Automotive Virtual Safety Simulation Testing

About virtual testing For Vehicles

Virtual testing for vehicles uses software and mathematical models to replicate thousands of different scenarios to ensure that new vehicles comply with global safety regulations. Virtual testing therefore does not only include traditional crash simulation, but NVH, durability, strength, stiffness testing and much more. Virtual testing is often correlated with physical testing results to ensure accuracy and reliability.

Virtual testing offers vehicle manufacturers and component suppliers multiple benefits, such as:

• Demonstrating compliance with international vehicle safety and quality standards for all the static strength, inertia and/or dynamic loads and various types analyses of vehicles, their systems or components
• Reducing development times on new vehicles by identifying weak points already before the prototype is produced
• Discovering weak points in the vehicle or its components under real-world conditions prior to physical testing
• Realizing cost reduction opportunities
• Accessing clear documentation and data generated by your tests

TÜV SÜD's Services

Within our accredited lab according to ISO/IEC 17 025:2005 we can provide you the best service possible. Our test approach for the simulation of dynamic events can also be extended to support other industries, including aviation, defense, energy, navy and rail.

All services (R&D and certification via simulation) can be provided virtually and, in most cases, no physical specimen is required. Our experts can simulate and identify any potential weak points in the structure and suggest improvements. The traditional area is the assessment of the safety requirements of commercial vehicles. Together with DYCOT, we are then able to fine-tune restraint systems such as seat belts and airbags that are highly sought for both frontal and side crash tests. Thereby, we support our customers with a whole variety of analyses ranging from single point loading to complex crash simulations.

We provide a full suite of virtual testing services.

Our lab is ISO/IEC 17025:2005 accredited and nominated to perform tests against the following standards:

• UN ECE R11, R29, R17, R21, R55, R58, R66, R67, R73, R93, R100 (structural integrity), R107, R110, R111, R129, R134
• Other standards: equivalent FMVSS, FIA J, xNCAP, ISO (3449, 3471 etc.), EN (1317, 1789, 12642, 12767 etc.), VDI 2700

Our virtual testing software:

• ANSA/μETA, MSCNastran/Eπilysis, LSTC LS-Dyna, LS-OPT, PAM-CRASH, ABAQUS/Standard, Altair Radioss, Madymo, CarMaker, SIMPACK, MatLAB/Simulink, SolidWorks

Our virtual simulation services for passenger cars:

• All types of car crash simulations (front, side, rear, roof, e.g. FMVSS/ENCAP/KNCAP/ECE etc.)
• Unique approach of side crash sled combines simulation and testing options via ALIS (Active Lateral Impact System)
• Development support – modal, stiffness, strength, NVH 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 optimization (linear, crash, DoE etc.)
• Performing sensitivity and robustness analyses and studies based on complex car vehicle models in terms of safety performance and structural behaviour

Our virtual simulation services for trucks:

• Development support - all types of virtual simulations - (crash, NVH, durability, strength/stiffness and modal) may be coupled with physical test lab (strength, vibrations etc.)
• Truck cab strength homologation via simulation according to ECE R29 standard
• Underrun protection homologation via simulation according to ECE R58/73/93
• 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 optimization
• Performing sensitivity and robustness analyses and studies based on complex truck vehicle model in terms of safety performance and structural behavior
• Physical material testing and subsequent implementation into analysis (material model development)

Our virtual simulation services for busses:

• Development support - all types of virtual simulations (crash, NVH, durability, strength/stiffness and modal) – may be coupled with physical test lab (strength, vibrations etc.)
• Cab strength evaluation via simulation according to ECE R29 standard
• Homologation of bus superstructure strength via simulation according to ECE R66 – may be coupled with physical test (on-site)
• Bus weight-to-stiffness/strength optimization (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)

Our virtual simulation services for road infrastructure:

• Road barrier crash simulations TB 11 to TB 81
• Strength of the structures of the road equipment

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