For more efficiency in hardware development

31.03.2022  — 

Virtual development methods provide vehicle manufacturers with clear advantages: Fewer hardware prototypes, reduced development costs and shorter time-to-market cycles are prime examples. IAV also wants to leverage synergies in the field of drive systems with a new simulation-based development methodology. Ronny Mehnert, Head of Powertrain & E-Traction Simulation, explains the innovative approach and its effect.

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The use of digital development methods is standard practice at IAV in many technology areas. What is new in the field of powertrain systems that is currently being implemented?

We have set up the calculation department in a portfolio-oriented way, i.e. experts are on board in the teams we have bundled, e.g. for fluid mechanics, system analyses, strength, multi-body analyses or NVH. These teams can act cross-sectionally and realize a complete development process for a portfolio item up to virtual release. This is something completely new. We are giving new impetus to the topic of virtual development to generate holistic new solutions from the component to the system, for example for topics in e-traction, battery technology, thermal management or drive systems.

How does the new approach “work” in practice?

In the past, a simulation model was created several times by different departments for their respective purposes, which cost time and money. Now, by bundling experts in one team, for example, only one master model will be developed, and partial models derived in the future. This makes us more efficient, enables us to answer urgent customer enquiries more quickly and we are perceived even more positively on the market. If we locate the concentrated expertise in one team, we can let the knowledge from other sub-domains interact to generate new solution proposals. Our methodology is a major contributor to IAV’s new target vision as a tech solution provider.

What is the goal?

Up to now, 70 to 80 percent of our development work has involved trials and perhaps 30 percent simulations. In the digital age, our goal must be to realize more than 60 percent with virtual development and rather underpin it with high-quality trials. This is what the new focus on portfolios is aiming at. We want to become powerful and efficient in hardware development and build the bridge to function development. We are already using this methodology in various development projects. Our goal is to enter the market even more strongly in the future.

Contact us!
Ronny Mehnert
Tel.: +49 371237 34703