COMPANY PORTRAIT
Content:
ESORO
Concept vehicles
Drive Trains
Product development
Component development
Innovative production processes
Contact :
Diego Jaggi
CEO
ESORO AG
Tämperlistrasse 10
8117 Fällanden
Tel. # 41 (0)44 782 04 40
Fax # 41 (0)44 782 04 50
Info@esoro.ch
esoro.ch
THE ESORO COMPANY
Since 1990, ESORO has been a successful development contractor and offers innovation, engineering, prototyping and seriesproduction preparation as an all-in service. ESORO operates only in the civilian sector.
ESOROs core competences focus on the sectors of fiber-reinforced plastic, concept vehicles, product development and system
integration. Thanks to the broadly diversified experience from a range of technology sectors, ESORO avails of an extensive and
well-founded know-how. This makes it possible for us to efficiently familiarize ourselves with and solve interdisciplinary problems
in an innovative way.
All activities of ESORO are certified according to ISO 9001:2008.
The ESORO AG company is independent. It is owned by management and staff.
WHAT YOU CAN EXPECT OF US
You can expect ESORO to provide you with a committed team.
Our motivation is familiarizing ourselves quickly and comprehensively with projects, analyzing the task in integral manner and
elaborating innovative proposals for solving the problem.
A professional and efficient approach, state-of-the-art development tools and reliable forecasts are our bottom line.
We can guarantee you responsibility, experience and high-quality execution.
Honest and uncomplicated communication, confidential handling of data and high personal commitment are part of our very
nature.
WHAT WE WANT
ESORO wishes to handle projects involving a high share of innovation, all the way from the initial idea through to the functional
individual product, specimen component, serial product or production process.
ESOROs core competences are lightweight construction and fiber-reinforced plastics - both components and production - and
this is where we wish to take the lead in the future as well.
In its capacity as system integrator and in prototype development, ESORO implements very complex projects in a very short time
and with high quality. We wish to cultivate these specialities in the future as well.
ESORO places great value in sustainable development. This applies to the content and to the alignment of the projects which are
generally targeted at a careful handling of resources. But sustainable development is equally as important to us in our
relationships to our customers and in building up the company itself.
TEAM
Our capital is our team - carefully chosen and growing all the time. Specialists and generalists with proven technical competence
and high motivation form our team. The team is currently made out of 18 people, 10 of them with engineering degrees. The very
low staff turnover allows us to build up our know-how and lets us fall back on over 100 man-years of development experience.
Additionally, ESORO has a selected network of experienced and time-proven partner companies with a wide variety of special
fields, allowing efficient and flexible cooperation..
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www.esoro.ch
CONCEPT VEHICLES BY ESORO
Concept vehicles by ESORO - we consider the extraordinary ordinary. ESORO designs, develops and implements high-quality
concept vehicles from the initial idea through to the "ready-to-show" vehicles. Prototypes are fully operable and homologated so
that the concept can also be experienced and driven. An innovative and experienced team is able to handle complex projects
very efficiently and in a very short time by the appointed deadline. When doing this, ESORO can fall back on state-of-the-art
development tools, an excellent prototype workshop, experience from over twenty vehicle projects and a choice network of
component suppliers. In its capacity as prime contractor, ESORO is the direct contact for customers and assumes responsibility
for the overall project.
UC?- URBAN COMMUTER – YOU SEE?, 2010
For the first time in its long history of developing groundbreaking concept cars, Rinspeed created an entire mobility concept.
ESORO developed and realized for Rinspeed the associated city car UC?. The highly likable two-seater is powered by an electric
motor. The little speedster measures just 2.50 m in length and is intended to help avoid gridlock in the inner cities. At the same
time an advanced railcar loading system will add the option to cover long distances by train, comfortable, without traffic jams and
stress-free.
The lightweight “lovebug” is operated with a central joystick and delivers 124 Nm of torque. It reaches a top speed of 110 km/h
and has an operating range of 120 km.
The engineering team of ESORO has realized the 11th concept car for Rinspeed. ESORO was the general contractor and
responsible for project management, engineering, the implementing of the novel technologies, the design and rendering, as well
as the realization of the Rinspeed UC?.
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www.esoro.ch
ICHANGE – ELECTRIC SPORTSCAR WITH FLEXIBLE REAR END, 2009
The iChange is an environment friendly sports car. The lightweight body structure has an extremely low aerodynamic drag and
offers only a seat for the driver – in the normal configuration. But at a push of a button, the flexible rear end lifts and offers seats
for two additional persons. So the aerodynamic drag is minimal for every type of use. The 130kW electric motor with high and
constant torque starting from zero and a high power LiIon battery system provide enough power for excellent acceleration and top
speed – free of emissions and noise.
SQUBA – THE THIRD DIMENSION, 2008
James Bond still needed “Q” and a box of movie tricks in 1977, today it also works in real life: the sQuba – a thoroughbred
electro-sportscar – can, if necessary, swim and dive to depths of up to 10 meters. The entire drive train works with zero
emissions. On the street, a 37 kW electric engine gives enough power. On the surface of the water, two electric propellers in the
back guide it through the waves, while two electric jet propulsion engines drive the sQuba in the third dimension. The energy for
all that comes from LiIon batteries.
EXASIS – TRANSPARENCY ON WHEELS, 2007
The transparency „dematerializes“ the new concept car eXasis made from Makrolon® - a high-tech plastic by Bayer Material
Science. This opens the view into the car, the ideas, thoughts and imagination behind and the technical solutions for this fully
functional and fascinating concept car. The eXasis is powered by a compact and powerful Bioethanol engine from
Weber/Swissauto, which provides some 150 environmentally friendly horsepower.
SPLASH – CAN FLY, 2004
The Splash – best performing amphibious vehicle in the world. The Splash speeds up to 200 km/h on the road and over 50 km/h
on water. At the push of a button, the Splash transforms automatically from a car into a sophisticated hydrofoil.
ESORO masterfully met the challenge with the help of its highly competent suppliers Naval (Marine), Swissauto (Drivetrain
adaption) and Protoscar (Design). Starting with initial concepts, it took the highly skilled development team just seven months to
realize the entire project including tests on the road, on the water and in the "third dimension" by flying at high speed over water.
March 10
www.esoro.ch
DRIVE TRAINS
ESORO's roots lie in sustainable mobility. Since the company was founded, ESORO has been working intensively in the field of
conception, implementation and tests of alternative and optimised vehicle concepts and drive systems. Electric-powered racing
vehicles, various passenger cars suitable for everyday use with electric propulsion system, a very efficient IC-engine propulsed
vehicle, the TwinTrak hybrid system and the HyCar fuel cell vehicle have been designed and developed by ESORO. ESORO is
thus one of the few companies in the world with well-founded experience in development and operation of electric, hybrid and fuel
cell drives.
And all this is certainly not just an academic exercise. We have implemented all drive trains in concept vehicles and tested them
in everyday use. Good design and perfect workmanship are also part of our commitment of our vision.
HYCAR – SWITZERLANDS FIRST FUEL CELL VEHICLE, 2002
Zero Emissions - Fuel Cell - Hydrogen
Terms which are currently hotly discussed in relation to sustainable mobility. During the course of a development project, ESORO
dealt in-depth with specific implementation of various ideas. The result was the HyCar, a fully operable concept vehicle with fuel
cell drive train and battery in a hybrid configuration. With its top speed of 120 km/h and range of approx. 360 km, the HyCar is
more than a match for traffic - and is almost absolutely silent. The HyCar is fuelled with gaseous hydrogen and the only "waste
gas" produced is water vapour. The Hycar is Switzerland's first fuel cell vehicle.
The fuel cell system located
under the load floor in the rear
of the HyCar. It is visible
through a glass window and
allows a look at this novel
drive train technology.
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The front license plate
hides a conventional
230V power socket.
Therefore the HyCar
becomes
a
mobile
energy
source
for
workmen or spare time
activities.
Using the demonstration
hydrogen
fuel
station
HyStation
developed
by
ESORO- the HyCar is
refueled as safe, as fast and
as easy as a conventional
car.
Two 76l high pressure
vessels made out of
wrapped carbon fibres
store gaseous hydrogen
at 200 bar.
www.esoro.ch
PACCAR – 5’385 KM WITH THE ENERGY OF ONLY ONE LITER OF FUEL, 2005
The possibilities of consequent optimization of energy consumption are demonstrated by PAC Car II of ETH Zurich: With energy
of one liter gasoline, the fuel cell vehicle has a range of 5385 km! By this low consumption, the team of students sets a new world
record during the Shell Eco Marathon in Ladoux (F) on June 26th, 2005.
ESORO supported the students in design and engineering of the vehicle and manufactured the light-weight body of the vehicle in
carbon reinforced material. The monocoque weighs only 10 kg.
ESORO H301 – THE FIRST “HYPERCAR”, 1994
The H301 family is the hybrid limousine version of the E301. The TWIN TRAK hybrid system of parallel configuration, developed
and patented by ESORO, serves as the drive. In urban areas, the vehicle is operated purely electrically and, as of approx.
50 km/h, the internal-combustion engine cuts in. The interior comfortably accommodates four persons - even large persons - and
the hybrid drive means that even long trips are no longer a problem. The H301 was referred to as the first Hypercar in the "Factor
4" book by Weizäcker/Lovins owing to its low consumption amounting to just a little more than 2 litres/100 km.
After about 70’000 km real-life operation, the H301 was equipped with state-of-the-art LiIon batteries in late 2007.
ESORO E301 – A DECADE AHEAD IN DESIGN, CONCEPT AND TECHNOLOGY, 1993
The E301 was designed by ESORO in early 1991 and presented at the 1993 Geneva Motor Show. With its well-balanced overall
concept, a wealth of technical innovations and a convincing design, it caused a sensation and set a new standard for efficient
lightweight electric-driven cars but also for compact vehicles in general.
Its drag coefficient of 0.195 is, even today, an absolute record value for a four-seater vehicle and its consumption of
9 kWh/100 km from the mains means that the E301 is still the record holder in its category.
Safety, efficiency and comfort were combined for the first time with lightweight construction, a modular bodyshell concept and an
open system for three different drive concepts – electric, hybrid and small IC-engine.
ESORO E2 – THE WORLD CHAMPION, 1998
The E2 is ESORO's first electric vehicle and, with its consumption from the mains of 5.5 kWh/100 km, is still the world's most
efficient two-seater car. It is able to fully cover its energy demand for 10,000 km/year with only 4.5 sq. m of stationary photovoltaic
solar cells. The E2 won the following races and competitive events: World champion (Tour de Sol) 1988 / 1989 / 1990 / 1991,
European champion 1990 / 1991, Best lightweight electric-driven car in 1989 (suitable for everyday use), Winner in the Austro
Solar 1989, Winner in the Grand Prix E 1990. With its drag coefficient of 0.165, the vehicle has the world's lowest aerodynamic
drag for a twoseater and is also the first lightweight electric-driven car with ASR/ABS.
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www.esoro.ch
PRODUCT DEVELOPMENT
From the initial idea through to the product ready for series production - ESORO supplies the entire scope of services or partial
aspects of it.
Complex problems are considered integrally and implemented in solution concepts. In this process, design, simulation and
engineering come into being as the result of constant, mutual interaction, thus leading to efficient and customer-orientated
elaboration and assessment of the concepts.
The solutions elaborated are "hardwareized" in our workshop - the possibilities extend from the simple function specimen through
to the high-quality prototype, almost ready for series production.
IDEA
Your idea can be the starting point of our work - or the result of a discussion of your needs with our team.
CONCEPTIO N
The concept largely determines the functionality, the acceptance and, thus, also the success of a product. Suitable tools,
experience and a lived innovation culture help us to work out the right decisions.
DESIGN
Design is not only styling but an integral part of the conception process.
3D MODELS
Virtual mock-up enables a efficient development, allows an early visualization and simplifies the production of the product.
SIMULATION
Where complex and dynamic systems can't be described anymore by simple assumption, multidimensional or real-time
simulation helps to understand analyze and optimize.
ENGINEERING
Engineering means to find an optimal solution in constant interaction between design, construction, calculation and production and of course your input as customer.
SYSTEM INTEGRATION
With rising complexity of today's products, the efficient integration of all functions in the product and of the product itself in its
environment is a major task in every product development.
PROTOTYPING
Some times, simulation is not enough. Therefore ESORO can offer a experienced and well-equipped workshop to produce simple
function specimens as well as high-quality and fully-functional demonstration prototypes.
TEST
Prototypes are usually as close to the end product, that all kind of testing - sometimes up to the approval - can be done. For
structural and thermal tests, ESORO operates a well equipped testing facility.
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www.esoro.ch
SUPERFOUR – CAN’T FLY, 2006
The SuperFour is the first outdoor wheelchair featuring all-wheel-drive and all-wheel-steering. Otto Bock GmbH succeeded to
redefine the autonomy and individual freedom for people with limited mobility. The SuperFour features four-wheel-drive powered
by hybrid technology which enables an enormous climbing ability and nearly unlimited range. All-wheel-steering, a navigation
system, single-wheel suspension, automatic seat-tilt and seat-position adjustment, halogen lights and weather protection help to
improve the comfort of wheel-chair users. Urs Schönauer, the designer of the SuperFour, managed to integrate all these features
in an elegant appearance. ESORO was responsible for the development and manufacturing of this fully functional concept chair
and realized the SuperFour in only 3 months. The SuperFour was presented to public during the Paralympics and the Reha Care
2004 in Düsseldorf. Due to the very positive public response, the SuperFour was developed ready for serial production by
ESORO and is now produced and market by Otto Bock GmbH.
PARAGOLFER, 2005
The Paragolfer is an all-terrain wheelchair that enables people to stand upright. This makes it possible for them to play golf and to
communicate on eye height. The strong drive-train and the good traction offers a lot more mobility for people dependent on
wheelchairs, additionally, standing-up fulfills also therapeutic functions. The Paragolfer was developed to series production
readiness by ESORO together with Otto Bock GmbH according to a concept of Anthony Netto und Christian Nachtwey for
Parabasetec.
POWER-PLATE NEXT GENERATION, 2003
ESORO developed the most recent version of the Power-Plate which is used for treatment of muscular diseases and more and
more in public gym’s for conventional fitness training. The scope of the order included a complete redesign, integration of new
functions, production of a design mock-up, production of an operable prototype and paving the way for series production.
SUPERTRANS 2000, 2000
The Supertrans 2000, as a "Concept Chair" demonstrates the future of luxurious electric wheelchairs. It was developed from
design sketches through to the operable prototype for the Otto Bock Orthopädische Industrie GmbH. Particular attention was paid
to the situation of restricted mobility. The design process thus focussed on optimum accessibility, accessible operating controls
within arm's reach and practical storage options for personal effects. The innovative “wings” - a novel design of the armrests contain components which are still not yet the norm for wheelchairs today. A bright halogen lighting system, a Windows CE
minicomputer with integrated mobile phone, Internet access and hands-free facility, storage compartments for keys, a hi-fi system
with CD changer, a GPS system, a chilled drinks holder and an IR remote control for controlling doors, lifts and TV sets. The
"rucksack" can be folded out to provide an additional seating area.
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www.esoro.ch
COMPONENT DEVELOPMENT
As a competent partner to various customers, ESORO develops components from initial conception through to pre-production
samples. In-house specialists optimize the component properties and characteristics throughout the entire development process.
The ESORO know-how is based on many years of experience in the composite sector. The use of modern software tools for
modelling component, process and material allows efficient and reliable component design. The various development stages are
outlined and the implementation process on a specimen component is presented in the following.
STRUCTURAL ANALYSIS / FEM / OPTIMIZATION
ESORO makes use of numerical simulations (ANSYS) at a very early stage in the component development process. One of our
strengths is modelling the anisotropic and non-linear material and structural behaviour simply but informatively. This means that,
even at the early phase in which design work is commenced, we are able to incorporate results from analyses and simulations in
the design process. This minimises the need for cost-intensive tests for optimum-strength and optimum-cost components. Further
FE calculations are conducted for detailed problems in parallel with the design process. In the case of crash-related components
we also conduct explicit FE calculations (LS-Dyna). ESORO specialises in analysis of composite components and is able to offer
the following calculations:
-
-
Structural analysis
Thermal analysis
Non-linearities
o Geometrical (contact)
o Material (anisotropy, visco-elasticity and creepage)
Crash
Subsequent validation of our simulation parameters by testing is one of the reasons of our strength in the simulation field.
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www.esoro.ch
DESIGN / CAD / MOLD CONSTRUCTION
ESORO uses 3-D CAD for component design. Structural and process-engineering informations are incorporated directly in the
design process. The component, together with all its parts, is elaborated right down to the very last detail. Data is used directly for
tool and mould design. Here as well, process knowledge is incorporated so that components can be produced successfully with
the first mould.
SAMPLE INSPECTION / PILOT PRODUCTION
ESORO has the capability of producing small lots and initial component samples in its own technical training facility. This involves
defining component-specific process windows for the various parameters and producing testable pre-production batch parts. The
systems and operating resources correspond to series-production equipment. This allows a successful transition to series
production with slight adaptations on the basis of these inspection samples.
TESTING
ESORO avails of various test facilities in-house. The starting point for the development of a component is the selection of the
material. Elementary material data can be determined in our test laboratory using tensile testing and bending machines. In
addition, ESORO also avails of capabilities for determining composite-specific material data, such as creep curves and relaxation
curves. These form the basis for material modelling. ESORO takes advantage of the know-how for testing components and both
developing and providing instrumentation for component-specific test set-ups. Crash-sled tests are run with our test partners.
SERIAL PART: TAILGATE OF SMART FORTWO
The smart fortwo tailgate is the first serial E-LFT application (structural part) and first crash resistant LFT component (cover) with
completely visible colored grained surface. Compared to the previous model, the tailgate of the new smart fortwo complies with
much higher rigidity and crashworthiness requirements. The tailgate consists of a structural part with a storage compartment and
a hinged inner cover with a completely visible grained surface. Both components comply with crash requirements. The structural
concept was designed and validated by means of numerical simulations and a series of tests. Main emphasis was laid on the
behavior of the inner cover in a frontal crash and the increase of the stiffness of the structural part. The inner cover has to retain
the two top roof edges (5.2 kg weight) in case of a frontal crash (at 64km/h with the very high time-lag peak typical of compact
cars) in order to ensure occupant safety. To have a minimal investment the same structural concept which can be used for the
cabrio and coupé version was elaborated. As consequence of the consequent engineering process, the tailgate fulfils the higher
load and stiffness requirements, while a cost reduction of over 10% has been achieved. Since 2007, WeberFibertech has
produced and delivered the components for 300'000 tailgates.
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www.esoro.ch
NEW PRODUCTION PROCESSES
ESORO develops innovative production processes on behalf of its customers. One example of this is the development of the
new E-LFT process which was presented to the public for the first time in late 2002. This new process is based on the need of
low-cost, environment-friendly, lightweight components with a high structural loading strength. It was developed, patented and
made ready for series production on behalf of the Albert Weber GmbH company.
E-LFT PROCESS
E-LFT stands for Endlessfiber reinforced Long Fiber Thermoplastic. This one-shot production process is a combination of the well
established LFT compression moulding with the direct implementation of unidirectional continuous fibers. The main idea of the ELFT process is to reinforce a component exactly in its high-stressed areas and to create structural lightweight components on a
cost efficient basis. E-LFT can be used for many challenging applications, since it is the only process to build real framework
structures with the intermediate EF layers to substitute metals.
BASE MATERIALS
EF and LFT consist mainly of the same materials: glass fibres in a polypropylene matrix. However, it is also possible to process
other fibers (e.g. carbon or aramide) and matrices (e.g. PET, PBT, PA and ABS). LFT moulding compound has relatively modest
mechanical values but it features excellent design freedom and allows an efficient production of large components. Unidirectional
continuous filament strips (EF) have excellent mechanical properties and can be inserted threedimensionally according to the
load paths and the component geometry. Thus LFT components can be reinforced specifically to solve local stress problems.
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www.esoro.ch
PROCESSING
The system engineering of the E-LFT process is designed for a fully automatic production. The main components are EF
processing, LFT processing, handling (robot) and press. The LFT extrudate can be provided either directly (LFT-D) or with
conventional rod granulate processing (LFT-G). The EF processing and the handling system for this process are completely new
developments. In the E-LFT process a frame press with parallel mechanism is used as it is the case with LFT processing. LFT
and EF are processed parallel and placed together into the mould by a handling-system. Old parts and scrap can be recycled in
the LFT-extruder.
DESIGN FREEDOM
One of the big advantages of the E-LFT process is its design-freedom. EF tapes can be placed in almost any shape according to
the load paths and the component geometry. They can be placed plane or as rip-geometries. The integration of different 3Dshaped EF's allows an optimal reinforcement of critical sections with a minimum of additional weight. Due to this, the E-LFT
process has an immense potential for the light-weight industry.
APPLICATION FIELD
The E-LFT process is designed for high volume production of large components with high structural loads and a high integration
potential and where light-weight and cost efficiency are important requests. Therefore automotive components are the main
application sector. E-LFT components can be applied where conventional GMT or LFT components come to their limits. E-LFT
parts offer up to 50% weight savings compared to steel. E-LFT products will furthermore replace components, which are up to
date the sole domain of metallic solutions due to their excellent structural behaviour.
As first serial application, the structural part and the inner cover of the tailgate of the new smart fortwo have been produced in the
E-LFT production process. Since 2007, over 300’000 sets have been delivered by WeberFibertech.
CONTACT
Diego Jaggi, CEO
Tel: #41 (0)44 782 04 40
Fax: #41 (0)44 782 04 50
diego.jaggi@esoro.ch
March 10
ESORO AG
Taemperlistrasse 10
CH-8117 Faellanden
www.esoro.ch