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
N O . 1 2 0 2 3
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
N O . 1 2 0 2 3
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
N O . 1 2 0 2 3
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
1 3
1 2
N O . 1 2 0 2 3
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
1 5
1 4
N O . 1 2 0 2 3
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
vehicle
1 6
N O . 1 2 0 2 3
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
1 9
1 8
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.