Accelerate The Vehicle Development Process

Earlier, faster, cheaper, better
How to accelerate the vehicle development process

and utilize the in-use phase?
Rainer Schantl, Veronika Obersteiner, Martin Absenger, Katrin Moser
AVL List GmbH (Headquarters) Public

Today’s Presenter
Rainer Schantl
In 2002 Rainer Schantl started as a

development engineer at AVL Graz.
He earned experiences in 1D fluid dynamic

simulation, real time simulation, Hardware-in-
the-Loop applications, testbed automation,
measurement technologies as well as
development methodologies in the powertrain
development process in different roles.
Since 2014 he is part of the IODP team

responsible for process innovation &
implementation.
2020 he became a team leader in IODP.
Rainer Schantl, Veronika Obersteiner, Martin Absenger, Katrin Moser | IODP | 10

Public /3
Dezember 2020 |
Today’s Agenda
1 The Main Drivers

Number of prototype vehicles, time-to-market, TCO
2 Process innovation & implementation

The 6-step approach: How to improve efficiency in the development process at our customers?
Customer project examples linked to the expended V-Cycle
3 Summary
Key success factors
4 Q&A

Public /5
Dezember 2020 |
About Us
Public
AVL COMPANY PRESENTATION
 IODP bridges the gap between the virtual and real world to create
an open development ecosystem.
 Our holistic development approach considers the whole system at

every stage – from concept design over SOP to vehicle in-use
phase.
 IODP enables connectivity data sharing between tools,

departments and even third-party solutions to accelerate your
workflow.
 It is built on a philosophy of openness that goes beyond tools and

manufacturing techniques.
Development Ecosystem
• Focus on the vehicle

development process
• Functional oriented view
• Interplay of
domain/application focused
activities in different
departments
• Need for a seamless and

connected process to foster
process innovation

Public /8
Dezember 2020 |
The Main Drivers
Public
AVL’s answer to deal with complex decisions –
The holistic view on product development
Business strategy Product cost analysis

Market potential Organizational change
Vehicle Portfolio mix Energy consulting
Technology roadmap
Vehicle strategy &
VEHICLE portfolio are boundary
STRATEGY & conditions for us
PORTFOLIO
Process benchmark Capacity &

Process innovation & technology benchmark
EFFICIENT EFFICIENT
implementation DEVELOPMENT SIMULATION & Efficient operation
PROCESS TEST FACTORY
The development We define
process is in the requirements for
Digitalization benchmark Virtualization roadmap & simulation, test
center of our
analysis implementation factory & process
digitalization
Public / 10
Dezember 2020 |
Main Driver - Motivation
Comprehensive approach:
Customer Customer needs:

strategic targets: Delivery of suppliers:
• Application know how
• Reduction of (in Powertrain dev. Process) • Engineering services
prototype vehicles • Testing & measurement solutions
• Reduced time to • Tools to support
market development efficiency • Simulation software
• Lower TCO • Tools to enable virtual • Methodology & tools
product development
AVL’s Process innovation & implementation approach:

• Scoping: Customer focus and target: e.g.: reduce no. of prototype vehicles
• Experts: Workshop in order to define most sexy tasks
• Prove: Pilot projects in order to quantify technical & quality benefits
• Invest: Cost reduction calculator to quantify commercial benefits
• Implement: Integration into process including ramp-up
• Support: AVL experts help customer engineers
Public / 11
Dezember 2020 |
The 6-Step Approach
Public
Support the change process at the customer: Legend:
Consultative lead
AVL’s generic 6-step approach Engineering lead
Equipment lead
Project phases:
1 2 3 4 5 6
Expert Pilot Commercial Implementation
Scoping Service
Workshops Projects Analysis Ramp up
Project/program management
Milestones:
Define Identify low Technical Commercial Customer

focus topics hanging fruits benefits benefits ready to go
INVEST
DECISION
Time 3M 6M 1Y 2Y
Public / 13
Dezember 2020 |
1) Value streaming
I Increasing the productivity in same working environment (automation, new methods,..)
II Shifting workload to other testing environment (e.g.: shifting RDE tests from road to
powertrain testbed)
Testing environment
Simulation Virtual
Virtual Component
Component Engine
Engine Powertrain
Powertrain Chassis
Chassis Road
Road
Simulation
Test Bed
Test Bed Test Bed
Test Bed Test Bed
Test Bed Test Bed
Test Bed Dyno
Dyno Testing
Testing
I
Development
II
and testing
today
Performance
activities
10% 20% 10% 60%
future 15% 10% 18% 10% 5% 40%
today
Emissions
3% 1% 20% 50% 26%
future 10% 20% 13% 15% 25% 15%
today
Fuel consumption
10% 5% 35% 25% 10% 15%
future 15% 5% 5% 32% 25% 5% 10%
today
OBD
8% 2% 2% 40% 48%
future 15% 25% 5% 25% 30%
today
Drivability
3% 1% 4% 8% 84%
future 15% 5% 8% 25% 15% 30%
today
Handling
10% 90%
future 20% 8% 20% 10% 40%
today
ADAS
10% 5% 10% 75%
future 20% 20% 15% 20% 25%
today
Sound / NVH
5% 5% 25% 15% 20% 30%
future 15% 10% 28% 20% 10% 15%
today
Functional safety
5% 30% 10% 10% 5% 40%
future 10% 45% 15% 15% 5% 10%
today
Durability / Robustn.
5% 20% 20% 10% 10% 35%
future 10% 30% 28% 15% 5% 10%
today
Climate comfort
10% 15% 75%
future 20% 25% 10% 45%

Public / 14
Dezember 2020 |
Consultative lead
Equipment lead
Project phases:
1 2 3 4 5 6
Scoping Service
Milestones:

INVEST
DECISION
Time 3M 6M 1Y 2Y
Public / 15
Dezember 2020 |
2) Expert workshops: Approach & Example results
Consider: Effort of tasks, maturity of methods & tools, attractivity considering customer
specific boundary conditions
Example: transmission driveability calibration
Customer & AVL

experts:
• xCU Calibration
• Testbed/testing
• Automation
• Tools
• Methods
• …
Example: Results from European based OEM

Analyzed calibration tasks: 70
Meaningful tasks to apply methods: 29 ca. 40%
Most attractive tasks to apply methods: 6 ca. 10%
Public / 16
Dezember 2020 |
Consultative lead
Equipment lead
Project phases:
1 2 3 4 5 6
Scoping Service
Milestones:

INVEST
DECISION
Time 3M 6M 1Y 2Y
Public / 17
Dezember 2020 |
3) Pilot project (Example)
Customer Reference: US OEM hybrid calibration on powertrain testbed
Published @ 12th CTI conference Novi, MI 2018

Public / 18
Dezember 2020 |
Consultative lead
Equipment lead
Project phases:
1 2 3 4 5 6
Scoping Service
Milestones:

INVEST
DECISION
Time 3M 6M 1Y 2Y
Public / 19
Dezember 2020 |
4) Commercial Analysis
Cost Reduction Calculator: transparency

for commercial targets
Calculates:
• Total cost of ownership (TCO) graph
• Cost reduction graph
• Reduction of prototype vehicles/parts
• Reduction of engineering effort
Considering customer specific:

• Costs of testing environment & UUT
• Effort for development tasks
• Invest / Operating costs
 For all possible working environments

Public / 20
Dezember 2020 |
Consultative lead
Equipment lead
Project phases:
1 2 3 4 5 6
Scoping Service
Milestones:

INVEST
DECISION
Time 3M 6M 1Y 2Y
Public / 21
Dezember 2020 |
Customer Project Examples

Linked to the expended V-cycle
Public
Vehicle development process
SOP
Concept Develop/Calibrate Validate In-Use
Topic: Virtual shift strategy calibration and validation
Objective: Shift vehicle tests to virtual world

Public / 23
Dezember 2020 |
Anonymized Customer Reference
virtual shift strategy calibration & validation
Frontloading and virtualization of shift strategy Results:

Criteria Initial optimized
calibration
Number of shifts 48 20
Virtual prototype:
Toggle shifts 12 1
Average acceleration reserve 1,06 1,19
Model integration and
Co-simulation
Objective Assessment
of shift strategy
Virtual test track: Rechberg
Published @ 13th
CTI conference
Novi, MI 2019
Benefits:
 Significant lower prototype vehicle usage (-50%)
 Reduce calibration/validation effort by simulation(-30%)
 Due to high maturity of virtual calibration result more focus on
details in the real vehicle

Public / 24
Dezember 2020 |
SOP
Topic: Simulation based optimization in concept phase
Objective: Vehicle performance and driveability
Opportunity: Re-use of models later in the development process

Digitalization of the vehicle development process – what to do next?
Public / 25
Dezember 2020 |
Official Customer Reference
Mercedes-AMG
Simulation-based optimization of vehicle performance and driveability targets in digital concept phase
AVL frontloading tool-chain Project results (example)
Tool Contribution:
 AVL VSM™ Vehicle dynamics simulation
 AVL-DRIVE™ Objective vehicle attribute assessment
 AVL CAMEO™ Model-based optimization
Goal of the common project

Development of a tool-based methodology for automatic closed-loop optimization
of vehicle attributes on system and component level.
Approach:
1. Vehicle Benchmarking
2. Target definition of vehicle driving attributes (performance, driveability…)
3. DoE-based optimization of engine torque characteristics (stationary and transient):
4. Output: specification data of engine relevant hard- and software components
Goals:
• Optimal design of different technologies (downsizing, turbo-charging, hybridization, …)
• Increased product maturity already at begin of hardware-based development phase
• Fulfill ever stringent legislative requirements
• Ensure fulfillment of customer expectations regarding comfort, efficiency, driveability
and performance for everyday driving and on the race-track
• Reduce development loops, time and costs

Public / 26
Dezember 2020 |
SOP
Topic: Advanced calibration of driveability
Objective: - Correlation between road and testbed

- Integration in testbed environment at customer

Public / 27
Dezember 2020 |
BMW – Correlation Road vs. Vehicle Testbed vs. Powertrain Testbed
Correlation of vehicle (Mini Diesel) on test track vs. Scope and benefits
vehicle on PTTB vs. powertrain on PTTB  Driveability maneuvers:
AVL tool contribution:  Tip-in Comfort / Sport / LSD off in M
AVL VSM™ Realistic vehicle dynamic simulation  Tip-out Comfort / Sport / LSD off in M
 Tip-in in D with / w/o Sailing
AVL-DRIVE™ Objective driveability assessment Scope  Tip-in from Creep
 Acceleration - constant load
 Integration of toolchain incl. CAMEO @ BMW
 Comparison of over 4700 evaluable driveability

maneuvers
 10 hours net testbed runtime for vehicle on PTTB
and powertrain on PTTB each (vs. 59 hours testing
Performance
time with vehicle on test track)
 5 repetitions of each maneuver and operating point
 Overall driveability rating nearly identical

 More than 80% of criteria below 0.5 DR difference
Quality
 Very high repeatability
 Proof of portability from road to powertrain testbed

Public / 28
Dezember 2020 |
Customer Reference
ACD on Chassis Dyno Testbed
Advanced Calibration for driveability for DCT on Chassis Dyno Testbed
AVL frontloading tool chain Project results
AVL Tool Contribution:
 AVL CAMEO™ Realistic vehicle dynamics simulation
 AVL-DRIVE™ Objective driveability assessment
 AVL DriCon™ Vehicle actuation and interfaces
 AVL IndiCom 2™ Combustion excellence
 Groud Fixing Device
Ground Fixing Device
Scope of the project Results of correlation:
 Installation of prototype vehicle on chassis dyno tested
 Execution of driveability maneuver performed with AVL-Drive™ and AVL
DriCon™ on LOMMEL test track and on chassis dyno including correlation
analysis
 Torque accuracy check: Analysis of crankshaft torque compared to the
ECU calculated engine torque on CAN bus for steady state and dynamic Drive Away – Standing Pareto front
conditions including automatic result analysis and report generation Start (at multi criterion optimization)
 Label sensitivity study based on AVL CAMEO™ DOE testing (Tip-in
downshift from constant speed, 30 kph, 10-100%)
 Multi-parameter optimization and calibration based on different
target settings (comfort, sport, …)
In Gear Torque Tip-in Downshift DoE
Difference Iso-Plot

Public / 29
Dezember 2020 |
SOP
Topic: Advanced calibration of driveability and NVH
Objective: Finding compromise between competing targets

Public / 30
Dezember 2020 |
Customer Reference
HMC R&D – Powertrain NVH Development
Model-based Driveability Development frontloading on NVH-Powertrain Testbed
AVL frontloading tool-chain Overview

Tool Contribution:
 AVL VSM™ Vehicle dynamics simulation
 AVL-DRIVE™ Objective vehicle attribute assessment
Contribution
 Model-based frontloading of Powertrain mounting development with respect to vehicle Hyundai Sonata 1.6 TGDI, 8AT
driveability on a NVH Powertrain Test Bed MY2019
NVH Powertrain test bed
 Real Powertrain in-the-loop with virtual vehicle incl simulation of powertrain mountings
 Correlation of 9 different operation modes at different operation points
Comparison of different
 Comparison of different torque stiffness rod variants with respect to Driveability torque rod stiffness
 Driveability test maneuvers: variants:
 Tip-In / Tip-Out at different speeds, gears, acc. pedals
 Drive away including gear shifts
 Performance acceleration – 0-100kph
 Acceleration with constant loads and load increase
 Engine start and shut off
 Correlation regarding:
 AVL-DRIVE™ rating
 Physical signal level (chassis acceleration, engine speed, turbine speed, etc.)

Public / 31
Dezember 2020 |
SOP
Topic: Highly reproducible emission and RDE testing
Objective: - Root cause analysis

- Preparation of test trips
- Fuels & lubricants analysis (contribution to CO2 reduction)

Public / 32
Dezember 2020 |
TOTAL efficiency development
Identify the influence of engine oils to the fuel consumption
AVL proprietary tool Project results
AVL Tool Contribution:
 AVL FRED realistic driver simulation (concept tool, available earliest 2020)
 AVL-DRIVE™ Objective driveability assessment
Goal of the common project

 Identify the influence of different engine oils to the fuel consumption in legal
cycles
 Perform a statistical relevant number of test per engine oil to identify
differences in the fuel consumption.
 Use a robotic driver to eliminate the driver influence.
 Use an emission bench AMA and exhaust flow meter EFM to determine the
fuel consumption.
 Effective test procedure using a rapid cooling unit to cool down the vehicle to
cold start temperatures within 30min. Cooling the components:
• Engine coolant
• Engine oil
• Exhaust aftertreatment system

Public / 33
Dezember 2020 |
SOP
Topic: Battery life cycle management
Objective: - State of health assessment

- Residual value assessment
- In-use lifetime optimization
- Optimize cell testing duration
- …
Public / 34
Dezember 2020 |
In-Use phase: Battery Lifetcycle Management
AVL Solution - Modular Offers
FLEET MONITORING BATTERY LIFETIME Update over the Air
& ANALYTICS PLATFORM METHODOLOGY

Monitor battery condition KPI generation
Analyze data
LIMIT POWER IN ON-BOARD
Battery state of health
Battery degradation BATTERY MANAGEMENT
Battery remaining value SYSTEM
System Development
Optimization
USE IN-USE AGING FOR

NEXT GEN BATTERY
DEVELOPMENT
DATA COLLECTION RECOMMENDATIONS TO
Secure data transfer EXTEND LIFETIME Maintenance
& Operation
PREDICT END OF LIFE

IN OPERATION FOR EACH
VEHICLE IN THE FLEET

Public / 35
Dezember 2020 |
SOP
Examples for electrification: (mostly without official customer reference yet)

• Speed up e-motor & inverter development: Reduce TTM by >50% - virtualization, digitalization
• Innovative Lösungen zur Applikation hybrider Antriebe: ATZ Experten-Forum Powertrain, Oct.2020
• Improve efficiency for development of electric powertrains: system integration, FUSI & calibration
• Real-life electric range validation and optimization in the lab
• Advanced calibration for driveability for BEV on PTTB: JLR
• Reduction of battery cell testing effort by battery lifetime prediction via digital twin
• Simulation based NVH optimization of PEM fuel cell
• Efficient mode change calibration of (P)HEV on PTTB
• Efficient design & validation process including mechanic development & validation
• Thermal optimization of electric powertrains: German OEM – Methodic Symposium Wiesbaden, Nov. 2019
Public / 36
Dezember 2020 |
What are the key factors for successful
implementation?
Summary
Public
Key factors for success
Consideration of the human

Management contribution Relationship with suppliers
factor
• Clear top management • Introduction of supplier as • Team-building-friendly

decision regarding focus partner in this change boundary conditions
areas and strategic process
direction • Early involvement of
engineers
• Prioritization &
enablement of boundary • Openness of team
conditions (people, members
budget, resources,
prioritization)
• Demonstrate personal
advantages of every
involved engineer
(incentive)

Public / 38
Dezember 2020 |
Integration of new methods in standard processes
considering the human factor
 Change in process is always a top management decision!
 Humans in the spiral of change:

Changes causes uncertainty
 uncertainty causes fear
 fear causes resistance
 resistance causes refusal for change
 The application workshops consider the human factor on an engineer level via:
Turn change into an

Concentrate on the Start a opportunity
Be part of the change most promising and
meaningful tasks team building process (e.g. visibility @ CTO for
involved engineers)

Public / 39
Dezember 2020 |
Summary

Scoping Service
IODP project/program management
1. The 6-step program – AVL’s lessons learned out of 20 years experience in supporting
customer change processes
2. Key success factors for implementation:
− Clear management decision incl. communication & set-up of boundary conditions
− Consider the human factor
− Cross-domain team is key to succeed (@AVL: 1 team coordinate >300 AVL engineers
globally & leads these projects as single point of contact for our customers)
Finally, it’s not rocket science: it just has to be done

Public / 40
Dezember 2020 |
Webinar Series: The Development Ecosystem
What does a future-proof open development

ecosystem look like?
How can decisions on development efficiency be

made for a competitive vehicle portfolio?
Digitalization of the vehicle development process –

what to do next?


Public / 42
Dezember 2020 |
Contact
LOCATION PHONE EMAIL WEBSITE
AVL List GmbH +43 316 787-0 iodp@avl.com www.avl.com/iodp

Hans-List-Platz 1
8020 Graz
Austria

Public / 43
Dezember 2020 |
Thank you
www.avl.com
Public

Accelerate The Vehicle Development Process

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Accelerate The Vehicle Development Process

Uploaded by

Copyright:

Available Formats

Earlier, faster, cheaper, better

How to accelerate the vehicle development process

Rainer Schantl, Veronika Obersteiner, Martin Absenger, Katrin Moser

AVL List GmbH (Headquarters) Public

In 2002 Rainer Schantl started as a

He earned experiences in 1D fluid dynamic

Since 2014 he is part of the IODP team

2020 he became a team leader in IODP.

Rainer Schantl, Veronika Obersteiner, Martin Absenger, Katrin Moser | IODP | 10

1 The Main Drivers

2 Process innovation & implementation

Rainer Schantl, Veronika Obersteiner, Martin Absenger, Katrin Moser | IODP | 10

 Our holistic development approach considers the whole system at

 IODP enables connectivity data sharing between tools,

 It is built on a philosophy of openness that goes beyond tools and

• Focus on the vehicle

• Need for a seamless and

Rainer Schantl, Veronika Obersteiner, Martin Absenger, Katrin Moser | IODP | 10

The Main Drivers

Business strategy Product cost analysis

Process benchmark Capacity &

Customer Customer needs:

AVL’s Process innovation & implementation approach:

The 6-Step Approach

Define Identify low Technical Commercial Customer

10% 20% 10% 60%

future 15% 10% 18% 10% 5% 40%

future 10% 20% 13% 15% 25% 15%

future 15% 5% 5% 32% 25% 5% 10%

future 15% 25% 5% 25% 30%

future 15% 5% 8% 25% 15% 30%

future 20% 8% 20% 10% 40%

future 20% 20% 15% 20% 25%

future 15% 10% 28% 20% 10% 15%

future 10% 45% 15% 15% 5% 10%

future 10% 30% 28% 15% 5% 10%

future 20% 25% 10% 45%

Rainer Schantl, Veronika Obersteiner, Martin Absenger, Katrin Moser | IODP | 10

Define Identify low Technical Commercial Customer

Customer & AVL

Example: Results from European based OEM

Define Identify low Technical Commercial Customer

Rainer Schantl, Veronika Obersteiner, Martin Absenger, Katrin Moser | IODP | 10

Define Identify low Technical Commercial Customer

Cost Reduction Calculator: transparency

Considering customer specific:

 For all possible working environments

Rainer Schantl, Veronika Obersteiner, Martin Absenger, Katrin Moser | IODP | 10

Define Identify low Technical Commercial Customer

Customer Project Examples

Concept Develop/Calibrate Validate In-Use

Topic: Virtual shift strategy calibration and validation

Objective: Shift vehicle tests to virtual world

Rainer Schantl, Veronika Obersteiner, Martin Absenger, Katrin Moser | IODP | 10

Frontloading and virtualization of shift strategy Results:

Virtual test track: Rechberg

Rainer Schantl, Veronika Obersteiner, Martin Absenger, Katrin Moser | IODP | 10

Concept Develop/Calibrate Validate In-Use

Topic: Simulation based optimization in concept phase

Objective: Vehicle performance and driveability

Opportunity: Re-use of models later in the development process

 AVL-DRIVE™ Objective vehicle attribute assessment

 AVL CAMEO™ Model-based optimization