Case studies
Whether you develop complete vehicles or vehicle subsystems, simulation helps you to reduce time and costs. Below you will find some examples of the successful use of our solutions in industry, research and teaching.
"The new rollover simulator for trailers, recently launched by Haldex, leads the way far into the future. (...)"
The new Passat CC is full of advanced technologies with its innovative driver assistance systems like the "Park Assist" (PLA), the active cruise control (ACC) with environment observance system "Front Assist" and the "Lane Assist" (HCA). The integration of the networked driver assistance functions in the full vehicle was systematically supported by the consistent use of the HIL simulation and a maneuver and event based test methodology.
Driver assistance systems provide an enormous potential for the improvement of active safety. However, the multitude of possible scenarios makes high demands on the system development. This article will present solutions to identify the most important scenarios and to reconstruct them with the simulation environment of CarMaker. This enables the user to systematically analyze and optimize security and performance of advanced driver assistance systems.
Hardware-in-the-loop simulation makes it possible to make a full test of control units in a virtual driving test. At Volkswagen, HIL tests are currently being carried out for the application of a new ESP system for the Golf V platform. A CarMaker/HIL test bench from IPG Automotive is being used as the simulation environment.
Due to the increasing complexity of control systems and the variety of different vehicle variants, virtual development methods become more and more important. For years, GME Engineering has been aiming to increase the application of simulation methods to systematically support the driving test on the road concerning the integration of chassis control systems. IPG Automotive's vehicle dynamics software CarMaker supports this objective through high-precision simulation models for Software-in-the-Loop and Hardware-in-the-Loop simulation.
Last year, the vehicle dynamics software CarMaker was ported onto the dSPACE hardware platform. We spoke to Dr. Henning Holzmann, Head of Driving Performance Simulation at GME in Rüsselsheim and his team members, Dr. Michael Kochem and Karl Michael Hahn, about their first experiences with the CarMaker/DS test bench, and about the importance of virtual vehicle development at GME.
The electronic wedge brake (EWB) is a brake-by-wire system with a dry actuator at each wheel. An electrical brake system poses special challenges to safety engineering as the system has to be operational in case of a single fault and must not lead to a dangerous situation in this case. Special focus has to be put on the two dangerous cases of undesired braking and on insufficient brake force at one or more wheels.
The new Citroën C4 Picasso features an electric parking brake enabling automation of this function and the addition of new functions. The system is controlled by two ECUs. The process of validating the system as a whole was optimised using a HIL test bench for two networked ECUs. This test stand has been developed by IPG, the specialist in this area. More...
High speed in a bend, suddenly appearing obstacles, different road surfaces - there are many reasons why a driver loses control of his vehicle and goes off the track. The Institute of Industrial Information Technology in Karlsruhe researches nonlinear control procedures using CarMaker in order to avoid the crashing of a vehicle in critical lateral dynamic situations.
Smart vehicles require smart testing methods. A smart vehicle, in this context, is one which is equipped with intelligent systems designed to improve safety, comfort and handling.
HIL test stands for the virtual testing of both subsystems and complete vehicles have become standard tools in automotive development. BMW AG uses this test procedure to optimise active steering applications for series production.
The goal is obvious and with CarMaker and IPG-KINEMATICS the Formula CarMaker teams have the right ammunition to achieve an ideal construction of their racecar. But what is the best way to start? Christian Fritz from the HighSpeed-Karlsruhe team worked out a guideline during his diploma thesis at IPG to help the students to develop step by step the chassis of their Formula Student racecar and to optimise the vehicle for use on the racetrack.
The Ka-RaceIng team passed their first Formula Student event at the Hockenheimring with flying colors. The students from the University of Karlsruhe reached 10th position for the overall results and were nominated as the best newcomer team. One of the guarantees for the success was their very professional approach towards chassis development.
Virtual test driving in the auditorium - nothing extraordinary if you are a student at Stralsund's College. Since Autumn 2005, the vehicle dynamics software CarMaker has been used at this University to offer a practical education to the mechanical engineering students with automotive engineering as the major subject. The prospective engineers learn interactively the fundamentals of driving dynamics by simulating and analysing driving maneuvers with CarMaker both in lectures and practical courses. This successful teaching concept will be continued during the winter semester 2007/2008. The master study course "automotive engineering" will offer a module "simulation and test driving", in which vehicle dynamics simulations using CarMaker will be closely integrated.
CarMaker, the vehicle dynamics software for virtual test driving from IPG Automotive now also provides the acquisition of internal ECU variables at hardware-in-the-loop test benches with CCP and XCP.
A test environment for the model based development of Active Cruise Control must not only contain detailed models of the test vehicle but also simulate the traffic around the vehicle. For this purpose CarMaker offers an excellent solution: From offline simulations through to hardware-in-the-loop tests, CarMaker can be used for the development of control systems with object detection.
The Formula Student Team of the Politecnico di Milano has great plans. In the coming race season they want to compete in the Formula Student events in UK and Italy with a race car having totally automated gear changing and actively steered rear wheels. The Italian students use CarMaker and IPG-KINEMATICS to develop and test the control systems and the newly designed suspension.
Thanks to the close co-operation between Sherpa Engineering and IPG Automotive, the complete Sherpa-Engine model library has been integrated into CarMaker. Sherpa Engine covers detailed motor models, which have - like CarMaker - a modular design and an excellent model performance.
Virtual test driving in the auditorium - nothing extraordinary if you are a student at Stralsund's College. Since Autumn 2005, the vehicle dynamics software CarMaker has been used at this University to offer a practical education to the mechanical engineering students with automotive engineering as the major subject. The prospective engineers learn interactively the fundamentals of driving dynamics by simulating and analysing driving maneuvers with CarMaker both in lectures and practical courses. This successful teaching concept will be continued during the winter semester 2007/2008. The master study course "automotive engineering" will offer a module "simulation and test driving", in which vehicle dynamics simulations using CarMaker will be closely integrated.
"Quality and Reliability under any operating conditions, matched with time and cost efficiency" - These are the central goals which stand high on the list for vehicle development. Therefore Ford counts on Hardware-in-the-Loop simulation for its new four-wheel-controls' functional tests. As a testing tool, they use a CarMaker/HIL test stand from IPG Automotive.
New season, new racecar - obviously, that does not leave a lot of time to relax. The last season has just ended for Munich's College Formula Student Team and yet they are already working hard on their new vehicle. Their professionalism is impressive. Just like their idols in Formula 1, the students trust in sophisticated technologies and latest development tools.
Virtual test driving in the auditorium - nothing extraordinary if you are a student at Stralsund's College. Since Autumn 2005, the vehicle dynamics software CarMaker has been used at this University to offer a practical education to the mechanical engineering students with automotive engineering as the major subject. The prospective engineers learn interactively the fundamentals of driving dynamics by simulating and analysing driving maneuvers with CarMaker both in lectures and practical courses. This successful teaching concept will be continued during the winter semester 2007/2008. The master study course "automotive engineering" will offer a module "simulation and test driving", in which vehicle dynamics simulations using CarMaker will be closely integrated.
The TU Graz Racing Team trusts in IPG-KINEMATICS and CarMaker to optimize the kinematics of their race car, and to test its engine in the hardware-in-the-loop simulation.
The institute for Combustion Engines and Automotive Engineering (IVK) at Stuttgart University has recently started to work with CarMaker and the axle kinematics calculation program IPG-KINEMATICS. The programs will support both the teaching activities of the institute and the research of controller systems in the automotive area.
At Coventry University CarMaker has already been used for the practical training of students for several years. In practical courses the students improve their knowledge in vehicle dynamics and automotive control engineering. Furthermore they do their final year projects with CarMaker. They learn to apply professional vehicle dynamics simulation - before they start their professional career.
In systems, which should be able to react to environment objects, the software used for object simulation purposes is an important element, but is not sufficient in itself for a seamless, all-in-one SIL/HIL solution.
A well known German OEM uses CarMaker/HIL to test prototype and production controllers and controller networks in all vehicle lines.
The Volkswagen Phaeton includes numerous intelligent, convenience and active safety systems designed to give its occupants the best driving experience modern technology can provide.
The majority of commercial trucks on the road today use rigid axles or air suspension systems, while independent front suspensions are usually reserved for passenger cars and trucks.
The tires of the FT2007 have scarcely cooled down after the recent European Formula Student competition in Hockenheim. Nevertheless the students from the Berlin FaSTTUBe team are already working on the design of their new racecar. Model based development methods play a particular role during this important concept phase.
