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INTELLIGENT TECHNOLOGIES

IN VEHICLE DEVELOPMENT
Engineering Centers

Founded in 1978, FEV has become an internationally in Aachen, Detroit, Dalian and Pune. In addition, FEV
recognized leader in the design and development of also offers its engineering competency in the form of
internal combustion engines and a supplier of ad- resident engineers who are placed at client locations.
vanced test and instrumentation systems. FEV has
consistently expanded its range of expertise into This brochure provides examples of FEV’s develop-
powertrain, calibration, electronics / electrification, ment capabilities in vehicle-related systems, which in
vehicle NVH and chassis mechanics. Germany are concentrated in Alsdorf, near Aachen.
These capabilities are also provided by FEV’s other
Today, more than half of the FEV’s 1,800 employees engineering centers.
are working on vehicle system projects. They are
primarily placed in FEV’s engineering centers located

FEV Vehicle Application Center near Aachen, Germany

FEV has access to a new test track that is located


within a 10 minute driving distance of FEV’s Vehicle
Application Center. It includes a 3.0 km autobahn
loop and skidpad. Additional driving trials as well as
hill climbing test areas are also under development.

2 Test track near FEV Vehicle Application Center


Vehicle Development

Modern vehicle development has to be quick,


efficient and reliable. FEV provides superior develop-
ment quality for any form of vehicle development FEV’s unique experience includes:
program.
 Benchmarking database of over 100
FEV’s engineering portfolio contains many aspects of vehicles
 Vehicle powertrain integration
performance and vehicle subsystems. Our portfolio
 Chassis, ride and handling
is also complimented in all vehicle body and struc-
 NVH, sound design
ture-related topics with the engineering expertise of
 Homologation
FEV’s preferred partner, EDAG.  Future vehicle concepts

 Full vehicle development with partner EDAG

 Derivative vehicle development

FEV Vehicle Development Portfolio

Active Chassis
Safety
Project
Durability Management
Testing

Package Ride & 
DMU Handling
FEV Scatter-bands Noise
Vibration

Electrics / 
Thermal
Electronics

Intake Homolo-
System gation

Heating / 
Air Conditioning

Exhaust
Energy
System
Management

Powertrain
Powertrain Calibration
Mounting
Driveline
Development
Engine
Development

Opel Meriva development in


cooperation between GM, EDAG, FEV 3
Chassis

The chassis team consists of qualified engineers,


who have gained valuable experience working for
FEV, OEMs and Tier1 chassis / vehicle dynamics FEV’s chassis engineering capabilities include:
teams. FEV’s chassis experts have proven their
competence to many satisfied customers.  Chassis development from concept up to SOP
 Chassis tuning for optimized ride and handling
The test facilities available consist of workshops performance
 Benchmarking and target setting based on FEV’s
with divided areas (allowing confidentiality for each
worldwide accepted scatter-bands
customer), proving grounds with a vehicle dynamic  Troubleshooting to obtain the best short-term
platform, as well as measurement equipment for all solution
of the relevant vehicle dynamic parameters,  Development and calibration of active chassis

such as: devices, e.g. active damper and active steering


 CAE and testing support

 Steering wheel angle


 Steering wheel torque
 All 6 Degrees of Freedom (DOF)

for the complete vehicle Chassis Development Tasks


(position, speed and acceleration)
Concept Layout Design
 Brake pedal force and travel

 Additional equipment for measuring force, dis-

placement or acceleration regarding any desired


component or system of the vehicle

The following CAE tools are used to provide


strong simulation performance: Kinematics and Prototype
Compliance Workshop

 ADAMS/ADAMS Car, Motion View


 Nastran, Ansys
 Hypermesh, I-DEAS
® ®
 MATLAB   / Simulink 

 Design of Experiments (DoE)

 In-house coding for quick and easy set-up Vehicle Dynamics Tuning and
Evaluation Measurement

Validation Chassis Electronics

SOP Temp.-Sensor 2
Phone System

Navigation

Entertainment
MOST

Gateway
Diagnostics
Tester Communication

Release
Temp.-Sensor 1 Air Conditioning
LIN Body CAN
Sunroof CU Display Cluster

Door CUs Engine CU Powertrain CAN

Transmission

ABS / ESP

4
Noise Vibration Harshness (NVH)

FEV can manage overall vehicle NVH development FEV’s project managers are skilled in coordinating
programs. These programs are typically conducted in activities between the different working groups,
close cooperation between OEM specialists, suppliers ensuring a streamlined development process.
and FEV. FEV provides all of the necessary testing FEV has successfully covered programs from small
and CAE facilities, as well as 40 years of experience in motorcycles up to heavy-duty trucks.
NVH development.

Interior NVH Quality:


Sound Insulation
Squeak and Rattle
HVAC Noise
Electro-Servo Motor Noise
Audio and Entertainment Systems
...
NVH “fingerprint” Campbell diagram

Aero Acoustic:
Body Shape
Sealing
Windows
Side Mirror(s)
Chassis NVH: Wipers
Stiffness of Axles ...
and Subframes
Bushing Insulation
Tire Noise Powertrain-induced NVH:
Steering NVH Engine and Transmission
Brake NVH Driveline
... Body NVH: Powertrain Mount
Global Stiffness Intake and Exhaust System
Stiffness of Front-End Section ...
Impedances at Interface Points
Vibro-Acoustic Transfer Functions
Heavy Layer Distribution
...

FEV’s NVH engineering capabilities include:

 Interior and exterior noise development


 Full responsibility for vehicle NVH development

 System and component level target setting

 Development for the OEM, according to

specific processes and strategies


 NVH robustness for production

 Sound design

 CAE and testing support using FEV’s unique

in-house tools and methods MBS driveline model

5
Automotive Software

Integrated Model-Based
Requirements Software Development and Calibration Process Acceptance Tests
for the Development of Control Units by
Feasibility Studies
System Simulation

System Design Integration

Detailed Simulations Vehicle


Calibration
Control Design Component

Model-in-the-Loop (MiL) Calibration on the Test Bench


Hardware-in-the-Loop (HiL)
ECU Code
Software Design SiL/PiL Unit Testing
MiL Unit Testing Prototype or Base Calibration
Software-in-the-Loop (SiL)
Production Target Processor-in-the-Loop (PiL)

Coding

FEV is experienced in developing software functions, The models can be used as “executable specifica-
from initial concept to production code, for engine tions” and can be applied to simulations, control
control, hybrid-electric powertrains, transmissions, design, verification and validation. This enables an
engine-generator sets and other systems. early understanding of the challenges and can provide
direct responses for each phase of development,
FEV offers the design and implementation of standard as well as help define appropriate testing.
control concepts, as well as model-based methods
for advanced technologies, such as CAI, HCCI, Flex-
Fuel, turbocharged CNG, new hybrid and exhaust gas Functional Development and Integration
aftertreatment concepts, and even fuel cell systems.
 Model-based control concept and
Specially designed human-machine interfaces, such software development
as the display in a hybrid vehicle, facilitate consumer  Rapid control prototyping for demonstrators

acceptance and promote their identification with  Production vehicle software code

new products and technologies. Software quality  Diesel, gasoline, alternative fuels

is ensured by using standardized and managed  Automated transmissions

processes throughout the development process,  Hybrid electric vehicles, fuel cell vehicles
from requirement specifications to acceptance tests  Advanced technologies (HCCI, SCR, etc.)
for the vehicle. FEV software development is CMMI ®
 Simulink  / Stateflow / RTW /TargetLink, ASCET SE, C
Maturity Level 2 certified.  CMMI process model for software and

hardware development
6
Validation and Verification
Hardware-in-the-Loop (HiL)

Based on experience from a number of


production vehicle projects, FEV is capa-
ble of generating relevant test cases for
validation and verification using Model-
in-the-Loop (MiL), Software-in-the-Loop
(SiL) and Hardware-in-the-Loop (HiL)
simulations.

FEV can complete functional, commu- FEV Model Library

nication, network, I/O- and regression


tests on HiL test benches or on-site. Our
extensive experience in simulation and
calculation with MATLAB ® / Simulink ®
can provide the detailed modeling of
control systems for internal combustion
engines, hybrid drives, all electric drives
or fuel cell systems.

Hardware-in-the-Loop Support

 Real time model development


 HiL-test bench setup
 Test plan generation
 Test execution and documentation
 Support of test automation
 Network testing
 Offline vehicle calibration

7
Calibration
Passenger Cars

FEV’s diesel and gasoline calibration knowledge is FEV uses standards and tools (TOPexpert Vehicle
based on many years of calibration experience with Suite) for the calibration tasks, to ensure an effective,
a large number of OEMs and other clients. This broad robust, fast and cost-efficient calibration process.
base of project experience affords
FEV engineers the opportunity to Design of Experiments (DoE)
work with different project require- methods and dynamic measurement
ments and applications in a variety of procedures are used to calibrate the
target markets. This experience con- complete engine map.
tributes to FEV’s capability to serve
as a proven development partner for Additionally, a global optimization of
production calibration and turnkey specific map areas leads to a target
development solutions. Emission chassis Dynamometer focused development on the following:

Cold climate test trip Climatic test cell

Meeting customer requirements


for drivability, engine performance ✓  Limiting emissions
and robustness, emissions and fuel ✓  Fuel consumption
economy, among others, is a key to ✓  Combustion noise
ensuring customer satisfaction. In ✓  Calibration stability
addition to the calibration of control ✓  Interactions between
strategies using modern standard different calibration
software architectures, FEV has also Hot /Altitude trip parameters
developed advanced controller con-
cepts in conjunction with its partners.

One of the main topics in the course of modern ve-


hicle development is achieving a robust calibration of
FEV’s Passenger Car Calibration
the exhaust gas aftertreatment system control maps.
 Turn key
 Global emissions and fuel consumption Independent of whether the system is a catalyst, a
requirements particle trap or NOx-reduction device, FEV’s experts
 Drivability (highest customer expectations) offer the expertise to provide optimal cost-effective
 Certification and post-launch support aftertreatment production calibrations.
 Function development

 Automated test bench and in-vehicle In order to fulfill the strong emission durability
 Tool supported calibration process
requirements, FEV provides aftertreatment systems
8
that are aged on FEV’s advanced hot gas aging test
benches.
Calibration
Trucks and Commercial Vehicles

From its inception, FEV has focused on the develop-


ment of heavy-duty and industrial diesel engines.
To initiate development, we have generated a wide
range of technologies and procedures, dedicated to
the specific demands of commercial vehicles and
industrial engines. In addition to the classical emis-
sion and performance tasks, FEV is accustomed to
working on engine integration, hybrid drivetrains and 0.5
NVH optimization.
0.4
FEV engineers perform diesel combustion system
development projects for high fuel efficiency and low
PM [g/kWh]

0.3
emission engine concepts, as well as special services,
such as engine certification and emission deteriora-
EURO I
tion factor evaluation programs. Great emphasis is 0.2 EURO II
placed on the development of control strategies and EURO III
software functional design to implement effective and 0.1
EURO IV
robust advanced exhaust gas aftertreatment technolo- EURO V
EURO VI
gies.
0.0
0 2 4 6 8 10
Calibrations for altitude correction, hot and cold NOx [g/kWh]
operation, and the vehicle’s starting and warm-up
phases will be optimized and validated under real-life
conditions. Engine certification
in close cooperation with
As a special task during the truck calibration process,
the different engine brakes are also tested and
calibrated on the truck.

Truck and Commercial Engines

 Integration
 High efficiency combustion layout
 ECU calibration for all existing

- emission scenarios
- control strategies
- exhaust gas technologies
 Functional development

 Certification

© Team de Rooy - all rights reserved

9
Transmission
and Hybrid Powertrain Calibration

FEV’s unique production calibration approach allows


calibration of the transmission, engine and diagnostic
 functions to be combined under the direction of a
FEV enables rapid and effective calibration
with the following modern tools and processes: single team of experts. This close interaction between
the different subjects guarantees a very effective
 FEV Shift Analyzer: Effective model-based application process. FEV has gathered a tremendous
calibration of shift strategy amount of experience through AT, CVT, DCT, AMT
 FEVos: Objective shift quality evaluation
and hybrid system calibration.
and optimization
 Automated calibration testing using HiL test

benches
 Use of transmission test benches

 Universal TCU and rapid prototyping systems

(MATLAB ® / Simulink ®, dSPACE, ASCET)


for a fast application of initial prototypes and
demonstration vehicles
 Support for all common calibration systems,

such as INCA, ATI, CANape and CalDesk


 Effective and reliable requirement-based

parameter set handling

Supporting all common calibration systems

FWD / RWD transmission test bench

10
Calibration of New Powertrain Concepts
and Demonstrator Vehicles

In today’s market, the continually increasing


customer and legislative requirements demand
new powertrain concepts. These concepts must
employ new control functionalities, due to the FEV provides these Calibration advantages:
growing number of influencing parameters.
 Expertise in all future engine and trans-
mission technologies
FEV has developed a variety of powertrain
 Benchmarking analysis to compare and
concepts, which have been shown in demonstrator assess all state-of-the-art technologies
vehicles. Some of these concepts include:  Rapid prototyping for components and

controller hardware and software


 Downsizing with charging concepts,  Rapid design and optimization of a variety
direct injection and CAI of demonstration vehicles
 Alternative fuels (see page 16)
 Close interaction between simulation,
 Mild and full hybrids combustion development and calibration
 Plug-In Electric Drive with range extender departments for the best compromise
 Advanced Diesel Combustion and controls between vehicle performance, fuel
consumption and emissions.
(HECS: High Efficiency Combustion System)

Gasoline two-stage turbocharger Diesel Demonstrator with High Efficiency Combustion System

11
Plug-In electric vehicle with Wankel range extender Full hybrid vehicle with electric torque converter
On-Board Diagnostics (OBD)

In addition to legislative conformity, On-Board Diag- FEV offers significant knowledge and experience in
nostics (OBD) also have a strong impact on customer OBD calibration for any type of powertrain, engine
satisfaction and the OEM’s image, upon which the management system and vehicle market.
commercial success of the vehicle depends. Increas-
ingly strict emissions limits, advances in combustion The increasing complexity of OBD systems makes
technology, aftertreatment systems, alternative fuels the use of numerical solvers and tools essential to the
and hybrid/electric vehicle developments create more development process. These tools and methods are
and more challenges in implementing a successful not only implemented for time and workload reduc-
OBD system. These ever tightening OBD regulations tion, but also to ensure a sound calibration which
demand significant changes in OBD development fulfils all legislative and customer requirements.
processes. For example, In-Use-Monitoring-Perfor-
mance-Ratio (IUMPR) legislation stipulates that OBD One example of a tool that has been designed and
monitoring must be effective over a broad range developed at FEV is the Diagnostic Failure Simula-
of engine modes and driving conditions. Thus, the tion (DFS) Box. The tool allows On-the-fly simulation
robustness and reliability of the OBD monitors and of Lambda-sensor failures without influencing the
calibrations is of utmost importance. engine management system or hardware changes.
Thus, accurate and comprehensive testing of all
Lambda-sensor related monitors can be easily ac-
complished, safeguarding legislative compliance.
250
Monitoring Enable Conditions
Number of Monitoring Events

Regular Operation Narrow Range Monitoring


200 Wide Range Monitoring Influence of enable conditions
on monitoring results
150 Fault Case

100 Overlap inhibits


clear monitoring results
50

0
- 1.0 - 0.5 0.0 0.5 1.0 1.5
Governor Deviation

FEV OBD calibration capabilities:

 OBD II and (E)OBD calibrations integrated into turn-key


calibration projects or individual solutions
 Broad knowledge of many types of engine management systems,

from a variety of powertrain control system suppliers


 State of the art and advanced vehicle and emission concepts

 Software functional development

 High level calibration tools, off- and online

 Validation programs and test programs/facilities for worldwide markets/

OBD fleet verification Diagnostic Failure


Simulation (DFS) Box
 Homologation / certification support and preparing certification

documentation at FEV or on-site


12  Excellent contact with global legislative governing bodies
Fleet Testing

FEV has been performing vehicle testing for many Intensive testing programs, covering a variety of
years, with a focus on performance, fuel consump- driving profiles can be applied with the following
tion, emission, durability, NVH, and ride & handling. options:
Robust vehicle testing programs are still a key to
developing successful vehicles for the marketplace.  Professional drivers and technicians
 Test operations 24 hours a day / 7 days a week
FEV has served the demand for quality and reliabil-  Data recording and processing on client’s demand

ity with a close collaboration between its durability  Automatically controlled vehicle safety limits

team and the calibration specialists. FEV employs  Established data analysis procedures

a specially trained and experienced driver pool that  Transportation and preparation of the

has performed more than 35 million kilometers of vehicles on site


durability runs with the highest levels of safety. The
examination program, which is conducted by a fleet Hot Test track at City / Highway and Cold-Test in
Nardo, Italia Overland, Germany Sweden
management group and driven on specifically defined
worldwide test routes, offers statistically confirmed
results.

These routes can lead our team through the cold


temperatures of Scandinavia, the high altitudes of
the Sierra Nevada Mountains, the heat of South Af-
rica, and the demanding roads and low quality fuels
of China, Brazil, Russia and India. Testing can also
be conducted on-site at our customer’s facilities, as
well as on the challenging Nürburgring Nordschleife,
which is near Aachen. FEV offers the service of direct
collaboration in vehicle testing on customer-approved
test routes and on accessible proving grounds.
Test program
Testing under
race conditions
on the Nürburg-
FEV fleet testing capabilities: ring Nordschleife

 Experience and contacts within all


global markets
 Access and driving experiences on a

variety of proving grounds


 Professional and skilled drivers

 Robust program control in close

cooperation with our clients


 Calibration and durability experience

within one team

13
Test Facilities

The workshop contains divided areas, allowing


confidentiality for each customer.

Divided workshop areas Emission chassis dyno

Climate chassis dynamometers are available with a tem- Emission chassis dynamometers are available, which
perature range capability from -30 °C up to +50 °C. are capable of measuring low future emission levels.

Climatic chassis dyno Anchoic chassis dyno

A new test track is available within a 10 minute driving


distance of the FEV vehicle center in Alsdorf / Aachen,
Germany:

 3.0 km loop and skid pad in use (2010)


 Additional trials and climbing hills being planned
 Directly located near the FEV Vehicle Center

 Shielded from external viewing

 Initial driving trials and drive-by noise measurements

 Access to several large test tracks including F1

circuits within a short distance (e.g. Circuit de


Spa-Francorchamps, Belgium ➞ 30 min.
14
Nürburgring, Germany ➞ 60 min.)
Test track near FEV Vehicle Center
Calibration Tools

FEV’s long history of calibration knowledge has been The TOPexpert Vehicle Suite is commercially available
incorporated into the TOPexpert Vehicle Suite, which to customers and is delivered with calibration guide-
is the central platform for all of the vehicle calibration lines, individual training courses, service and main-
tools used by FEV. tenance. It can also be customized to accommodate
customer requirements.

TOPexpert Vehicle Suite (Commercially available) Combined multi-criteria


map optimization

The TOPexpert Vehicle Suite provides model-based Based on their calibration expertise, FEV engineers
calibration tools for both base and OBD calibrations have designed the PROcal tool for model-based test-
(e.g. misfire detection, thermal diagnostics, dynamic bench calibrations. Its intuitive nature enables FEV’s
AFR compensation, engine warm-up adjustment, engineers to efficiently deal with the continuously
exhaust temperature models, cold start analysis, increasing complexity of ECU calibration.
particle filter load estimation and oil dilution). The
Vehicle Speed Tracer provides real-time images of PROcal provides routines for optimal test planning,
individually configurable driving profiles. Additional model-based engine analysis and automated calibra-
TOPexpert tools enable the flexibility of data to be tion optimization.
imported, filtered and exported. It also contains tools
that can perform numerous other data processing
operations and simulate any function of the control
unit for offline calibration.

Sensitivity analysis

Calibration Methods:

 Model-based calibration solutions


 Well-defined and tool-aided calibration process FEV also offers a range of workshops, which enable
 High quality standards our customers to apply cutting-edge DoE methodol-
 TOPexpert Vehicle Suite ogy to their projects. As a customer you will gain
 PROcal for DoE-based modeling and optimization valuable insight into exactly what is needed in the
 Sensitivity analysis of control and sensor concepts field of statistics and optimization. The participants
 Tailored automotive calibration trainings gain hands-on experience, using real-world calibra-
 Customized tool development tion examples.

15
Alternative Fuels

Alternative fuels are gaining importance worldwide, A special focus is given to the interaction of these
as a substitute for oil-derived fuels, to increase re- alternative fuels with powertrain technology. FEV
source diversification, and to reduce greenhouse gas demonstrated the benefits of combining ethanol E85
and toxic emissions. FEV has developed a variety of turbocharging and a variable compression ratio.The
alternative fuel concepts for production and gathered prototype vehicle demonstrated additional benefits
vital experience in research programs, such as the through a reduction in CO2 emissions.
new cluster of excellence for tailor made fuels from
biomass.

Shell/Audi/FEV GTL Demonstrator car

Cluster of excellence for tailor made fuels at RWTH Aachen

FEV has investigated the following alternative


fuels:
 Alcohol fuels, such as ethanol, butanol, methanol

and various blends Fuel Cell Range


Extender Module
 Natural gas, biogas and liquefied petroleum gas

 Hydrogen in combustion engines and fuel cells

 Diesel substitutes as: GTL, HVO, 2nd and 3rd

Generation Biofuels, Naphtha, Gasoline / Diesel


blends

FEV´s experience with alternative fuels:

 Natural gas, GTL, LPG, alcohols, HVO, 2nd and


3rd generation biofuels, naphtha, hydrogen,
gasoline / diesel blends
 Research, mixture improvement and combustion

system development and production develop-


ment and including advanced combinations
(e. g. natural gas and lean burn, ethanol and CAI,
ethanol and VCR)
 Software development and ECU calibration,

including advanced functional development for


Combination of Flex-fuel and VCR – maximized benefit multi-fuel control gasoline and diesel; closed
loop combustion control, and model-based air
loop control
16
E-Mobility

The battery development process at FEV consists of FEV has built up a special test bench for batteries, with
a variety of different technical tasks as shown in the a power unit cycler.
E-Mobility Development Process figure. FEV’s experi-
ence covers each element of that development process.
Simulation tools are available, which have proven to be
FEV LiionMan Key Functions:
successful for establishing the system layout. FEV’s
battery design includes underbody packs, which of-  Protection of battery-cells from critical operating
fer the advantage of virtually no interference with the
points (voltage, current, temperature)
vehicle´s infrastructure. The FEV LiiONMAN system is
 Calculation of important system variables
available, offering a number of key functions, shown in
(such as SOC, SOH, power prediction)
the figure below.
 Cell- and system-diagnostics (such as detection

of worst cell, short circuit detection)


 Advanced cell diagnostic functions (such as
E-Mobility development process at FEV
model-based condition estimation, parameter
adaption concepts)

Performance Vehicle
simulation and Module and Battery manage- Battery assembly integration
requirement Cell election and
pack design ment system and testing
specification calibration

Battery Test Bench Equipment:

 Available as a container system


 Power unit (Cycler): up to 240 kW
FEV underfloor battery
 Climate chamber: -30°C up to 80°C design
 Simulation of various cooling systems

 FEV Control and Measurement System BEHR battery module with


FEV LiiONMAN
 Battery management simulation

 Separate control center

 Li-Ion Safety System

17
References

Vehicle Physics and Acoustics Development

 Saab 9-3 XWD


NVH AWD integration

 Mercedes Sprinter
Vehicle NVH development support
Chassis tuning and testing for ride and handling

© Volkswagen AG

 VW Transporter T5
Chassis / Road noise analysis

Gasoline Engines Calibration

 Mercedes 55 SLK AMG engine calibration

BMW 1.6L 4 cylinder Valvetronic


engine and transmission calibration

 Fiat Coupe 5 cylinder turbo, engine,


vehicle and OBD calibration

18
Transmission Calibration and Hybrid Development

Alfa Brera transmission calibration


Engine and hybrid calibration for


BMW X6 V8, software development in


cooperation with BMW

 Development and build of


15 ChangAn Jiexun parallel
hybrid demonstrator vehicles,
used as taxi cabs during the
2008 Olympics in Bejing, China

Diesel Engine Calibration

 Integration and calibration of Renault 3.0L V6 diesel engine


into Nissan Pathfinder and Navara, Infiniti EX, FX and M.
➞ SOP 2010

 CO2 reduction through calibration of actual


Volvo 1.6D DRIVe-vehicles

 CO2 reduction through calibration


of Peugeot 207 Blue Lion towards
99 g/km CO2 (3.8L / 100km)
 DPF Calibration development with

PSA vehicles, including the first


production program in 2000
99g CO /km 2
19

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