41
01
For many OEMs, the current calibration and release
process is too slow and too error-prone, as modern
software development is pushing the current sequential meth-
odology to its limits. This demands tighter integration of soft-
ware development, calibration, and testing while also meeting
compliance requirements such as UNECE R 156 SUMS. With
software components growing in number and complexity,
over-the-air (OTA) readiness requires fully automated work-
flows, traceable variant management, and integrated testing.
AVL provides a DevOps-ready solution based on the calibration
platform AVL CRETA™, enabling parameter lifecycle automa-
tion, seamless versioning, and API integration. This allows
for continuous release pipelines – with significantly shorter
update cycles, higher compliance, and full OTA transparency.
02
Meeting market expectations for innovation and per-
formance requires shorter development cycles without
compromising quality. Traditional, sequential processes
rely heavily on costly hardware prototypes and perform key
validation steps very late in the program – increasing the risk
of delays and budget overruns. AVL’s shift‑left approach brings
critical testing activities into earlier phases of development,
combining Model‑in‑the‑Loop (MiL), Software‑in‑the‑Loop
(SiL), Hardware‑in‑the‑Loop (HiL), and Power‑HiL environ-
ments into an integrated toolchain.
By connecting virtual and physical testing, OEMs can validate
components and systems under realistic vehicle, thermal, and
environmental conditions long before a prototype is built. This
includes integrating BMS development into HiL setups, using
Active DoE to optimize test planning, and automating data
evaluation and reporting. The result: up to 50 % shorter test
times, fewer prototype cycles, and a faster time to market – all
while maintaining or improving product robustness.
03
Recalls and warranty costs remain a major financial
and reputational risk for OEMs. In many cases, issues
only become apparent after vehicles are in customer hands
– when fixing them is slow, expensive, and disruptive. AVL ad-
dresses this by enabling continuous fleet monitoring through
advanced vehicle health management systems.
Big data analytics and AI‑based trend prediction detect
anomalies early, long before they escalate into critical failures.
By integrating field and test data into a centralized platform
with automated anomaly detection, engineers can analyze
performance deviations and quickly identify root causes.
Closed‑loop data feedback between operation, testing, and
development ensures that corrective measures are imple-
mented rapidly, improving overall product quality. Compliance
with SUMS and cyber security requirements are built into the
monitoring process, enabling OEMs to take preventive action
and significantly reduce the risk of recalls.
04
Battery degradation and thermal behavior are among
the most critical – and most complex – factors in
BEV development. If not managed properly, they can limit
driving range, extend charging times, and shorten service life.
Classical aging tests are time-consuming and expensive, often
taking more than a year and providing insights too late to steer
pack design or control strategies. In addition, pack validation
typically occurs very late in the development process, creating
a high risk of costly and time-intensive rework and re-valida-
tion.
AVL addresses these challenges through battery pack vali-
dation with a Battery-in-the-Loop (BiL) setup. These testbeds
integrate realistic vehicle and thermal simulations, enabling a
broad range of vehicle-level validation tasks, such as as-
sessing range, performance, and battery degradation under
real driving conditions. At cell level, model-based testing can
reduce aging test duration by up to 40 % through the combina-
tion of advanced Design of Experiments (DoE) methods and
machine learning. Leveraging predictive aging models and
AI-driven analysis, engineers can accurately evaluate perfor-
mance and aging effects across different chemistries, validate
State-of-X (SoX) parameters at an early stage, and optimize
pack design and control strategies under real-world load and
temperature profiles. This holistic approach enables OEMs to
maximize energy efficiency, ensure thermal stability, and ex-
tend battery lifetime - delivering consistent performance from
the first charge to the end of service.
Develop BEVs Faster
Master Battery Performance
Minimize Recalls. Maximize Trust
Accelerate Software Updates
Let’s Release!
With EVolve Mobility, AVL acts as a bridge builder for
reliable results. We support OEMs in achieving their
goals by upholding the highest quality standards and
breaking down silos. By fostering collaboration across
teams, we drive sustainable development and unlock
the value of decades of accumulated data. By inte-
grating extensive software expertise with a holistic
perspective on BEV development, we empower organi-
zations to master the complexities in the development
– from the initial concept to the finished product. “Let’s
Release” stands for enabling seamless cross-disci-
plinary interaction, mastering complexity, and delivering
vehicles that meet the highest expectations - faster,
safer, and more efficiently.
Challenges
Toolchain