20. June 2017

FEV presents Solutions for Efficient Test Center Operation at Testing Expo 2017

Road-Rig-Desktop: FEV’s model-based, collaborative development and validation framework is able to execute even complex models in real time at the test bed (Source: FEV Group GmbH)

”The testing center for future mobility“: This year’s attendance of FEV at the Testing Expo in Stuttgart is following this theme. In addition to solutions for latest testing procedures such as Hardware- und Software-in-the-Loop, Road-to-Rig-to-Desktop or Real Driving Emissions (RDE), FEV is concentrating on mechanisms and tools which optimize the operation of testing facilities. An important role in this context is played by the collaborative framework. This framework combines simulation and virtual calibration which results in reductions of up to 30% of the physical tests required during development.
In addition, FEV’s experts stand ready at booth 1200 for technical discussions about testing of alternative powertrain concepts and their components, including e-drives and batteries.

Especially new vehicle concepts with an increasing amount of software, electronics and additional powertrain components cause a wide range of development tasks to grow”, explains Professor Stefan Pischinger, President and CEO of FEV Group. “In addition, test results have to be ever more precise and generated in ever shorter time frames while costs have to reduce. Advanced testing solutions and optimized processes are key features to meet these differing and conflicting demands.”

FEV’s model-based, collaborative development and validation framework features a cross-disciplinary approach, thus replacing complex methodologies using numerous different techniques and tools. The framework supports the whole development process from design to validation on the road. Its co-simulation capability enables the possibility to represent the different vehicle and engine components, and to simulate their interactions. This makes it a powerful tool, for example during the validation of new hybrid powertrain concepts. During the Hardware-in-the-Loop stages, physical components are introduced in addition to real-time data: The physical components are combined with simulated models representing the vehicle, the driver or the road. As a result, at each stage, the physical component can be validated in an environment extremely close to that of the entire vehicle and to real driving conditions. Here, the framework is able to execute even complex models in real time at the test bed.

Efficient Testing Operation
More efficient use of test facilities and prototypes is the most important question but, increasingly, the use of knowledge capital is becoming a key productivity factor and, thus, a competitive advantage. FEVFlex as a central data and information management software features a highly efficient and integrated solution that both connects employees with information and ensures its preservation. An automated reporting function with all important parameters for the testing facility, item tested, etc., ensures absolute transparency during the test and development process.

In addition, FEV has set up a program to increase efficiency of testing facilities: throughout the world. At the core of this service, FEV translated step-by-step optimization of a testing facility into a clearly structured project approach with six thematic clusters: These include strategic alignment of the individual testing facilities, analysis of the existing and future product program and evaluation of testing capacity that will be needed in the future. It also includes adjustment to the testing facility organization, the core competencies needed, the testing methods and the tools and testing equipment. Especially the processes within the testing operations, such as testing facility planning, setup and work planning on day and night shifts, shift changes, etc., are analyzed and optimized.

Highly accurate measurement systems
With FEV AirRate and BlowbyRate FEV presents efficient tools for high-precision operation of test benches: FEV AirRate, which is now available in an improved and completely redesigned version, is used for the contactless measurement of combustion air on engine test benches. Thanks to the compact design, the entire measurement technology fits into a single casing, without the need for wiring between the measuring unit and the output unit. During the redesign, special attention was paid to a simple and clear user interface with a touchscreen display and low maintenance and calibration requirements.

The FEV BlowByRate device results in an easy determination of the condition of valve guides, piston rings, pistons and cylinder walls, possible without engine disassembly. The system provides conclusions about possible wear by measuring the blow-by gas quantity. Blow-by gases generally pass out of the cylinder via leaks – for example at the pistons, piston rings and/or valve guides – or, through the bearings and bearing seals into the crankcase, and escape through the crankcase ventilation.  The FEV BlowByRate is characterized by a robust, reliable construction and precise blow-by measurement – despite the contamination that is entrained in the blow-by gas.

About FEV
FEV is a leading international, independent service provider for hardware and software in vehicle and powertrain development, as well as the energy industry. The range of competencies includes the development and testing of innovative solutions up to series production and all related consulting services. The range of services for vehicle development includes the design of body and chassis, including the fine tuning of overall vehicle attributes such as driving behavior and NVH. FEV also develops innovative lighting systems and solutions for autonomous driving and connectivity. The electrification activities of powertrains cover powerful battery systems, e-machines and inverters. Additionally, FEV develops highly efficient gasoline and diesel engines, transmissions, EDUs as well as fuel cell systems and facilitates their integration into vehicles suitable for homologation. Alternative fuels are a further area of development. The service portfolio also includes tailor-made test benches and measurement technology as well as software solutions that allow efficient transfer of the essential development steps of the above-mentioned developments, from the road to the test bench or simulation. For defossilization of the entire energy value chain, FEV offers energy management and infrastructure solutions from a single source, which intelligently link and holistically optimize power and heat generation, mobility, and industry. The FEV Group currently employs 6500 highly qualified specialists in customer-oriented development centers at more than 40 locations on five continents.