Virtual Front Loading for Early Insights
To master the complexity of brake emissions within tight time-
lines, simulation becomes essential. AVL CRUISE™ M enables
the creation of Virtual Twins where emission maps, braking
strategies, and vehicle controls interact under real drive cycles.
Brake temperatures, recuperation, BMS, battery state of
charge and temperatures can all be considered. Complemen-
tary CFD models provide insights into particle behavior in the
wheelhouse – including dispersion, deposition, and resus-
pension, which are essential considerations for brake emis-
sion RDE (Real Driving Emissions). This combination allows
emission-relevant effects to be understood and addressed
early in development, long before physical prototypes are built.
Simulation also enhances physical tests by revealing details
that measurements alone cannot capture.
Proof on the Testbed
Validation remains the decisive step. AVL operates a global
network of brake emission testbeds with facilities in Graz, a
GTR-24-compliant site in Japan with 24/7 operation, and a
heavy-duty installation currently being set up in Steyr. The AVL
Brake Emission Test System measures both particulate mass
(PM10, PM2.5) and particle number down to 10 nm, using
advanced APC technology and gravimetric filter methods. Its
CFD-optimized sampling system ensures uniform particle con-
centration and minimizes losses. Testing times are optimized.
The PM Sampler xChange enables up to 16 automated tests
with no manual interaction, supporting 24/7 and weekend
automated testing, reducing manual effort and speeding up
development. Customers can choose between testing at the
AVL Test Factory or implementing AVL’s turnkey test systems
in-house.
A Seamless Toolbox
The decisive factor is integration. AVL combines components
and system development, simulation, and testing into a single
consistent workflow. OEMs and suppliers can identify emis-
sion sources, test countermeasures, optimize designs, and
ultimately validate systems – all with a single partner. This
seamless approach shortens development cycles, reduces
costs, and provides confidence in Euro 7 readiness.
Beyond Compliance
Euro 7 is a strong driver, but the benefits go beyond regulation.
Cleaner brakes improve urban air quality, protect public health,
and support broader sustainability goals. At the same time,
brake emission engineering fosters innovation in materials,
components, system architectures, and digital methods. With
its comprehensive portfolio, AVL not only ensures compliance
but also empowers customers to take the lead in shaping
cleaner, safer, and smarter mobility.
Euro 7 at a Glance
Timeline
• Applies to new vehicle types from
end of November 2026
• Applies to all vehicles from end of
November 2027
Limits (light duty)
• PM10 ≤ 7 mg/km for ICE & hybrid
vehicles
• PM10 ≤ 3 mg/km for electric vehicles
What makes it new
• First regulation to include non-ex-
haust emissions (brake & tire wear)
• Applies to both original and replace-
ment parts
AVL solutions
• Engineering: low-emission materials,
advanced coatings, new brake con-
cepts
• Simulation: Virtual Twins, CFD
particle analysis, brake emission
maps in AVL CRUISE™ M
• Testing: GTR-24-compliant brake
emission testbeds, Testing as a
Service, instruments, full test and
turnkey test systems, revamps
2025