Agricultural Machinery Engineering Can Learn from the Automotive Sector ‹‹

December 2012

powertrain & drive

The AVL Magazine for Powertrain Development, testing and Simulation

›› Agricultural Machinery .08 high Performance Technology Engineering Can Learn From Demonstrator: AVL Coup-e 800 .18 high-tech Exhaust Emission and The Automotive Sector. ‹‹ Particulate Measurement Systems Martin Richenhagen, Chairman, President and CEO of AGCO .22 Electrification in Motor Racing AVL Powertrain World App

AVL’s new Powertrain World app for the first time Download now ! provides engineers across the auto industry with insight and information into the latest innovation, wherever they are. Powertrain World is a content-based app for smart- phones and tablet devices like the iPad that delivers exactly what it promises – comprehensive information on The unique new app everything to do with the very latest on powertrains. The for auto engineers to content is a combination of different types of articles, keep in touch with images and videos, as well as information on events and industry innovation. products, intelligently categorized and tagged so that the app is easily navigable. editorial

.04 cover Story > interview with Martin Richenhagen, Chairman, President and CEO Prof. Helmut List of AGCO Chairman and .08 POWERTRAIN ENGINEERING CEO AVL The all-electric high performance demonstrator vehicle Coup-e 800 .12 Portrait

uwe Dieter Grebe, Executive Vice President of Global Business Achieving the future CO2 fleet Development, Sales & International Operations in Powertrain Engineering limits presents a huge challenge for the global automotive indust- .18 instrumentation and TEst Systems ry. It is imperative to develop drive high-tech exhaust emission and particulate measurement systems solutions that lower consumpti- for R&D as well as for certification tasks on while remaining affordable and attractive to our customers. .22 rACING Peter Schöggl, Head of Business Field Racing, on the growing significance Conventional drive systems still of electrification in motor racing have tremendous potential for improvement in this respect. Effici- ency-optimized combustion engines combined with modern transmission Sections: systems are capable of reducing car- 16 _ Around the World: The AVL California Technical Center bon emissions by up to 20 percent. 17 _ events: 25th Anniversary Conference “Engine & Environment” 2013; Hybrid technology will also contri- 7th AVL International Commercial Powertrain Conference 2013 bute significantly to meeting the tar- 26 _ Innovations: Waste heat recovery improving commercial vehicle fuel efficiency; gets, but only if the technology of A new method for faster and more efficient calibration of all-electric vehicles all components – from the electric 30 _ Products: AVL BOOST 3D Modeler; AMA i60 Exhaust measurement system; motor to the converter and the bat- AVL CAMEO – a key for efficient powertrain calibration tery – are developed further. 33 _ AVL Integrated & Open Development Platform AVL is ideally positioned: with our comprehensive component and system expertise, our simulation tools and our state-of-the-art instrumentation and test systems, we are 08 already able to develop hybrid module solutions in the concept phase, which helps to effectively counter- act higher costs.

Together with our customers we will continue to succeed in developing affordable drive systems, which are both environmentally friendly and 04 attractive to our customers.

Helmut List Editor and media owner: AVL (TM, RM) List GmbH, Hans-List-Platz 1, A-8020 Graz, Tel.: +43 316 787-0 Publisher and producer: Scoop and Spoon, Breite Gasse 4, A-1070 Wien, Tel.: +43 1 523 4088 150, www.scoopandspoon.com

3 Focus cover story

4 Focus Interview with Mr. Martin Richenhagen, Chairman, President and CEO of AGCO ›› Agricultural Machinery Engineering Can Learn From the Automotive Sector ‹‹

AGCO, based in Duluth (Georgia), USA, is the world’s third-largest manufacturer of agricultural equipment. Being a leading global company, AGCO offers a broad variety of products, which are distributed through more than 3,100 dealers in more than 140 countries. Focus spoke to Martin Richenhagen, President and CEO of AGCO, about developments in drive engineering, the role of alternative fuels and new challenges in the growth markets.

‹F›: Mr. Richenhagen, ‹Richenhagen›: AGCO assumes solutions available in the automo- AGCO is a globally active man- very stable markets with global tive sector. ufacturer of agricultural equip- growth. China, Eastern and Cen- ment with sales of around 10 bil- tral Europe and Africa have a lot ‹F›: Do you already have special lion dollars. Please tell us what of catching up to do. AGCO is re- low-emission engines or filter sys- kind of equipment your business sponding to this fact by investing in tems for diesel engines? activities focus upon most. three factories in China, and is the first manufacturer in our industry to ‹Richenhagen›: Yes, we do. Where ‹Richenhagen›: In 2012 sales will have a manufacturing site in Africa. this is concerned, AGCO Power, even be reaching 10.5 billion dollars, our diesel engine line, is complete- making it yet another record year. ‹F›: Does the reduction of con- ly state of the art. AGCO’s main focus is on wheeled sumption, and thus carbon emis- tractors, and we’re additionally ex- sions, play a similarly big role in ‹F›: AGCO Corporation joined panding our range of harvesting the agricultural industry as it does the Diesel Technology Forum in equipment rapidly. with passenger cars and trucks? March 2012. What role do you think bio fuels will have as a fu- ‹F›: What is your view of long- ‹Richenhagen›: Of course it does, el for agricultural machinery in term trends in the tractor mar- however with a slight delay, which the future? kets in Western nations and the has the positive effect of giving ag- BRIC states? Do you think there ricultural equipment technology a ‹Richenhagen›: We regard this as will be a market shift in one way chance to learn from the technical a very interesting prospect, and or another, and how will AGCO farmers, being the producers of re- respond to it? Photos: A G C O

5 Focus cover story

newable energies, are very keen on solutions like this.

‹F›: Powertrain electrification is becoming increasingly important with passenger cars, and also with several heavy-duty type vehicles. Do you think that tractors will someday also have hybrid drives?

‹Richenhagen›: FENDT already developed a prototype together with a renowned university some years ago. I find that particular technology rather unlikely to be put on the market, though.

‹F›: What would you say are the key innovative forces in the area of tractors after the implementation of low-emission engines? Martin Richenhagen Chairman, President and Chief Executive Officer ‹Richenhagen›: Where this is concerned, the big issue will be how the tractor can be controlled by the re- spective accessory equipment. Martin Richenhagen (*1952) was appointed President and Chief Executive Officer of AGCO Corporation in March 2004. Since August 15, 2006, ‹F›: What role do research & de- Mr. Richenhagen has been Chairman of the Board of AGCO Corporation. He velopment have in your corporate continues to sit on the Board as well as the Committees on Strategic Plan- group? Are these activities central- ning and Succession Planning. Mr. Richenhagen is also member of the ized, or is R&D done in more than Supervisory Board of Phelps Dodge Corporation, where he also sits on the one location? Audit, Finance and Corporate Governance Committees. Previous to that, Mr. Richenhagen was Executive Vice President of Forbo International SA, a ‹Richenhagen›: Research & develop- Swiss group specialized in the production of flooring systems. And before ment is an extremely important area that he served as CEO of Germany-based agricultural equipment manufac- to me personally and, of course, to turer CLAAS KgaA mbH, where he was responsible for the entire operations, AGCO. We spend roughly 350 mil- Export, Marketing, Sales and Human Resources Management. In the years lion dollars on R&D a year. In key before 1995, Mr. Richenhagen was Senior Executive Vice President of areas, for example where the Platform Schindler Holding GmbH in Germany, where he was responsible for the Solutions are concerned, we take a areas Sales, Customers Support and Logistics. In 2009, Mr. Richenhagen centralized approach. became Chairman of the AEM (the Association of Equipment Manufacturers), which has more than 800 members around the world and represents the in- ‹F›: How significant are advanced terests of the industry. Mr. Richenhagen is a Life Honorary Director of AEM. measuring and testing systems for In 2011, he was appointed Chairman of the Board of Directors of the Ger- your R&D activities? man American Chamber of Commerce of the Southern US, Inc. Richenha- gen is married and has three children. He graduated from the University of ‹Richenhagen›: In compliance with Bonn and is fluent in several languages thanks to his long-standing interna- the importance we attach to mod- tional career. In December 2008, Mr. Richenhagen was appointed Honorary ern measuring and testing equip- Professor to the Faculty of Agricultural Machinery at the TU Dresden.

6 Focus ment, we invested accordingly in tinguished, but we attach great im- active agricultural equipment man- new technology again this year. portance to using the same compo- ufacturer? nents. ‹F›: In what areas – engine, pow- ‹Richenhagen›: The challenge we face ertrain, etc. – do you globally work ‹F›: Do you also engage in business is to help farmers make advances in together with AVL? activities in growth markets like productivity by offering them intel- India, China or Brazil? How do ligent technology, as they try to meet ‹Richenhagen›: We collaborate with the demands there differ? Do these sharply rising demand for food and AVL in all of the relevant fields such customers require simpler and thus renewable energies. as engine and powertrain. more cost-efficient technology? ‹F›: All over the world, there is a ‹F›: AVL is heavily involved in trans- ‹Richenhagen›: In the BRIC regions, lack of good engineers while the mission development. What role do the situation varies, but over a cer- technical demands on the tractor, modern automatic transmission tain period of time the standards will and, consequently, on the develop- systems play in tractors or combine ultimately be the same the world ment team are on the rise. What do harvesters? Are there any trends? over. you tell young people in order to

AGCO offers a broad variety of products through more than 3,100 dealers in more than 140 countries.

‹Richenhagen›: In this respect, we’ve ‹F›: Is there such a thing as a high- get them interested in agricultural been setting the trend for years, and end market for agricultural ma- engineering? were first movers in CVT transmis- chinery, where people demand no sions. less than the latest technologies ‹Richenhagen›: Our industry is cur- where cost plays a minor role? rently experiencing a major surge in ‹F›: You have many different brands growth, and over the next few de- in your portfolio: Challenger®, ‹Richenhagen›: Yes there is. These cades the demand will continue to be Massey Ferguson®, Fendt® und are the professional farmers who much higher than the supply. AGCO Valtra®. Are technologies developed base their purchase decision primar- and its brands are global technology jointly for several brands? Or are ily on ROIC (note: return on invest- market leaders with 2,500 develop- there certain technologies which ed capital) and the costs over the en- ment engineers in all of the relevant help to distinguish the brands from tire life cycle. markets. AGCO’s vision makes jobs each other? for well-trained young people very ‹F›: What do you think are the big- attractive and our internal human ‹Richenhagen›: Our core brands are gest challenges facing a globally resources development program is uniquely positioned and clearly dis- really great. <

7 Focus powertrain engineering

A look behind the scenes of the Coup-e 800 project reveals the comprehensive expertise demonstrated by AVL in the domain of pure electric vehicles. The entire engineering project was carried out within the world-wide AVL group, from system design through to component development and software. The result is a high performance technology demonstrator that shows that it is indeed possible to deliver both sportiness and driving pleasure with e-drives.

“Our aim was to develop a An powerful, purely electrically pro- pelled vehicle that fully meets the requirements of sporty drivers. Anoth- er aspect we focused on was to ensure that there was no adverse impact on Electrifying the passenger compartment or the rear trunk volume. But at the center of our considerations was obviously a level of performance that could deliver acceleration from 0 to 100 km/h in 6 s and a maximum speed of Premiere 180 km/h,” says Anton Angermaier, Head of E-Mobility, describing AVL’s most recent all-electric demonstrator vehicle, the Coup-e 800. Its development was lead-managed by AVL Software and Functions GmbH in Regensburg.

The AVL Coup-e 800 is based on a Mercedes C-Class Coupé, which, thanks to its rear wheel drive, offers the ideal platform for the sporty AVL prototype. “The name Coup-e 800 is derived from the fact that in certain operating situations we are capable of achieving a system voltage of almost 800 volt. The electric traction motor additionally enables us to get very close to the peak torque of 800 Nm,” Angermaier explains, adding, “The drive segment in which our demonstrator vehicle is positioned can be referred to as the six-cylinder segment > of electric mobility.” The high performance demonstartor vehicle Coup-e 800, based on a Mercedes C-Class Coupé.

8 Focus >

The compact electric motor is directly flanged onto the rear axle transmission. It is equipped with direct liquid cooling of the stator coil (internal winding cooling) and a dry running rotor in order to avoid plashing losses.

Fundamental concept become very heavy and, due to their gy and a battery with a nominal DC- thickness, the bending radii would voltage of 675 volt. The battery with Our decision to increase the DC-volt- create considerable problems during a gross energy content of around 28 age level from the usual 300-400 volt integration. Larger-sized cells would kWh is installed in the same space common in electric vehicles to up to also need to be put into the battery, where the engine and the transmis- 800 volt was based upon several con- or alternatively cells connected in par- sion would normally be. The com- siderations: achieving electric driving allel, which would be trickier to han- pact electric motor is directly flanged onto the rear axle transmission, driving the rear wheels without interme- diate transmission. Based on this geo- ›› The drive segment in which our metric integration concept, a weight demonstrator vehicle is positioned can distribution of 53 percent (front axle) be referred to as the six-cylinder and 47 percent (rear axle) is achieved. segment of electric mobility. ‹‹ Traction motor with high performance density performance above 100 kW would dle in the sense of cell management. imply an electric current of more The Coup-e 800’s traction motor is than 350 ampere in the HV-power- During the development of the Coup-e a permanent magnet synchronous net (DC), if 600-Volt-IGBT technol- 800, AVL and its development part- motor. It is equipped with direct liq- ogy is being used in the inverter of ner Infineon tackled this problem uid cooling of the stator coil (internal the traction motor. These high cur- by using 1200-volt IGBT technolo- winding cooling) and a dry running rent loads increase resistive losses in rotor in order to avoid plashing losses. the HV cables; in addition, the cables Photos: AVL

9 Focus powertrain engineering

This cooling concept is achieved by the use of a sealing-tube, which is integrated inside the synchronous motor’s air gap. This innovative cooling system enables a continuous power of 140 kW and a continuous torque of 500 Nm at 2700 rpm with e-motor dimensions no bigger than 390 mm in length and a diameter of 245 mm Peak torque is at almost 800 Nm. “Our cooling concept optimizes heat dissipation directly at those spots in- > side the electric motor – in the cop- The HV battery used for the Coup-e 800 consists of 180 lithium-ion pouch cells all connected in series. per windings and at the edges of the stator teeth – where most of the heat is normally generated. This makes it possible to achieve a very high contin- managed to achieve a very high ener- This technique offers numerous ben- uous rating, which conventional mo- gy and power density while keeping efits, such as high mechanical robust- tors cooled by a water jacket are only the dimensions compact. This makes ness, enhanced electrical performance able to achieve temporarily,” the AVL the battery ideal for driving a power- compared to conventional methods as electric vehicle expert explains. ful sports vehicle. The vehicle range well as cost advantages in production. is between 115 km (NEDC) and 135 km (FTP-72).” HV battery The battery uses an innovative, inte- Active short-circuit avoidance grated cooling concept: the cells are The HV battery used for the Coup-e cooled via the two cell poles (conduc- The 1200-volt system in the Coup-e 800 consists of 180 lithium-ion pouch tor cooling), a concept which makes it 800 also offers a great advantage cells all connected in series. Arranged possible to implement efficient ther- when it comes to safety and driving in 15 battery modules, each module mal conditioning. As no additional dynamics in the event of failure: in controller monitors 12 cells. The bat- cooling plates are needed, very little conventional electric vehicles, a failure tery cell capacity is 41 Ah, which cor- package space is required inside the requires the activation of the so- responds to a gross energy content of battery. Another AVL innovation, called “active short-circuit”, which almost 28 kWh at a nominal voltage of which concerns the HV battery is yields an undesired (!) braking torque, 675 V in the HV battery. Angermai- the applied cell connecting method, that may cause critical driving situa- er: “With a weight of 255 kg, we have which is referred to as “clinching”. tions. In the case of the Coup-e 800’s 1200 volt system, however, this active short circuit is not needed. This is due to the fact that the motor’s max- Anton Angermaier, Head of E-Mobility and Customer Segment, imum induced voltage at maximum AVL Software and Functions GmbH. speed is significantly lower than the threshold voltage of the power elec- » We have the in- tronics. Peripheral components like capacitors are designed in such a way house development that transitions between regular operation modes and safety shutdown are capability for all uncritical. This means that the motor core components of never needs to be switched to active the electric drive short circuit. System. ‹‹

10 Focus >

The Coup-e 800 was one of the technological highlights at the international AVL conference “Engine & Environment” 2012 in Graz.

Excellent simulation tools second. “Something like this requires or supplier can then integrate their The Coup-e’s entire electronics were not only profound knowledge of the own algorithms into this environ- developed in different AVL-locations operating system’s real-time behavior, ment, for example to give the vehicle spread all over the globe. AVL offers but also perfect optimization of the its brand-specific features,” Angerma- outstanding simulation tools, partic- software with respect to run time,” ier says, describing the advantages of ularly suited to this task, which were the specialist in electric drive solutions AVL’s open power electronics control applied over a range of applications points out. system, which is currently the only in the Coup-e 800. “AVL CRUISE one of its kind in the market. was employed upfront to create the entire system design; by simulating “Open” power control the whole vehicle it was possible to for customers Complete in-house development work out the component dimensions. Even the motor’s power and torque Yet the technology employed in the With its prototype Coup-e 800, AVL characteristics were simulated. Based Coup-e 800 represents just one appli- demonstrates that the customer re- on these simulations, the configura- cation for the components and tech- quest for a powerful and sporty ve- tion and dimensioning of all compo- nologies, which AVL has developed hicle can also be met with an all-elec- nents were defined long before we for full electric powertrains. “The tric drive system. Anton Angermaier: even started designing the first com- fact that AVL has all components “Due to the driving performance de- ponent,” Angermaier explains. Apart and technologies available in-house, manded by the customers, aiming from battery development, tasks such means that we are also in a position at higher voltage levels in this class as traction motor integration or pow- to provide our customers with open seems to be a step in the right direc- er electronics development were al- development platforms for their own tion. Due to the in-house develop- so completely taken care of by AVL. particular electric drive development. ment capability for all three core com- Another of the prototype’s highlights If a customer, for instance, wants to ponents of the electric drive system is the way the electric motor is con- develop their own electric motor – electric motor, inverter and HV bat- trolled by means of power electron- control system, we can provide them tery – and its control software, AVL is ics. Depending on speed, load or ef- with AVL control electronics with an the ideal development partner – from ficiency optimization, the controller “open” software package. The OEM system configuration by simulation developed by AVL checks the accu- all the way to series production.“ < racy of control up to 10,000 times a

11 Focus portrait

›› Seizing Opportunities Together with our Customers ‹‹

Uwe Dieter Grebe, the new Executive Vice President of the Global Business Development, Sales & International Operations in Powertrain Engineering on his plans on intensifying customer relations, the continued strengthening of AVL’s market position and the new opportunities opening up as a result of the CO2 emission reduction standards.

12 Focus CO2 emissions reduction has ident of Global Business Develop- Development & Sales with special been one of the most dominant top- ment, Sales & International Opera- focus on passenger cars, it is his task ics in Uwe Dieter Grebe’s career tions at AVL, Grebe was delighted “to establish partnerships with cus- for quite some time. Before join- to accept the offer which he regard- tomers and expand them further, so ing AVL, he held the position of ed as “fascinating”. “In the devel- that new solutions can be created “Executive Director – GME Lead opment of powertrains and the en- jointly”. The important thing here

Executive CO2 Strategies” at Gen- tire integrated systems, engineering is not only to anticipate technical eral Motors Europe, where he was responsible for compliance with the

future CO2 fleet limits. His cross- functional activities not only cov- ›› In the development of powertrains ered the technical level, but also the manufacturer’s strategic prod- and the entire integrated systems, uct planning. “At GME I worked in three different work fields with dif- engineering partners will become an ferent effects in terms of time: The extremely critical factor in the years to long-term component involved de- fining architecture and technology come – and that is exactly where I see a aspects of future vehicles, so that these would technically be in a po- big opportunity for AVL. ‹‹

sition to comply with the CO2 limits. In the medium term, it was important to define the portfolio. The partners will become an extremely trends for our customers – this def- third area concerned the control of critical factor in the years to come. initely requires a technological lead customer behavior by means of The reason for this is the growing on the part of AVL – but also to fo- pricing. So my job had a technical, a complexity and the diversity of cus more on our customers’ respec- planning and a strategic character,” variants in modern drive systems. tive needs. Focusing on customers Uwe Dieter Grebe said describing All the more important, therefore, “means you have to be a good lis- his work at GME in Rüsselsheim will be the role of the engineering tener and understand their road where he worked before switching partner – and that is exactly where map and overall conditions so that over to AVL Graz this September. I see a big opportunity for AVL. you can make the most of the exist- In future, we will have control over ing opportunities together.“ Grebe’s connection to AVL dates an even greater range of variants, back to the time he studied at the which will make us one of the pre- Grebe’s second key area is Inter- Technical University in Darmstadt. ferred partners of manufacturers,” national Operations, which in- “AVL was omnipresent at the uni- AVL’s new business manager said, cludes most of AVL’s international versity. Being a former executive at who describes his new task at AVL tech centers. In this respect, Uwe AVL, my doctoral thesis supervi- as “hugely multi-faceted.” Dieter Grebe will primarily be in sor, Professor Dr. Günter Hohen- charge of strategic alignment as well berg, maintained very close con- as research & development. Techni- tacts with the company, which Making AVL a preferred cal implementation will remain the made me familiar with the com- development partner responsibility of Robert Fischer, pany very early on,” the new AVL Business Manager of Engineering executive told Focus. Throughout In AVL’s Powertrain System Devel- and Technology, Powertrain Sys- his further career, he constantly re- opment (PTE) business unit, Uwe tems. According to Grebe, it is cru- mained in close contact with AVL Dieter Grebe’s scope of responsi- cial to maintain close contact with as an engineering partner, which bility covers two key areas. In his customers “whose current needs led Grebe to “value the company position as manager of Business have to be satisfied in the best way very highly.” When he was offered possible, while at the same time it is a position of Executive Vice Pres- Photos: Christian Jungwirth

13 Focus portrait

Uwe Dieter Grebe

Prof. Dr.-Ing. Uwe Dieter Grebe (47) wrote his doctoral thesis in 1996 after studying General Mechanical Engineering at the TU in Darmstadt. Since 2000, he has been giving lectures at the TU Darmstadt and the TU Vienna. He was appointed honorary professor for Internal Combustion Engines at the TU Vienna in 2006. Uwe Dieter Grebe launched his career in 1991 as development engineer in Advanced Engineering at Adam Opel AG in Rüsselsheim where he became Head Engineer for medium and large-sized four-cylinder DI gasoline engines following several career stations in serial development and DI gasoline engine construction. In 2004, Grebe joined General Motors in the U.S. where he was head of Global Powertrain Advanced Engineering and also managed the research and development activities in North America. In 2011, Grebe returned to Gener- al Motors Europe in Rüsselsheim, where he was in charge of advanced engineering activities relating to the entire vehicle for European models. In his most recent position of Executive Director – GME Lead

Executive CO2 Strategies – he was responsible across functions for

meeting the CO2 targets of the European vehicle portfolio and for the advanced engineering activities for vehicle, powertrain and manufacturing systems within GM Europe. In September 2012, Uwe Dieter Grebe took on the position of Executive Vice President of Global Business Development, Sales & In- ternational Operations in Powertrain Engineering (PTE).

14 Focus necessary to be optimally prepared tion with its vast wealth of vari- cal spectrum ranges from thermal for the customers’ future needs in ants – from the mild hybrid to the management to recuperation so- order to become the preferred de- all-electric vehicle with or without lutions and even includes the op- velopment partner.“ range extender. Here, its compre- tion of giving the powertrain the hensive know-how and experience ability to look ahead via driver as- puts AVL in a position to identify sistance and navigation systems,” Dominant topic CO2 reduction the perfect solution for each of its Uwe Dieter Grebe explained. Un- customers very quickly. One great like its competitors, AVL has a sig- Asked in what areas there was still advantage of AVL is its ability to nificant advantage in that it can take room to maneuver for CO2 reduc- simulate all components and the energy optimization measures like

›› We have to listen properly to what our customers are saying, so that we can make the most of our opportunities together. ‹‹

tion in advanced powertrain sys- way they interact in different op- these at a very early stage on the tems, Grebe said that the main- erating modes. Even when it comes test bed under real-life conditions, stream powertrain still offered to component selection and design which could result in a huge reduc- great savings potential. “Both with – all the way to serial production – tion both in development time and DI gasoline and diesel engines, we AVL can provide optimal support development costs. will still be seeing significant im- to its customers. “In this respect, provements. And in this respect, energy management in vehicles is Uwe Dieter Grebe: “With all mea- AVL is optimally positioned in all gaining particular significance. I sures we take to optimize energy partial aspects – from the combus- like to compare this with a broker efficiency and reduce CO2 emis- tion process to mechanical optimi- on Wall Street who buys stocks as sions, our priority is always to zation. Added to this is the trans- cheaply as possible to sell them off make the product more attractive mission which offers AVL a very at exactly the right time. Trans- and affordable for the customer. big growth potential. In this referred to the powertrain – and this The CO2 emission reduction stan- spect, it is vital to develop optimal applies both for mainstream pow- dards open up many new opportu- solutions all over the world, which ertrains and electrified drive sys- nities for us, and we will use them meet the varying regional require- tems – it is all about generating with our customers in order to de- ments.” the energy “cheaply” and then us- velop modern, efficient and envi- ing it at the right time. The techni- ronmentally friendly drive solu- Another big field of activity, ac- tions.“ < cording to Grebe, is electrifica-

15 Focus around the world

Bruce Falls, Managing Director of AVL’s California Technology Center. The CAL has constructed 47 prototype whole vehicle electric and hybrid electric vehicle builds over the past few years, bringing together different areas of expertise to create concepts for the greener vehicles of the future. California’s Visions of the Future Bruce Falls is the Managing Director of AVL’s California Technology Center, which has been at the very cutting edge of hybrid and electrification projects for the past few years. Focus finds out more about what they do that makes them special.

Es It is almost five years since Bruce fantastic multi-disciplinary teams ac- California is notorious for its tough Falls set up the AVL California Tech- ross the company that reflect the inte- emissions legislation and Falls says nology Center (CAL) in Lake Forest, grated vehicle systems approach you that this is one of the things that ma- just south of Los Angeles near the Pa- need in order to make real progress.” kes it such a good testing ground for cific coast. California, home to Holly- other regulatory regimes around the wood, Silicon Valley and now many The CAL has constructed 47 proto- world. emerging green technology compa- type whole vehicle electric and hyb- nies, has long been conceiving dreams rid electric vehicle builds over the past “California sets the highest bar for and visions that have gained global in- few years, bringing together different emissions in the US and one of the fluence. The CAL fits in to this visi- areas of expertise to create concepts highest in the world,” he says, “and onary category. for the greener vehicles of the future. because the state wants to minimize the impact that vehicles have on the “We started out in 2007 with a core “We’re actually completely dedicated environment that gives us an oppor- group of engineers who had experi- to seeing cleaner transport because we tunity to make sure that we’re com- ence in alternative fuels and advanced think that it benefits everyone,” says pletely on top of our game here. And technologies, electric vehicles and hy- Falls, “and it’s good that the industry if we know we’re getting it right he- brid technology,” he says. AVL saw has been attempting to catch up with re, we know it’ll work elsewhere. In the strategic importance of having a AVL’s pioneering efforts, because it Detroit and perhaps the rest of the California facility to support these ad- shows that something of a consensus world California is sometimes viewed vanced technology initiatives. is emerging over the fact that hybrids as a regulatory problem, but I think and electrification are the future for that we need an attitude adjustment “At the beginning the projects we we- the automotive industry as a whole.” on this – tough regulation can be good re involved with were most limited for the industry.” < to CAL resources, but now we have

16 Focus events

Anniversary Conference “Engine & Environment” 2013 THE CONNECTED POWERTRAIN Interaction of Mechanics & Software, Vehicle, Driver and the Environment

The 25th AVL „Engine & Environment“ congress will take place in the Helmut-List- Halle in Graz on the 5th and 6th of September, 2013. The congress will be dedicated to modern powertrain concepts in the context of increasing connectivity.

Connectivity is a key topic a multitude of questions: how should for the future in many spheres, and the powertrain be configured to op- this is also true for automotive tech- timally make use of the plethora of nology. The vehicle of tomorrow data available within the powertrain will communicate with the envi- and also take full advantage of the ad- ronment, making efficient, accident- ditional data originating externally? free and perhaps even autonomous How can vehicle operation with low driving possible. emissions and optimized fuel con- The powertrains of tomorrow’s vehi- > sumption be enabled and further en- cles will also be connected; not only hanced? What form will the sub-sys- Demonstrator vehicles with pioneering will they communicate with the en- AVL technologies at the 2012 conference tems in future connected powertrains vironment (e.g. the driver, other ve- “Engine & Environment“. take, and how can they be optimized? hicles, and the road infrastructure), How can drivability and operation- but also the connectivity and opti- Below: Scan QR code and access the app. al comfort be optimized in order to mized interaction of all powertrain guarantee customer acceptance? sub-systems such as the engine, trans- These and many more questions will mission, e-machine, battery and vari- be examined by international experts. ous control systems will become in- Information, registration and app- creasingly important. The developers ENGINE & ENVIRONMENT download at: www.avl.com/engine- of future powertrains need to answer environment-2013; [email protected] <

7TH AVL INT. COMMERCIAL POWERTRAIN CONFERENCE 2013

The 7th AVL International Com- conference is entirely dedicated to ation, future transmission technolo-

mercial Powertrain Conference will CO2 reduction. As a result, the scope gies, electrification of drive systems be held on May 22/23, 2013 at the of topics addressed is very broad: and farm implements in agricultur- Helmut-List-Halle in Graz, Austria. market trends, combustion engine al machinery, increases in efficiency The conference is globally unique optimization with hybrid drive sys- in construction equipment by system and focuses jointly on heavy-du- tems, waste heat recovery systems, optimization with new powertrain ty vehicles, agricultural tractors auxiliary power units, transporta- solutions and many more. and construction equipment. It is tion logistics, driver assistance sys- Information and registration at an important information platform tems and active powertrain control www.avl.com/icpc < and an attractive forum for the ex- considering the current driving situ- change on topics relating to strategies and technologies. The 2013 ICPC Photos: AVL

17 Focus instrumentation and test systems

The top address for high- tech exhaust emission and particulate measurement Increasingly stringent emission standards, new drive concepts as well as the demand for fuel-efficient vehicles with low CO2 emissions are some of the major challenges engine and vehicle developers have to face these days. AVL, with its exhaust emission and particulate measurement systems, offers high-tech solutions for R&D as well as for certification tasks for all current exhaust emission legislations worldwide.

AVL is the preferred partner in Gaggenau, Graz and Plymouth (US). ”The emission measurement techno- the automotive industry, with 40 With the iGeneration product fami- logy is driven by two main forces: years of experience in exhaust emis- ly, launched in 2007, AVL ETS has On the one hand, the legislation with sion measurement. The business unit set new standards in exhaust emissi- increasingly stringent emission stan- AVL Emission Test Systems GmbH on measurement technology and can dards and increasingly complex tes- (AVL ETS) has locations for pro- currently offer the most advanced ting procedures and, on the other duction and development in Neuss, high-tech products on the market. hand, the demand for more fuel-efficient vehicles and engines and con-

18 Focus >

AVL measuring devices can be optimally integrated in the testbed environment (Picture: the modular AVL Smart Sampler for gravimetric particle measurement)

sequently lower CO2 emissions”, the U.S. Environmental Protection says Uwe Krummenöhler, mana- Agency (EPA), the California Air ging director of AVL ETS. ”In the Resources Board (CARB), the TÜV developing process of these new drive and many others belong to our cus- solutions we closely cooperate with tomers,” says Uwe Krummenöhler. our customers and go to the physi- cal limits of measurement technology in order to be able to provide mea- Success product iGeneration surement devices and systems that > can meet these development objec- AVL ETS managing director Uwe Krummenöhler With the iGeneration AVL provides tives. A major advantage of AVL is (2nd left) and his management team the most advanced exhaust emissi- that we have a large powertrain engi- on measurement systems for engine neering area within the company. So all developers of internal combusti- and chassis dynamometer testbeds. we know exactly which new measu- on engines, which are subject to the The AVL high-tech gas analyzers in rement systems and technologies are according regulations - large marine combination with the new gas pre- required by the developers. In additi- diesel, truck and car engines or small paration unit provide accurate re- on, we immediately receive feedback combustion engines in a chainsaw or sults, reliability and faster response from our colleagues from the field – in a leaf blower for which emission times. The intuitive software plat- which is globally unique“. standards have been introduced re- form iGEM offers, in addition to a cently too. In addition, many renow- common operation and user inter- The international clientele of AVL ned institutions and agencies such as face, unique interactive and graphical exhaust emission test systems is ve- diagnostic functions, network capa-

Photos: AVL ry varied: ”Our customers include

19 Focus instrumentation and test systems

ticle Counter, a high-tech device for particulate counting. “Due to the increasingly stringent legislation – also in terms of the number of particles – the demand for such solutions is very high: Today AVL’s engine and chassis dyno testbeds are virtually always delivered with particle measurement technology. One advantage is the possible integration of the AVL Particle Counter into the analytics ca- binets - even in the case of retrofitting – thus saving valuable floor space in the test cell. Due to the common software iGEM Engine/iGEM Ve-

> hicle also the system integration is very quick and easy”, says the emis- Efficient development and certification with AVL emission measurement systems for chassis dynamometer testbeds. sion expert. The AVL equipment for particle mass measurement and par- bility as well as plug & play func- nent exhaust measurement system ticulate counting are of course also tionalities. But not only the software SESAM i60 FT. With this device up available as stand-alone devices. provides a common look & feel, also to 30 different gas components can be the AVL iGeneration hardware has a measured within one analyzer. The common concept. All modules and SESAM i60 FT is most suitable for components are based on the same the application of engines and com- “family-platform”, offering conside- plex exhaust aftertreatment systems. rable advantages for maintenance and In addition to this comprehensive services. With this concept AVL can performance range as development guarantee a maximum availability of tool, the multi-component analyzer the iGeneration devices. All together can be also used for legal certification customers can save up to 30 per- of some components,“ states Engel- cent on total cost of ownership with jehringer. iGeneration products.

The iGeneration “Flagship” is Particle Measurement the exhaust measurement system AMA i60. “This system, which is AVL is the leader not only in gaseous fitted with analyzers for each indivi- exhaust emission measurement, but > dual gas component, is ideally suited also in the particle measurement tech- - besides various development tasks - nology. With the products Smoke Newest member of the AVL iGeneration: The multi-component exhaust measurement for certification of combustion engi- Meter and Opacimeter AVL has set system SESAM i60 FT nes in order to meet current and fu- a new industry standard worldwide. ture emission regulations in Europe, Based on the success and the know- the US and Japan,“ says Kurt Engel- how of AVL a whole product family Another significant advantage is that jehringer, business development ma- around particulate measurement has the AVL Particle Counter can be cali- nager for Emission Test Systems. been developed. Besides the devices brated professionally and conforming for particle mass measurement, AVL to the law in the newly established ”Our newest member of the iGene- additionally provides the AVL Par- AVL service and calibration centers ration family is the multi-compo- in Graz and Detroit. In these centers the devices are tested and validated.

20 Focus If the measured values lie within the tolerance, a certificate is issued ap- proving the accuracy. In case of > deviation an adjustment (UN-ECE Picture right: The AVL R83 calibration) is required. As part M.O.V.E PEMS series is a modern portable sys- of the calibration services the AVL tem for on-board emission Particle Counter undergoes mainte- measurement nance procedures and will be auto- Picture bottom left: The matically updated to the latest tech- common AVL iGEM software allows easy system nology standard - at no extra costs integration and provides for the customer. an intuitive user interface.

Picture bottom right: The AVL Particle Counter is available as stand-alone On-Board Emission Measurement device or can be integrated in existing systems. Primarily due to the legislation re- garding the “in-use conformity” for commercial vehicles, in force in the US since 2007, the market sees a great demand for mobile emission testing devices. 2013 this legislation will also come into force in Europe for heavy duty applications. AVL offers with the M.O.V.E. PEMS series (Portab- le Emission Measurement System), which is part of the M.O.V.E platform for portable measurement technology, a modern system for gaseous emission and particle mass measurement, providing customers with gislators are planning worldwide,” This security of investment is also highly accurate results. In addition, explains Kurt Engeljehringer. ”In emphasized by the managing direc- the devices are characterized by low addition to this legislative know- tor of AVL ETS Uwe Krummenöh- power consumption and are “built ledge we also have detailed know- ler: ”Due to our own engine and for the road”. Another great benefit how of current and upcoming tech- powertrain development within AVL, is the consistency between all AVL nologies due to our own engine and we can identify technology trends in emission test systems, which substan- powertrain development within advance and can derive the impacts tially simplifies the development pro- AVL. This combined knowledge of on the necessary developing tools. cess and consequently contributes si- AVL – which is globally unique – is This enables us to provide improved gnificantly to an improved efficiency. reflected in our measurement sys- measurement devices already in a tems. Our customers use the systems very early stage and consequently a decade or more – for this long pe- offer our customers a competitive Excellent Emission Expertise riod of time a reliable partner is nee- advantage and an early start with their ded, who knows about all future product development. AVL emission ”With the active participation of developments and can provide long- measurement systems can provide fu- the AVL emission experts in ma- term support. AVL measurement ture technologies already today. Our ny boards in which the methods devices guarantee a secure investment customers can rely on the highest for emission measurement are ad- for the future. security of investment and on a part- opted, AVL is intensely involved al- ner who proactively and reliably ready in the early legislation phase accompanies their projects.“ < - so we know exactly what the le-

21 Focus racing

›› Racing Victories in Formula One and Le Mans Now Require Hybrid ‹‹

Peter Schöggl, Head of Business Field Racing, on the growing significance of electrification in motor racing, the wide-ranging AVL racing expertise and AVL’s role in creating the new FIA Formula E championship powered by electric energy.

22 Focus ‹F›: For the first time ever, a hybrid racing car won the 24 Hours of Le Mans race in June 2012. Has this victory marked the opening of a new era in motor racing?

‹Schöggl›: In Formula One, it has ba- rely been possible to win races without a good hybrid KERS (kinetic energy recovery system) for the last two years. In the Le Mans Prototype > Series (LMP), they did introduce the The AVL Vehicle Simulation Model (VSM) is used successfully by many racing teams. regulation that allows hybrid drives a little later, but it grants a much higher four-wheel drive achieve much bet- ‹F›: What kinds of hybrid technolo- level of freedom, too. It is quite clear ter lap times than can be achieved gies were used in Le Mans? that the regulations in both racing se- in the Formula One. Of course the- ries deliberately favor hybrid drives. re are drawbacks though too, such as ‹Schöggl›: The variety of technologies applied was surprisingly broad. Au- ‹F›: What are the differences between di stores energy mechanically in the the regulations of the two racing se- fast spinning rotor of an electric ma- ries where you need a hybrid to win? chine that works both as a generator ›› The new and motor. Toyota, on the other hand, ‹Schöggl›: The regulations do have so- stores energy purely electrically in came fundamental differences. The For- Formula One pacitors, so-called supercaps. Both mula One regulations specify that the storage systems are connected elec- hybrid energy boost is limited to 400 regulations trically to the electric motors, which kilojoules per lap. The maximum are connected to the wheels. Audi dri- hybrid power output is limited to open up new ves the front axle, whereas Toyota dri- 60 kW. Depending on the racing track, ves the rear axle. this achieves an improvement in lap possibilities to time of up to 0.5 seconds. The Le ‹F›: With the new regulations, hy- Mans regulations grant much greater generate, store brid drive will be playing a much freedom and merely limit the amount greater role in the Formula One too. of energy that can be transmitted bet- and distribute What will change in 2014? ween two braking phases to 500 kJ. So if you have around ten braking pha- energy. ‹‹ ‹Schöggl›: The maximum amount of ses in Le Mans, you have even mo- energy that can be used per lap will re energy you can use. Apart from increase tenfold from 400 kJ to 4 MJ that, the LMP Regulations allow you higher weight and increased cooling per lap. The electric power will doub- to have an electric drive on the front requirements. le to 120 kW. Depending on the racing and rear axle. The higher energy, the track, this will help hybrid drives im- non-limited output and the electrical prove lap times by considerably more Potos: H elmut Lunghammer

23 Focus racing

than one second. The hybrid system is ‹Schöggl›: We use the AVL product boost energy – at the end of a straight becoming part of a very complex ener- AVL VSM (Vehicle Simulation Mo- or from inside a curve? On the racing gy system with totally new compo- del). This development tool is being track, AVL VSM is used to optimi- nents. From the 2014 season onward, used very successfully by many racing ze the simulation using current data the 1.6-liter turbocharged V6 engine teams, and it plays a leading role in se- from the racing car. Racing track da- may be linked to a motor/generator. veral racing series already. To remain ta – such as grip conditions – are in- On the one hand, the electric motor “best of class”, the racing simulation corporated into the simulation just as can be used to rapidly spin up the tur- is continuously adapted to the new re- carefully as weather data to optimi- bo and minimize the turbo lag and, on gulations. New tire types are just as ze the racing strategy. These data are the other, it can be operated as a gene- carefully integrated as new turbo en- often transferred back to the factory, rator, allowing extra electrical energy gines are, or various hybrid compo- too, where they are utilized. The third to be generated. If not stored interme- nents. Unique is its use on PCs, on large application area of AVL VSM is diately, this energy can be converted AVL test beds and on driver simula- on the engine and powertrain test bed. unlimitedly into propulsion force. It tors. becomes obvious that we are dealing ‹F›: How does the AVL racing simu- with a very complex way of handling lation program cooperate with the energy in order to make optimum use different test beds? And how does of a multitude of energy flows. We at the racing team benefit from it? AVL Racing have been working very hard on this kind of energy manage- ‹Schöggl›: At the AVL test bed, the ment system in simulations for some VSM simulation is fully integrated time now. The high temperatures ge- into the AVL PUMA test bed soft- nerated and the turbocharger’s high ware, which enables maximum real- rotational speeds pose a high chal- time performance. The high-precisi- lenge. on simulation of vehicle, driver and > racing track allow the unit under test ‹F›: Could you give us a more de- This is how purely electrically driven (an engine or a transmission) to be tes- racecars with variable aerodynamics tailed description of the simulations could look in the future. ted or optimized under realistic condi- AVL Racing is working on for the tions. In other words, the engine vir- Formula One? tually leaps over curbs. This realistic environment simulation and its exact ‹Schöggl›: The new Formula One Re- reproducibility provide the basis for gulations open up new possibilities to ‹F›: Is the AVL racing simulation improved performance and service generate, store and distribute energy – VSM a development tool, or is it life of the components and the enti- and with our simulations, we are able also utilized on racing tracks? re vehicle. to determine the optimal variant. We additionally simulate the optimal ra- ‹Schöggl›: Both. There are several pro- ‹F›: A German trade journal re- cing strategy, which results from the cesses in which AVL VSM is used. A ported that AVL took part in crea- new hybrid drive. In short, it’s all process starts several weeks ahead ting a future fully electric racing se- about how to put the energy to opti- of the race. Teams simulate virtually ries. Could you give us some more mum use to win the energy battle. We thousands of laps on high-perfor- details? consider all components – engine, bat- mance computers, optimizing virtu- tery, electric motor as well as the very ally the vehicle settings – chassis, gear ‹Schöggl›: The racing series mentioned complicated control strategies. Even ratio, wing position, etc. The racing is the Formula E, which is organized the new electric system linked to the strategy can also be simulated, such as, subject to the rules of the FIA. The turbocharger has already been integ- for example, the optimal energy uti- first races will be taking place in 2013 rated into our simulations. lization in a hybrid system I menti- with larger cities being the potential oned earlier: Where should the driver venues for events. A full racing series ‹F›: Which simulation program is is planned for 2014. Commissioned by being used for this at AVL? Drawing: Auto, Motor und S port

24 Focus FIA President Jean Todt, AVL had the tered, making them as flat as requi- certain period of time – here, too, the pleasure of making an essential contri- red, while in curves they are adjusted new Formula Electric gives suppliers bution to this new electric racing se- to a steeper angle to create more sur- the attractive opportunity to develop ries. face pressure. This generates energy new technologies and present them to savings of up to 40 percent – with the a broad public. ‹F›: Please tell us what role AVL had same lap time and a maximum speed in the creation of the Formula E which is up to 35 km/h higher. There ‹F›: Will in the near future the new regulations. technologies developed for the For- mula E be used in series vehicles too? ‹Schöggl›: In a team together with the responsible people from the FIA we ‹Schöggl›: One of the FIA’s objecti- practically started out with a blank pi- ves is to use the new Formula Elec- ece of paper. The FIA’s goal was to im- tric to boost the further development pose as few restrictions as possible in of electric drive systems and electric the Formula E regulations in order to storage systems. An example for this is expedite future innovation in electric that the battery must not weigh more drives – particularly where energy sto- than 300 kg. Otherwise it can be de- rage and electric drives were concer- signed freely. Here too, the intention ned. To make the Formula E Cham- is to offer suppliers a kind of playg- pionship attractive to spectators, the round, where they can present and try electric racing cars will achieve top out their new technologies. The tech- speeds close to what we are used to in nologies developed for the Formula E the Formula 1 (exceeding 300 km/h); will not immediately be found in a se- lap times are expected to be faster than rial vehicle, as they are technologies in those in the Formula 3. Based on the- an advance development stage, which se FIA requirements, we carried out will still require four to five years of some comprehensive simulations of a development before they are ready for number of possible vehicle configu- series production. rations. Due to the expected develop- ›› Commissioned ment costs and safety considerations, ‹F›: Drawing on its comprehensive the tests very soon delivered certain by Jean Todt, electrification know-how, is AVL in basic values. a position to develop the powertrain AVL made an of an electric racing car or even an ‹F›: How is the still rather low ener- essential entire vehicle? gy content of batteries compensa- ted for in the new Formula Electric? contribution ‹Schöggl›: We naturally offer our customers and their engineers to work ‹Schöggl›: For technical reasons, to to the new with us in a team, so that we can bund- achieve the energy content of one ki- le our capabilities in the areas pow- logram of gas, it still takes a battery electric racing ertrain development, storage techno- weighing roughly 80 kg. With one ki- series. ‹‹ logy and vehicle engineering with the logram of gas this does not sound all aim to develop the future winning car that bad. But 10 kg of fuel would me- – from simulation and design all the an an 800-kg battery. To compensa- way to the production of the racing te for the storage system’s low ener- will also be innovation where batte- car. < gy density, a totally new and highly ry recharging is concerned: The char- innovative aerodynamic system with ging process has to take place inside freely adjustable wings was designed, the pits between two races within a especially for the Formula E. “Driving on a straight line, the wings can be al-

25 Focus innovation

Waste Heat Recovery Improving Commercial Vehicle Fuel Efficiency

Reduction of fuel consumption for commercial powertrains has always been a high priority. Consequently, traditional optimization potentials like combustion system optimization or friction reduction seem to be mostly exhausted. However, a new opening seems to be the recovery of waste heat.

From the various possibilities After comprehensive evaluations, of waste heat recovery investigated both, water and ethanol were used as by AVL, the Rankine cycle has be- working fluids. In order to fully ex- en selected as the likely solution for ploit the potential of the WHR sys- commercial vehicle applications. Af- tem under real world conditions the > ter intensive simulation and concept development also included a WHR Heimo Schreier, Product Manager evaluations AVL demonstrated the control system for the transient con- Commercial Powertrain Systems real world fuel saving potential of trol of the entire system. This was such a WHR system on a HD truck calibrated to achieve the highest ef- working fluid as well as the chosen engine meeting Euro VI emissions ficiency gain in the system, as well hardware. It has been demonstrated norms. The system tested included as to manage appropriate system that a fuel efficiency improvement one evaporator replacing the EGR durability under transient operation. of more than 5% can be realized by cooler and a second evaporator in A key part of the developed closed- applying such a WHR system. This was possible even on a highly optimized commercial vehicle engine. Consequently it can be assumed that this technology will be applied by OEMs to further improve fuel efficiency respectively to further reduce Total Cost of Ownership for the end customer. > The WHR technology can be ap- It has been demon- plied for both, on-road as well as strated that a WHR system can deliv- off-road applications. However, er a fuel efficiency improvement of the achievable efficiency gains will more than 5 percent depend on the individual load cyc- can be. le of the application, whereas cycles with a high load factor will provide the highest potential. the exhaust system, downstream of loop model based functionality are Based on the results achieved, AVL the aftertreatment system. A pis- virtual sensors (models) controlling is continuing to industrialize the ton expander was selected allowing the mass flow for the EGR and ex- WHR system for commercial en- flexible operation with regard to haust steam generators. The develo- gines and to develop the technolo- choice of working fluid and waste ped control software can be applied gy towards series production imple- heat sources. independently from the selected mentation. <

26 Focus innovation

Operating strategy, driveability, driving range and service life of the battery: when electrified drives are calibrated, all of these features have to be optimized and co-ordinated with one another in the best way possible. A new method developed by AVL now helps to perform calibration tasks much faster and more efficiently – even with all-electric vehicles. Efficient E-Vehicle Calibration

AVL performs calibrations for Another important field is diag- conventional powertrains and hyb- nostics calibration which is done to rid drives – but also for all-electric ensure the electric vehicle’s safety drive solutions, which, in future, will and reliability. “Where this is con- increasingly be put to use in urban cerned, the entire vehicle is automa- transport. As electric vehicles (unlike tically tested in its different driving hybrids) only have one drive motor, modes on the dynamometer (speci- Focus asked Gerhard Kokalj, Head of Transmission and Hybrid Calib- ration, whether he thought that ca- > librating electric vehicles (EV) was Gerhard Kokalj, Head of Transmission and less trouble than calibrating hybrids. Hybrid Calibration “Basically, it is,” said Kokalj. “But in this case, we face many new challenges, the biggest of which is probably Calibrators carry out electric ve- the battery range and service life. By hicle driveability calibrations using taking a new approach, we are trying HyHab, a methodology develo- to make better use of the battery’s ped by AVL. With this new me- energy. The fundamental idea is to thod, which is also applied in hyb- > temporarily leave the ideal charge rid vehicles, the automatic execution range behind in order to temporari- AVL is improving battery range and service life. of tests on the test bed is combined ly increase its range without dama- with offline calibration. This can also ging the battery in the process. An fically the parameters SOC, SOH, give the electric vehicle a very speci- intelligent operating strategy, which electric moment, battery tempera- fic character: “By means of filtering, would also process, say, geographical ture, etc.). The data are then fed in- we can attenuate the moment of the data about the conditions ahead sup- to AVL fOX, a special tool for this electric motor or else achieve a clearly plied by a satnav has a key role. What purpose. Based on these data, the ca- noticeable acceleration. This can give is special about our approach is that librator can then ensure offline that electric vehicles very individual cha- we at AVL develop the entire strategy e.g. the bounds of the plausibility racteristics, spanning from an excep- within a testing environment – from corridor for electric moment are not tionally comfortable to a very sporty the simulation on a battery test bed exceeded. Unlike conventional cali- driving behavior. This aspect is beco- to the vehicle test on a dynamome- bration in the vehicle, this can be ac- ming more and more important, as ter in a virtual vehicle environment”. complished much more efficiently manufacturers want to be able to give and faster than before.“ future electric vehicles a brand-specific character,” Kokalj concluded.< elmut Lunghammer, AVL Photos: H elmut Lunghammer,

27 Focus chronicle

Joint Venture with SET Power Systems

Joint venture in Allgäu: AVL CEO Helmut List with Horst Hammerer, CEO of SET Power Systems GmbH.

In Wangen, Allgäu (Ger- put us in a position to drive forward

> many), AVL has acquired the ma- advanced technology solutions for jority stake in the joint venture of customers all over the world.” Horst A great honor for AVL Racing: at the ADAC Form- el Masters race at the Lausitzring in Germany, AVL SET Power Systems GmbH. This Hammerer, CEO of SET Power Sys- engineer Georg Knoll (right in picture) received the will provide synergies in the ar- tems GmbH: “Where electric motor winner’s trophy on behalf of the Motopark team. Georg Knoll has been driver Jeffrey Schmidt’s eas power electronics, embedded emulation is concerned, we have man- race engineer in 2012. systems and electric motor mod- aged to achieve a clear developmental els. AVL CEO Helmut List: “By edge. By teaming up with AVL, it will combining their profound experi- become possible to extend this lead ence and capabilities, the teams of even further. We are delighted to be both AVL and SET Power Systems part of the AVL Group.” < First International Exhaust Gas and Particulate Emissions Forum in China >

Experts from all over the world came to the The ever more stringent glob- this gap if not AVL?,” Zhang Hong, first AVL Particulate Emissions Forum in Shanghai where they exhibited great interest al emissions legislation presents huge Business Manager at AVL China, told in the presented papers and the testing challenges for the automotive indus- Focus with a chuckle. And that is how equipment showcased by AVL. try. Many conferences currently fo- the idea was conceived to bring the cus on this topic – as does the well-es- AVL Emissions Forum from Germa- research center. So we had the part- tablished Exhaust Gas and Particulate ny to China. ner we needed,” Mario Walenta, Man- Emissions Forum. “Up to now, all “It takes a powerful partner to be aging Director, explained. As a result, the good conferences for profession- successful right from the start with an extraordinary conference program als have been held in Europe. China, an event like that. A short while ago, with speakers from state authorities, as however, the world’s largest selling AVL signed an agreement on strategic well as international experts, drew al- market for cars, was never included. cooperation with CATARC, China’s most 300 participants to Shanghai on But, obviously, who else was to close leading automotive technology and October 18 and 19, 2012.“ < Photo: AVL

28 Focus Decoration of AVL EMISSION TEST SYSTEMS GMBH Honor in Gold AWARDED TWO STEVIES® In the categories “Best New Pro- for Don Manvel duct of the Year” and “Management Team of the Year”, AVL Emission Test Systems GmbH was recently presented with the Bronze Stevie® Award. The Stevie® Award is one of the most renowned international prizes awarded in the world of business. “By parti- cipating in the International Business Awards 2012, our achievements were for our AVL SESAM i60 FT put us in benchmarked against major internati- an excellent position for global com- onal competitors for the first time. We petition,” Uwe Krummenöhler (right are very proud to have received awards in picture), Manager of AVL Emissi-

> in not one but two categories. The tro- on Test Systems GmbH, said who was phies “Management Team of the Year” present to receive the awards at the gala Thomas Schnöll, Consul General in Chicago, honored Don Manvel (f. l. t. r.) and “Best New Product of the Year” event in Seoul, South Korea. <

In recognition of his meritorious services, Don Manvel, CEO of AVL North America, was recently awarded the “Decoration of Honor in Bavarian State Prize for Electric Gold” conferred by the Republic of Austria. The decoration ceremo- Mobility GOES to AVL Coup-e 800 ny that took place in Detroit was at- tended by Christian Buchmann, Member of the Styrian Govern- ment, Kathryn List and others who congratulated Don Manvel on his award. Don Manvel has been successfully helping to bring innovative top technologies on the market for more than 25 years – ten of which for AVL. He additionally backs pro- > > grams and initiatives that inspire The all-electric high performance demonstrator Awarded: M. Schlecker, W. Schelter, M. Deiml, young people, such as the robot vehicle Coup-e 800 A. Engstle and A. Angermaier (f. l. t. r.). competition for pupils and the “A World in Motion” program for stu- To speed up innovative devel- was delighted to win the prize with dents, as well as Austrian initiatives opments in electric mobility, the its Coup-e 800 in the category “Drive in the US such as the network of eCarTec Award – the Bavarian State Technology, System Electrics, Test- Austrian scientists in North America. Prize for Electric Mobility – was ing Systems”. The company has been Activities like these are responsible awarded in eight categories on the oc- an AVL software and function devel- for the fact that Don Manvel enjoys casion of the eCarTec 2012, the inter- opment location since 2008. AVL al- an excellent reputation in business national leading trade fair for elec- so does research in innovative en- circles, both in Austria and in North tric and hybrid mobility in Munich. gine and drive engineering solutions America. AVL Software and Functions GmbH at this location. (see also p. 8–11) <

29 Focus products

The modelling is a 3-stage process: Geometry definition, mesh specification and network generation.

AVL BOOST 3D Modeler The new AVL BOOST enables highly accurate 3D Modeling.

The clear advantage of BOOST 3D: more accurate results at higher frequencies as the higher order modes are well predicted.

The acoustic simulation of For the detailed examination of common gas exchange components, internal combustion engine exhaust single components, such as exhaust e. g. air cleaners. systems is an important aspect in mufflers, the calculation model has early development phases to meet now been enhanced by the advan- The modeling of single components customer expectations as well as ced “BOOST 3D Modeler”. In an in the BOOST model is not only the increasingly stringent legislati- integrated 3D Sketcher, the user ge- limited to acoustics but can also be on targets. nerates the geometry, which subse- used to illustrate 3D effects for char- quently is automatically linked with ge-cycle calculations. It should be In order to calculate the duct acous a network of 3D cells. The user noted that a single BOOST model tics of intake and exhaust systems does not require prior knowledge can be used for both applications. AVL BOOST offers the following of how a system acts acoustically. simulation methods: a frequency The direct CAD-import will be sup- The BOOST 3D Modeler thus pre- domain solution for the quick cal- ported by the next program versi- cisely takes into account 3D ef- culation of pre-dimensioning possi- on. The main focus of this techno- fects for complex flow components ble without engine data and a time logy has been for exhaust mufflers during simulation for the acoustic domain solution for the detailed de- but it can also be applied to other optimization of the entire intake and sign of the overall system. exhaust system and for the simulation of charge-cycles in the engine.

Photos: AVL

30 Focus products

AMA i60 Exhaust measurement system The flagship of the AVL iGeneration

A modern exhaust measurement All major diagnostic functions are system needs to cope with various supported by the device software requirements. From a legal perspec- iGEM AMA and can be automa- tive the system has to handle cur- ted through an integrated schedu- rent and future emission standards ler function. Furthermore, pending such as EPA 40 CFR Part 1065/1066, maintenance intervals can be dis- Heavy Duty Euro VI and Light Du- played on time, avoiding service in- ty Euro 6. From a technical aspect it terruption. A special feature is the is important to take a close look at intelligent error handling of the sys- additional exhaust gas components vice tasks. The time required for tem, which provides solutions for

(NH3, N2O, NO2, etc.) as well as maintenance has been reduced by fast elimination of operation errors. consider the increased use of alterna- about 25 percent compared to the If further help is required, the com- tive fuels. The business perspective previous model. plete trouble shooting down to the focuses on the reduction of testing sensor and valve level can be carried time with faster analyzing methods All gas lines and valve manifolds ha- out by remote diagnosis, minimizing and significant lower costs of ow- ve been improved in terms of mi- down times. nership. nimal gas consumption, which has been reduced by up to 30 percent For the conventional exhaust gas The AMA i60 exhaust measurement in comparison to other systems on analysis the AMA i60 can be indi- system has been developed under the market. Due to improved mea- vidually adapted to the correspon- these specific aspects and has been surement accuracy and repeatabi- ding measurement applications (di- optimized in every detail in order lity excellent measurement results luted/undiluted exhaust or gasoline/ to perfectly meet the various requi- are achieved. The innovative CLD diesel/H2/etc). Special versions and rements. In combination with diffe- i60 analyzers meet the strict quen- mobile remote- or stand-alone-units rent sampling systems, the AMA i60 ching guidelines of EPA 40 CFR with an optimized system design are is ideally suited for the development part 1065, hence representing cut- offered e.g. for SULEV, EGR and and certification of combustion en- ting-edge technology in this field. SCR applications (NH3) as well as gines in accordance with all global for marine diesel (SO2). Moreover, exhaust emission regulations. The intuitive, interactive graphical the combined exhaust gas measure- user interface iGEM is the platform ment and dilution system AMA i60 The system is characterized by new for all iGeneration systems. Due to COMBI for small engines and mo- gas analyzers with faster response this common concept the user can torcycles is available. times (up to 40 percent in compari- easily navigate through all systems son to other systems on the market), and operating errors are minimized. Therefore, more and more users optimized gas paths and a compact, With individual interactive flow dia- confirm that the combination of modular design. The flexible system grams of the system and of all com- high measurement accuracy, easy allows for easy retrofitting - for ex- ponents directly displayed on the operation and optimized total costs ample of further analyzer channels user interface, the AMA i60 has set of ownership makes the AMA i60 or entire streams. In addition, all the industry standard. the first choice in modern exhaust modules are easily accessible from emission measurement. < the front for maintenance and ser-

31 Focus products

AVL CAMEO™– The key for efficient powertrain calibration

The world leader in testbed systems also leads the pack in model-based calibration in the office.

CAMEO Office offers a quick overview of all optimization possibilities.

Calibration has long since step-by-step to his required results. CAMEO has evolved into a well- established itself as a decisive factor The calibration effort is minimized established, industrial solution, that in the field of modern powertrain thanks to the use of model generation supports clients in their daily work. engineering. The extreme complexi- on the basis of DoE methods (Design This shows that the courageous de- ty of the calibration task, due to the of Experiments), model optimizati- cision of AVL, who started to work range of powertrain variants or legal on and rapid calculation of control intensively on the subject of calibra- requirements, can no longer be ma- tables and maps, leading to reliab- naged by conventional means. With le results. Calibration engineers no CAMEO, AVL avails itself of the longer have to rely only on their in- world-leading software that univer- stincts, but obtain certainty due to sally reflects the complete powertrain statistically sound data. The effort of calibration process and thus provi- calibration can be reduced by up to des considerable support for effici- 80 percent compared to conventio- ent calibration. nal methods. Calibration targets such as fuel consumption while remaining Apart from the normal online calib- within legislative emissions limits can ration, that is the automated execu- be reliably reached for all operating tion in the 1990s, has proved itself tion of test procedures directly on a states of the vehicle. today to be sustainable and correct. test bed, the calibration process steps in the office environment are beco- Thanks to continuous further deve- Whoever wants to achieve extreme- ming increasingly important. This is lopment and extension of the tools ly good calibration results, needs where CAMEO Office, as a part of – in conjunction with notable au- extremely fast and reliable tools – the CAMEO toolchain, comes into tomotive manufacturing clients – tools such as AVL CAMEO. its own. The software guides the user (www.avl.com/cameo). < Pictures: AVL

32 Focus innovation

An Ideal Basis for Collaboration

With its Integrated & Open Development Platform, AVL has created a consistent and open solution that contributes significantly towards increased efficiency in development and testing processes.

“One central aim of the AVL train variants is to distribute calibra- Integrated & Open Development » This ‘collabo- tion tasks among different develop- Platform is to provide our custo- ment environments (office, hardware mers with software solutions offering ration platform’ in the loop, engine or powertrain test data and process consistency throug- gives us a fast and bed, chassis dynamometer or road). hout the entire development and tes- Adapted software tools, such as ting process – from simulation over straightforward those offered by AVL, create the test bed testing all the way to road conditions for smooth collaboration tests. Similarly, we will make the user way to exchange across the entire process. experience and the way users inter- Even where exhaust gas emission act with the software as uniform contents between measurement is concerned, consis- and as simple as possible,” Herwig different devices, tency between different testing en- Schelch, Head of ITS Integration vironments has a number of ad- Software Products in AVL Instru- test environments vantages. Tests that are normally mentation and Test Systems, explai- performed on a chassis dynamome- ned. “This ‘collaboration platform’, and content ter can now also be run on an pow- which is also what we call it, will gi- ertrain- or engine test bed, thanks to ve us a fast and straightforward way management simple and fast methodology transfer. to exchange contents between diffe- systems. « rent devices, test environments and “The Integrated & Open Develop- content management systems. These ment Platform is being expanded contents may take on many different further. In future, it will be capable of forms such as simulation models, tes- integrating all AVL software products ting methods and results, configura- available. All of AVL’s business units – tions, workflows, etc. They may even Simulation (AST), Engineering be supplied by our customers or third (PTE) as well as Instrumentation party vendors – hence the ‘Open’ in and Test Systems (ITS) – are wor- the product name.” king very closely together on this A crucial benefit of the consisten- matter. At ITS, the software pro- cy is that simulation models can also ducing units have been integrated

be used ‘in the loop’. Already today > into a business area of its own (‘ITS-I AVL CRUISE powertrain models, Integration Software Products’) in Herwig Schelch, Head of ITS Integration Soft- for example, can be used on the AVL ware Products in AVL Instrumentation and Test order to strengthen and intensify Virtual Vehicle engine test bed where, Systems the activities,” Herwig Schelch told for example, the behavior of a dual- The consistency offered by the AVL Focus. “Right now our customers are mass flywheel is then simulated un- platform also leads to significant- already benefiting considerably from der true-to-life conditions. This sup- ly increased efficiency in calibration the noticeable consistency between ports the strategy of shifting tests work. A solution to meet the chal- the different AVL software solutions from the road to the test bed in order lenges presented by the steep rise in and the many associated advantages to save development time and costs. the number of vehicle and power in a variety of areas.” < Pictures: AVL

33 Focus powertrain world

AVL’s new Powertrain World app for the first time provides engineers across the auto industry with insight and information into the latest innovation, wherever they are. Welco me to the AVL Powertrain World

> Powertrain World is a content- Download the app now (iOS and based app that delivers compre- Android) and start exploring the hensive information on everything Powertrain World, wherever you are. to do with the very latest on powertrains. It is available to download now for Android, iPhone, iPad engineering. It means that the Po- and as Web App for Blackberry and wertrain World App has something Windows devices. for everyone with an interest in automotive engineering, and makes it The content is a combination of dif- easy to find. ferent types of articles, videos and information on events and pro- The content is regularly refreshed ducts, intelligently categorized and to reflect the very latest innova- tagged so that the app is easily navi- tions, the newest products and cut- gable. Users can read an interview ting-edge expertise in the auto-en- with an expert in simulation pro- gineering world. Users of the app ducts, find out more about AVL’s rent powertrain elements, and in- can also contact AVL experts di- latest e-car concept and get to grips cludes an option for content that rectly, meaning that they are able with the subject of hybrid calibrati- addresses the whole powertrain. to find out more about what they on, and much, much more. The second wheel breaks down are most passionate about. content into categories of vehicles: There are three different naviga- passenger vehicles, heavy duty and Users can also share articles via tion wheels that can be turned to large engines. The third, meanwhile, Facebook and by email, and add easily get to the content that inte- categorises content by AVL busi- their favorite pieces of content to rests the user most. The first wheel ness area: simulation, testing and ”My Collection“, which means they divides the content into the diffe- are also available to read offline.< Photo: AVL

34 Focus SPEED UP YOUR PROCESSES

BOOST and FIRE® are the industry‘s prime choice when reliable results are needed for engine and combustion development.

The intelligent integration of the two software tools enables solutions for even the most complex tasks.

Your Benefits: • Verified engine development solutions • Speeding up your processes • Less experiments, more creativity • Tremendous time savings AVL VIRTUAL VEHICLE ENGINE TEST BED TESTING REAL ENGINE DYNAMICS

Gear up to launch the vehicle fleet on the engine test bed. Shift up to next generation dynamic testing.

• Transfer calibration tasks from road to engine test bed • Consequently reduce number of prototypes • Realistic cold start calibration and application • Driveability calibration and optimization • Powerful “Engine in The Loop” platform • Development XiL control systems

High Dynamic Engine Testing with AVL VIRTUAL VEHICLE ENGINE TEST BED enables the engine to generate its own characteristic dynamics. The system allows to load the engine with environment, vehicle and powertrain simulation up to 40Hz, at the same time uniquely no mechanical parasitic influence during start, stop and idle phase. This state of the art Engine Testing System opens the door to new test methods and efficiency boost in engine development. www.avl.com, [email protected]