

2024.05.29 Hyundai MOBIS
As the global electric vehicle era dawns, the race to secure technological superiority is intensifying. Electric vehicles require every small component to be considered for performance impact, necessitating the development of new technologies. Hyundai Mobis has been continually introducing new technologies related to the front of the vehicle, which is often considered the 'face' of the car. The front end of an electric vehicle is a vital area that integrates crucial technologies directly linked to driving performance and design, including parts that affect aerodynamic performance, advanced driver-assistance systems (ADAS), autonomous driving technologies, sensors for communication, and charging ports.
The newly developed 'Front Face Integration Module' by Hyundai Mobis combines all these elements into one. It retains the grille design similar to internal combustion engine vehicles, ensuring design diversity while incorporating various technologies to enhance aerodynamic performance. Additionally, it includes sensor protection technologies such as LiDAR and has improved charging convenience. And, its specific features are introduced below.
The 'Active Air Flap' is a technology that opens and closes a cover to reduce air resistance based on cooling needs. Since electric vehicles generate less heat compared to internal combustion engine vehicles, this has led to the elimination of upper radiator grilles. However, as cooling is still required for the electric motor and battery, most electric vehicles include a small grille at the bottom with an active air flap.
Hyundai Mobis's Front Face Integration Module uses a large moving grille to implement the active air flap. Senior research engineer Kim Jang-ho at Hyundai Mobis Exterior Module Design Cell, explained the innovative approach:
"Customers want revolutionary and futuristic designs in electric vehicles, and the front face is the best area to showcase this. However, to improve aerodynamics, most electric vehicles have rounded fronts, which can lead to a homogenized appearance. We found a solution by maintaining the traditional grille design and enhancing aerodynamic performance to increase the driving range per charge."
Creating a variable grille system is not an easy task. It needs to withstand strong wind forces and operate quickly, necessitating a simple yet robust structure. However, Hyundai Mobis didn't stop there; they also added lighting to the grille to enhance design quality and incorporated an 'Active Aero Hood' to further improve cooling efficiency. Kim elaborated:
"Integrating lighting into moving parts was challenging, but we wanted to offer a design innovation. In the era of autonomous driving, lighting grilles could be used to communicate with pedestrians. The Active Aero Hood focuses on cooling efficiency. Previously, there was no proper outlet for air entering through the grille. Like opening both front and back windows at home for ventilation, opening the Active Aero Hood allows air passing through the cooling module to exit via the hood, enabling more air intake."
About 25% of air resistance during vehicle movement originates around the wheels. Thus, managing air flow around the wheels can reduce air resistance, increasing the driving range per charge and enhancing stability. Most vehicles apply wheel curtains at the front bumper sides to control airflow and reduce turbulence around the wheelhouses.
Hyundai Mobis has improved the wheel curtain in developing the Front Face Integration Module. Traditional wheel curtains are always open, but aerodynamic analysis showed that synchronizing them with the Active Air Flap to open and close could enhance effectiveness. Therefore, an 'Active Wheel Curtain' was developed to operate as needed.
Additionally, the module houses Hyundai Motor Group's 'Active Air Skirt' technology, which reduces air intake under the vehicle, including around the tires, to improve aerodynamic performance. This technology covers only necessary parts of the bumper, considering the underbody layout of electric vehicle platforms. For SUVs and CUVs, which have higher ground clearance at the bumper, aerodynamic losses occur, but deploying the air skirt at speeds over 80 km/h improves aerodynamics around the wheels.
Kim stated, "Active Wheel Curtain and Active Air Skirt are particularly useful for electric vehicles like SUVs, which have difficulty lowering the vehicle height. SUV bumpers are significantly higher compared to sedans, allowing more air to enter the underbody and wheel area, where significant aerodynamic losses occur. The improvements in these areas can significantly enhance performance."
Autonomous vehicles are equipped with various sensors, including LiDAR, which uses lasers to detect objects and is typically mounted in a protruding fashion on the vehicle's exterior, disrupting the design harmony. Hyundai Mobis has addressed this with the 'LiDAR Hidden System' integrated into the Front Face Module. The system conceals the sensor when not in use, enhancing the vehicle's front design while protecting the sensor.
Hyundai Mobis has introduced a new semi-automatic charging system featuring a sliding charging door. This semi-automatic system simplifies the charging process by requiring only the connection of the charger to start, after which the charger's retraction and the closure of the charging area are automated once charging is complete. This innovation is significant as it reduces the inconvenience of manually completing the process and presents a cost-effective alternative to charging robots. Kim explained the semi-automatic charging technology:
"Considering convenience, automatic charging robots are the best option, but they are still expensive to install. That's why we thought it was necessary to improve on a more cost-effective level. Semi-automatic charging offers a much cheaper way to enhance convenience compared to automatic systems. You connect the charger manually, but the retraction is automated. Imagine the future with autonomous robo-taxis; if someone just plugs in the charger, the car can automatically depart after being fully charged, reducing the workload for charging facility managers. It would also be highly applicable in the business-to-business marketplace."
The front face integration module developed by Hyundai Mobis could also contribute to production innovation. The front end of a car, encompassing various new technologies, autonomous sensors, and designs, demands high levels of technological development capability. Furthermore, the increase in new technologies makes it increasingly difficult to integrate all technologies, and the demand for integrated solutions will continue to grow.
The front face integration module is a consolidated solution that merges various technologies designed by Hyundai Mobis, who designs essential components for all areas of the vehicle. Implementing the front face integration module facilitates the supply of integrated modules necessary for smart factories, easing car manufacturing and contributing to production innovation, which will be a crucial axis of technological evolution in the future. Kim talks about what the future front end of electric vehicles would look like.
“Currently, the lamp is the essence of EV designs, but as electric vehicles become more widespread, relying solely on lamps to define the front's impression will have its limits. Hyundai Mobis envisions 'convergence' as the ultimate phase of technology. If we can merge dynamic motion of aerodynamic components with lamp technology, we can improve both aerodynamics and design. It is incredibly challenging to blend different parts and technologies to create new value. This approach will be an opportunity to showcase Hyundai Mobis's technological capabilities.”
Hyundai Mobis is transforming into a custom mobility solutions provider through the integration of core future mobility technologies like electrification and autonomous driving. Due to aggressive overseas market strategies and increased efforts to expand orders, Hyundai Mobis achieved $9.22 billion in orders from overseas automakers in 2023, accelerating its long-term growth momentum through focused strategic efforts. Their continued technological advancements and innovative ideas make it a company to watch.
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