Automotive

Intelligent Automotive Services

AUTOMOTIVE Intelligent Automotive Services

Full range of services: realisation, operation and accompanying computations on the IABG cylinder head test stand

Full range of services: realisation, operation and accompanying computations on the IABG cylinder head test stand

Automotive

IABG has been a partner of the automotive manufacturing and supply industry for over 30 years. Today, we are one of the leading providers of testing and development services in Europe. IABG’s state-of-the-art test centre features a modern infrastructure (central supply of hydraulic fluid, cooling water, compressed air, electricity and gas) and numerous test benches for qualification testing and examination of the fatigue strength of complete vehicles, systems, components and materials. Our test laboratory is accredited and certified in compliance with established standards. As an independent service provider, we guarantee our customers absolute confidentiality.

We develop and build test benches for our customers. Our portfolio includes standard products like resonance spring and stabilizer bar test benches, test systems for steering systems as well as HiL simulators and test benches. We also build customized test systems. As general contractor, we plan and erect large test benches complete with the necessary infrastructure.

With an interdisciplinary networked pool of experts we also provide our engineering services externally. Our engineers are deployed on customer sites as project leaders, simulation experts and function developers, for example in method development projects, and often work as an independent and autonomous team at the customer’s location.

testing and fatigue strength

Complete vehicle � Roller dynamometer testing

� Exhaust gas analysis

� Vibration testing

� Solar Simulation

vehicle body � Road simulation

� Corrosion

� Fatigue strength testing laboratory

Chassis � Wheel testing

� Tyre testing

� Spring and stabilizer bar testing

� Air spring and shock absorber testing

engine and powertrain � Cylinder head testing

� Powertrain testing

� High-pressure & low-pressure testing

� Overspeed testing

� Component testing (crankshaft, valve springs etc.)

interior � Temperature & climate testing

� Solar simulation

� Materials testing laboratory

electronics � Control devices

� Vibration testing

� Temperature & climate testing

yo

ur

test

pa

rtn

er

in t

he

de

ve

lop

me

nt

pro

ce

ss

4 5

testing and fatigue strength

Complete vehicle � Roller dynamometer testing

� Exhaust gas analysis

� Vibration testing

� Solar Simulation

vehicle body � Road simulation

� Corrosion

� Fatigue strength testing laboratory

Chassis � Wheel testing

� Tyre testing

� Spring and stabilizer bar testing

� Air spring and shock absorber testing

engine and powertrain � Cylinder head testing

� Powertrain testing

� High-pressure & low-pressure testing

� Overspeed testing

� Component testing (crankshaft, valve springs etc.)

interior � Temperature & climate testing

� Solar simulation

� Materials testing laboratory

electronics � Control devices

� Vibration testing

� Temperature & climate testing

Development services

technical computations � FE modelling

� Strength analysis, joining techniques

� Structural component durability analysis

� Structure optimisation

� Oscillation, vibration

� Non-linear structural dynamics

� Flow analysis, temperature fields

� Method and software development

vehicle and system simulation

test management and functional tests

Function development

safety and functional reliability

Acoustics and vibration behaviour

Design and realisation of test benches

iABg products � Resonance test benches

� Rotating bending fatigue test benches

� Stone chip simulators

� Test benches for steering systems

� HiL simulators and test benches

� Radial impact simulators

general contractor for special test benches

examples � Multi-function shaker for exhaust systems testing

� Test benches for mechatronic chassis control system

� Road simulator in combination with climate and solar simulation

� Thermo mechanical exhaust gas system test bench

te

sti

ng

and

fa

tig

ue

str

eng

th

Fatigue strength testing of chassis components

6 7

Top: Ottobrunn test centre

Middle: Flat track tyre test bench for determining tyre parameters under stationary and dynamic operating conditions

Bottom: Automatic half axle test bench

testing and fatigue strengthThe headquarters in Ottobrunn houses a covered test hall (5,000 m2) with a modern infrastructure, central supply of hydraulic fluid, compressed air and cooling water as well as safety facilities (e. g. works fire brigade). Our stand-ard and special test benches are used to examine, test and qualify complete vehicles, functional units and individual parts and components. We analyse the design, the materials used as well as their behaviour when exposed to defined loads. Furthermore, we develop innovative test equipment. We would be glad to advise you personally - right at the onset of product devel-opment, during the complete product cycle and to solve specific problems.

Our range of services in testing and qualifying covers all the major parts of a vehicle:

� Complete vehicle Not all functions and aspects of fatigue strength can be covered by component testing. This is why it is often essential to test the complete vehicle. IABG uses various test benches and test chambers for this purpose.

� Chassis We test chassis components using established standard methods and test benches. We also develop future-oriented test procedures for specific innovations.

� Vehicle body Test facilities, for example our vehicle body test bench or our tempera-ture, climate and corrosion test chambers, are at your disposal for testing your vehicle bodies and vehicle structures.

� Engine and powertrain We qualify engine and powertrain components and carry out the necessary examinations in the development process.

� Interior To ensure that interior components do not fail in service, they must be qualified beforehand under conditions that are as realistic as possible. We have the appropriate test equipment for all the relevant influencing factors: temperature and climatic chambers as well as solar simulation units and shaker tables.

� Electronics Increasingly more control devices and electronic components are integrated in the development and production of new vehicles whose reliability is decisively influenced by their fail-safe performance. We test your control devices for function, susceptibility to failure and suitability for daily use by exposing them to extreme temperatures, high humidity and mechanical loading, for example.

De

sig

n a

nd

re

alis

ati

on

of

test

be

nc

he

s

Resonance spring test bench with corrosion unit (optional with climatic simulation)

8 9

Top: Test bench for testing

active steering system

functions

Middle: Multi-component

vehicle body test bench with

climatic chamber and solar

simulation

Bottom: Stabilizer bar test

bench with axle kinematics

Design and realisation of test benchesWe configure and implement test facilities at the highest of technical levels. The salient features of our test facilities are safe operation, easy handling, flexible application options, cost-effective maintenance and problem-specific expandability. In this way we ensure cost-efficiency and future proofing.

Our Services

� Test benches for axle springs, stabilizer bars, steering systems and wheels Our test facilities embody our many years of broad experience in dealing with fatigue strength and in the development and fine-tuning of test procedures. Our portfolio includes the following test benches: - Resonance test benches for springs and stabilizer bars - Test benches for rotating bending - Stone chip simulators - Impact simulators for wheels and steering columns - Test benches for steering systems - HiL simulators and test benches We also develop customized test systems.

� Customer support and advice A feasibility study is always the first step towards implementing an innovative test bench. We analyse the task, develop and evaluate different solutions and accompany their implementation as requested. We advise and support you in drafting specifications and invitations to tender.

� Realisation of large test benches as general contractor As a general contractor, we realise large test benches for our customers and implement them on site in the existing infrastructure or, if necessary, we create the environment required. We focus on building innovative test facilities offering for the first time a network of different technical systems.

De

ve

lop

me

nt

se

rvic

es

MBS vibration analysis for a virtual prototype on a four-poster test rig

10 11

Top: Gearbox analysis

Middle: Topology

optimisation of a rear

axle gear casing

Bottom: CAD package for

an active steering system

Development servicesIncreasing demands on new products in terms of functionality, quality, costs and development time can only be met by employing the latest CAE methods. Applying a wide range of methods is essential for virtual product development. IABG can actively support you in this respect with its many years of experience. We offer analyses, optimisations as well as production and functional simulations. Our experts support your development depart-ments with their own hardware and software, also on your own premises as required. In most cases, our engineers work on site at the customer’s in efficient, autonomous and independent teams, so-called “Centres of Competence” (CoC).

Our centres of competence work in the following areas: � System integration and test management for steering systems � Configuration of a comprehensive simulation environment for chassis � Simulation and modelling of a complete vehicle in preliminary development

� Conceptual car design for vehicle body development � Gearbox calculation supported by our own tools

Our services

� Technical calculationsBy applying advanced CAE methods, we improve the functionality and quality of your products, reduce costs and shorten the development time.

� Vehicle and system simulationWe assist you in the development of complex mechatronic systems. We provide you with services including concept drafting, modelling, simulation and analysis or optimisation during tests - all from a single source.

� Test management and function testsWe accompany the development process of your mechatronic systems - starting with the test specification and ending with release testing.

� Function developmentWe develop and test new functions for your mechatronic systems. You benefit from the tight link between simulation and testing.

� Safety and functional reliabilityWe ensure early qualification of safety-critical electronics and associated control software. This helps minimise risks.

� Acoustics and vibration behaviourWe run experimental and numerical analyses of the dynamic behaviour of units, components and systems liable to vibrate.

Automotive

iNFoCom

trANsport,eNviroNmeNt & power eNgiNeeriNg

AeroNAutiCs

DeFeNCe & seCurity

spACe

IABGEinsteinstraße 2085521 Ottobrunn

GermanyPhone +49 89 6088-4454

Fax +49 89 6088-4066automotive@iabg.de

www.iabg.de

Berlin Bonn Dresden Hamburg Hannover Ingolstadt Karlsruhe Koblenz Lathen Letzlingen Lichtenau Meppen Noordwijk (NL) Oberpfaffenhofen Wildau