From the idea ...

TaskThe specific components of special-purpose vehicles must be integrated in the existing basic vehicle in the best way possible.

Due to the ongoing decrease in available installation space, the package ofmodern vehicles makes it very difficult to integrate additional components. This is true for visible areas, such as the instrument panel, as well as for installation positions “hidden” behind cladding or panelling.

Smart concepts and detail solutions are required that do not entail substantialchanges to the basic production version of the vehicle. Another challengedevelopers are faced with is to adapt the specific components to the high-quality interior design of modern vehicles.

The integration of electric components into the vehicle’s production powersupply system requires major interventions, especially on modern vehicles fullyinterlinked by a CAN bus. Electric components can no longer be integratedinto the CAN control unit system and messages no longer be imported andexported by simply “connecting” the respective components, as in the past. It is, for example, no longer possible to subsequently add functions to thebasic vehicle’s CAN bus without performing special measures.

From the Design Sketch to the Finished Test Vehicle

SolutionIAV is ideally equipped to deal withthese demanding tasks. We providea depth of competence inelectrics/electronics, developing specific exterior and interior components, parts list systems aswell as in testing and constructingtest vehicles. We use modern projectmanagement tools to reach the targets set by the “magic triangle” ofdeadlines, quality/technology andcosts.

Development of Special-Purpose Vehicles

Excellence in Automotive Research and Development www.iav.de

Special-Purpose Vehicles

u Public-authority vehicles,

e.g. police cars

u Emergency ambulances

u Fire command vehicles

u Taxis

u Driving-school vehicles

u Vehicles equipped with driver

assistance systems

Armored VehiclesIndividualization

u IAV also has a broad range

of development expertise in

relation to individualizing

vehicles and to armored

vehicles (armoring classes

B4 to B7).

Concepts – Design – Product Development

Conceptsu Package layoutu Development of concept variantsu Concept visualization/design sketches (to support decisions)

Designu Virtual and actual package analysesu Components and assemblies designu Preparation of drawings

Development of Power Supply Systemu Concept selectionu Component selectionu System diagramu Wiring diagramu 3D wire routing (package)u Electromechanical designu Form-board drawing (production drawing)

Control Unit Developmentu Feasibility analyses (CAN connection, validation, etc.)u Algorithm definitionu Preparation and monitoring of specificationsu Algorithm integration (power supply control unit/door control

unit/steering column switch module, etc.)u Vehicle testing (CAN/special functions)u Preparation of drawingsu Clearance support

Documentationu Assembly instructions, installation documentationu Circuit diagramsu Support in preparing user manuals and service documents

Development of Special-Purpose Vehicles

Comfort CAN Comfort CAN

Power supplycontrol unit

Door controlunit

Steeringcolumn switch

Instrumentcluster

Testingu Planning and coordinating test drivesu Assembly and disassembly testsu Component and vehicle tests

1 Environmental simulation (cold and hot weather, paint resistance, sunlight simulation, corrosion)

1 Component tests (e.g. continuous operation of doors and lids)1 Misuse tests1 Support for vehicle endurance and fatigue strength tests

u Vehicle safety1 Offset, lateral and rear impacts1 Head impact tests1 Airbag inflation tests

u Function testsu Preparation of EMC measurementsu Stall-current measurementsu Start-up

Process IntegrationDepending on the client’s need, IAV's special-purpose vehicles team also takes care ofintegrating these vehicles in the production or assembly processes concerned. Here, it makes no difference to the special-purpose vehicle experts whether vehicles areto be assembled by hand or "polished" on the mass-production line. Support starts asearly as in the planning phase and is provided in close consultation with the Production,Quality Assurance and Logistics departments of the manufacturing site until pre-production and start of production. If needed, IAV also provides a task force after SOP.

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Door endurance testing

Prototype Construction

u Construction of test and press

demo vehicles

u Manufacturing of prototype

parts1 Stereolithography1 Selective laser sintering1 Fused deposition modeling1 Vacuum casting1 Deep drawing

u Calibration of prototype parts

System Integration

u Entering data into the database

u Definition of technical

constraints and prohibitions

u Preparing, coordinating and

monitoring clearances

u Change management

Contact: torsten.masson@iav.de +49 (53 71) 8 05-12 55

Contact: markus.gellersen@iav.de +49 (53 71) 8 05-15 30

Development of Special-Purpose Vehicles

www.iav.de

F05

/05 Further Activities

u Product managementu Project managementu Marketing/sales supportu Procurement supportu Support in financial controllingu Support in quality assurance

Marketing/sales support includes the evaluation of customer complaints and, based on the results, the preparation of model improvements, analyzingcompetitors’ products, observing and introducing new technologies as well ashelping with the preparation of marketing campaigns, service and repairmanuals.

IAV’s scope of services may, upon request of the client, even go as far as providing support in procurement processes, i.e. selecting, assessing andmonitoring suppliers and coordinating sample delivery processes, in financialcontrolling, e.g. elaborating cost-saving measures, and in quality assurance,e.g. by examining and guaranteeing conformity with group guidelines, standards, rules and laws.

… to Mass Production

Cost Optimization

Fierce competition and strong cost

pressure in the special-purpose

vehicles sector are counteracted by

cost-effective solutions. This includes:

u Optimizing component costs by

way of close cooperation with

component suppliers as early as in

the design phase

u Adapting production processes to

the number of units ordered

u Optimizing production methods and

assembly processes

u Closely cooperating with the client’s

Procurement and Controlling

departments

Product planning

Project management

Package, concepts, design

Product development, design

Prototype construction and testing

Clearances and system integration

Process integration, production

Procurement activities

Marketing and sales

Quality assurance and measures

18-24 months of special-purpose vehicle development

Preproduction, production