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2024-10-03

A Tribute to the Internal Combustion Engine!

How Its Achievements Drive the Electrification of Vehicles.
The internal combustion engine has revolutionized mobility for decades, laying the foundation for many technologies that are now indispensable in the electrification of vehicles. Although the future of the automotive industry lies in electrification, we should not forget the technological achievements made during the era of the internal combustion engine. These achievements are key to accelerating the transition to electric vehicles (EVs) more efficiently. Let’s take a closer look at the various areas where innovations from the internal combustion engine are paving the way for electromobility.

1. Advances in Material Science: 
One of the major challenges for both internal combustion engines and electric vehicles has been and continues to be the optimization of material use. Lightweight construction, originally developed to improve the efficiency of internal combustion engines, also plays a central role in the development of electric vehicles. High-strength steels, aluminum alloys, and increasingly carbon fiber composites, initially optimized for fuel consumption, are now crucial in offsetting the heavy weight of batteries in electric cars. Lighter vehicles require less energy to drive, which directly affects the range and efficiency of EVs.

2. Manufacturing Technologies: Precision and Scalability
The highly developed manufacturing processes perfected in the automotive industry over decades are now a significant advantage in the production of electric vehicles—particularly in the vehicle manufacturing steps. While facilities specifically for internal combustion engines cannot be directly used for electric motors or battery systems, electric vehicles benefit from existing automated vehicle assembly lines. These can be adapted to the specific requirements of EV production. Manufacturing technologies such as robotic assembly and advanced bonding and joining processes enable high precision and scalability, further improving the quality and reliability of electric vehicles.

3. Active and Passive Safety Systems: Legacy of the Safety Revolution
The automotive industry has made significant advances in vehicle safety, driven by the internal combustion engine. Active safety systems like Anti-lock Braking Systems (ABS), Electronic Stability Programs (ESP), and driver assistance systems, originally developed for internal combustion engines, are now standard in electric vehicles as well. Moreover, technologies such as cameras, radar, and LIDAR are facilitating the development of advanced autonomous driving systems. These safety systems, both active and passive, make the integration of EVs into existing traffic structures safer and faster.

4. Electronics and Sensors: From the ECU Revolution to Sensor Variety
One of the most significant technological developments that began during the internal combustion engine era is the introduction of electronic control units (ECUs). These played a central role in the automation and monitoring of vehicle functions. From engine control to comfort and safety functions, ECUs have become indispensable for vehicle management.

ECUs and CAN Bus Standards
As vehicles became more complex, the number of control units increased. To network these and ensure smooth communication, CAN bus standards (Controller Area Network) were developed. This network protocol enables fast and reliable communication between various control units without the need for a central computer. These standardized communication pathways are now also essential in electric vehicles for synchronizing and efficiently managing the numerous electronic systems.

Sensors for Measuring Physical Quantities
In addition to ECUs, sensors have played a key role in vehicle development. Originally designed to monitor the state of internal combustion engines (e.g., mass air flow sensors, oxygen sensors, coolant temperature sensors), the number and variety of sensors in modern vehicles have greatly expanded. Today, sensors measure not only engine parameters but also physical quantities such as:
• Temperature (coolant, battery, tires)
• Pressure (tire pressure, brake pressure, oil pressure)
• Acceleration (G-sensors for ESP systems)
• Environmental conditions (rain and light sensors, radar, and LIDAR for driver assistance systems)
• Electric current and voltage (on-board voltage, alternator)
These sensors form the basis for many modern technologies such as autonomous driving, intelligent energy management, and improved safety features. They are essential for efficiently managing the highly complex systems of an electric vehicle.

5. Software: Achievements and New Challenges
Achievements from the Internal Combustion Era
In the internal combustion era, software played an increasingly important role, especially with the introduction of electronic control units (ECUs) and the development of functional safety standards like the E-Gas standard. This standard was created to ensure that electronic controls in vehicles—such as those for engine management or brake control—operate reliably and safely. These achievements in software development laid the foundation for the use of electronic systems in modern vehicles and are indispensable in electric vehicles as well.
New Challenges: “Software Defined Vehicle” and Over-the-Air Updates
However, with the electrification of vehicles and the digitalization of the entire vehicle, new challenges—both for electric vehicles and internal combustion engines—have emerged. The increased use of software has led to the development of the “Software Defined Vehicle” (SDV) concept, where vehicles are largely defined by software and can be continuously updated via over-the-air (OTA) updates. While vehicle software used to be updated only during maintenance visits or in exceptional cases, today’s vehicles—both electric and combustion-powered—require regular software updates to implement new features, optimizations, and safety improvements.
This not only requires continuous software maintenance but also presents new challenges for development processes. Whereas software in the internal combustion era was often released once and then operated stably, it now needs to be developed more agilely. Manufacturers must ensure that the software remains safe and reliable throughout the vehicle’s lifetime. This continuous update process brings additional challenges regarding functional safety, data protection, and the compatibility of software with hardware.

6. Artificial Intelligence (AI): Evolution from the Internal Combustion Era to Electromobility
Artificial intelligence (AI) is another groundbreaking technology that has been relevant in both the internal combustion era and electromobility. AI was already used in vehicles with internal combustion engines, for example, in automatic transmissions, to recognize driving behavior and adjust shifting patterns accordingly. These algorithms analyzed the driver’s behavior and dynamically adapted the shifting strategy to maximize both comfort and efficiency.
Today, AI is even more intensively used in electric vehicles. It plays a central role in the development of autonomous driving functions, optimizing energy management systems, and analyzing large datasets to continuously improve the driving experience. Electric vehicles use AI to optimize battery management, reduce energy consumption, and analyze driving patterns to maximize range. AI is also increasingly used in driver assistance systems and autonomous driving to improve safety and comfort.

7. Thermal Management: Know-How from the Internal Combustion Era for EVs
One of the greatest technical challenges for electric vehicles is thermal management, especially for batteries. Here, the know-how gained from internal combustion engines can be directly applied. Internal combustion engines generate a lot of heat, leading to the development of sophisticated cooling systems to safely dissipate it. These technologies and concepts are now applied to electric vehicles to keep the batteries within an optimal temperature range. Efficient thermal management is crucial to maximize battery lifespan and ensure their safety. Moreover, effective thermal management has a direct impact on the range of electric vehicles.

8. Digitalized Development and Simulation Tools: Key to Efficiency
One of the most significant technological achievements from the internal combustion engine era is the development of digitalized development and simulation tools. These were originally used to virtually test and optimize internal combustion engines and vehicle components. These tools are now being reused and further developed for electromobility. They enable the rapid simulation and optimization of electric drives, battery management systems, and EV aerodynamics. Such tools not only save development time but also reduce costs, enabling manufacturers to bring innovative vehicles to market more quickly.

9. Circular Economy
A particularly forward-looking aspect is the circular economy. Materials and components from old internal combustion vehicles can be recycled and reused in the production of electric vehicles. The circular economy reduces dependency on raw materials and lowers the ecological footprint of vehicle production. One key goal is to efficiently recycle batteries, so valuable raw materials can be reused, contributing to the long-term sustainability of electromobility.

Conclusion: The Internal Combustion Engine as a Pioneer of Electromobility
The internal combustion engine has shaped the automotive industry and brought about many technological advancements that now facilitate the transition to electromobility. Progress in material science, manufacturing technology, safety systems, and software has significantly contributed to accelerating electrification. Particularly notable are the expertise in thermal management, which can be directly applied to electric vehicles, and the digital simulation tools that revolutionize the development of modern vehicles.

The future undoubtedly belongs to electric vehicles, but the internal combustion engine remains a crucial part of history, laying the foundation for this development.

A tribute to the internal combustion engine—not only for what it was, but also for what it leaves behind for the future of mobility!