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Chassis Test Center

Mastering Chassis Development for Tomorrow's Mobility 

With our cutting-edge technologies and extensive in-house testing capabilities, we enable comprehensive and holistic chassis development, ensuring that every component works seamlessly together to deliver an unparalleled driving experience. Let’s pioneer the chassis for the software-defined vehicles of tomorrow together.  

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Holistic Testing

IAV offers comprehensive testing for chassis systems, starting from the early development phase. Our virtual testing capabilities help avoid costly detours at the beginning of the development process. As development progresses, we provide testing for chassis components such as brakes and tires, XiL testing of control units, sensors, and actuators, as well as material properties, culminating in prototype testing on the vehicle. Our brake and tire test benches assist in meeting ambitious CO2, wear, and particle emissions targets.

Smart Test Bench Coupling

Our highly dynamic brake test benches can be coupled with our HiL test benches, allowing brake control functions to be tested alongside real brake systems without needing a prototype vehicle. This enables the definition of matching material properties at an early development stage and evaluation of their effects on wear and particle emissions.

Road to Rig & Road to Sim

We help reduce outdoor vehicle testing to enhance reproducibility and save costs. This includes brake endurance testing on the chassis dynamometer, incorporating airflow simulation to mimic real ambient cooling conditions and lateral forces from cornering maneuvers. We develop solutions to advance testing into the virtual realm, utilizing physical and data-driven models combined with real physical testing on the test bench.

Tire Test Center: Tire roll resistance test bench for EU tire labeling and optimization of C02 and range targets.
Brake Test Center: Multiple brake test benches for any testing purpose from NVH to particle emissions – Power: up to 1500 kW Torque: up to 7500 Nm.
Components Test Center: Test benches for components and sensors e.g. ride height devices.
Application of braking and steering robots on the test track or the chassis test bench for brake and tire testing.

Our Chassis Test Capabilities

Tire Test Center

Roll Resistance Test Bench

  • Testing standards: ISO 28580 (EU-tire labeling) for tire classes C1, C2, and C3
  • Research focus: CO2 emissions and range increase for electric vehicles
  • Speed capability: up to 270 km/h
  • Max wheel load: 63 kN
  • Adjustable camber angle
  • Quality approval: standard tire lifecycle quality
     

Tire-Vehicle Testing

  • Evaluation of common tire tests: objective and subjective assessments 
  • TPMS development: vehicle application and self-certification tests
  • Tire acoustics: pass-by-noise, interior noise analysis
  • Special fleet testing: endurance testing (Euro 7 Abrasion)

Brake Test Center

Brake Component Test Benches

  • Cycle testing: standardized and customer-specific cycles (AMS test, AK-Master, etc.)
  • Fatigue and durability tests: E.g. disc cracking analysis
  • NVH testing: SAE-J 2521, judder testing including thermal cameras
  • HiL testbench coupling: component testing incl. control strategies
  • Brake emission testing: according to UN-GTR No. 24
  • Static brake pad testing: ISO 6310 & ISO 6312 standards for hot/cold compressibility etc.
     

Specifications

  • Power: 330 – 1500 kW
  • Max torque: 950 – 7000 Nm 
  • Max RPM: 8000 – 10,000 rpm
  • Brake pressure: up to 180 bar
  • Cooling air temperature control: -40°C to 160°C
  • Cooling air humidity control: 10 % to 90 % 
     

Brake Vehicle Testing

  • Type approval: FMVSS126, ECE R13, FMVSS138
  • Application of control functions 
  • Availability of steering and braking robots
  • Testing locations: Germany and abroad (Großglockner, Mojácar, Nardo, etc.)
  • Road to rig: simulating outdoor vehicle tests on chassis dyno

XiL Test Center

HiL Test Benches Characteristics

  • Availability: wet and dry brake as well as steering HiL test benches
  • Real sensors and actuators: brake hydraulics, pedal, and steering actuation
  • Application of complex vehicle dynamics model: simulation of dynamic maneuvers
  • Expandable models: steering, transmission, etc.
  • Co-simulation: virtual control units (vECUs)


Test Focus

  • Virtual system validation
  • Driving maneuver simulation
  • Scenario testing: FMVSS126, ECE R13, ISO3888-x, etc.
  • Signal manipulation: CAN, protocols, electrical interfaces
  • Diagnostics: measured values, adjustments, event memory
  • Short circuit and open wire tests
  • Voltage curves
     

SiL Test Benches Characteristics

  • Scalability and availability: no real hardware required
  • Parallel validation: cloud structures utilization
  • Early development support: starts with basic software or model availability
  • Environment simulation: detailed simulation of various environmental influences (friction values, weather, etc.)
     

Test Focus

  • Functional validation: ABS, ESC, ASR, etc.
  • Communication interfaces: residual bus manipulation
  • Diagnostic interfaces: measured value, adjustment, coding
  • Internal signal measurement: XCP signals

Components Test Center

We offer comprehensive testing and validation for automotive sensors and actuators using a variety of test benches. Our capabilities include measuring, analyzing, and recording communication between sensors and control modules. We test components from early stages to release recommendations, including comparisons between production and prototype sensors.

Ride Height Sensor Test Bench

  • Motion range: +/-1.5° to +/-70°
  • Frequency: up to 13 Hz
  • Sensor analysis: signal delay, accuracy
     

Acceleration Sensor Test Bench & Shaker

  • Sensor analysis: frequency band, signal delay, clipping
  • Dynamic range: high pass, low pass, band pass properties
     

Wheel Speed Sensor Test Bench

  • Testing capabilities: wheel speed sensors, wheel bearings, magnetic encoders
     

Electric Pedal Position Test Bench

  • Testing capabilities:non-hydraulic pedals
  • Analysis: force needed, pedal-control unit communication
     

Temperature Test and Shock Chambers

  • Temperature range: -80°C to 300°C
  • Rate of change: up to 12°K/min
  • Humidity control
     

Physical Analysis

  • Surface grinder: analysis of failed parts
  • Chemical test chamber: controlled chemical exposure

Material Tests Center

We conduct physicochemical analyses of components and particles, focusing on macroscopic and microscopic structures, composition, porosities, and thermal properties.

Common Methods

  • Microscopy: REM/EDX, light microscopy, CT
  • Chemical analysis: ICP-OES, HPLC, GC, XRD, XRF
  • Porosity and thermal analysis: Hg-porosity, DSC/DTA
  • Comprehensive analysis: internal/external partners
     

Investigation Topics

  • Brake pad: wear, composition, phases
  • Brake disc: wear, cracks, morphology
  • Brake dust: elemental composition, phases, size distribution
     

Objectives

  • Damage characterization: mechanisms and states
  • Particle emissions impact: quantity, type, composition
  • Future vision: best practices for emission reduction

Virtual Test Center

At IAV, we offer specialized services to enhance vehicle performance and reliability.

CFD Fluid Simulation

  • Thermal management: brake system and heat critical components (actuators, sensors, cables, hoses)
  • Comparison of powertrain configurations
  • Water flow Investigation: buoyancy movements
     

FEM Mechanical Simulation

  • Fatigue and durability analysis: thermal stress and load conditions
  • Brake disc cracking behavior
     

FEM NVH Simulation

  • Structure-borne and airborne noise calculation
  • Modal behavior and dynamic stiffness: Topology optimization to frequency-dependent target values
     

Full Vehicle Simulation

  • Driving maneuver evaluation: road excitations, vibrations
  • NVH-critical components identification: topology, vibration, noise
  • Wear and emission prediction 
  • Energy distribution and driving maneuver 
     

Tools Available

  • CFD: STAR-CCM+, OpenFoam, COMSOL, GT-Suite
  • FEM: Nastran, Abaqus, Optistruct, COMSOL, IAV Sbnoise
  • MBS: SimulationX, ADAMS, SIMPACK
  • Vehicle simulation: Carmaker, Simao, SimulationX, AdamsCar, SIMPACK
„We drive innovation in chassis development, offering unparalleled expertise from concept to completion, ensuring every journey is safe, comfortable, and exhilarating”

Dr. Toni Feißel

Products & Services
IAV GmbH
Carnotstrasse 1
10587 Berlin
Germany

+49 30 3997-80
© IAV 2025