VW Touareg

Pleasure in the Extraordinary

The VW Touareg made its debut on the German market in the autumn of 2002. This premium SUV marks VW’s entry into a new vehicle segment,guaranteeing not only an extremely high level of driving comfort but also a great deal of off-road fun. As the development partner, Bertrandt Tappenbeck ensured that the Touareg is optimally equipped for the future with its innovative technology and functionalities.

Digital Mock Up – Prototype Build – Start-up Support
Bertrandt began work on the virtual design of the front end of the 6 and 10-cylinder Touareg in 1999. Their specific task was to accommodate the engines into the front end of the car. The bodyshells were then built by VW’s prototype build department and the very first attempts at integrating the 6 and 10-cylinder power units were made at Bertrandt in Tappenbeck. After a two-year development period, the first release date arrived: the body for the 10-cylinder was to go into preseries production.


For this purpose, representatives from all of VW’s specialist departments went to Bertrandt: quality assurance, engine development, electrics, chassis, acoustic insulation, damping, climate control and cooling, fuel and body design. This date also saw the release of the front end and the underbody. It was already clear: the Touareg was going to be a car that people will want to drive. In cooperation with the VW team responsible for the front end and the pilot production facility in Bratislava, the vehicle was built under series production conditions. Back in Tappenbeck, the front end then underwent fine-tuning to production readiness.

The VW Touareg can do just about everything that is possible on four wheels: it masters 45-degree slopes just as majestically as it wades through rivers up to 58 cm deep. A car that leaves nothing to be desired offering fun without limits.

Virtual Product Data Management optimises development
A decisive success for the development engineers was the use of Virtual Product Management (VPM), involving a digital mock-up (DMU). The objective of this is to enable data matching to be performed at any time and to make the design status transparent throughout the development process. This allows the data status within the project to be continuously optimised in the subsequent process. Virtual data matching was carried out in a structured DMU-VPM process on Bertrandt’s in-house system, before being transferred to the VW system. Tappenbeck is linked with the DMU centre in the main VW plant in Wolfsburg via a 100-Mbit line for the direct exchange of data. A further advantage was that the Bertrandt workshop had a special DMU room. This ensured that the virtual world could be brought right into the workshop, allowing any changes between the real and virtual vehicles to be executed with real-time data matching. The scope of the Bertrandt project also included compiling the database required for the front end DMU. The use of VPM gave a completely new dimension to the development period, thus providing cost-cutting potentials that have a considerable effect on the development costs of a new vehicle.

Series maintenance
Now that the car is in production, the aim is to structure, analyse and further develop the platform of the Touareg with the engines introduced so far. This includes maintenance of the component statuses as well as the introduction of new power units. These tasks are facilitated in the long term by the intensive preparatory work carried out over several years.

Online Link with VW due to many years of partnership
On the basis of mutual trust, expertise and innovation, the team in Tappenbeck has succeeded in establishing an online link with the VW partner for the necessary data maintenance. Following many years of fruitful cooperation with the responsible persons in Wolfsburg, this unique regional achievement was made possible in August 2003. After coordination with VW’s data security centre, the specialists in Tappenbeck are now able to directly match the design status data in the VW data structure in their online room. Bertrandt fulfils the high security standard required by VW. The structured process thus created allows other subsidiaries in the Group to access these data structures. In the future, Bertrandt Tappenbeck will continue to be responsible for all design services for the front end, as well as maintenance of the virtual data. For this purpose, they will also support the VW Group’s prototype build department by supplying experimental vehicles. In the initial stage, this will involve the testing of components, involving such aspects as temperature, acoustics and the durability of alternators and component parts. All in all, this represents a comprehensive service programme that the VW Group is happy to take advantage of.