IPG pioneers simulation-based homologation
In collaboration with Haldex, one of the world’s leading manufacturers of brake systems for commercial vehicles, IPG Automotive GmbH achieved the first successful simulation-based homologation.
In collaboration with Haldex, one of the world’s leading manufacturers of brake systems for commercial vehicles, IPG Automotive achieved the first successful simulation-based homologation. The simulation project tested electronic stability functions for truck trailers according to ECE 13/11. For the first time, the KBA (German Federal Motor Transport Authority) issued a confirmation based on these test results obtained by extensive use of simulation.
The new option of using simulation not only leads to enormous time savings for the entire homologation process. It also offers highly attractive cost benefits to automotive OEMs and suppliers. The successful homologation yet again underscores IPG’s pioneering role in the field of simulation solutions. IPG has already been using its know-how with respect to passenger vehicles to which an ECE regulation applies as well.
Electronic stability control systems (ESC) will be mandatory in the EU from 2011 onwards to increase the safety of commercial vehicles. Up to now, the large number of variants has been challenging manufacturers to run extremely complex tests. To limit this complexity, the ECE regulation now permits the use of simulation systems and methods to complement physical testing. The use of IPG’s TruckMaker simulation software in collaboration with Haldex marks the first successful project of this kind.
Simulation as a milestone in the approval process
The test and validation process was defined in close collaboration between Haldex, the Technical Service TÜV Nord and IPG. The project was carried out with hardware-in-the-loop (HIL) simulation – a test method which integrates real-world active control systems into simulation.
From the total of 33 vehicle variants eight master variants were aggregated. After running tests with the three master variants the results were compared. Type tester Winfried Gaupp from TÜV Nord summed up the findings: “The simulation results were validated using two different methods. We found that the data from both simulation techniques highly matched reality. Therefore, we have come to the conclusion that TruckMaker delivers reliable results and is superbly suited to test the effectiveness of stability control systems.”
The ESC performance of all other product variants was then fully run using the TruckMaker/HIL simulation solution, which encompassed more than 1.000 single test cases. Use of the simulation software significantly shortened the conventional, highly time- and cost-intensive process. Based on the technical report presented by TÜV Nord, the KBA issued its certification.
Haldex: expectations were surpassed – higher speed and efficiency, lower costs
Haldex decided early on to use a simulation solution since the conventional approach involved considerable costs, time and complexity. The company’s clearly stated goal was to find a faster, more efficient, and more-cost effective method.
While searching for a partner, Haldex soon opted for IPG. Jim Crawley, who is responsible for homologation at Haldex, said, “IPG’s long-standing experience in vehicle dynamics and in-depth simulation know-how convinced us. The company not only excels at handling the requisite hard- and software but also possesses a wealth of testing expertise. In addition, IPG precisely understood our specific requirements.”
This homologation of ESC products enables Haldex to further strengthen its worldwide position in the field of innovative brake systems. Project manager Dudley Harrison is highly pleased with the project and the results obtained. “Our expectations were surpassed. We are benefitting from significant time and cost savings. The processes are much more transparent and flexible. In addition, we will be able to simulate and approve future software releases and variants in this area,” he said. “Haldex has already decided to increasingly rely on simulation software in the future and to continue the successful collaboration with IPG.”
IPG is pleased with the homologation project as well. Bernhard Schick, head of business development & innovation, who brings personal homologation experience to the company as a former TÜV employee, sees the potential for a wide range of attractive uses: “Homologation is a demanding field for simulation applications. Based on our extensive know-how we have been able to extend IPG’s TruckMaker and CarMaker simulation tools by key functionalities for this area. The knowledge we have gained in the process is already making its way into new projects, particularly in the passenger car area, for ESC but also for Advanced Emergency Brake, Adaptive Cruise Control and Lane Departure Warning.”
