Passion. Innovation. Solutions.

Advanced
Vehicle Development
FULL CHAIN OF HIGH-QUALITY

ENGINEERING SERVICES

[Link]
Prof. Dr.-Ing. Dr.-Ing. Ralf Marquard Sami Sagur Dr.-Ing. Ernst Scheid Dr.-Ing. Patrick Hupperich Dr.-Ing. Jens Ludmann
Stefan Pischinger Executive Vice President Executive Vice President Executive Vice President President and CEO of Executive Vice President
President and CEO of and COO of FEV Group and CFO of FEV Group Hol- of FEV GmbH FEV North America Inc. of FEV GmbH
FEV Group Holding GmbH Holding GmbH ding GmbH and FEV GmbH

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 Europe
Germany Asia
France China
United Kingdom India
Italy Japan
Sweden South Korea
Russia Taiwan
North America South America Poland Thailand
USA Brazil Spain Turkey

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 Door CUs

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 Vehicle engineering services

 Vehicle / powertrain integration

 Proven project management and development processes
 Styling / Branding
 Design
 Safety
 Electrics / Electronics
 NVH
 Energy
 Thermal management / interior climatisation
 Vehicle dynamics
 Aerodynamics and -acoustics
 Vehicle system development
 Supplier management
 Prototype build
 Engine and transmission calibration
 Fleet endurance testing
 Homologation
 Launch support

Highly skilled specialists of FEV, familiar with

OEM’s development processes, as well as
reliable project methodologies allow for cost
and time effective systems and vehicle engi-
neering.

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FEV offers – in co-operation with its develop-


ment partners – the comprehensive develop-
System design and integration
ment capacity and competence for all vehi-
cle systems and components. The scope of
 System Technical Specifications
worldwide activities leads from development
 Concept layout and design
and integration of single component or mo-
 Package, DMU, DDMU and tolerance chain
dule up to the complete vehicle. Highly skilled
 3D data/ drawing management, check and release
specialists in combination with well proven
 Manufacturability and serviceability
and effective development processes allow
 D/P-FMEA
for realization of technological and economic
 Release management
development targets.
 Change management
Within the development process the amount
 Supplier management
of virtual validation by CAx methods is incre-
 BOM
asing significantly as development timings
 Testing at system and vehicle level
and quantity of prototype vehicles are red-
 On-site coordination and appliance of development
ucing more and more. FEV and its partners
process (customer specific)
stay abreast of this change by extensive use
 Physical Mock-Up and prototype build
of simulation tools with respect to component
 Launch support
and system layout and performance validation.
From the beginning all main vehicle attributes
as e.g. fuel consumption, performance, drivea-
bility, NVH and durability are already in the
focus of the component/system development
in order to minimize re-engineering efforts and
to assure product quality targets.

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System design and integration – references

 Interdisciplinary engineering approach for

optimum interaction between passive and
active systems
 Crash simulation and testing
 Development and integration of crash safety
relevant components and restraint systems
Adult
head
 Supplier management
Child
head
 Active safety systems
Upper
leg  Functional safety of High Voltage systems
for HEV and BEV

Leg
 D/P-FMEA
 Certification support

40%
overlap

Risk analysis Safety concept

Functional safety
management

Requirements & specification

Support for
certification
Audits, reviews and assesments

FMEA FTA HIL

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 The services include 1D and 3D simulation with
respect to coolant circuits, optimum external
air flow guidance and interior compartment air
flow distribution to achieve best heating and
cooling system performances in the vehicle.

 Concept and layout of powertrain
cooling system
 CFD air flow simulation (front end, engine
compartment, underbody)
 Component technical specifications
 DMU, BOM, 3D data management
 Supplier management
 Radiator fan and control strategy
 Heat shield concept
 Vehicle testing (climate tunnel, open road)
 Launch support
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 Thermal management of HEV and BEV









TOPEXPERT

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Noise, Vibration and Harshness - NVH

 NVH benchmark incl. NVH target cascading
from vehicle to component level
 Highly skilled NVH troubleshooting
 Powertrain induced NVH
 Road NVH
Aeroacoustics
 
 Body acoustics
 Noise quality (components and systems)
 Sound insulation layout and refinement
Pass-by noise testing and optimization
 
 Sound design
 Squeak & Rattle

FEV has over 40 years of experience con-

ducting industrial and scientific NVH projects
worldwide and employs more than 100 highly Interior NVH Quality
qualified NVH specialists in Germany and the
US. We have a solid reputation as a reliable Aero Acoustic
engineering partner to OEMs and suppliers.
Chassis
NVH
Our scope of work includes a variety of projects Powertrain-
induced NVH
such as NVH troubleshooting, low noise pow-
ertrain and driveline development, NVH support Body NVH

during vehicle integration up to full vehicle NVH

development. We also tackle challenges outside
the automotive field, such as NVH optimization Vehicle NVH sources

of industrial machinery.

Our partnership with universities and our con-

tinuous involvement in industrial and public
research projects ensures that our
methodologies are always up to MBS Simulation of driveline
date and thorough. The high
quality standard of our work is

Key methodologies for systematic vehicle
guaranteed by modern testing equipment
NVH development and optimization:
and facilities combined with cutting-edge NVH
simulation tools and methods.
 FEV-VINS: Vehicle Interior Noise Simulation
 FEV-V-VINS: Virtual Vehicle Interior Noise Simulation
 FEV-C-VINS: Chassis Vehicle Interior Noise Simulation
 FEV-VENS: Vehicle Exterior Noise Simulation
11  FEV-SME: Sound Metrics for specific noise phenomena
 Concept tuning

 Chassis development from concept to SOP

using up-to date simulation tools and qualified
testing by highly skilled R&H specialists
 Benchmark and Target Setting based upon
FEV’s unique R&H scatterbands
 Chassis tuning
 Adaptation and calibration of active safety devices
(e.g. ABS, ESP …)
 Development and calibration of active chassis
systems (e.g. active damper, steering system …)
 Chassis induced NVH optimization based upon
FEV’s Chassis Vehicle Interior Noise Simulation

Phone System MOST

Navigation Diagnostics
Tester Communication
Temp.-Sensor 2 Entertainment Gateway

Temp.-Sensor 1 Air Conditioning

LIN Body CAN
Sunroof CU Display Cluster

Door CUs Engine CU Powertrain CAN

Transmission

ABS / ESP

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The true potential of advanced powertrain
technologies can only be exploited with pow-
erful control strategies in combination with
modern electronic control units ensuring max-
imum reliability and functional safety. FEV’s
tremendous competence covers the full devel-
opment range from rapid prototype solutions
up to mass production and includes almost
all of the controller platforms used in automo-
tive industry. Our scope of work includes E/E
hard-/software engineering and integration for
combustion engine powered, hybrid and bat-
tery electric vehicles. Our development meth-
odology is supported by highly effective HIL

testing and up-to-date project management

tools certified according to CMMI.


FEV is one of the world’s leading development

partners for hybrid and electric vehicles with

the battery as one of the key components.

The entire battery development process is

covered starting with requirement specifica-

tion to benchmarking, concept layout, design

and vehicle integration. The design process

includes passive and active safety measures,

thermal and battery management systems.


TOPEXPERT

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 FEV has been performing vehicle testing for
many years, with focus on performance, fuel
consumption, emission, durability, NVH and
Ride & Handling as an essential part of a suc-
cessful vehicle development program. FEV’s
vehicle engineering and testing services in
Germany are concentrated in Alsdorf, near
FEV’s Headquarters in Aachen. Besides of-
fices, laboratories and workshops the Engi-
neering Center features also specific vehicle
testing facilities, as e.g. climatic chassis dyno,
semi-anechoic vehicle dyno, Pass-By noise
track etc.

In 2013 a new vehicle test track area (3km

distance to FEV Vehicle Engineering Center)
has been completed including mid speed oval
circuit, vehicle dynamics area, brake tracks,
bad road area, ride and handling course, uphill
grade etc. Specific vehicle testing activities
(high-speed, Off-Road etc.) are performed on
worldwide test tracks. The Nürburgring race
circuit is 90 km located from Aachen.







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FEV offers comprehensive and unique vehicle
benchmarking covering worldwide technology
and market trends. Our extensive benchmark
data base comprises all up-to-date powertrain
 technologies including driving strategies, e.g.
energy management for HEV and electric ve-
hicles. Benchmark projects can be performed
according to FEV’s standard procedures or
customer specific.
FEV-CSL:

Tailpipe Noise

Market Survey Evaluaon Target Seng Technology

& Trends & Comparison & Design Recommendaons Studies
500
Efficiency

460
%

420
[g

380

340

MODEL YEAR 300

COSTS

- Database
FMEP [bar] - etc. Design Parameter: etc.
FMEP [bar] - Crankshaft Design Parameter: Piston Group
FMEP [bar] - Piston Group Design Parameter: Big - End Bearing
Combustion System

Exhaust Aftertreatment

FMEP [bar] - Valve Train Design Parameter: Oscillating Mass

FMEP [bar] - Power Train Drive Torque Main Bearings [Nm]
40 45 50 55 60 65 70 [mm]
Transmission

FMEP [bar] - Complete Engines 1,00

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Design

Scatter Range
0,75
2
0,50

Scaer
Vehicle

1
0,25
FEV, 01/99
Friction

62 Engines
0,00
Costs

0 0 100 200 300 400

Bands
0 2000 4000 6000
Engine Speed [rpm] Bearing Diameter³ [cm³]
NVH

FMEP Scatter Ranges Design Para meters

- Standardised
- Customised

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Vehicle Development I/2015