AVL Focus - Issue 2023

THE AVL MOBILITY TREND MAGAZINE - No. 1 2023

T H E A V L M A G A Z I N E F O R P O W E R T R A I N D E V E L O P M E N T , T E S T I N G A N D S I M U L A T I O N

N O . 1 2 0 2 0

Tore Enger

Group CEO of TECO 2030

NOBODY

CAN ACHIEVE

NET-ZERO

ALONE

T H E A V L M O B I L I T Y T R E N D M A G A Z I N E

FEATURING

SPECIAL

SOFTWARE

SECTION

p. 36 – 60

N O . 1 2 0 2 3

Editor and media owner:

AVL List GmbH

Hans-List-Platz 1, 8020 Graz

Tel.: +43 316 787-0

www.avl.com

Publisher and producer:

SCOOP & SPOON GmbH

Kirchberggasse 10, 1070 Wien

Tel.: +43 1 523 4088 150

www.scoopandspoon.com

C O V E R S T O R Y

4 Interview with Tore Enger,

Group CEO of TECO 2030

C O R P O R A T E I N S I G H T S

8 Female Powered Innovation

10 Launch of a Female Engineer Program

12 Pushing Forward Energy Reduction and Environmental Protection

13 Leading in Digital Transformation

V E H I C L E

14 Designing the Driving Experience

16 One Step Ahead of Future Brake Emission Legislation

18 AVL Test System for Electromagnetic Conformity (EMC)

E - M O B I L I T Y

20 Electric Driveline – the Core of E-Mobility

22 Master the Heartbeat of the Battery

24 Introducing AI for Battery Design Confidence

H Y D R O G E N A N D F U E L C E L L

25 Taking to the Skies with Fuel Cells

26 Leading the World in Hydrogen and Fuel Cell Testing

28 Tackling PEM Fuel Cell Freeze Start Challenges

with System Simulation

30 AVL RACETECH Builds Hydrogen Combustion Engine

Prototype for Motorsport

editorial

Index

A U T O M A T E D A N D C O N N E C T E D M O B I L I T Y

32 Taking Autonomous System Testing to the Next Level

34 Ground Truth Calibration for the Validation of

ADAS/AD-Sensor Systems

S O F T W A R E S P E C I A L

36 Solutions for a New Age of Driving

38 Interview with Georg List

40 “Significant Progress” – Interview with McKinsey

42 The Future Comes Embedded

45 Controlling the Future Autonomously

49 Compliance by Experience

50 Fighting the Enemy Within

53 Simulation: From Side-lines to Center Field

56 Functional Beats Performance

57

Test Effectiveness as a Guiding Principle

58 Interlinking Virtual and Real Testing

P R O D U C T N E W S

62 AVL Fuel Cell Production Test Solutions

63 AVL vSUITE™

Customizing cars to suit the needs and

tastes of the end user has long been a key

driver in the automotive industry. In an

era when powertrains are converting to

more electrified and autonomous mo-

bility, and as everything becomes more

connected, overcoming complexity is

the new challenge. The risks that come

alongside must be analyzed and man-

aged cautiously though: Cybersecurity

has become a major issue for OEMs.

AVL offers a diverse range of solutions

for this new age, from simulation and

testing solutions to embedded software

development tools and services. They

are based on four principles: delivering

software that grows with you, reduc-

ing the burden of complexity to find the

fastest solution that works for you, an-

swering today’s challenges and uncov-

ering tomorrow’s solutions. Together,

we are defining the safe key for the “car

quartet” of the 21st century. It calls for

new perspectives on everything from

how we manage our carbon footprint

around the world, to how we simulate

and test an infinite number of scenarios

to be ready for the road.

Diversity is not only manifested in our

holistic technology portfolio, or the way

we manage our own operations around

the world, but also in our workforce.

Once a male-dominated industry, engi-

neering is increasingly benefitting from

the skills and perspectives of a growing

female contingent. Women are playing

a decisive role, in our labs, and in the

office, where our creative minds shape

future mobility solutions.

Helmut List

Prof. Helmut List,

Chairman and CEO AVL

Images: © TECO 2030 ASA

cover story

cover story

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focus: Thank you for speaking with us. Tell us about TECO 2030,

what the company does and how it came to be.

Enger: TECO 2030 is a Norway-based clean tech company developing zero

emission technology for maritime and heavy industries. We are develop-

ing PEM hydrogen fuel cell stacks and PEM hydrogen fuel cell modules,

that enable ships and other heavy-duty applications to become emissions-

free. TECO 2030 will industrialize the PEM fuel cells in Narvik, Norway

where it is building up Europe’s first gigafactory for fuel cells.

TECO 2030 was founded in 2019 in Lysaker, Norway. It is a spinoff from

TECO Maritime Group, a group that has provided technology and ser-

vices to the global shipping industry since 1994.

I have worked in the shipping industry for over 30 years, and dreamed for

a long time about being part of the green transition in the maritime indus-

try. Many years ago, it was clear to me that something had to be done to

reduce greenhouse gas emissions. After a few years of travelling, research-

ing and investigating which technology would be the winner, we finally met

AVL in late 2019 and decided to kick off a project on exhaust gas cleaning

systems for ships. Together with AVL we completed the project in a record

time-to-market and decided to start another exciting project – the develop-

ment of the first purpose-made marine and heavy-duty hydrogen fuel cells.

There is no doubt that an industry like shipping needs to reduce emissions

while trade volumes are increasing. If the industry does nothing, it will be

one of the largest polluters in 2030. This is why TECO 2030 is accelerating

the green transition in the maritime and heavy-duty industry with its lead-

ing PEM hydrogen fuel cells.

I N T E R V I E W with Tore Enger,

Group CEO of TECO 2030

“ NOBODY CAN ACHIEVE

NET-ZERO ALONE”

Focus magazine speaks

to Tore Enger about

TECO 2030’s collaboration

with AVL, and the future

of the fuel cell in global

heavy-duty transportation.

cover story

cover story

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focus: What roles can hydrogen and fuel cells play in the marine sector,

and what are the challenges that you see in this respect?

Enger: International shipping is an important enabler of world trade, but

also causes greenhouse gas emissions and pollution. The industry is facing

increasingly stringent environmental restrictions and this regulatory back-

ground is key to TECO 2030’s strategy. The International Maritime Orga-

nization (IMO) aims to reduce carbon intensity in international shipping

by 40 % by 2030, and to cut the total annual greenhouse gas emissions

from the sector by at least 50 % by 2050 compared to 2008.

There are several challenges with creating a bunkering network that will

achieve this, however I am confident that by the time fuel cells are widely

on board commercial vessels there will be hydrogen fueling stations. This

is why large corporations have pledged to become carbon neutral over the

next few decades, and this will only increase.

focus: Please tell us more about the TECO Marine Fuel Cell – and how

it can overcome these challenges?

Enger: The first TECO 2030 400 kW fuel cell module will be ready soon

and will go immediately onto the testbed at AVL’s headquarters in Graz.

It will be exciting to see how well it performs in the testing environment.

The purpose-made marine fuel cell has been developed in collaboration

with AVL as a design and simulation partner. Using sophisticated, indus-

try-leading simulation software we simulated real life scenarios to devel-

op a modular and scalable design with 400 kW as the building block. This

makes it the most footprint-efficient fuel cell solution on the market. In a

standard 6 meter ISO container, we can fit 3.2 MW of fuel cells. This is an

attractive solution for shipowners wishing to retrofit zero emission solu-

tions onboard marine vessels, as space is limited on a ship.

We are also aiming to automate the production of the systems with cost-

effective production equipment delivered by thyssenkrupp, to reduce pro-

duction risk. This will allow for steady supply of fuel cells to our customers

who want to upgrade full heavy-duty fleets.

focus: Are you based solely in Norway, or do you have a growing foot-

print in hydrogen technology around the world?

Enger: TECO 2030 is headquartered at Lysaker, Norway, with a 15,000

square meter production facility in Narvik, in the north of the country. In

Narvik, we will automate fuel cell production over the coming years and

in 2024, our fuel cell production output will grow to 120 MW, 400 MW in

2025 and 1.6 GW in 2030. Our strategic sales offices are located in Miami,

USA and Singapore and our sales network covers a global footprint to meet

an increasing demand globally. Our production facility in Narvik will pro-

vide the world with leading energy efficient marine and heavy-duty fuel

cells. Our projects involve several segments ranging from trucks to ships,

ferries and construction sites, and is well suited for mining, data centers,

trains, and emergency generators among other applications.

focus: What’s the next big milestone for TECO 2030?

Enger: The next big milestone for TECO 2030 is to see our first FCM400

fuel cell module on the testbed at AVL, and of course seeing the AVL Hy-

Truck commercial hydrogen demonstrator vehicle on the road in Summer

2023. And we are also planning to commission a gigafactory to begin auto-

mated fuel cell production in the first quarter of 2024.

focus: How is the gigafactory positioned in the global competitive land-

scape? And do you expect other companies to position themselves in

the same way?

Enger: The gigafactory will be Europe’s first state-of-the-art production fa-

cility for PEM fuel cells. It will kick-start the establishment of gigafacto-

ries around the world. TECO 2030 expects to position itself as the leading

supplier for fuel cell stacks and modules, as well as a partner in large scale

hydrogen projects. I assume we will see more announcements of fuel cell

factories all over the world over the next decade as hydrogen infrastruc-

ture concepts mature.

focus: What were the key aspects of the collaboration with AVL that con-

tributed to the market introduction of the TECO fuel cell?

Enger: TECO 2030 values collaboration for achieving the green transition.

Nobody can achieve net-zero alone. We are living in a time where global

warming and climate change are global buzzwords and our largest chal-

lenge. A close and successful collaboration between stakeholders through

the entire hydrogen value chain will be the key to the market introduction

of our fuel cells. Working together with partners on a project to realize lead-

ing environmentally friendly projects is what we strive for every day. Who

doesn’t want generations to come to have a fantastic place to live as well?

Tore Enger

Group CEO of TECO 2030

Mr. Tore Enger founded TECO

Group in 1994. Tore is a true

entrepreneur and has created

many products and services for

the maritime industry over the

last 28 years. He has an extensive

network in the industry which is

crucial for TECO 2030’s access

to shipowners. Mr. Enger was also

the Chairman and major share-

holder of Scanship Holding ASA

(now Vow ASA), which has been

listed on the Oslo Stock Exchange,

for approximately 10 years

(2008 – 2017).

Through our collaboration with AVL, we achieved complete fuel cell in-

dustrialization at our Innovation Center in Narvik. The quick production

ramp up is possible thanks to the consistent planning from the TECO 2030

and AVL teams working together. Our collaboration enables rapid expan-

sion within the development and industrialization of our hydrogen fuel

cell stack and system. It will be among the highest quality and most energy

efficient fuel cells on the market for heavy-duty applications.

focus: If we look beyond 2030, which global endeavors will be required

to accelerate the race towards carbon-neutrality?

Enger: The race towards carbon-neutrality has just started, and I believe our

partnership with AVL is an important contributor to implementing a hydro-

gen economy and infrastructure. As things accelerate, I believe we will have

a solid growth of hydrogen hubs and infrastructure for refueling and con-

suming hydrogen. Complete infrastructure networks will have been tested

and validated. The future is not far away, and together with partners such

as AVL I believe we are seeing the beginning of the implementation of fuel

cells in the Nordics and beyond. �����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������

The FCC 3200™

fuel cell container

TECO 2030’s

fuel cell stack

THE RACE TOWARDS

CARBON- NEUTRALITY

HAS JUST STARTED…

THE FUTURE IS NOT

FAR AWAY.”

corporate insights

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corporate insights

occur. I was always supported by

my parents and loved physics and

chemistry experiments at school!

Leitner: In my case, my computer

science teachers said: “You are a girl,

you will never use this knowledge.”

That is when I thought: “Now more

than ever!” However, this negativi-

ty was demotivating for most of the

other learners. Nearly no one chose

a career in technology.

focus: What challenges did you

face, especially in male-dominat-

ed environments?

Leitner: In meetings, sometimes peo-

ple assume you are someone’s assis-

tant. You have to establish yourself,

especially when you are young.

Segura Carrasco: By the time you get

to the first introductory round, it

becomes clear what one is respon-

sible for. But Andrea is right, at the

beginning of your career, colleagues

look at you like: “What is this wom-

an doing here?”

focus: What do you think is the

biggest obstacle to success for

women? Or is the female defini-

tion of success different to men’s?

Segura Carrasco: I think, if someone

goes to work and is happy, that is

success – no matter whether it is

a woman or a man. And as far as

building a career is concerned: It is

difficult for women to have a strong

network and a good mentor because

there are not many women in higher

positions. Female networks are, un-

fortunately, not as influential as male

networks – and that is exactly where

you need someone to support you.

focus: Why do you think more

women are needed in the techno-

logical industry?

Leitner: It is extremely important

that women get involved in inno-

vation and engineering topics as

they convey other aspects and think

differently. This generates a lot of

creativity, which is very enriching.

focus: What advice do you wish

you had received at the beginning

of your career?

Segura Carrasco: At the beginning of

my career, what I needed most was

encouragement: “Believe in your-

self! Be daring!” It is important

that somebody supports you and

believes in you.

Leitner: “Dare to ask questions,” is

what comes to mind. In my early

days, I often had to deal with elo-

quent colleagues, and I would think

to myself, that sounds right, but it

makes no sense to me. Back then I

did not dare to ask questions: Okay,

why is it like this? Or: How can

you make an argument for that?

It would have helped if somebody

had encouraged me to express my

thoughts. 

I N T E R V I E W

M A R I A S E G U R A C A R R A S C O studied Mechanical

Engineering in Spain, majoring in internal combustion engines. She completed her

Master’s degree in renewable energies, and started as a Development Engineer

at AVL more than 22 years ago. Here she led the team for Fuel Injection Systems

and has been the Product Manager and Key Account Manager for High-Power

Systems since 2020. She is responsible for business development, market evalu-

ation and R&D planning in the field.

A N D R E A L E I T N E R studied at the Graz University

of Technology. After completing her doctorate in Information

and Communication Engineering, she started working in the

research section of The Virtual Vehicle Competence Centre nine

years ago and shortly afterwards joined AVL as a Project Manager

and Research Engineer. Since May 2022, she has been Head of

Development ADAS/AD Testing Solutions, which mainly involves

test systems for the safety around autonomous driving.

AVL managers Maria Segura Carrasco

and Andrea Leitner discuss how to awak-

en an interest in tech among young girls,

how to assert oneself as an expert in meet-

ings, and why women need to be involved

in innovation and engineering.

focus: Which career moment shaped you

the most? What are you most proud of?

Segura Carrasco: A turning point in my career

was my first project as a project manager at

AVL, and I saw how satisfied the customer

was at the final meeting. Later, I was respon-

sible for the Fuel Injection Systems team;

there, too, I really enjoyed working with

the technical team. Since 2019 I have been

Product Manager for High-Power Systems

– a challenging but amazing task.

Leitner: While I worked in the AVL research

section, a European research project coordi-

nated by AVL began, focusing on safeguard-

ing and testing automated driver functions.

My boss asked me to take on the overall

project coordination. At first, I thought I

knew too little about the subject, and be-

sides, I was very young and had never led a

research project before. But then I thought,

let me try! I had to coordinate 70 partners

from diverse fields and was invited to con-

ferences to introduce the project. In the end,

it was a huge success.

Female Powered

Innovation

focus: How do we encourage more

girls into technical careers?

Segura Carrasco: We need to start

early in kindergarten or primary

school. Very young girls are often

interested in technology, especially

when it comes to experiments. But

in secondary school or even earlier,

they lose interest. Later, when

companies look for talent in high

schools, it is too late for most girls

who were once tech-savvy. Had

they been supported through the

years, this disjuncture would not

The importance and value of increasing gender

diversity in the tech-industry is a well-known topic,

yet women are still underrepresented in tech-

focused roles

Female engineers are still un-

derrepresented in motor sport. To

rectify this, AVL RACETECH has launched a Female Engineer

Program for AVL employees. The initiative puts AVL’s women in

pole position for a career in motor racing.

The program combines two objectives: supporting women in tech, and

diversity. AVL RACETECH already supports female racing drivers through

its ambassador program: Tatiana Calderón and the “Dakar Sistaz” Aliyyah

and Yasmeen Koloc, three strong women that represent the AVL colors

on the international motorsport stage. Tatiana is the woman who has pro-

gressed furthest in motorsport and currently races in Formula 2 – the sec-

ond highest class, after Formula 1. Aliyyah recently claimed the title in the

FIA Middle East Cup for Cross Country as the first women ever.

The Female Engineer Program offers participants the opportunity to re-

ceive training within AVL’s motorsport division while still working in their

departments and projects. From getting involved in various racing fields

to first-hand experience at the racetrack, over the course of the year they

gain a deep insight into the world of professional motorsport. In practi-

cal workshops on the topics of race engineering, simulation, testbeds and

driving simulators, the engineers acquire expertise to work in the industry.

The engineers also get to spend a longer duration working in racing teams,

with which AVL RACETECH maintains cooperations. In return, female

technicians from the respective teams will learn from AVL’s motorsport

expertise. The program starts in the first quarter of 2023. Initially, two

places are available for female AVL engineers. Depending on the success

of the program, it will be extended in years to come.

Ellen Lohr, Director Motorsport AVL, says: “The time is right for a pro-

gram like this, as motorsport has no longer been a male-only domain for a

while. However, we need more female role models. The more female engi-

neers play a visible role in motor racing, the more women will identify with

them, which can only be positive for the sport and also for AVL.”

AVL RACETECH

ambassador

Tatiana Calderón

Photos: © Dutch Photo Agency

AVL RACETECH champions

female talent in motorsport

Launch of a Female

Engineer Program

corporate insights

1 0

Marie-Alice Lahaye

Race Engineer

Tatiana Calderón

AVL RACETECH Ambassador

AVL RACETECH

FEMALE ENGINEER PROGRAM

www.avlracetech.com

Female engineers are still underrepresented in motorsport, however more and more are

getting into decision-making positions. To get more women interested in motorsport,

AVL RACETECH has launched the Female Engineer Program.

Within the “Female Engineer Program”, the selected participants will experience a

motorsport scholarship at AVL RACETECH. From working at different motorsport

departments to getting on track experience in collaboration with AVL RACETECH´s

technical partners. Our goal is to support their path into motorsport.

corporate insights

corporate insights

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Our vision of CO2 neutrality

across our global operations

starts with our Austrian

headquarters

PUSHING FORWARD ENERGY

REDUCTION AND ENVIRONMENTAL

PROTECTION

Climate change and environmental impact have been, and will contin-

ue to be, the biggest drivers of change within the automotive industry. It

is something we take very seriously at AVL, as we work with our partners

and customers to achieve climate-neutral mobility. But it is also something

that we have always been and of course still are passionate about at AVL,

and we’re taking steps to reduce our own environmental impact across our

business, starting with our head office in Graz, Austria.

GLOBAL PATHWAY TOWARDS A GREENER AND MORE

SUSTAINABLE FUTURE

Making AVL climate-neutral is not a single task, but a series of activities with

the aim of continuously optimizing, improving and monitoring our CO2

footprint. Our employees are the changemakers, innovators and pioneers

towards sustainability – not only with their work but also, for example, on

their way to work. As a company, we encourage people to cycle to work

and we subsidize the increased use of public transportation. Furthermore,

more than half of our internal carpool is either electric or hybrid. We charge

these vehicles on-site using renewable power, and when they are out on the

road, we use the 100 % renewable Shell Recharge network.

We are already using 100 % renewable electricity at our headquarters in

Graz, and heat produced by our own solar thermal plant, measuring more

than 3,300 m², is fed into our internal heating network. The system offers

an energy generation capacity of 2,424 kW, and boasts a cooling capacity

of 650 kW using the high temperatures of summer for process cooling

via an absorption chiller. This makes it one of Europe’s largest process

cooling systems.

Built in collaboration with SOL-

ID Solar Energy Systems and

solar.nahwaerme.at, the plant can

save 320 tons of CO2 every year

and offers a practical example of

how any industry can reduce CO2

emissions. We have also installed a

waste heat recovery infrastructure

throughout our Graz facility to

supply our internal heating system.

HOW WE ENSURE THAT OUR

ACTIVITIES MEET OUR GOALS

The basis for our sustainable actions

is the ISO 14001 certificate, which

the headquarters has held since 2002

and we are working to roll it out at

all locations worldwide. Further-

more, we have been part of the

ECOPROFIT® initiative of the city

AVL’s Executive Vice President, Jens Poggenburg,

has been elected as the AVL board’s new representative

of suppliers at the prostep ivip Association. The associa-

tion brings together members from a variety of industries

to tackle the big issues around digitalization. Founded in

1993 with a focus on the STEP data format, then expanded to integrated virtual

product creation, the association has now strategically realigned itself towards

digital transformation.

“Since there is a huge overlap in the strategy of prostep ivip with the mid- and

long-term objectives of AVL, I am happy to contribute as a board member of

the association to its future success,” says Poggenburg. “We are all facing the

same challenge: How to ensure seamless collaboration in cross-organizational

networks. Digitized processes, well-defined interfaces, appropriate skills, and

global interaction are essential success factors which I would like to move

forward. I am very optimistic to create relevant impact for the member group

of suppliers in the association.”

AVL has been an active member of the association since 2008. ��������������������������������������������������������������������������������������

Leading in Digital

Transformation

F I N D O U T M O R E : www.prostep.org

AVL’s Jens Poggenburg

joins influential industry

body to shape the future

of digitalization

of Graz for decades, which aims

to conserve natural resources and

reduce waste and emissions.

We already have global energy

and CO2 measurement and mon-

itoring practices in place. For this

purpose, we have developed our

own in-house energy monitoring

tool that provides the energy con-

sumption and CO2 emissions data

of AVL globally to determine the

most efficient measures to achieve

our environmental targets, taking

into account local conditions.

Together we move towards our

vision of carbon neutrality at our

head office and across our global

business – creating a more sustain-

able world for future generations.

�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������

Extended board of the prostep ivip Association with Jens Poggenburg, second from right.

© prostep ivip Association

vehicle

vehicle

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Examining hundreds of different characteristics and tech-

nologies, including innovations such as torque vectoring

for electric all-wheel drive systems, and vehicle dynam-

ic control, we are able to create a roadmap for differ-

ent driving experiences. These are then functionally de-

fined, developed, calibrated, and considered collectively

in a way that meets the demands of vehicle makers and

the end user.

By transforming our knowledge of market trends, system

performance and technology into KPIs for target setting,

we can then support our customers in creating a func-

tional vehicle development approach to realize products

that compete in specific market segments, with specific

performance goals. This is especially vital for the devel-

opment of new electrified vehicles, whose geometry and

driveability are heavily impacted by systems such as the

battery and its influence on the vehicle’s center of gravity

and aerodynamics. Similarly, e-axles and e-motors impact

driving dynamics and comfort features, which in turn im-

pacts development methodologies, timescales, and cost.

Thanks to our experience, we can help you manage, and

optimize, all of these many different factors.

SIMULATING A SUCCESSFUL PROJECT

At AVL one of the keystones of our business is our sim-

ulation know-how. The various software tools in our

portfolio enable us to build a vehicle – from individu-

al components and systems right up to the whole prod-

uct – fully virtual. We use tools such as AVL-DRIVE™

and data from our benchmarking program to assess and

model the performance characteristics of different sys-

tems in relation to each other. This means that we can

ensure a vehicle will meet its driveability tar-

gets right from the start of development.

Other products in our software

toolkit include AVL VSM™ for

simulation, and AVL CAMEO™

for calibration, both of which

contribute real value when de-

signing and developing vehicles

with particular user experience

traits.

Ultimately, the goal is to create a driving ex-

perience that is competitive in a specific market seg-

ment. And as vehicles and their systems are becoming

increasingly complex, to achieve this requires specialist

functional development methodologies, know-how and

expertise. And at AVL that is just what we are able to

provide to our industry partners. 

DESIGNING

THE

DRIVING

EXPERIENCE

The market position of a vehicle and the driving experience are influ-

enced by tangible driving characteristics. Chassis attributes, braking and

traction control, and comfort factors for example, all influence the driv-

ing feel and are created by the behaviors of different systems, functions

and parameters.

But the vehicle is growing in complexity, as the automotive industry re-

sponds to customer demands for an increase in functions provided by

systems such as electrified powertrains, ADAS and Automated Driving.

These result in more systems – both physical and software – impacting

the driving experience, and call for an intelligent design approach at both

the system and complete vehicle levels.

To tackle this complexity, at AVL, we use a systems engineering approach

that considers each system in relation to the complete vehicle, to optimize

the end-user experience. The result is a product that meets user expecta-

tions for the market segment that it is in, while reinforcing the brand iden-

tity of the manufacturer, and aligning with their goals.

BENCHMARKING FOR TARGET

SETTING

Understanding the type of driving

experience – and therefore the types

of vehicle systems – that are expect-

ed throughout the automotive mar-

ket requires a deep understanding

of the vehicle itself. Thanks to our

AVL Global Benchmarking Pro-

gram we can analyze the perfor-

mance and system characteristics

of vehicles across the market, with

special attention to the premium

segment which often sets the stan-

dard for other market segments to

follow.

With our expertise in functional

vehicle development, and our diverse

portfolio of tools and services, we can

help you create the ideal experience

for your target market

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One Step Ahead

of Future

Brake Emission

Legislation

Continuous improvements in combustion-based mo-

bility, driven by increasingly stringent exhaust gas regu-

lations, have led to a significant reduction in particulate

matter pollution. Today, the majority of vehicular partic-

ulate matter no longer originates from exhaust gases, but

from other sources such as tire, road and brake abrasion.

Of these, brake abrasion is considered to have the great-

est potential for reduction.

Under the Particle Measurement Program (PMP) of the

United Nations Working Group on Pollution and Energy

(UN-GRPE), a methodology has been developed to de-

scribe the procedure and conditions for measuring brake

particulates and which metrics should be used. Subse-

quently, this methodology, known as the United Nations

Global Technical Regulation (UNGTR) will become the

foundation for future legislation with which vehicle and

AVL is leading the

world in brake

emission measure-

ment systems

brake component manufacturers

will have to comply, in addition

to already existing requirements

for brake development like brak-

ing performance, noise and driv-

ing stability. To support this com-

pliance, there is a need for suitable

testing solutions.

AVL EXPERTISE SETTING THE

STANDARD

As an industry leader, AVL played

a role in the definition of this UN-

GTR and we have developed a so-

lution – AVL Brake Emission Test

Systems – that delivers repeatable

and comparable measurement re-

sults through comprehensive opti-

mization of the entire measurement

chain. This starts with flywheel-free

loading machines, air conditioning

systems, volume flow generation,

and the enclosure of the brake sys-

tems to be measured. It also includes

suitable sampling systems with ap-

propriate sampling probes, measur-

ing devices for particulate mass, par-

ticle number and flow measurement

up to test run automation and eval-

uation. All of which meet the re-

quirements of the GTR. Modular

in design and consisting of self-con-

tained subsystems, it can be tailored

to your precise requirements.

DEEP KNOW-HOW FOR

ACCURATE RESULTS

The success of our solution is based

on a deep understanding of the

physical behavior of the particles

generated during braking process-

es. In addition to cooling the brak-

ing system, the solution’s enclosure

is designed to dissipate the emissions

generated during braking as com-

pletely as possible, without major

particle losses. The transfer lines of

the measuring equipment are built to

minimize particulate losses and sup-

port efficient test rig operation. Air

mass measurement as well as air con-

ditioning with temperature and hu-

midity control complete the system.

Main components

of the AVL system

for measuring brake

abrasion particles.

The iGEM 2 test automation system guides you through

the entire brake test procedure, including pre-test dialog,

test preparation and the test run itself. The test cycle is

run automatically in an unmanned mode.

We have years of experience as a

developer and manufacturer of par-

ticle measurement equipment, and

this allows us to support modern

electrified vehicle development as

well as conventional combustion-

powered vehicles. Brake systems

in electrified powertrains must be

considered as a whole due to their

interfaces and interactions with the

vehicle and the need to recuper-

ate braking energy. The required

consideration of vehicle operating

strategies for optimized emission

behavior and the use of appropri-

ate simulation tools. Fortunately,

when it comes to co-simulation on

the testbed, we can draw on many

years of experience, and our solu-

tions cover all current development

requirements.

In addition to the testing system

AVL also developed the testing

automation tool AVL iGEM 2™

for brake wear testing. This solu-

tion enables the execution of legal-

ly required tests and offers simple

modification options for custom-

er-specific development tasks. The

application’s associated test evalu-

ation and automatic test report-

ing round off this lean, optimized

package. Furthermore, we have

also developed a solution to con-

vert your existing testbed infra-

structure for brake emission tests.

This could help to gain utilization

of existing testbeds with minimum

investment.

In analogy to exhaust gas legisla-

tion, it can be assumed that in the

medium-term braking emissions

will be examined not only on the

basis of component tests on the tes-

tbed, but also in real driving opera-

tion. Here, too, we are already tak-

ing the first development steps, and

will build on our success in exhaust

emission reduction. ������������������������������������������������������������������������������������

vehicle

1 7

Analysis of EMC results

under real-driving-

con ditions with an

advanced Software

Interface between

AVL PUMA 2™ and

R&S® ELEKTRA EMC

TEST Software (right).

Data post-processing

in AVL CONCERTO™

AVL ROADSIM EMC™

AVL E-Axle TS™ EMC – fixed

AVL E-Motor TS™ EMC – fixed (left) and mobile (right)

image data missing

vehicle

vehicle

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N O . 1 2 0 2 3

ANALYSIS OF EMC RESULTS UNDER REAL-DRIVING-CONDITIONS

The behavior of components such as the e-drive changes depending on

different uses. This forces the testing operator to dodge steady state mea-

surements for real driving conditions. And EMC measurements with fixed

operating points, as in conventional internal combustion engine vehicles,

do not show the same effects as in the electrified vehicle.

Additionally, the EMC test setup comprises of the device under test (DUT),

the load simulation, conditioning systems and the EMC measurement

hardware and chamber. All these components have separate automation

and/or control systems for their operation, and must be interconnected

to measure their dependency to each other.

To tackle this we have collaborated with Rohde & Schwarz, a provider

of measuring and testing systems, on an exclusive solution for automated

EMC data analysis. The system works under real operating conditions of

an electric vehicle or any of its components.

AVL PUMA 2™ automation drives the test cycle and stores the measured

data, in sync with the R&S®ELEKTRA test software, which exchanges

information between the testbed and the EMC measurement equipment.

Ensuring electromagnetic compatibility in driving systems,

vehicle control units, and ADAS systems

AVL Test Systems

for Electromagnetic

Conformity (EMC)

EMC E-MOTOR TEST SYSTEMS

The AVL E-Motor TS™ EMC –

fixed provides the highest perfor-

mance and EMC capabilities. Cus-

tomers do not have to compromise

between the mechanical and the

EMC performance of the test facility.

The AVL E-Motor TS™ EMC –

mobile solution performs high-

speed EMC testing under load in

existing EMC chambers without

major modifications. The mobility

of the system allows complete pre-

setup outside and transfer into the

chamber, resulting in high efficiency.

EMC E-AXLE TEST SYSTEMS

The AVL E-Axle TS™ EMC is

an extension of the fixed E-Motor

EMC test system. This scalable so-

lution can be extended to all perfor-

mance classes of AVL’s dyno port-

folio, reaching up to 5,000 Nm and

3,500 rpm.

EMC VEHICLE TEST SYSTEMS

Integrable into both anechoic and

shielded EMC chambers, AVL

ROADSIM EMC™ is a chassis

dynamometer that supports EMC

testing for everything from passen-

ger cars to heavy trucks. It complies

with most international regulations

(CISPR 12 and 25, ISO 11452,

GBT 18387-2008 and ECE-R10).

AVL CONCERTO™ post-pro-

cesses the measured data automat-

ically, delivering a full test report

according to pre-defined pass and

fail criteria. It supports automated

testing with simulation of real driv-

ing conditions while covering typi-

cal automotive standards. The ben-

efits include:

• Complete EMC results under real

driving conditions

• Reduced complexity of EMC

measurement procedure for com-

ponents and vehicles

• All test specifications and exam-

inations can be carried out de-

pending on the different DUT

and EMC parameters

• Synchronization of EMC mea-

surement and DUT operating-

data, which shows the dependen-

cy of the operating state and EMC

data, and the behavior of EMC

parameters depending on the op-

erating variables of the DUT

• Repetitive and deterministic test

procedures allow for fast compar-

isons between testing cycles and

their visualizations

• Individual monitoring criteria can

be defined for any channels. Devi-

ations and violations of tolerance

bands are evaluated automatically

Our EMC test solutions guarantee

that the DUT is the only focus of

each EMC measurement. They also

reduce test setup complexity to en-

sure that testing is safe, precise and

as time efficient as possible. This

empowers our customers in their

e-mission. �����������������������������������������������������������������������������������������������������������������������������������������������

An increasing number of electrical and electronic (EE) subsystems

are being integrated into vehicles. Operating high-performance electric

propulsion under all conditions and in close proximity to sensitive com-

munication systems is one of the most significant hurdles the automotive

industry must overcome. EMC measurement should therefore be consid-

ered early in development.

At AVL we have continuously expanded our portfolio of EMC test systems

from component level to the complete vehicle, and always compliant with

EMC standards. The three major test areas are e-motor, e-axle and vehicle.

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