Honda Insight Concept at Melbourne Motor Show

Visitors to the 2009 Melbourne Motor Show will get a sneak peak into the future with the unveiling of the world’s most affordable hybrid, the Honda Insight concept, which is making its Southern Hemisphere debut.

First seen at the Paris Motor Show (Mondial de l'Automobile) in 2008, the production version of the all-new Insight was recently introduced in North America and Japan.

Honda plans to introduce the production version of the Insight to the Australian market in the near future.

The five-door, five-passenger hatchback features a lightweight, compact hybrid system that combines exceptional fuel economy with fun-to-drive performance.

Designed to set the standard for compact cars for a new era, the Insight concept combines outstanding environmental performance with fun, responsive driving and efficient, versatile packaging. The all-new Honda Insight was developed with the goal to provide these attributes in a car that is affordable for more customers across the globe.

Offering exceptional fuel economy, the Insight features a newly developed hybrid system including a 1.3-litre i-VTEC engine and Honda’s proprietary Integrated Motor Assist (IMA). The aerodynamic body achieves a world-leading coefficient of drag of 0.28*. To further support fuel-efficient driving, the Insight features the Ecological Drive Assist System (Eco Assist) as standard equipment on all variants.

The name Insight was chosen to denote that this new vehicle provides ‘insight’ into a new era in which hybrid vehicles come within reach of most car buyers.

KEY FEATURES

• 5-door family hatchback with Honda’s petrol-electric IMA system
• Combines practicality and flexibility in an affordable package
• Low emissions and excellent fuel economy based on real world driving conditions
• Unique Eco Assist driver coaching system that can help any driver maximise fuel economy
• Sleek, sporty and aerodynamic design influenced by FCX Clarity
• Practical and spacious interior to accommodate five passengers
• Flexible and class-leading load space of 408-litres
• Generous value for money specification
• Honda’s enviable build quality and low running costs
• Excellent crash protection for occupants and pedestrians

MAKING IT AFFORDABLE

The Insight is the culmination of over 20 years of hybrid development and more than 35 years of lower impact petrol engine development, which started with the CVCC engine in the Honda Civic in 1972.

The Honda Civic was the first car in the world to be awarded the US Clean Air Act 1970.

That experience and technical knowledge has enabled Honda to develop the components and parts in the IMA system so they can be produced at a lower cost.

Honda has also been building production hybrids for a decade. In that time, a lot has been learnt about the production of electric motors and other key parts of the hybrid system. This understanding has led to improved production equipment and techniques, which will reduce production costs. And because the major hybrid components are produced in-house, this also helps to control overall costs.

“Our engineers have shown great tenacity and skill in reducing the cost of our IMA system to allow us to reduce the build costs of the Insight. By using so many components that are manufactured in-house, we have the ability in the market to continuously refine our processes in a way an outside supplier might not.” Yasunari Seki, Honda Insight Large Project Leader.

The plan to produce and sell a much larger number of hybrid cars than before leads to economies of scale, and thus a lower final cost per unit. To achieve these numbers, a new electric motor production line has been added to the Suzuka factory, in Japan, which will double its per hour production capacity for IMA motors.
There are also specific product developments that helped keep the costs down:

1. 95 per cent of the IMA unit was redesigned to reduce both size and cost
2. It was a bespoke model, so any additional costs required to ‘shoe-horn’ technology into an existing model (eg. Civic Hybrid) were eliminated
3. The platform and chassis share many components with that of the new Jazz

All the cost-saving doesn’t mean cutting corners or compromising on performance or durability. Engineers have focussed on finding engineering solutions to drive costs down, developing the most efficient hybrid technology at the lowest possible cost to the customer.

THE MOTIVATION FOR BUILDING AN AFFORDABLE HYBRID

A key part of Honda’s global philosophy is to be “a company that society wants to exist”. And while that may at first sound like another piece of marketing strategy speak, it is a mantra that is followed the world over, starting with the R&D centres.

This philosophy helps explain why the marketing of a more affordable hybrid car; is part of Honda’s efforts to have a positive impact on society.

Honda could have chosen to place this cleaner technology in high-end cars; showpiece environmental machines to sell at a premium rate to a low number of customers. There’s probably an argument that says there’s more money per unit in that approach.

However, in line with Honda’s philosophies, beliefs and heritage, the approach was to bring low emission hybrid technology to the masses by using our engineering experience to reduce the costs and therefore the retail price.
As well as introducing new sections of society to cleaner cars, this should also help increase the sales volume of hybrid cars – which will have a positive effect on overall emissions figures, and therefore the environment.

EXTERIOR DESIGN

The exterior evokes the design of Honda’s flagship for environmental performance, the zero emissions FCX Clarity fuel cell vehicle. The line traversing the middle of the body in a single motion emphasises the low vehicle height, contributing to a sporty design. The high tail adds to both the aerodynamic performance and the stylish look of the Insight.

INTERIOR DESIGN

The interior is advanced and futuristic-looking and features a two-tiered instrument panel divided vertically, allowing the driver to access important information at a glance. The interior features elegantly contrasting colors, textures and materials to further emphasise the futuristic hybrid feel.

HYBRID POWERTRAIN

The Integrated Motor Assist (IMA) proprietary hybrid system offers exceptional fuel economy and extremely low emissions. The petrol engine serves as the main power source while the electric motor provides additional power as needed.

Offering exceptional fuel efficiency and ample torque, the 1.3-litre i-VTEC engine now features Variable Cylinder Management (VCM) for the first time, which controls the idling of all cylinders. The combination of engine and motor offers the consistent responsiveness and acceleration performance one might expect from a 1.5-litre engine.

The ultra-thin DC brushless motor is approximately 22% thinner and approximately 15% lighter than previous-generation technology**.

Adjusting to driving conditions and battery charge level, the Power Control Unit (PCU) optimally controls the power assist and electrical regeneration functions of the electric motor.

As compared to previous-generation technology, the modules of the high-output nickel metal hydride (Ni-MH) battery feature a 30% enhancement in both output and durability, allowing for a decrease from 11 modules to 7**. As a result, while providing ample output and capacity for the motor, the battery is approximately 31% more compact and approximately 35% lighter than previous-generation technology**.

Composed of the PCU and battery, the Intelligent Power Unit (IPU) is approximately 19% more compact and approximately 28% lighter than previous-generation technology** allowing for placement of the IPU beneath the rear cargo area and more-efficient packaging overall.

The compact, efficient, Honda Multimatic S continuously variable transmission (CVT) helps the Honda hybrid system produce even more torque and achieve even higher fuel efficiency. In off-the-line acceleration, the CVT engages at lower rpms, enhancing acceleration performance and fuel-efficiency at the same time.

In braking, accelerating and cruising, the Insight optimises the combination of engine valve operation and motor assist for precise energy management. As a result, the Insight offers both high fuel economy and fun driving in a wide variety of driving conditions. To further enhance fuel efficiency, the Insight features idle stop capability

ADVANCED ENVIRONMENTAL TECHNOLOGIES

To help Insight owners realise the full benefits of Honda hybrid technology, the new Ecological Drive Assist System (Eco Assist) is included as standard equipment on all models. Eco Assist combines multiple functions:

• ECON MODE: With the touch of a button, this function adjusts engine output, extends the duration of idle stop, increases regenerative recharging during deceleration and achieves energy-saving control of the air-conditioning unit. As a result, more fuel-efficient driving can be achieved.
• GUIDANCE FUNCTION: This function assesses acceleration and braking practices in real time, changing the speedometer background color to indicate the level of fuel-efficiency of the driving style. Drivers can achieve more fuel-efficient driving simply by referring to this intuitive color display.
• SCORING FUNCTION: Located in the center of the instrument panel, the Multi-Information Display provides a scoring function, in which the number of ‘leaves’ displayed indicates the level of fuel-efficient driving performance. When the ignition is turned off, both a score for the latest driving cycle (startup to shutdown) and a score for cumulative lifetime performance are displayed. Since leaves appear and ‘grow’ as driving practices become more fuel efficient, the scoring function encourages drivers to take interest in fuel efficiency and develop more fuel-efficient driving habits over the long term.

With the available Honda HDD InterNavi System, a driver can access a full history of personal scoring function results and additional detailed scoring statistics. InterNavi customers may also access via the Internet a detailed fuel-efficiency assessment of their driving practices, a history of their fuel-efficiency scores, their ranking among subscribers throughout Japan and other information relevant to fuel-efficient driving.

BODY

The lightweight, aerodynamic body is compact with a low overall height. Thanks to the aerodynamic design and meticulous wind tunnel testing of all exterior parts as well as specially designed aerodynamic underbody parts, the Insight boasts a world-leading coefficient of drag* 0.28, and outstanding overall aerodynamic performance.

Unique to the Insight and designed to accommodate the IPU beneath the rear cargo area, the body features high rigidity in the rear frame and floor, contributing to safety and vehicle stability during cruising. With a 52% high-tensile steel content***, the frame is highly lightweight and rigid.

SAFETY PERFORMANCE

The production version of the Insight features Honda’s Advanced Compatibility Engineering (ACE) body structure as well as front, side and curtain airbags to help reduce the risk of head injury in a side impact. Vehicle Stability Assist (VSA), which assists the driver in maintaining control during cornering, is also standard equipment.

HONDA HYBRID HISTORY

Honda first marketed the original Insight Hybrid in 1999 and has been working on the technology for almost two decades.

The motivation behind pursuing this technology is fundamental and basic, avoiding waste. In simple terms, the energy from braking on a car with a conventional drivetrain is lost by being converted into energy that disappears into the atmosphere as heat and noise. The task Honda’s R&D engineers set themselves was to harness this energy to the benefit of the customer and the environment.

One decade on, Honda is launching a new Insight that takes those core principles and extends them, allowing a customer to carry their family and luggage in an efficient, flexible and affordable vehicle.

THE DIRECTION OF THE HONDA INSIGHT

The aim was to make petrol-electric technology available to more people by developing a family hybrid car that was more affordable.

The Insight is a 5-door hatchback with Honda’s IMA hybrid system that offers low-emission, fuel efficient motoring in a practical, no-compromise offering –to make an attractive, lower cost package.

Honda expects this car to have a significant impact on the industry. Because the Insight will be more affordable to more people, it makes cleaner car technology accessible to a completely new group of car buyers – opening the hybrid market to a new section of society.

That’s why the main aim in the development to reduce the size, complexity and price of components and systems to drive that final retail price down. Honda wants to bring hybrid technology to a wider market, but knows that the price, or the perceived price, of cleaner cars has prevented some car buyers from even looking at them seriously. Honda wants those people who’ve never considered buying a hybrid car to try one for size.
It is one thing to develop an ultra-green product, that only the affluent can afford, but in its quest to be a company that society wants to exist, Honda challenged its engineers to build a hybrid for everyone.

* Five-passenger production automobiles (Honda calculations)
** As compared to the 2006 Civic Hybrid
*** By-weight comparison

HONDA’S GLOBAL GREEN HERITAGE

1972	The CVCC engine is developed – the world’s first low-emission petrol engine that meets strict US clean air act regulations without a catalyst
1986	The CR-X coupe becomes the first mass-produced 4-cylinder to break the 5.6l/100km (50mpg) barrier
1993	Honda wins prestigious World Solar Challenge with the solar-powered Type Dream car. A new and improved Type Dream was built for the 2006 Challenge and won again
1997	Honda started sales of EV Plus electric vehicle – capable of carrying four adults nearly 140miles on a single charge – in the US and Japan and sold more than 200 units by the year 2000
1997	Honda unveils the Civic GX, which runs on natural gas and is available in America. It becomes the world’s cleanest internal combustion engine car of that era
1999	Honda launches the Insight – a petrol-electric hybrid car capable of 3.4 l/100km (83mpg) on the combined cycle, with emissions of just 80g/km of CO2
1999	Honda shows the first version of the FCX with its revolutionary, zero emission, fuel-cell power source
2003	Civic IMA hybrid sedan is launched, with CO2 emissions of 116g/km
2006	New Civic Hybrid goes on sale, with fuel economy of 4.6 l/100km (61.4mpg) (combined) and emissions of 109g/km
2006	American Honda started production and sales of Civic and Fit FFV, capable of running on 100% biologically derived bio-ethanol fuel
2007	A lightweight hybrid sports car concept, named CR-Z, is revealed at the Tokyo Motor Show and a version is confirmed for production
2008	The hydrogen fuel cell-powered Honda FCX Clarity rolls off the production line in Japan and leasing of these zero emission vehicles starts in the US
2009	Reviving the Honda Insight name, a more affordable hybrid car will go on sale in North America, Japan and Europe throughout 2009 – making cleaner motoring technology available to more people

OTHER GREEN INITIATIVES

• In 1956, founder Soichiro Honda said: “After materials are carried into the factory, nothing but products should be carried out.” The aim is zero waste to landfill at all manufacturing plants worldwide by 2010. Nearly all Honda factories, including all in Japan and the UK, have achieved this target already.
• Since 1976 Honda has planted roughly half a million trees around its factories, absorbing over 4,000 tonnes of CO₂ and making over 3,000 tonnes of oxygen.
• In 1989 Honda started introducing water-based paint, which seems like a small detail, but when you use as much as they do, the details count. Fortunately it caught on.
• The lessons learned from Honda’s record-breaking Solar Car were put to good use and Honda started developing really efficient, thin-film solar panels for houses and factories.
• Fourteen factories, including Suzuka where the Jazz and Insight are built, have been equipped with the next-generation thin-film solar panels, producing electricity with zero CO₂ emissions.
• Honda don’t just make clean engines, they make clean engines cleanly. What’s more, they’ve been doing it for a long time. For instance:
  • A cogeneration system installed at Kumamoto Factory in July 2006 completed the installation of cogeneration at all Honda’s factories in Japan. The cogeneration unit provides efficient electric generation, while the cogeneration unit’s exhaust gas produces steam and hot water, used in the Kumamoto's motorcycle painting operations. The result is a reduction of approximately 1,039 tons of CO₂ emissions in 2007 alone.
  • In Guangzhou, the Zengcheng Factory, which began production in September 2006, features an industry first: 100% recycling of water. Achieving zero-emissions of wastewater, the facility has saved an estimated 170,000 tons of water so far.
• Honda developed the Home Energy Station as a potential solution to the hydrogen infrastructure problem. The current version runs on natural gas and a solar energy version is being tested. The units not only refuel the FCX Clarity, but heat and power the home and return any surplus energy back to the electricity grid.
• The hydrogen-powered FCX Clarity, is the world’s first zero-emission fuel cell production car. It’s currently available for lease in the US and Japan and emits only water from its exhaust.
• Honda initiated a beach clean-up project in the USA to help reduce pollution of some seashores. A specially developed and lightweight beach cleaner is towed by an ATV, allowing for clean beaches.
• Considering the potential of a global food shortage in the future, Honda chose rice as a research subject over six years ago. Since then they have been at the forefront of identifying genes that significantly increase the yield of rice plants. A gene named Gn1a helps to increase the number of grains, while another gene, sd1, can now be isolated to reduce the height of the plants, making them less likely to topple over and spoil. Koshihikari rice bred with both these genes demonstrates a 23 per cent increase in crop yields. Meanwhile, they’ve also discovered a gene that dramatically improves the regeneration ability of rice, making it much easier to breed new varieties that surpass the potential of Koshihikari.
• To confront the rapid deforestation in China, Honda is supporting the Desert Planting Volunteer Association in its Joyful Forest Initiative, which aims to cultivate forest in the desert.
• Since 2003, Honda has been helping Brazilian people conduct their own environmental education initiatives. The projects include river clean-ups and art and craft workshops to re-use PET bottles and newspapers.