Tag Archives: history

New IIHS Study Confirms Brighter Headlights Reduce Number of Nighttime Crashes

To the surprise of no one, a new study completed by the Insurance Institute for Highway Safety confirmed brighter headlights help reduce vehicle collisions.

Audi R8
In 2016, Audi’s new laser headlamps were brighter than conventional lights so the maker adjusted the lights to shine low and wide.

The organization noted the number of nighttime vehicle accidents are nearly 20% lower for vehicles with headlights earning a “good” rating in IIHS evaluation, compared with those with “poor” rated headlights. Vehicles IIHS rates as having “acceptable” or “marginal” headlights crash rates are 10% to 15% lower than for those with poor ratings.

“Driving at night is three times as risky as driving during the day,” said IIHS Senior Research Engineer Matthew Brumbelow, who conducted the study. “This is the first study to document how much headlights that provide better illumination can help.”

An evolving light 

Until recently, there was little need to evaluate headlights, as all cars used sealed beam headlights, a technology that became an industry standard by the 1940s. Like the lights in your home, sealed-beam and halogen headlights are incandescent. They use electricity to heat a bulb’s filament, which in turn produces light.

The addition of halogen gas in the 1960s allowed the headlight’s tungsten filament to generate a brighter light that lasted longer. In 1983, the Federal Motor Vehicle Safety Standard was revised, allowing for all composite headlight assemblies to have replacement bulbs. Yet overall, headlights had changed little since electric headlights first appeared on cars in 1898.

IIHS headlight crash reduction chart

That changed with the introduction of high-intensity discharge headlights, or HIDs. These are arc lamps, much like a neon sign, which produce light by the sparking an electrical arc between two conducting electrodes inside the bulb. Far more efficient than halogen lamps, they not only produce more light, but also use less energy and last far longer. 

Then, in 2004, the first LED headlights appear on the Audi A8. An LED a semiconductor that emits light when a current is passed through it, using far less energy than other types of bulbs. This led to the creation of LED Matrix headlights, which uses LEDs, sensors and cameras to light the road depending on road conditions. Now, automakers are starting to employ laser lighting, affording 1.25 miles of visibility.

Testing counteracts an outdated federal standard

Given evolving lighting technology, IIHS began evaluating headlight effectiveness in 2016 to counteract the federal government’s outdate lighting standard, one that considered all headlight types equal. The problem is, they’re not. Five years later, IIHS has rated approximately 1,000 different headlights, bestowing them with the same good, acceptable, marginal and poor ratings used for the crash test evaluations.

The IIHS’s new study shows that good-rated reduces driver injuries in crashes by 29% and the rates of tow-away crashes and pedestrian crashes by about 25%.

“Better scores in our headlight tests translate into safer nighttime driving on the road,” said IIHS’s Brumbelow. 

Despite the changes in headlight technology, the Federal standard for automotive lighting hasn’t changed significantly since 1968. What’s worse, the standard specifies minimum and maximum brightness for headlights without taking into account how well it is installed. The standard also lacks any regulations for newer technology, such as curve-adaptive headlights. 

To address such failings, the IIHS’s evaluation of vehicle lighting are done while driven on a test track. Performance varies considerably; current low beam headlights illuminate anywhere from 125 feet to 460 feet. That’s a difference of as much as 6 seconds when driving at 50 mph. The tests have compelled OEMs to improve the quality of their lighting, IIHS says. 

“Our awards have been a huge motivator for automakers to improve their headlights,” Brumbelow says. “Now, with our new study, we have confirmation that these improvements are saving lives.”

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Ford’s New Electric Vehicle Center Links “Past and Future”

As far as Corey Williams is concerned, we’re walking on “hallowed ground.”

Model A sedans roll down the line at the old Rouge Assembly Plant, one of the first factories with a moving assembly line.

A year ago, there was nothing but a dusty parking lot where Ford Motor Co.’s new Electric Vehicle Center now stands. But dig deeper into the past and you realize this was the site of the original Ford Rouge Assembly Plant where generations of blue-collar workers built everything from Model A sedans to Mustangs to F-Series pickups — as well as armor, engines and tanks as part of the “Arsenal of Democracy” during World War II.

Starting next spring, this new factory will begin building the new Ford F-150 Lightning, the all-electric pickup truck has so far garnered over 150,000 advance reservations since it was unveiled in May. That’s part of a $30 billion electrification plan Detroit’s second-largest automaker has in play.

Rolling out the first battery-powered version of Ford’s iconic pickup — the nation’s top-selling truck for 44 years — might be significant enough on its own. But the new Electric Vehicle Center is also functioning as a research lab that could radically change the way cars and trucks are built all over the world.

“This is hallowed ground. This is history,” said Williams, the plant manager. “This is where we are going from the past to the future.”

Where’s the assembly line?

Automated Guided Vehicles, or AGVs, replace the moving assembly line at the Electric Vehicle Center.

Take a tour of the center, which is slowly launching early prototype production, and you can’t help but notice something missing. The moving assembly line that was originally introduced by company founder Henry Ford 108 years ago is gone. The assembly line is a fixture at all but the lowest-volume plants building cars virtually by hand — and slowly, very slowly.

That’s not the case here. With the $250 million expansion Ford announced on Thursday, the Electric Vehicle Center will be capable of producing as many as 80,000 Lightnings annually. That’s not quite as fast as the plant next door where traditional, gas and diesel trucks or built, but quickly enough that this is a radical departure.

Instead of a fixed line, partially assembled pickups are loaded onto AGVs, or Automated Guided Vehicles. These are, essentially, robotic pallets that creep along the shop floor, guided by thin magnetic ribbons carved into the concrete. Sonar sensors help make sure they don’t collide with one another or with the hundreds of workers who’ll soon populate the plant.

It’s not the first time AGVs have shown up in factories. General Motors started using them in the 1980s, primarily to deliver parts to workstations along the line. This is the first time they’ve been put to use in such a high-volume operation completely abandoning Henry Ford’s movable assembly line.

Getting workers plugged in

F-150 Lightning - body and chassis marriage
An F-150 Lightning body is “married” to a chassis containing its electric drive system.

A major change, yes, but as far as Williams is concerned, one of the real hallmarks of the Center is the way workers become active, intelligent parts of the production process. Reaching their post, they log in at one of three tablet-style screens and can check on what happened during earlier shifts, then report in during their own.

Among other things, that will help Ford track and quickly resolve problems, explains Christopher Skaggs, who oversees Ford’s EV planning and implementation.

The AGVs not only move vehicles from workstation to workstation but they recognize the operators at each point, rising or lowering to maximize ergonomics, reducing stress and strains.

As is today’s norm, even in traditional assembly plants, there’s a high dependence on robots, including Transformer-sized beasts that can weld, glue and handle jobs like mounting windshields.

Robots and cobots

Ford F-150 Lightning - cobots
Cobots — “collaborative robots” — check out a partially assembled Lightning

The center also introduces what Ford has dubbed “cobots,” or collaborative robots. Rather than being isolated and fenced off, they operate right alongside human workers. They can do tasks like sanding or, in this case, help their flesh-and-blood colleagues examine bodies for minor dings or damage using artificial vision.

The production process isn’t entirely unique. It still proceeds one workstation at a time and, as Lightning bodies follow their serpentine path they’re eventually snagged by an overhead conveyor, carried to the point where they are “married” to the chassis that contains each Lightning’s battery pack, motors and other drivetrain components, as well as wheels and suspension.

As the final assembly tasks are completed, the now operative electric pickups enter a series of inspection stations. One uses a massive robotic arm to press down on each Lightning’s cargo bed. Sensors built into the truck are designed to tell the driver how much weight it’s carrying. The test confirms that system is accurate to within a percent or so, explains manufacturing manager Liza Currie.

One last look

F-150 Lightning - in lighting booth
A final check for dings or paint problems and the F-150 Lightning is ready to go — though this is just a prototype to be used for testing.

Finally, each truck will roll into a blindingly bright booth featuring dozens of carefully positioned lights. Human and robotic vision work together to ensure some exterior flaw — a ding, perhaps, or a chip in the paint — doesn’t get passed on to a consumer without being repaired.

As he surveys the new plant, Williams said he’s confident, “We’ve incorporated the latest and the greatest.”

Many of the new features will reappear in other Ford plants. But Williams hesitates when directly asked whether the conventional F-150 plant next door will switch to AGVs, abandoning it fixed line, when the truck goes through a makeover around 2025. That’s for higher-ups to decide, he defers, but it’s clear he sees the Electric Vehicle Center as the high profile test for a radical new system that could replace what Ford Motor Co.’s namesake gave to the manufacturing world a century ago.

“I believe what you’re seeing here,” Williams said, “is the beginning” of a massive transformation in the manufacturing process.

The Alpina Story – From Typewriters to BMWs

The Alpina Story - From Typewriters to BMWs
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The Alpina Story - From Typewriters to BMWs
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“From a young age I was interested in cars, and I never had the intention of going into the family business of making typewriters,” recalls Bovensiepen in an interview with Classic Driver magazine back in 2015. “I was able to convince my father to let me use a small outbuilding on his business premises, and first I modified my own car, a BMW 1500. There was only one tine Solex carburettor, but it was otherwise a good engine – so I added dual-Weber carbs, which gave it a 0-60 mph time of 13 seconds, three seconds quicker than the base model.”

Alpina originally started out as a typewriter manufacturer and then tried to move into textiles without too much success. Burkard Bovensiepen, however, was getting noticed as his tune-ups impressed the era’s automotive journalists as well as BMW.

The Alpina Story - From Typewriters to BMWs
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The Alpina Story - From Typewriters to BMWs
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BMW Sales chief Paul G. Hahnemann developed a particular interest in Burkard’s work, which in turn lead to BMW’s decision to offer full factory guarantee to every BMW vehicle tuned by Alpina. And so, come January 1965, Alpina Burkard Bovensiepen KG company was established in the Bavarian town of Kaufbeuren with eight employees.

Three years later, Alpina goes racing. Between 1968 and 1973, the tuner enjoys a successful era in motorsport, securing the services of famed drivers such as Derek Bell, Harald Ertl, James Hunt, Jacky Ickx, Nikki Lauda, and Hans Stuck along the way. It all culminated in 1970, when Alpina clinched the European Touring Car Championship, the 24 Hours of Spa-Francorchamps, along with other local German competitions.

The Alpina Story - From Typewriters to BMWs
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The Alpina Story - From Typewriters to BMWs
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The ties with BMW get tighter in the early ’70s. The carmaker tasks Alpina to design and develop a lightweight version of the 3.0 CS and the 3.0 CSL is born. The Alpina version of the CSL developed 250 horsepower and could go from zero to 100 kph (62 mph) in 6.7 seconds on to a top speed of 243 kph (151 mph). This was possible through the use of forged pistons, three Weber carburettors, a new camshaft, and a custom exhaust system.

Alpina also powers through the 1973 oil crisis without staff layoffs and in 1975, it partners up with select BMW dealers to develop its own network in Germany, along with importers in England and Switzerland, and later on in Japan.

The Alpina Story - From Typewriters to BMWs
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The Alpina Story - From Typewriters to BMWs
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In 1978, Alpina introduces three cars – B6, B7 Turbo, and B7 Turbo Coupe – and they’re all fitted with a world-first feature: a fully-electronic, computerized ignition system. Five years later, in 1985, the German Kraftfahrtbundesamt (Ministry of Transport in English) officially recognizes Alpina as an automobile manufacturer.

The best 4-door in the world

That’s what car journalist and racing driver Paul Frere wrote about the BMW Alpina B10 BiTurbo in his review for Road & Track. Starting from the pedestrian 535i as the donor car, Alpina worked its way up the performance ladder by completely removing and tearing apart the engine only to rebuilt it after.

Forged pistons were added, as well as remachined combustion chambers, a new camshaft, and twin Garrett T25 turbochargers that offers as much as 11.4 psi of boost. Power? 360 horses at 6,000 rpm. Torque? 384 pound-feet at 4,000 rpm. Crazy? Of course. But not crazier than the fact that 90-percent of all torque was unlocked at 2,500 rpm. For this reason, the standard gearbox had to be replaced by a five-speed aggregate supplied by Getrag, together with a high-friction clutch.

The Alpina Story - From Typewriters to BMWs
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The Alpina Story - From Typewriters to BMWs
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What really set Alpina apart from other tuners was its attention to other areas of the car, not just the engine.

“In those days, the other tuners only cared about having the most powerful engine; the rest of the car was not very harmonious. With Alpina, it was always the complete package, and remains so today. We designed the cars to be used all year round as daily drivers, but to still have the performance of a weekend sports car,” Bovensiepen points out in the same interview with Classic Driver.

And what better example than the B10 BiTurbo? With the engine equation sorted out, Alpina went on to tweak the car in accordance with the newfound grunt.

The Alpina Story - From Typewriters to BMWs
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The Alpina Story - From Typewriters to BMWs
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The suspension was more firm, the spoiler and air dam were actually there for functional purposes, not just for show, and the 17-inch wheels got wider in the back (9.5 inches, compared to 8.5 inches in the front). All this coupled with the extensive mods brought to the engine made the B10 quicker in a standing half-mile than the likes of Ferrari 348, Porsche Carrera 2, and Acura NSX.

In 1990, Alpina had 120 employees and the word-firsts kept coming: in 1992, the company develops an electronic clutch management system (Shift-tronic), then in 1993 it coins the Switch-tronic, which let the driver shift gears using buttons on the back of the steering wheel, a la Formula 1. 1995 is the year Alpina introduces the Supercat, an electrically-heated metal catalytic converter as part of a joint project with BMW.

The Alpina Story - From Typewriters to BMWs
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The Alpina Story - From Typewriters to BMWs
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Cars, however, continue to be at the forefront of Alpina’s work. At the 1999 Geneva Motor Show the Alpina D10 BiTurbo makes its debut as the most powerful diesel saloon in the world. In 2002, Alpina launches the Roadster V8 based on BMW’s Z8 roadster, then the performance car charge continues with the B7 (featuring a mechanically-driven radial compressor), the B5 – considered by many the spiritual successor of the B10 BiTurbo, and the B3.

As it looks to keep up with the trends, Alpina launches the XD3, its first SUV built, of course, on the bones of the BMW X3. The XD3 would pave the way for the more recent S and the XB7 SUVs.

The Alpina Story - From Typewriters to BMWs
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The Alpina Story - From Typewriters to BMWs
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Looking back at Alpina’s work – which now stretches over more than 50 years, there’s only one word that could sum it all up: continuity. The company has always kept its path and never went astray from developing subtly-restyled cars that fill the performance gap in those areas where BMW wouldn’t or couldn’t deliver.

Today, Alpina delivers about 1,700 cars every year. Not bad, considering it all started with a young man who only wanted to make his BMW faster.

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