Automotive virtual testing for passive safety

What is automotive virtual testing?

Virtual testing, also known as computer-aided engineering (CAE), revolutionises traditional testing methodologies. It uses advanced computer simulations (finite element method) to predict the behaviour and performance of products under diverse conditions. Virtual testing uses state-of-the-art mathematical models and simulation software to analyse and optimise vehicle designs. It has unprecedented accuracy, accelerates the product development cycle, and reduces costs associated with traditional physical testing.

Using virtual simulations allows the safety of vehicles to be assessed under various real-world conditions and potential hazards without the need for physical prototypes. The virtual testing approach enables comprehensive testing of vehicle systems, including crash scenarios, component durability, and safety features effectiveness.

At TÜV SÜD we test the passive safety of vehicles, including crash, strength, and occupant safety simulations. By combining virtual testing with physical testing, TÜV SÜD supports you to validate results and provide a comprehensive safety assessment. We help you cover all relevant safety aspects early in the development process to meet regulatory standards and certification requirements.

Why automotive virtual testing is important?

Virtual testing significantly reduces the need for physical prototypes, saving material, manufacturing, and testing equipment expenses. In addition, simulating real-world conditions digitally accelerates the product development cycle and creates more robust solutions. This enables quicker iterations, minimising costs and time-to-market. It also ensures consistent performance and reliability in real-world conditions. Detailed analysis and simulation allow manufacturers and engineers to identify and address potential design flaws and performance issues early in the development process, facilitating timely adjustments and optimisation. This ensures your products meet or exceed desired specification.

How TÜV SÜD helps you with automotive virtual testing ?

With over a century of experience in vehicle safety, testing, and certification, we offer advanced virtual simulations for passive safety, including crash, strength, and occupant safety tests. Our experts utilise cutting-edge software to provide customers with global support, offering R&D and certification services virtually, often without the need for physical specimens. Our services include the virtual simulation and identification of structural weak points, along with suggestions for improvements. Integrating virtual and physical methods for front and side crash testing ensures optimal results.

Our ISO/IEC 17025:2017 accredited dynamic component testing laboratory enables precise analyses, from simple quasi-static loading to complex crash simulations. We fine-tune restraint systems like seatbelts and airbags to ensure optimal functionality in real-world scenarios. Our virtual testing services are also available to clients in several other sectors, including medical care, aviation, energy, the navy, and rail.

In addition, our global team of experts is involved in developing safety regulations and standards, ensuring that your product meets the highest and most recent safety and compliance standards.

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Partner with us for virtual simulation testing to ensure vehicle safety according to global regulations and standards

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What our automotive virtual testing service include?

Our full suite of virtual testing services include:

An ISO/IEC 17025:2017 accredited laboratory, nominated to perform tests against the following standards:

• UN ECE R66, R29, R55, R58, R67, R73, R93, R110, R127, R134

• Other standards: equivalent FMVSS, FIA 253 appendix J safety roll cage, xNCAP, ISO 3449, ISO 3471, EN 1317, EN 1789, EN 1846-2, etc.

Our virtual testing software:

ANSA/μETA, MSCNastran/Eπilysis, LSTC LS-Dyna, LS-OPT, PAM-CRASH,  MatLAB/Simulink, SolidWorks.

Our virtual simulation services for passenger cars:

• All types of vehicle crash simulations (front, side, rear, e.g. FMVSS/ENCAP/KNCAP/IIHS/ECE etc.).
• A unique approach of side crash sled combines virtual simulation and physical testing options via ALIS (Active Lateral Intrusion Simulation).
• Development support – modal, stiffness, strength and crash analyses of components and/or whole structure.
• Fine tuning of restraint systems (airbags, seatbelts).
• Linear/non-linear, static/quasi-static and dynamic simulations, implicit, and explicit methods.
• Car weight-to-stiffness/strength optimisation (linear, crash, DoE etc.).
• Sensitivity and robustness analyses, and studies based on complex car vehicle models in terms of safety performance and structural behaviour.
• Granting of type approval without an actual crash test in the case of individual approval (ECE R127 – pedestrian safety, etc.).
• Instrument panels testing.

Our virtual simulation services for trucks:

• Truck cab homologation (type approval) via virtual testing according to ECE R29 standard. No physical test sample required in most cases.
• Development support – all types of virtual simulations (crash, strength/stiffness, and modal) may be coupled with physical test lab (strength, vibrations etc.).
• Underrun protection homologation via simulation according to ECE R58, R73, R93.
• Powertrain components safety ECE R67/100/110/134 (battery, LPG, CNG systems).
• Development support according to ISO 3449 and ISO 3471 (FOPS/ROPS).
• Certification of load safety via simulation according to EN 12642 L/XL Code, VDI 2700, etc.
• Truck weight-to-stiffness/strength optimisation.
• Sensitivity and robustness analyses and studies based on complex truck vehicle model in terms of safety performance and structural behaviour.
• Physical material testing and subsequent implementation into analysis (material model development).

Our virtual simulation services for buses:

• Bus homologation (type approval) via virtual testing according to ECE R66. No physical test sample required in most cases.
• Development support – all types of virtual simulations (crash strength/stiffness, and modal) may be coupled with physical test lab (strength, vibrations etc.).
• Structure strength evaluation via simulation according to ECE R29, R73, R93 standard.
• Bus weight-to-stiffness/strength optimisation (linear, crash, DoE etc.).
• Performing sensitivity and robustness analyses and studies based on complex bus vehicle model in terms of safety performance and structural behaviour.
• Physical material testing and subsequent implementation into analysis (material model development).

Other virtual simulation services:

• Road infrastructure – EN1317/ EN12767 (road barrier crash test).
• Medical equipment – EN1789 (medical vehicles and their equipment for road ambulances).
• FIA – 253 Appendix J (safety roll cage stiffness).
• Pressure vessels calculation.

Frequently Asked Questions (FAQs)