EHV braved the chilly to learn how 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 car previous to its manufacturing has been one thing of a ceremony of passage for them. The typically -30 situations right here within the Swedish car testing outpost, the place camouflaged pre-production check vehicles and prototypes nearly outnumber these of the circa 2,000 native inhabitants, are excellent for this gruelling testing. Nevertheless, for this testing program – particularly for Mercedes-Benz’s new VAN.EA electrical structure – these engineers gained’t be flying again to check the identical car subsequent 12 months. 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 may underpin the substitute 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, nevertheless it’s additionally bringing components from passenger automotive division in addition to that of business automobiles.
That shift is a direct results of Mercedes-Benz’s ambition to discover the enlargement of the tremendous luxurious MPV market, someplace it’s already bought a foothold in with the V-Class. However there’s recognition that nonetheless many V-Class you see in costly postcodes all over the world, its industrial origins imply it’s unable to claim the true luxurious that consumers are more and more demanding, and Mercedes-Benz desires 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 automobiles, too. Tremendous luxurious raises the thought of the corporate’s Maybach model, and whereas no person’s admitting to that presently, nor are the denials significantly vociferous.
What’s plain 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 velocity of BEV mannequin introductions. Europe is presently the strongest market for Mercedes-Benz’s present providing with a 60% share and it desires to retain that, and develop, however the firm additionally sees substantial progress 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 constructed a purpose-built BEV platform with VAN.EA, which permits us to satisfy the necessities of a purely electrical car.” Naturally meaning the packaging of the EV battery and motors, however right here in a car that might be carrying as many as eight individuals, 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 inside 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 deal with materials combine, with focused light-weight fabrication combining with high-strength steels, with the battery pack itself including to the car’s stiffness. A van is hard too, as a result of, as Benjamin Kaehler, Chief Engineer Vans, Mercedes-Benz, explains: “It’s a field, and you then reduce 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 understand 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 car weights of three.5 tons to greater than 5 tons. And thirdly, we will provide each electrical automobiles 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 automobiles, particularly in design. We’re nonetheless satisfied that the automotive future is totally electrical, and it’s our ambition to play an lively position in shaping that.”
There’s acknowledgement – and a level of frustration – that the velocity of the transition to EVs isn’t fairly as speedy as initially anticipated, at the very least relating to buyer adoption and acceptance. That means this objective BEV platform has needed to be tailored to simply 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 velocity of this transition part, so we may even offer our prospects revolutionary and extremely enticing 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 totally electrical driving, can 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 observe.”
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 capable of 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 fully adjustments the earlier improvement for such automobiles.
Freezing the information
It’s not simply the main target onto BEVs that has switched with this structure, however the testing itself. “To realize our formidable improvement objectives, we reap the benefits of all alternatives provided by digitization,” says Kaehler. As such all check automobiles characteristic real-time information logging, which communicates with what the engineers describe because the ‘energy wall’ in a brand new VR studio. The result’s they will 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 capable of optimise the information of each check in actual time. This cross-functional cooperation between all departments in addition to the assist of mission management is essential. Right here, all information has monitored and evaluated. Points can now be eradicated as shortly as potential and in some circumstances whereas driving via over the air software program updates.”
Every car produces round 2.4 terrabytes of information per day, although there are much less prototypes constructed, and so they’re much less ‘full’. Getting within the VAN.EA check car 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 techniques, against your complete car: “You don’t must construct up a whole automotive right here, we will do that in parallel, this new testing is creating a brand new mind-set.”
The VAN.EA checks aren’t simply pioneering a brand new potential car phase then, however sooner, 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 virtually actually be adopted throughout the passenger automotive line, the brand new processes and concepts, and whereas that may solely imply one winter per car, the proliferation of fashions, and, presently at the very least, the necessity to develop combustion variations off this structure implies that the inhabitants of Arjeplog isn’t more likely 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 phase it’s aiming for, however the industrial automobiles may even profit, in driveability, agility and, because of the suspension design, load house. The engineers are remaining tight-lipped concerning the precise specs however what they do admit is the anticipated WLTP vary can be round 500km (round 310 miles).
Naturally, some industrial purposes would require much less vary, and can characteristic 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 said 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 basically 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 basically a battery provider, which might be fitted with differing capability batteries relying on the utilization case. The rear part incorporates the rear axle, which is both unpowered, or positive factors an electrical motor for 4Matic four-wheel drive fashions.
Just like the combustion automobiles the VAN.EA can be provided in camper van guises alongside the passenger and luxurious fashions, with the passenger automobiles gaining the choice of air-sprung suspension which can provide adaptive damping and the power to decrease and lift the car for relieving ingress/egress. With manufacturing variations attributable to arrive in 2026, and this car having undertaken its ultimate, and solely, winter check – in EA guise at the very least – Mercedes-Benz will proceed to drip-feed information 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 can be unveiled this Spring, with the GLC anticipated to observe it later within the 12 months. 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 most important capability battery, which the engineers admit is 85kWh in capability (a smaller 58KWh battery may even be provided). 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 financial 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 minimize the vagueness so typically related to EV braking techniques, significantly throughout that troublesome transition from regeneration to friction braking.
That know-how, in addition to the battery chemistry, two velocity motor and decoupling entrance motor (on 4Matic) variations is all additionally attributable to characteristic on the GLC. This new SUV BEV is a crucial one for Mercedes-Benz, because the GLC is the corporate’s best-selling mannequin. On proof of our temporary drive of each, and the dedication that the engineers must them, these new BEVs could have the vary, driving dynamics and charging potential to make them extremely compelling options to the prevailing and future competitors.
