neuromorphic computing. The hardware runs spiking neural networks, consuming energy only when a spike occurs and reducing energy consumption by orders of magnitude.

Mercedes-Benz engineers developed systems based on artificial intelligence expert BrainChip‘s Akida hardware and software. Structured along neuromorphic principles, the “Hey Mercedes” keyword detection is five to ten times more efficient than for conventional voice control.

Although neuromorphic computing is still in its infancy, when applied at scale throughout a vehicle it has the potential to radically reduce the energy needed to run the latest AI technologies, says Mercedes.

The software-driven user interface and user experience inside the concept are said to be more responsive and intelligent. It uses the first-ever completely seamless display in a Mercedes-Benz, spanning 47.5 in (1205 mm) between the A-pillars. The thin, lightweight, mini-LED display has 8K resolution—specifically 7680 x 660 pixels.

The concept shows the potential of game-engine-powered interfaces with leading-edge graphics and a highly adaptive design. A “star-cloud avatar” responds to the driver’s needs and takes care of the passengers for a luxury experience.

It also shows off the work of navigation experts at NAVIS Automotive Systems, Inc. to develop the first real-time 3D navigation system on a screen of such a large size. It is said to perform seamless zoom and scroll functions from satellite view down to a height of 33 ft in the 3D city representation.

Voice synthesis experts from Sonantic helped in engineering the concept’s road trip sidekick with further development of the “Hey Mercedes” voice assistant to be more emotional and expressive. As well as sounding impressively real, the emotional expression places the conversation between driver and car on a completely new level that is more natural and intuitive.

 

Simplified Zero Layer

The simplified interface is a further development of the Zero Layer concept first used in the EQS, which eases driver-vehicle interaction by removing submenus. The interface shows what’s needed when needed, with an intuitive zoom feature.

The main one-piece interior display uses mini-LED backlighting that consists of more than 3000 local dimming zones, so it consumes power only when needed for specific parts of the screen. The 3D navigation screen adapts to the type of content being shown; this has the added efficiency benefit of reducing the energy consumption of the display.

The efficiency assistant curates available information—from energy flow to terrain, battery status, and even the direction and intensity of the wind and sun—and suggests the most efficient driving style. The sensor data are augmented by map data to anticipate what lies ahead for the driver.

The sound system, which can be a significant energy consumer, is integrated into the UI/UX to deliver an impressive 4D experience with exceptional energy efficiency. Mercedes-Benz engineers looked closely at how to optimize the sound experience while minimizing energy consumption by focusing on reducing sound wave degradation when absorbed by or bounced off interior surfaces.

Reducing the overall number of speakers and positioning them very close to the individual occupants dramatically reduces the distance the sound travels. Two broadband speakers installed in each headrest are paired with a bass exciter in each seat.

The layout of the sound system also facilitates multiple sound zones. The efficiency assistant takes advantage of this to communicate its recommendations to the driver via a series of intuitive audio cues inspired by those used by Formula E to help the drivers perform more efficiently.