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Automotive e-ssentials

Your regular update for technical and industry information

Virtual simulation to ensure the safety of vehicles

To meet increasing safety requirements, also with regard to the ongoing development of smart mobility, various possible scenarios have to be tested to ensure the overall safety of vehicles. This not only includes traditional crash simulations, but NVH, durability, strength, stiffness and much more. By using virtual simulation the development time of new vehicles can be reduced and weak points often can be identified already before the prototype is produced and therefore offers opportunities for cost reduction. Virtual simulations thereby are very often correlated with physical testing to ensure accuracy and reliability.

What is virtual simulation?

Virtual simulation to ensure the safety of vehiclesWhile physical tests are using usually very expensive sample and prototypes, virtual simulation is based on mathematical reproduction of the physical world. For virtual simulation testing 3D CAD and material definition are already sufficient. Once the virtual model is built it is quick and simple to change any structure, material, thicknesses or just loading and boundary conditions to get an insight into the sensitivity of the complete model behaviour to any input parameters. Nowadays, virtual simulations are an integral part of both R&D and certification areas for the product development process in various industries.

How can we help you?

As an integral part of the testing laboratory, the TÜV SÜD department of computer aided services (CAS) uses cutting-edge technology and software to support customers around the globe. All services (R&D and certification via simulation) are provided virtually and mostly no physical specimen is required. Our experts are able to simulate and identify any potential weak points in the structure and suggest improvements. With new emission rules and limitations, there is a high demand on lowering mass while using the down-sized engines and hence decreasing emissions. Structural optimization offers a mass reduction while maintaining or even improving structural performance (stiffness, durability and/or crash performance). The department of CAS supports our customers with a whole variety of analyses ranging from single point loading to complex crash simulations.

Our laboratory is ISO/IEC 17 025:2005 accredited and can perform tests against the following standards:

  • UN ECE R14, R17, R21, R29, R55, R58, R66, R67, R73, R93, R100 (structural integrity), R107, R110, R111, R129
  • Other standards e.g. FMVSS, FIA, xNCAP, ISO (3449, 3471,…), EN (1317,1789,12642, 12767,…), VDI 2700

Available 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, trucks and buses

Virtual simulation services for passenger cars

  • All types of crash simulations (front, side, rear, roof, e.g FMVSS/ENCAP/KNCAP/ECE…) – may be coupled with physical sled test facility DYCOT
  • Unique approach of side crash sled combines simulation and testing options via ALIS (Advanced Lateral Impact System) – designed for sled testing of side impact
  • Development support – modal, stiffness, strength, NVH and crash analyses of components and/or whole structure
  • Fine tuning of restraint systems (airbags, seatbelts) – may be coupled with physical sled test facility DYCOT
  • Linear/non-linear, static/quasi-static and dynamic simulations, implicit and explicit methods
  • Weight-to-stiffness/strength optimization (linear, crash, DoE,…)
  • Performing sensitivity and robustness analyses and studies based on complex vehicle models in terms of safety performance and structural behaviour

Virtual simulation services for truck

  • Development support - all types of virtual simulations (crash, NVH, durability, strength/stiffness and modal) that may be coupled with physical tests lab (strength, vibrations,…)
  • Cab strength homologation via simulation according to ECE R29
  • 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.
  • Weight-to-stiffness/strength optimization (linear, crash, DoE,…)
  • Performing sensitivity and robustness analyses and studies based on complex vehicle model in terms of safety performance and structural behaviour
  • Physical material testing and subsequent implementation into analysis (material model development)

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,…)
  • Cab strength homologation via simulation according to ECE R29
  • Homologation of bus superstructure strength via simulation according to ECE R66 – may be coupled with physical test (on-site)
  • Weight-to-stiffness/strength optimization (linear, crash, DoE,…)
  • Performing sensitivity and robustness analyses and studies based on complex vehicle model in terms of safety performance and structural behaviour
  • Physical material testing and subsequent implementation into analysis (material model development)

Why choose TÜV SÜD?

TÜV SÜD has more than a century-long experience in vehicle safety, testing and certification. Our extensive knowledge and international recognition enables us to work as a partner with our global customers, including top OEMs and automotive suppliers. Our state-of-the-art testing facilities, combined with our global network of technical experts, can provide your company with a single source solution for achieving compliance with all applicable regulatory requirements, standards and voluntary industry schemes. As an innovative solutions provider, we are directly involved in the development of safety regulations, standards and efficient automotive testing solutions to drive the future of mobility. Besides, our test approach for the simulation of dynamic events can also be extended to support other industries, including aviation, military and rail.

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