Simulation Solutions

In component development we ensure integrity and that functions are validated. To do this, stiffnesses from numerical models are calculated and distortions, tension levels and strength levels are evaluated.

The simulations we offer in the stiffness area:

• Local / global and static / dynamic stiffness
• Axial /shear stiffness
• Flexural/torsional stiffness
• Local dent resistance
• Buckling loads calculated

Like stiffness, strength is another safety criterion. We use mathematical models to validate the fatigue strength and operational stability of a structure.
High load events are investigated to prevent components failing.

The simulations we offer in the strength area:

• Tensile/compressive/shearing strength
• Operational stability
• Thermomechanical strength
• Misuse/high load events
• High/low-cycle fatigue
• Norm-compliant certificate management

Structural vibrations and the associated noise emissions are a major issue when developing components. Simulation enables everything, from individual components to entire modules, to be thoroughly analyzed long before serial use.

The simulations we offer in the NVH area:

• Vibration/modal analyses
• Frequency response analyses
• Operational vibration analyses
• Structure-borne sound analyses
• Low frequency internal acoustics
• Noise emission
• Sound optimization for exhaust systems
• Noise transfer functions

Safety is the priority. We ensure that the requirements and functions are fulfilled for both individual components and complex systems. We take into account the client’s requirements, general (FKM) guidelines, and the requirements of the law, consumer tests and insurance companies.
We use explicit calculation methods to simulate these highly dynamic processes and derive targeted measures.

The simulations we offer in the area of short-term dynamics and electronic circuit simulations:

• Networking and model design
• Material charts created for crash calculations
• Component design and optimization
• Calculation models verified and validated
• Process and method development

Flows affect the behavior and functioning of vehicles and their components. In early development phases, CFD simulations provide information about flows through and around components, thus enabling time-efficient, cost-efficient modifications. We also examine influencing factors in temperature fluctuations and, through this, thermal management.

The simulations we offer in the flow and thermal management area:

• Aerodynamics and wind tunnel
• Interior air conditioning (incl. air ducts, outlets)
• Thermal management: entire vehicle, (electric) motor, brakes, lights, etc.
• Cooling of units: powertrain, exhaust systems, HV storage, renewable energy electronics
• Aeroacoustics and thermal comfort
• Multiphase and virtual water management
• Thermal simulations of: switching panels, cooling towers, converters, industrial roads, etc.
• e-Cooling: power electronics, control units, PCB
• Buildings and interior air conditioning
• Aeroacoustics and multiphase problems
• Virtual water management and fluid-structure coupling

Numerical optimization methods are successfully used to design complex assemblies, for lightweight design solutions and to eliminate design weaknesses. Reality can be represented in this way. The stochastics examine the robustness of components and assemblies.

The simulations we offer in the optimization and stochastics area:

• Sensitivity analyses
• Design of Experiments (DoE)
• Topology/parameter optimization
• Design/shape optimization, bionics
• Robustness research
• Method development

Given ever-shorter development cycles and the increasing lack of availability of hardware, there is a need to identify loads and assembly space in early phases of development. A highly effective, efficient tool is the multibody simulation (MBS). 
MBS is used not only in automobile manufacture but also in machine and plant construction and energy technology.

The simulations we offer in the multibody systems area:

• Load data calculation
• Driving maneuvers
• Kinematics validation
• Simulation with flexible bodies

Increasing digitization and advances in autonomous driving are increasing radiances in and around the vehicle.
To predict physical effects on vehicles, their components and human beings under conditions which are as realistic as possible, we use sophisticated tools to study these effects in combination (FSI) or singly.

The simulations we offer in the field simulations and multiphysics area include:

• Simulation of electrical and magnetic fields
• Parasitic effects calculated and studied
• Simulation of voltage/power losses
• Combining of different field problems
• Antennae simulation

Safety is the first command. We ensure that the requirements of the law, consumer tests and insurance companies are complied with. We use explicit calculation methods to simulate these highly dynamic processes and derive targeted measures.

The simulations we offer in the passive vehicle safety area:

• Vehicle crash
• Crash management for front and rear of vehicle
• Data generation for algorithm development
• Pedestrian protection
• Component design (interior, structure, battery)
• Material charts created for crash calculations
• Calculation models verified and validated
• Process and method development
• Occupant protection

Safety is the priority. We ensure that the requirements in terms of stresses on occupants are robustly fulfilled. Dummy and human models are used to develop the component properties of restraint systems and ignition times are aligned with these.

The simulations we offer in the occupant protection area:

• Front occupant protection
• Rear passenger protection and child safety
• Side protection
• Whiplash
• Airbag folding and deployment
• Out of Position
• Seat safety
• Human model
• Verification and validation