• Daimler Forschung, PSA, TU Darmstadt und AVL: Engine-in-the-Loop – efficient use of and new prospects for vehicle dynamics – in the development and networking of modern powertrain systems, and in relation to energy management.
• Hochschule München und Porsche: Steering-in-the-Loop – innovative steering test rig which enables fast and easy implementation of entire driving maneuver catalogues in virtual test driving. In addition, Porsche will demonstrate how this method is embedded in the development process variant validation.
• Continental: central role which virtual test driving plays in testing ContiGuard functionalities throughout the development process.
• Haldex: “Higher speed and efficiency, lower costs” – this is the conclusion that was drawn after the first simulation-based homologation according to the EU Directive.

Further Highlights of the Conference

• „Research Lab Tour“ – innovative forward-thinking concepts such as Autonomous Vehicles and Car2-X-Communications.
• Live Ride Event – hands-on experience of advanced driver assistance systems.
• High-caliber technology exhibition – direct information about the actual solutions.
• Exklusive Evening Event – with sufficient time for high-level professional exchange.

In contrast to empirical models TameTire considers tire forces and tire moments in a large range of conditions, including thermal effects, speed effects, tire inflation pressure and transient effects.

Additionally TameTire uses comprehensible physical properties with scaling parameters which are easy to handle.

Connectivity and integration are playing an increasingly important role in modern vehicles. Vehicle dynamics, today, is the result of control systems and vehicle components interacting with each other within a common network – accompanied by the growing influence of innovative driver assistance systems. In parallel, there is an unabated trend toward increasingly fuel-efficient and hybridized or electrified vehicle concepts.

For vehicle developers, this harbors a wealth of exciting innovation potential to be unleashed as well as new technological challenges to be mastered. Leading-edge vehicle dynamics simulation offers the appropriate tools for pioneering solutions in this area: it allows the integration of any vehicle component as a model or as soft- and hardware and enables realistic modeling of the complexity of the total system in “customer use cases.” An additional benefit: virtual track and road tests can achieve considerable savings through systematic front-loading within the integrated development process.

The IPG Technology Conference billed as “apply and innovate 2010“ will offer you an internationally attended discussion and information platform at which colleagues from relevant disciplines, scientists and users engage in a dialog about the current state of technology, the latest methods, techniques and research results as well as forward-thinking concepts for integrated vehicle development.

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.

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 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.”

Besides all of the usual functionality, which is already known within CarMaker, the new product in the IPG family, TruckMaker 3.0, additionally includes a comprehensive model library and features which are specific for the simulation of commercial vehicles. Included are: variable two- or multi-axle Truck and Trailer combinations, semi, center- or full trailer, fitted with single or twin tires, complex hitch systems, flexible truck and trailer bodies, braking models and all special suspension types like the driving cabin suspension, etc.

TruckMaker, as the very first software, could already provide proof of the functional requirements of the ESP in simulation, which is for the first time recommended in the ECE guideline 13/11 as an appropriate instrument for certification. In a completed homologation process, the efficient and universal software could already convince through hugh cost savings and a robust and capable performance. A standard 3-axle Truck and Trailer combination could be calculated 12 times faster than real-time. This results in high productivity for office applications and is also important when a high calculating performance is required for extended model enhancements on the HIL test rig.

The precise MBS models within TruckMaker have more than 50 degrees of freedom and can be combined with simple mouse clicks in various configurations – they are capable of real-time performance and are valid up to the limits of driving dynamics.

The proven and previously deployed models from CarMaker, for example IPGRoad, IPGTraffic, IPGDriver and the event based “maneuver control” facility were fully utilized and enhanced with truck specific features.

The IPGDriver model automatically adapts to the handling of large commercial vehicles and enables the reconstruction of complex test scenarios.

All models are arranged in a structured and manageable way in terms of individual sub-assemblies and can be modified or exchanged for in-house models within Simulink and on a C code level.

Besides the more traditional application areas like investigating the performance of driving dynamic simulations and the development of chassis control systems, TruckMaker also enables the simulation of adaptive driving assistance systems like adaptive cruise control, emergency brake or lane keeping assistance. TruckMaker is valid from the concept definition using office simulations, through to the HIL laboratory and large test rigs and on to the final production release.

The all round package of TruckMaker covers numerous application areas and enables the simulation of tomorrow, today!

One motivation for the new development of TruckMaker was the implementation of the ESC guideline ECE 13/11. In addition to classical test drives the EU guideline recommends, for the first time, simulation software as an appropriate instrument to operate the essential directional- and rollover tests for the certification of ESC.

However TruckMaker is not limited to ESC tests, it is also specialized in the performance of different simulations of adaptive driving assistance systems. The fields of application range from adaptive driving assistance systems like the adaptive cruise control, emergency brake or the lane keeping assistance system to the driving dynamic simulation of hybrid concepts, energy efficiency and chassis control.

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Virtual Test Driving - variable and simple

IPGDriver, the most successful driver model for sophisticated closed-loop driving tasks, accurately represents the actions and reactions of a real driver and now has special abilities for driving trucks and buses up to the vehicle limit. Self-learning and adaptation skills to truck typical behavior and a perfect integration into the unique event based TruckMaker maneuver control enable the reconstructions of complex test scenarios - quickly and easily. No matter what you wish to simulate - a defensive or aggressive driver, city driving or handling courses, driving uphill or downhill, launch, forward or backwards, stop&go, walking speed or parking - IPGDriver has everything under control.

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TruckMaker Model platform - wide and precise

Whereas all passenger cars are essentially built on similar architectures and concepts, trucks have a nearly infinite number of configurations and combinations: a two- or multi-axle truck, with or without truck trailer, with semi-, center- or full trailer, featured with single or twin tires, …?

TruckMaker provides the solution. The parameterization of the fully non-linear and extendable models can be done via a graphical user interface. Fast, with only one mouse click, the precise MBS models can be combined in various configurations - capable of real-time performance and valid up to the limits of driving dynamics.

Important model enlargements like cabin suspensions, retarder and braking models, special suspension types and different powertrain variants make TruckMaker a powerful application development system.

Additionally to the specifics, which are necessary for the use of heavy commercial vehicles, the user can use all the proven and deployed models implemented in CarMaker: IPGDriver, IPGRoad, IPGTraffic and the special sensor models. The models are arranged manageably in terms of individual sub-assemblies and can be modified or exchanged for in-house models within Simulink and/or on a C code level.

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Integrated concept - powerful and effective

Do you like to evaluate your concepts, develop and test controller and component models, test software codes as well as simulate on ECU and network HIL systems? Or do you like to optimize mechatronic systems in virtual test drives? TruckMaker provides an integrated application development system - in the office, in the HIL laboratory and on large test rigs.

Especially for the HIL applications, TruckMaker was enlarged to TruckMaker/HIL with special tools like ECU diagnostics, CCP/XCP, FailSafeTester Control, instruments, real-time performance, compiling and debugging tools. The ideal combination of software and hardware combined with the unbeatable real-time performance and large degrees of test automation offers you the possibility to shift the test drive to the laboratory. TruckMaker sets new standards for productivity.

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Real-time performance - fast and efficient

The large number of degrees of freedom (over 60 DOF), the cyclical ground scans of the many tires and the fully non-linear kinematics and compliance description of the numerous axles pose an extreme challenge to real-time behavior. Benchmarking tests have revealed that TruckMaker requires only a fraction of the calculating capacity which is available for the real-time simulation - ten times faster than the benchmark. This difficult challenge proved once more all the creativity and knowledge of IPG’s developers: efficient Mesa Verde MBS-formalisms, multi-threading and multi-tasking mechanisms as well as the optimization methods for ground scans and TruckMaker tables brought extremely beneficial effects to the real-time performance. This saves multi-CPU approaches, reduces the number of executables as well as set-up and operational effort, and offers sufficient computing reserves to integrate highly detailed models like pneumatics, powertrain, steering, tires, etc.

More about TruckMaker 3.0 ...

Almost 80 Universities from Europe, Australia, Canada, Russia and the USA participated in this year's international engineering competition Formula Student Germany 2009 at Hockenheim. From August 5th to 9th the teams compared their self designed and self built cars directly with other competitors in different categories.

Two weeks after winning the Formula Student Event in Silverstone, the Team University Stuttgart repeated their track record from 2008 and was placed first in the overall standings at Hockenheim. Besides the winner, six other teams, which benefit from the support program Formula CarMaker, placed in the Top15: the teams from University of Hertfordshire, UAS Köln, TU Darmstadt, UCE Ravensburg, TU Freiburg and TU Braunschweig.

The Helsinki Metropolia University of Applied Sciences, the University Karlsruhe (TH) and the University of Hertfordshire achieved a position under the Top15 in Silverstone.

Since 2005 IPG has offered young engineers within their Formula CarMaker program the possibility to widen their knowledge in the field of development of vehicle dynamics through intensive workshops and deepen it with practical simulation applications. Within the program IPG provides the CarMaker software package which allows the opportunity to increase the competitiveness of the automobiles planned and developed by students. In the process IPG encourages the teams with professional support during the different development phases of their racing cars.

Among other things, important advantages for the teams result from IPGDriver, which can realize in a unique way the processing of performance and lap time improvement in the simulation of the Formula racing cars.

The interest in the support program from IPG, a former spin-off company from the University Karlsruhe, is rising considerably: in the beginning there were 30 teams from different series like Formula Student and Formula SAE, now over 100 Teams from all over the world joined the program and profit from the 25 years experience of the company.

Today IPG is one of the world leading suppliers of simulation solutions, test systems and engineering services in the field of model based development and testing of ECUs, vehicle components and complete vehicles.

We are looking forward to a good and successful co-operation in the future and congratulate all the participants of Formula Student Germany 2009 on their excellent engagement and amazing performance!