multi-stage vehicles

formidable challenge for body builders and OEMs

CO2 EXPERT GROUP 11/12/2017

1
 MULTISTAGE VEHICLES
 Multi-stage vehicles are vehicles that are not completely built
by an OEM but finalized by a bodybuilder.
 Typical bodyworks are motor caravans, ambulances, refrigerator trucks, mobile
cranes, tippers and quite a few more. The possibilities are nearly endless,
depending on the customer’s business model.
 Only about 0,8% of the new registered passenger cars and light commercial
vehicles are completed by an body builder!
 We count more than 10.000 body builders, mostly SMEs.

Body
OEM
builder

base vehicle / 1st stage build-up / 2nd stage

2
 MULTISTAGE VEHICLES
The WLTP introduction leads to several problems

 The final CO2-value is calculated at the final stage – by the body builder
 The final CO2-value is attributed to the OEM – but the OEM is not responsible
for the final body work
 Today, the so called Default Added Mass approach is used to determine
CO2 emissions of a multistage vehicle – a statistical, predictable approach
 Under WLTP CO2 the final CO2 value is unknown to the OEM - therefore
timely fleet-forecast is not possible – the current solution does not provide
planning certainty
 MSV share is different between OEMs, same stringency is not fulfilled.
 Enormous increased testing effort for both, body builders and OEMs
3
 FINAL STAGE CO2 IS UNKNOWN TO THE OEM

 It is mandatory that OEMs need to know the CO2 emission in advance to develop
a CO2 compliance strategy.
 Between production of the base vehicle and the registration of the MSV
might be a time span of several month up to years!
 To get the CO2 figures first time in the monitoring is too late!

Year 2020 Year 2021

OEM fleet compliance plan

preview 5 …10 years

multistage CO2-Monitoring
registration
base vehicle build-up
1st stage 2nd stage
4
 ACEA PROPOSAL
Shared responsibility between OEM and body-builder

ACEA proposes an easy solution to calculate CO2 in two steps:

(1) First stage: the base vehicle manufacturer calculates the
CO2 value of the base vehicle which is used in the monitoring.
(2) Final stage: the manufacturer of the completed vehicle calculates the CO2 value
of the completed vehicle, which is used for customer information.
 With this shared responsibility approach both, the OEM and the final stage
manufacturer are forced to deliver as good as possible CO2 values. The OEM needs
to provide low CO2 figures to ensure the Co2 compliance. The final stage
manufacturer needs to deliver competitive CO2-figures to the customer.

5
 ACEA PROPOSAL
Sister vehicle approach with shared responsibility

Year 2020 Year 2021

base vehicle build-up multistage EU CO2-Monitoring

1st stage 2nd stage registration

OEM provides CO2

1 monitoring data
Final stage manufacturer COC-Data
2 provides CO2 customer
information data (COC)
250

6
 CO2 FOR FLEET MONITORING
Sister vehicle selection

 The manufacturer of the base vehicle selects a sister vehicle with most
representative interpolation family regarding to the incomplete vehicle.
 Identical engine, drivetrain and drivetrain characteristics

CO2 for
monitoring

base vehicle sister vehicle

7
CO2 FOR CUSTOMER INFORMATION
Realistic CO2 figures are calculated at the final stage

Mass
Rolling resistance
Frontal area
Base vehicle IP-Family
Body builder sends
M, A, R
OEM tool calculates
CO2 + fuel consumption
Frontal area(A)
Base vehicle Mass
(M) COC final
with
buildup

Rolling resistance (R) 250 g/km

8
CO2 INTERPOLATION FAMILY
of the sister vehicle

Final stage vehicle

248 g/km

Final stage vehicle

223 g/km

Monitoring vehicle
238 g/km

9
 HOW TO PROCEED
planning certainty  same stringency  justifiable effort

 Easiest way would be to exclude MSV from the CO2 monitoring like
the special purpose vehicles – 50% of the MSV are already excluded (0,4% remain)
 OEMs are willing to accept the CO2 responsibility for MSV, but
 planning certainty,
 same stringency, and
 justifiable effort
are mandatory
 Changes might cause serious problems to the entire body builder
business – more than 10.000 SME are affected >> EU & MS should take care

10