Special Edition 2021
Commercial Vehicles Commercial Vehicles | Content 3 Dear reader,
Commercial vehicle drives are already the benchmark nication will make the transport task more efficient in terms of efficiency and emissions. Powered by overall, increase availability and make the driver’s Virtual trucking with IAV 15 extremely challenging CO2 legislation worldwide, workplace more attractive. fleet consumption values must be further signifi- Trucks of the future 16 cantly reduced. So we are now at the beginning of With more than 35 years of engineering excellence Trucks of the next era. Whether electric drive, highly efficient for commercial vehicles, a global setup and our 16 “Don’t be afraid of unusual solutions!” 19 internal combustion engine, alternative fuel or fuel strong international network, IAV is the ideal partner the future for bringing new technologies reliably and safely to cell – the development of new solutions ready for “OEMs need to achieve optimal market – while adhering to all processes and safety series production and at the same time high mar- end-user value when selecting ket attractiveness (Total Cost of Ownership) poses aspects. technologies” 20 great challenges for us all. IAV considers itself well positioned to make a contribution to the long-term We support you from the business idea, through Innovative truck infotainment 22 “Vision Zero CO2” in commercial applications. initial demos, to the series product. Our development processes already rely on innovative methods such E-test bench to go 23 Future commercial vehicles will be fully connected. as the use of artificial intelligence to develop your Intelligent route planning, prediction and condi- product efficiently and robustly. Test management à la carte 25 tion-based maintenance, highly automated and au- tonomous driving functions as well as Car2X commu- Enjoy reading! Putting a stop to hackers 26 22 Innovative Ready for all powertrains truck & energy types 29 infotainment “Seamless testing is the key” 29
Digitized from scratch to delivery 30
New momentum for hydrogen mobility 32
“Similar mindset in Gifhorn and in Karlsruhe” 35
Matthias Kratzsch Carsten Rinka Dr Jörn Seebode IAV Teslin: Maximum efficiency New President, CTO Executive Vice President Senior Vice President for testing and appraisal 36 32 momentum Global Sales Commercial Vehicles Looking for hydrogen ahead: cost break-even mobility for new technologies 37 Content Mature battery system for special tasks 40 Minimizing sooting of exhaust gas recirculation 41 Content 2 “E-fuels would be ideal for us” 42 Our Mission 4 A deeper look inside your vehicle 44 “Trucks are leading technology” 6 Technology Looking ahead: 10 paths towards a IAV products: the easy way into 37 cost break- “In these disruptive times, what we new commercial vehicle mobility 46 even for new need above all are pioneers” 8 CO2-compliant fleet in 2030 One more thing… 48 technologies Technology paths towards a CO2-compliant fleet in 2030 10 Let’s meet! 50 Our Mission 4 Commercial Vehicles Commercial Vehicles 4 5 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards a CO2-compliant fleet in 2030 10
Virtual trucking with IAV 15
Trucks of the future 16
“Don’t be afraid of unusual solutions!” 19
“OEMs need to achieve optimal Our Mission end-user value when selecting technologies” 20 We need to re-think the trucking industry! Innovative truck infotainment 22 Global CO2 & emission regulations, total cost E-test bench to go 23 of ownership pressure – all this will bring up Test management à la carte 25
new powertrains, but also connected and Putting a stop to hackers 26 automated vehicles. Ready for all powertrains & energy types 29 IAV is your sustainable partner Digitized from scratch to delivery 30 to make your way even more New momentum for hydrogen mobility 32 successful. “Similar mindset in Gifhorn and in Karlsruhe” 35
IAV Teslin: Maximum efficiency for testing and appraisal 36
Looking ahead: cost break-even for new technologies 37
Mature battery system for special tasks 40
Minimizing sooting of exhaust gas recirculation 41
“E-fuels would be ideal for us” 42
A deeper look inside your vehicle 44
IAV products: the easy way into new commercial vehicle mobility 46
One more thing… 48
Let’s meet! 50 Our Mission 4 Market | Commercial Vehicles Commercial Vehicles | Market 6 7 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards a CO2-compliant fleet in 2030 10
“Trucks Virtual trucking with IAV 15
Trucks of the future 16 are leading “Don’t be afraid of unusual solutions!” 19
“OEMs need to achieve optimal technology” end-user value when selecting technologies” 20
Innovative truck infotainment 22
evelopments for commercial vehicles have E-test bench to go 23 been a key pillar for IAV for many years. In an Dinterview, Dr Jörn Seebode (Senior Vice Pres- Test management à la carte 25 ident Commercial Vehicles) and Tom George (Director Business Development Commercial Vehicles) explain Putting a stop to hackers 26 why projects in this field are particularly exciting and Ready for all powertrains what unique selling points distinguish IAV. & energy types 29
Digitized from scratch to delivery 30 What challenges is the commercial vehicle sector currently facing? Why is this market so interesting for IAV? outstanding expertise in commercial vehicles and mobile many start-ups that are now entering the commercial New momentum for hydrogen machinery. And we have a truly unique selling proposi- vehicle market. Many of them have exciting ideas but do mobility 32 Seebode: The European Unionʼs ambitious CO2 targets George: Because the impending technological upheaval tion: We have all the trades under one roof and can offer not know how to turn them into a product. This is where are certainly the biggest challenge. By 2025, carbon offers an engineering partner like IAV many opportuni- our customers a one-stop service. Developments for our service starts with the definition of requirements and “Similar mindset in Gifhorn dioxide emissions must be cut by 15 percent compared ties. We are dealing with highly interesting challenges commercial vehicles are now a firm pillar at IAV and a then extends through development to the transition to and in Karlsruhe” 35 to 2019, and then by a further 15 percent by 2030. And in many different areas. In the field of drive systems, for significant business for us. series production. Thanks to our professional project we see comparable pictures nearly worldwide. Thatʼs instance, we will see a variety based on use cases and management and process reliability, we can trustfully lead IAV Teslin: Maximum efficiency why manufacturers must now make great efforts to avoid existing platforms – in addition to highly efficient diesel In the commercial vehicle sector, IAV such complete packages to success – for established for testing and appraisal 36 the threat of fines that would otherwise be imposed. An engines, CNG drives, hydrogen combustion engines, pursues a three-pillar strategy. OEMs as well as for new players. important element here is the drive combination – but fuel cells, and battery electric solutions will play a role in What does that mean? Looking ahead: cost break-even this alone will not be enough. In order to reduce carbon future commercial vehicles. In addition, optimized aero- How have you positioned yourself internally for new technologies 37 dioxide emissions as required, possible solution scenarios dynamics will make an important contribution towards George: The first pillar is our aforementioned expertise for this? must be considered as a whole, taking into account the lower CO2 emissions. that covers the entire vehicle. The second pillar has to Mature battery system for specific fleet combination. do with the international market in which we operate: Our Seebode: We have established a cross-functional organi- special tasks 40 Seebode: And there will be other developments with high customers are global corporations. They need solutions zation and Centers of Excellence for commercial vehicle- George: This is why a holistic approach is particularly technological demands, such as highly automated driving, that are tailored to the different needs of their customers specific topics, for example “TCO & CO2 Efficiency” and Minimizing sooting of exhaust important for commercial vehicles. The manufacturers digitalization or the connectivity that is so important for and local conditions, for example in terms of fuel qualities, “E-Mobility.” Our colleagues here deal exclusively with gas recirculation 41 evaluate their portfolios and determine which vehicles fleet management. These projects will also be parti user behavior, goods traffic or TCO. Because buyers know special solutions for our commercial vehicle. They know with which technology package can contribute what cularly challenging due to the large number of variants exactly what they need and whether a commercial vehicle the markets and requirements and are therefore able to “E-fuels would be ideal for us” 42 proportion towards reducing fleet emissions. Application in the commercial vehicle sector, which makes virtual meets their requirements. Different technology packages combine the best technologies with the requirements of scenarios and load profiles are particularly important model-based development particularly important. This must therefore be put together depending on the market. our customers. As a global key account manager for the A deeper look inside your vehicle 44 here. Only vehicles that have been sold are evaluated makes future projects extremely exciting for engineers. IAV is represented worldwide and knows the respective commercial vehicle sector, I am responsible for the sales in the balance sheet. Therefore, in addition to the CO2 markets very well thanks to our local commercial vehicle interface with our customers. This gives them a central IAV products: the easy way into contribution, customer benefit is extremely important Why should a customer come to IAV experts. We are where our customers are and work with contact person who takes care of their concerns. new commercial vehicle mobility 46 in the choice of technology. This is the only way to put with his project? them to find optimum solutions. together a successful package consisting of drivetrain, Contact: One more thing… 48 auxiliaries, aerodynamics, axles or, for example, a pre- Seebode: Because we have been operating in this field for Seebode: The third pillar concerns project design. We [email protected] dictive navigation system. In other words: The products many years and have demonstrated in numerous projects assume greater responsibility and can take on develop- [email protected] Let’s meet! 50 must be optimized as a whole, taking into account the that we can make a significant contribution for our clients! ment packages on our own responsibility – this is very fleet, legislation and the usage profile of the end user. Our experts have proven time and again that they have interesting not only for established OEMs but also for Our Mission 4 Market | Commercial Vehicles Commercial Vehicles | Market 8 9 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards a CO2-compliant fleet in 2030 10 “In these Virtual trucking with IAV 15 Trucks of the future 16 disruptive What do these disruptive forces do? “Disruption means that “Don’t be afraid of unusual solutions!” 19 Disruption means that there is a sudden rather than a there is a sudden rather “OEMs need to achieve optimal times, what smooth transition – for example, when new technologies end-user value when selecting emerge that allow things to be done more efficiently or than a smooth transition – technologies” 20 more safely. This releases an enormous potential for change. In the case of commercial vehicles, for example, for example, when new Innovative truck infotainment 22 we need existing pain points could be converted into good points. This calls for innovative providers who see new business technologies emerge that E-test bench to go 23 opportunities. For example, they could establish a com- allow things to be done Test management à la carte 25 above all are pletely new service at the very top of the value chain, and thus, capture the largest share of the margin. Todayʼs more efficiently or more commercial vehicle OEMs and logistics providers could Putting a stop to hackers 26 thus become mere suppliers. A good example of this safely.” Ready for all powertrains pioneers” is Uber Freight: The company arranges unused space & energy types 29 on trucks, and thus, optimizes their capacity utilization. Customers donʼt care which logistics provider or truck is Digitized from scratch to delivery 30 used to transport the goods. Truck brands and designs being in an unknown country. No one really knows their are therefore becoming less and less important. And the way around there. Thatʼs why in these disruptive times we New momentum for hydrogen service provider has the bulk of the margin. need pioneers above all else – and thatʼs exactly what the mobility 32 established companies used to be themselves, otherwise, How can established OEMs still hold their they would never have become so successful in the first “Similar mindset in Gifhorn own in this world? place. They have to revive this pioneering spirit, which is and in Karlsruhe” 35 arkus Petzl is a strategy consultant specialized also being attempted through start-up purchases and the in disruption. In an interview, he describes the They may have to move up one step in the value chain various innovation labs and accelerators. Unfortunately, IAV Teslin: Maximum efficiency Mdisruptive forces that are important for the themselves and offer their customers more than just these initiatives often involved relatively unimportant ar- for testing and appraisal 36 commercial vehicle industry and how OEMs can adapt vehicles. And many companies are trying to do just that: eas, which meant that the whole thing could be dismissed to the new world. They are giving a lot of thought, especially in their “labs”, out of hand and quickly ended. But it does not have to be Looking ahead: cost break-even to how to respond to the disruptive forces. However, they this way: Even large and successful companies can be for new technologies 37 have one disadvantage: Many initiatives fail because pioneers; not just start-ups. Mr Petzl, which disruptive forces are rele- they jeopardize existing business and are therefore not Mature battery system for vant for the commercial vehicle industry? supported by sales, for example. The OEMs are in a How can this be achieved? special tasks 40 prison of sorts. Start-ups, on the other hand, have no There are three fields that offer starting points for disrup- such persistent forces and also have much more time: Through bipolar management that drives existing and Minimizing sooting of exhaust tive developments: technology, legislation and mindset. They are financed by venture capital and do not have to new business models in parallel. Instead of delegating gas recirculation 41 Technologically, the new drives are worth mentioning, but make a profit at first. In an established company, on the new initiatives to fringe areas, they must be returned to so too are topics such as autonomous driving, artificial other hand, the change agents always have controlling the company core and become a matter for management. “E-fuels would be ideal for us” 42 intelligence, connectivity, and Big Data for fleet ma and the banks breathing down their necks. New ideas are This is only possible with a cultural change that must be nagement. Legislators are promoting disruption primarily often buried there far too quickly. And because they have supported by the board of directors. This can take years, A deeper look inside your vehicle 44 through strict CO2 limits, but in the future perhaps also supposedly been burned at the hot stove, innovations but it also promises potentially big profits. After all, there through new regulations for noise in cities. The mindset are better left alone altogether. will always be a need for freight transport – the question is IAV products: the easy way into brings together several developments: For example, who can secure the bulk of the profits. IAV itself is a per- new commercial vehicle mobility 46 there are new business models based on sharing rather It sounds as though the established manu- fect example of this: The company has been successfully than ownership – keyword: Transport as a Service. But facturers have no chance against their new putting innovations on the road for decades, reinventing One more thing… 48 we also see a change in drivers, because there are fewer competitors… itself time and again in the process. This makes IAV the Markus Petzl, CEO and fewer people who want to do this job. And because perfect partner in these disruptive times. Let’s meet! 50 at disruptive of autonomous driving, the last human driver has already But this is not the case! Because the good news is: Right been born anyway. at the front, at the forefront of development, it is like Contact: disruptive.wtf Our Mission 4 CO2 & Vehicle | Commercial Vehicles Commercial Vehicles | CO2 & Vehicle 10 11 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards the one hand, CO2 legislation is expected to become a CO2-compliant fleet in 2030 10 stricter after 2030 (“EU Green Deal”) – this means that a technological lead will still pay off after 2030, and that Virtual trucking with IAV 15 it will become more difficult for manufacturers with a technological gap to achieve their targets. On the other Trucks of the future 16 hand, it can also secure a market segment that would otherwise be occupied by new competitors. “Don’t be afraid of unusual solutions!” 19
CO2 savings through optimized aerodynamics “OEMs need to achieve optimal end-user value when selecting A lot of new vehicle technologies can be brought into technologies” 20 series production largely independently of the powertrain and at comparatively low cost (Figure 2). Particularly in Innovative truck infotainment 22 long-distance traffic, the optimization of aerodynamics opens up high CO2 saving potentials. If tractors and E-test bench to go 23 trailers are aerodynamically matched to each other, fuel savings in the double-digit percentage range are possible. Test management à la carte 25 However, legislation currently only takes the tractor unit into account. Changes to this could be brought about by Putting a stop to hackers 26 the review of the CO2 target values scheduled for 2022. Ready for all powertrains & energy types 29 In the VECTO methodology, the determination of aero- dynamic parameters is mandatory. Active systems such Digitized from scratch to delivery 30 as radiator blinds are only permitted to a limited extent The legal requirements of the European Union envisage gy Consumption Calculation Tool). The TCO calculator when carrying out measurements (constant speed tests). New momentum for hydrogen a gradual reduction in CO2 emissions, and thus, fuel con- provides a holistic cost consideration, including fuel and However, the exact knowledge of the aerodynamic potential mobility 32 Technology sumption in the transport sector by 2030. Whereas fuel energy cost scenarios. that becomes visible with the specified test procedure is consumption was previously primarily relevant for end decisive for optimization. This is why IAV has conducted “Similar mindset in Gifhorn customers (Total Cost of Ownership, TCO), this is now For the following consideration, Figure 2 provides an intensive test series: In addition to the aerodynamic and in Karlsruhe” 35 paths to- changing: The vehicle manufacturer is moving into focus overview of possible technology packages. Figure 3 potential, additional potential can be seen in the tires through penalty payments. In addition, the perspective shows possible CO2 benefits for a synthetic fleet com- as well as in the regulation of the speed trajectory. If all IAV Teslin: Maximum efficiency is broadening – away from the combustion engine and position. As Figure 3 illustrates, a high proportion of the potentials that can be credited to VECTO are taken for testing and appraisal 36 away from individual vehicles, towards a fleet-based view Zero Emission Vehicles (ZEV) is required to achieve the together, IAV believes there is a possible benefit of eight wards a CO2- of the entire vehicle. targets. In addition, two percent ZEV must be available to ten percent less CO2. Looking ahead: cost break-even in the fleet annually from 2025. Otherwise, the specific for new technologies 37 Commercial vehicle fleets are generally characterized by a CO2 fleet value will increase. compliant high degree of heterogeneity. There are different configu- Mature battery system for rations, weight classes and superstructures (Figure 1). This In the area of ZEV, a relevant market penetration with Bat- special tasks 40 requires a holistic view. That’s why there is no generally tery Electric Vehicles (BEV) in urban areas or in hub-to-hub Axle Chassis Gross vehicle weight Vehicle type configuration (tonnes) group valid answer to the question of the CO2-optimized ve- traffic is possible in the short term. Up to a daily mileage Minimizing sooting of exhaust fleet in 2030 hicle fleet. Specific framework conditions of the vehicle of a few hundred kilometers, a BEV has advantages in Rigid (or tractor) 7.5 – 10 1 gas recirculation 41 manufacturers as well as particularities in the usage terms of local emissions and driving noise. It also meets Rigid (or tractor) > 10 – 12 2 profiles, performance requirements and infrastructure with high public and political acceptance. Class 4 and 5 4 x 2 Rigid (or tractor) > 12 – 16 3 “E-fuels would be ideal for us” 42 must be reconciled. vehicles are particularly interesting for electrification 4 further reduction in carbon dioxide emissions because of their high market shares. BEVs with todayʼs Rigid > 16 4 A deeper look inside your vehicle 44 cannot come from the powertrain alone. Rather, Fleet and TCO calculator for scenario technology are unsuitable for heavy transport tasks over 5 Tractor > 16 5 A a combined approach consisting of a CO2- comparison long distances – because of their short range, disadvan- 9 Rigid all weights 9 IAV products: the easy way into optimized combustion engine, complete vehicle mea- tages in payload due to heavy batteries and the currently 6 x 2 10 Tractor all weights 10 new commercial vehicle mobility 46 sures and an adapted fleet and zero-emission strategy is This is why IAV has developed a CO2 technology roadmap. insufficient charging infrastructure. This is why IAV is Rigid all weights 11 required. This is why IAV has developed a roadmap with It enables technology paths to be defined for vehicle and assuming a 50 percent share of BEVs in Class 4 and 10 6 x 4 One more thing… 48 which the savings potential of individual technologies powertrain technologies using a fleet and a TCO calculator. to 20 percent in Class 5 by 2030. Tractor all weights 12 can be assessed. The fleet calculator allows synthetic fleet compositions 8 x 4 Rigid all weights 16 Let’s meet! 50 to be generated, with the savings potential of vehicle and From IAVʼs point of view, it must be of great interest to the powertrain technologies being calculated on the basis established vehicle manufacturers to enter the market of the CO2 emissions simulation VECTO (Vehicle Ener- for alternative drive systems quickly and decisively. On VECTO-relevant vehicle configurations Our Mission 4 CO2 & Vehicle | Commercial Vehicles Commercial Vehicles | CO2 & Vehicle 12 13 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards a CO2-compliant fleet in 2030 10
Virtual trucking with IAV 15 Increases in efficiency are also possible with todayʼs Euro VI engines, but they involve comparatively high costs. Trucks of the future 16 From IAVʼs point of view, one scenario could therefore be the development of a high-efficiency diesel engine “Don’t be afraid of unusual solutions!” 19 (HED). The HED is designed by way of example as an In- line 6 engine in the 12 l class. A reduction in internal engine “OEMs need to achieve optimal friction ensures low CO2 values for the base engine. The end-user value when selecting consistent design of the combustion process for low fuel technologies” 20 consumption further reduces carbon dioxide emissions. The drive system also features waste heat recovery from Innovative truck infotainment 22 the exhaust gas, supplemented by phase change cooling. From IAVʼs point of view, the HED engine concept has a E-test bench to go 23 possible CO2 potential of seven to ten percent. Test management à la carte 25 It could also be used as a development basis for a H2 combustion concept that could then achieve ZEV status. Putting a stop to hackers 26 This requires the implementation of a direct injection Ready for all powertrains system with adjustments of the air and exhaust gas path. & energy types 29
Digitized from scratch to delivery 30 Specific scenarios for a synthetic vehicle class New momentum for hydrogen composition 30 % owertrai Aerodynamics mobility 32 aria le air i ta es Radar idar tegrated ste s d a ced trailer Vehicle fleets, and thus, the basis for achieving the CO2 tar- “Similar mindset in Gifhorn gets are manufacturer-specific. For the following scenarios aerodynamics Engine -7 to -10 % necessary and in Karlsruhe” 35 all grill area d e irror ca s ero wheels (Figures 4 and 5), a synthetic fleet composition of a typical 18 % to e gi e hase heel co ers European OEM is used as a basis. A high proportion of BEV IAV Teslin: Maximum efficiency
potential Vehicle -8 to -10 % possible cha ge cooli g Tractor a d trailer vehicles is important, as they contribute most towards CO2 2 for testing and appraisal 36 as a aero io reduction. These are considered with 50 percent in Class 4 12 % High efficiency and 10 percent in Class 5 in both scenarios. Based on this, Looking ahead: cost break-even co stio e gi e the decision is made as to which vehicle and powertrain for new technologies 37 ( iesel ₂ e els) technologies must be brought into the fleets. Due to the
improved cost-benefit ratio, the vehicle technologies must BEV Class 4 Vehicles 50 % Mature battery system for be prioritized. These are included in both scenarios with ZEV BEV Class 5 Vehicles 10 – 20 % special tasks 40 an eight percent reduction in CO2 emissions. CO2 saving potentials on the basis of a synthetic Minimizing sooting of exhaust From IAVʼs point of view, the fuel cell is an important vehicle fleet gas recirculation 41 component of mobility in the long term. For robust oper- ation, however, it currently requires high-purity hydrogen “E-fuels would be ideal for us” 42 (H2). A H2 engine, on the other hand, also operates with a less pure and less expensive quality, and thus, plays off relevant for VECTO, and thus, for fleet considerations and A deeper look inside your vehicle 44 further advantages when considering the TCO. It can be must first be considered by the legislator. In scenario 1, developed relatively quickly to standard eries production the development of H2-ZEV technologies therefore plays IAV products: the easy way into readiness and can act as a pioneer of the fuel cell in the the central role in achieving the goals. This includes the new commercial vehicle mobility 46 development of the infrastructure. risk of missing these targets in case of low market pen- etration (especially in 2025). One more thing… 48 In the long term, it is expected that fuel cell systems will become more powerful, cheaper and more robust. They Through the parallel development of the H2 engine and Let’s meet! 50 will therefore become the preferred solution for innova- the high-efficiency diesel, scenario 2 additionally uses the tive drive concepts. Fuel cells can already be optimal for margin of the HED with a 10 percent CO2 advantage. As Efficiency measures and technology packages niche applications today. However, they are currently not a result, the 2025 targets appear to be safely attainable. Figure 2: Efficiency measures and technology packages Our Mission 4 CO2 & Vehicle | Commercial Vehicles Commercial Vehicles | CO2 & Vehicle 14 15 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8 Fleet scenario 1 Flottenszenario 1
Flottenszenario-0 %1 CO₂ -15 % CO₂ -30 % CO₂ Technology paths towards 100% -0 % CO₂ -15 % CO₂ -30 % CO₂ a CO2-compliant fleet in 2030 10 Scenario 1: ZEV 100% Virtual Virtual trucking with IAV 15 80% 80% Trucks of the future 16 • Development of H2 combustion 60% engines and fuel cell systems 60% trucking “Don’t be afraid of unusual solutions!” 19 • Retention of the current diesel 40% leet o ositio leet engine generation (no CO2 40% leet o ositio leet “OEMs need to achieve optimal benefit) 20% with IAV end-user value when selecting • Achievement of the 2030 goals 20% Diesel E-Fuel technologies” 20 primarily through ZEV 0% Diesel E-Fuel 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038 0% Innovative truck infotainment 22 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038 Flottenszenario 2 Fleet scenario 2 Scenario 2: HED Flottenszenario-0 %2 CO₂ -15 % CO₂ -30 % CO₂ E-test bench to go 23 100% -0 % CO₂ -15 % CO₂ -30 % CO₂ ast and high-quality overall system and H2 engine 100% simulations of commercial vehicles Test management à la carte 25 80% Fand mobile work machines – also 80% in combination with cosimulations and Putting a stop to hackers 26 • Development of the HED 60% commercially available tools: This is what (10 percent CO2 benefit) Ready for all powertrains 60% our model-based development toolchain and long market use & energy types 29 40% offers. By using Matlab/Simulink and IAV’s • Slow replacement of the diesel o ositio leet 40% own libraries, as well as GT-Suite, customer- leet o ositio leet Digitized from scratch to delivery 30 engine by the H2 engine and specific models can be created in a short 20% fuel cell systems time and with high precision. IAV ZEYA is 20% Diesel E-Fuel New momentum for hydrogen • Achievement of the 2030 goals used throughout the development process 0% Diesel E-Fuel mobility 32 by HED and ZEV 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038 and is based on more than 15 years of 0% 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038 experience in the field of complete vehicle rre t iesel ( ₂) igh e d iesel ( ₂) “Similar mindset in Gifhorn simulation. rre t ₂ o stio iesel ( ₂) el igh e d ell iesel ( ₂) and in Karlsruhe” 35 ₂ o stio el ell IAV Teslin: Maximum efficiency There are many typical questions at the IAV has created basic models for entire tools, which presupposes error-free signal for testing and appraisal 36 The scenario is thus less dependent on a rapid and high the combined use of vehicle measures (aerodynamics), beginning of a development project in the commercial vehicles using state-of-the-art transmission.” Typically, IAV ZEYA is connect- market penetration with alternative drives. At the same powertrain technologies (development of HED) and the commercial vehicle sector: What does a technology, for example for trucks or agri- ed with models for fuel cells, for hydrogen Looking ahead: cost break-even time, the HED can be used in the long term and is avail- targeted development of ZEVs. However, the real use of powertrain that fulfills both customer re- cultural tractors. They can be adapted to the combustion (co-simulation with GT-Power) for new technologies 37 able as a basic engine for markets with less stringent all available potentials requires consideration by the leg- quirements and legal specifications look specific requirements of a customer project or battery electric drives. CO2 regulations. The costs associated with the system islator. Hydrogen and e-fuels as drop-in fuels are of great like? How can the operating strategy be without major modifications, meaning the Mature battery system for complexity of the HED should be mentioned as a risk. importance. In addition, it is essential that the solutions optimized? What specifications, for example, preparatory work carried out by IAV results “Fast and high-quality simulations are in- special tasks 40 implemented are accepted by customers – because only must the electrical components have? The in significant time savings. dispensable today in light of the complex Continuing the development of combustion engines vehicles that are actually sold contribute to the balance large number of application scenarios and powertrains”, summarizes Jünemann. “We Minimizing sooting of exhaust has a decisive advantage: In the long term, the introduc- sheet. One thing is clear: A “diesel-only” strategy will not the multitude of future drive options make it Simple combination with domain- developed IAV ZEYA because there are no gas recirculation 41 tion of CO2 targets based on well-to-wheel or life cycle lead to success! even more difficult to find reliable answers specific simulation tools commercial tools on the market for this pur- considerations can be expected. This would enable the to these questions early in the development pose. Thanks to the integrated interfaces, we “E-fuels would be ideal for us” 42 use of e-fuels, which can form a closed CO2 cycle in the Contact: process. IAV ZEYA supplies this information The tool has been intensively enhanced over can work with it across domains and answer powerful and efficient HED engine. [email protected] and is used at IAV from the concept to the the past months: On the one hand, its opti- all new questions very well with simulations. A deeper look inside your vehicle 44 [email protected] start of production. “The tool specializes in mized bus structure allows the sub-models By collaborating with our colleagues from Adapted fleet strategy required [email protected] the overall energy simulation of commercial to be connected even better with each other. the synthesis & testing department, we are IAV products: the easy way into vehicles”, explains Dr Dennis Jünemann, On the other hand, the simulation experts also able to make use of synergies and to new commercial vehicle mobility 46 In order to achieve the CO2 reduction targets for com- simulation engineer and expert for overall have improved the signal management to validate our models optimally.” mercial vehicles in the EU, an adapted fleet strategy is vehicle simulation at IAV. “We use our own ensure low-error modeling. “This is essential One more thing… 48 required, which depends on the technology portfolio of For more information libraries with commercial-vehicle-specific for the complex models in the commercial Contact: the manufacturers. More than ever before, holistic sys- watch our video on subsystems such as vehicle longitudinal vehicle sector and an important prerequisite [email protected] Let’s meet! 50 tem approaches will be required to limit the costs of an YouTube! dynamics with trailer or a twelve-speed for cooperation between different teams”, [email protected] increasing number of technology variants. The achieve- switching logic.” From the submodels for the explains Jünemann. “Especially with the ment of the 2030 targets will depend to a large extent on individual commercial-vehicle subsystems, new powertrains, we must combine different Our Mission 4 CO2 & Vehicle | Commercial Vehicles Commercial Vehicles | CO2 & Vehicle 16 17 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards a CO2-compliant fleet in 2030 10
Virtual trucking with IAV 15
Trucks of the future 16 Trucks of “Don’t be afraid of unusual solutions!” 19 “OEMs need to achieve optimal end-user value when selecting the future technologies” 20
Innovative truck infotainment 22 Stricter CO2 limits and changed legal requirements for E-test bench to go 23 vehicle registration: These are the main drivers of current Test management à la carte 25 truck development. IAV is looking to the future with its Putting a stop to hackers 26 own truck design and has developed two variants for the US and European markets. Ready for all powertrains & energy types 29
Digitized from scratch to delivery 30
New momentum for hydrogen mobility 32
“Similar mindset in Gifhorn For European truck drivers, the new nose at the front is optimize the airflow around the vehicle. Here, however, it and in Karlsruhe” 35 probably the most striking innovation. Thanks to changes was important to avoid undesirable side effects: The new in legal regulations, it can now be 80 to 90 centimeters design should neither lead to a lens effect when looking IAV Teslin: Maximum efficiency long, which means that future trucks on European roads outwards nor to excessive heating of the driverʼs cab – for testing and appraisal 36 will be more reminiscent of their US counterparts. Never- and the associated additional load on the air conditioning theless, differences remain: “As before, the front axle of system. Movable flaps on the radiator grille open when Looking ahead: cost break-even the European model is at the height of the driver further required and also contribute towards improved aerodynam- for new technologies 37 back,” says Olaf Jacob, project engineer for commercial ics. Finally, the elimination of the classic exterior mirrors vehicles at IAV. “In addition, the wheelbase of the EU also leads to lower driving resistance – their function is Mature battery system for version is shorter than that of the US truck. Whatʼs more, now taken over by cameras that protrude from both sides special tasks 40 the latter is only available with two rear axles in a 6x4 of the truck and hardly obstruct the air flow. Additionaly, configuration as is customary in the USA.” camera-based systems offer increased safety due to a Minimizing sooting of exhaust wider field of view. gas recirculation 41 IAVʼs experts and designer Nils Poschwatta were guided by the big drivers in truck development: the desire for lower The windscreens, which are pulled down further, and the “E-fuels would be ideal for us” 42 CO2 emissions and the new specifications for vehicle lower parapet line, lead to better visibility. In addition, the dimensions. “Many manufacturers are currently on the Future Truck is to be fitted with sensors for pedestrian A deeper look inside your vehicle 44 lookout for solutions that will reduce fuel consumption,” detection to increase traffic safety. Other assistance says Jacob. “This is where the Future Truck comes up systems such as a distance radar and an emergency IAV products: the easy way into with numerous innovations.” braking system are integrated. Optimum night vision is new commercial vehicle mobility 46 another element in preventing accidents – this is what Measures for better aerodynamics the LED matrix headlights in the Future Truck promise. One more thing… 48 And even the tractorʼs light band has more than just an For example, the nose and the stem of the EU version aesthetic function: It surrounds the entire driverʼs cab Let’s meet! 50 provides significantly better aerodynamics compared to and also serves as daytime running light, turn signal and the previously common front designs. In both versions, position indicator. the windshields have also been tilted and curved to Our Mission 4 CO2 & Vehicle | Commercial Vehicles Commercial Vehicles | CO2 & Vehicle 18 19 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards a CO2-compliant fleet in 2030 10
Virtual trucking with IAV 15 Open for different powertrains innovative and, on the other hand, suitable for everyday “Don’t be afraid use and already designed for standard production. We Trucks of the future 16 The Future Truck can be operated with different power- had the great advantage of being able to work free from trains, which makes it future-proof. “This could be a highly the constraints of existing designs,” summarizes Jacob. “Don’t be afraid of unusual solutions!” 19 efficient diesel engine that is likely to dominate long-haul “We are currently using the Future Truck as a basis for of unusual transport for years to come,” says Jacob. “But, of course, discussion with OEMs and suppliers. It shows that IAV is “OEMs need to achieve optimal the layout is also prepared for alternatives such as fuel capable of developing complete commercial vehicles – end-user value when selecting cells, hydrogen engines or battery electric drives.” To fur- while also taking into account the various usage scenarios solutions!” technologies” 20 ther increase efficiency, the trucks are ready to fit a waste in the logistics process.” heat recovery system and phase change cooling, which Innovative truck infotainment 22 allows to reduce the number of air intakes in the front. Contact: [email protected] E-test bench to go 23 For IAV, the Future Truck provides a basis for talking to [email protected] Test management à la carte 25 potential customers. “On the one hand, the design is highly Nils Poschwatta ogether with IAV experts, Nils Poschwatta has designed the IAV Putting a stop to hackers 26 TFuture Truck. In an interview, he After studying industrial design at the Ready for all powertrains explains what was particularly important How does the new design differ Muthesius University of Applied & energy types 29 in terms of design and what trucks will be from existing trucks? Sciences in Kiel, Nils Poschwatta making the difference in the future. worked for Volkswagen Design in Digitized from scratch to delivery 30 In the EU variant, the nose on the front end Wolfsburg for eight years. During this is certainly the most striking new feature. It time, he created the interiors of several New momentum for hydrogen You usually design cars and mo- ensures better crash behavior, its radial base concept and production vehicles, mobility 32 torcycles. What was it like for you also optimizes aerodynamics and gives the including the “IROC,” “Scirocco” and to develop the design for a truck? vehicle a new look. Up to now, trucks in the “the Beetle.” Since 2009, he has been “Similar mindset in Gifhorn EU have tended to be “rolling shelves”. The Managing Director of Modus GmbH and in Karlsruhe” 35 Commercial vehicles are not a new topic for US version is also more aerodynamic. For and in charge of the Poschwatta me, although up to now I have developed this reason, we have tilted the windshields Automotive division. IAV Teslin: Maximum efficiency light trucks as a whole and only designed of both models more and added a stronger for testing and appraisal 36 interior concepts for heavy trucks. So the base to make the greenhouses and stem IAV trucks were my first project where I was more closely resemble one unit. A visual as Looking ahead: cost break-even able to design the exterior of a heavy truck. well as functional highlight is the light band Could such a truck also be built for new technologies 37 This gave me the opportunity to design that extends over the front and around the and marketed? the appearance of a future European truck grille, continues along the sides and closes Mature battery system for rather than “just” formally editing existing again around the rear. It serves as a daytime Yes, certainly. Everything is designed in special tasks 40 packages. As many innovations as possible running light in the front area and forms such a way that it can also be registered. were to be embedded in the new form and the characteristic face of the truck, which I deliberately did not want to build design Minimizing sooting of exhaust new functional concepts integrated. I had is normally defined by the main headlights. locks and I wanted to follow the criteria for gas recirculation 41 to comply with current legislation as well as In addition, it takes over various functions approval. And the result shows: You can the requirements of aerodynamics. And there pertaining to the truck and can be used to comply with the legal requirements and still “E-fuels would be ideal for us” 42 were to be two variants for the EU and the communicate with the surroundings through break new ground. This is also my wish for USA. During the project, I worked together the freely programmable RGB LEDs. Another all truck manufacturers: Try to meet conven- A deeper look inside your vehicle 44 with many colleagues from IAVʼs specialist innovative concept is the entry level. We use tions with innovations and donʼt be afraid of departments. And although IAV is a large a sliding door, which is not yet available in unusual solutions! IAV products: the easy way into company, we always had very short lines of trucks in this form. In this way, we improve new commercial vehicle mobility 46 communication and were able to implement the staircase or entrance clearance, but also Contact: everything quickly. It was very precise work! the accessibility between parked trucks. poschwatta.de One more thing… 48
Let’s meet! 50 Our Mission 4 Market | Commercial Vehicles Commercial Vehicles | Market 20 21 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards “OEMs need to a CO2-compliant fleet in 2030 10 Virtual trucking with IAV 15 achieve optimal Trucks of the future 16 “Don’t be afraid of unusual solutions!” 19
end-user value “OEMs need to achieve optimal end-user value when selecting when selecting technologies” 20 Innovative truck infotainment 22 technologies” E-test bench to go 23 Robert Dolan, Director of Test management à la carte 25 Commercial Vehicles and Government Programs at IAV Putting a stop to hackers 26 Are customers in the USA prepared to pay positioned at the component, sub-system and full system Ready for all powertrains more money for environmentally friendly development levels to meet customer needs. Another & energy types 29 solutions? example is fleet simulation, where individual and combined n the USA, future regulatory requirements are putting What role does proposed legislation play for technologies can be studied on application-specific Digitized from scratch to delivery 30 commercial vehicle manufacturers under pressure. your customers? Outstanding and relevant question! Short answer: rarely. drive cycles to identify the mix of technologies needed In an interview, Bob Dolan (Director of Commercial Unlike the passenger car sector, CV customers simply to achieve a sales weighted fleet solution to regulatory I New momentum for hydrogen Vehicles and Government Programs) reports on what A major role. And a lot is happening here at the moment do not make impulse or emotional purchase decisions. requirements. Aside from the direct engineering support, mobility 32 makes the market there so special and how IAV Inc. because many individual measures are positioned to have a Total Cost of Ownership (TCO) is the main driver for the IAV Inc. Northville, MI facility is equipped with four and IAV in Germany support their customers in making compounding impact on our customersʼ development pro- fleet managers when specifying their equipment. To medium duty and heavy duty sophisticated transient “Similar mindset in Gifhorn technology decisions and developing products. grams. For example, the EPA is poised to enact demanding illustrate the market challenge, consider the 24-month emission test cells, where our highly talented staff sup- and in Karlsruhe” 35 particulate matter (PM) reductions, from 0.01 grams per leasing model that is prevalent for US Class 8 long haul ports US customer product development activities with brake horsepower hour (g/bhp-hr) to 0.005 in 2024. At the trucks; TCO considerations dictate that add-on costs engine and aftertreatment system calibration activities, IAV Teslin: Maximum efficiency What does the US market for commercial same time, it is also considering significantly extending the for CO2 reduction equipment pay for themselves within OBD development and compliance testing. for testing and appraisal 36 vehicles (CVs) currently look like? “Useful Engine Life” from 10 years or 435,000 miles, to 18 24 months or 200,000 miles. Very challenging where years or 850,000 miles, and emissions-relevant warranty $2.50/gallon Ultra Low Sulphur Diesel is concerned. As a What is the cooperation between IAV Inc. Looking ahead: cost break-even It can be divided into four principle areas: Heavy-duty periods from 5 years or 350,000 miles to 14 years or result, major changes in technology adoption are typically in the USA and IAV GmbH in Germany? for new technologies 37 and medium-duty on-highway products are the most 800,000 miles. Keep in mind, Green House Gas Phase 2 only driven by new regulatory requirements. Considering recognized and subject to the most demanding regulatory is still in implementation phase to realize CO2 reductions. the competitive landscape, this underscores the need for In terms of CV activities, the level of cooperation is out- Mature battery system for requirements. Off-highway products range from adapted And in the background, the current voluntary CARB Ultra vehicle manufacturers to achieve optimal end-user value standing. Many CV customers are in fact global players and special tasks 40 on-highway products, to real industrial engines with more Low NOx program is under consideration by the EPA as when selecting technologies for meeting future regulatory we are able to present one IAV Team to them, independent than 19 liters displacement, and are applied into incred- a 50-state mandate. Individually, each of these initiatives requirements. Innovation companies like Nikola, pursue of geographic location. The IAV Global CV team is driven Minimizing sooting of exhaust ibly diverse, specialized applications, e.g., stationary, drives significant development activities for our customers, novel approaches to the New Tech – TCO challenge, by by a robust and well aligned customer strategy plan, we gas recirculation 41 wheeled, tracked and marine. The US Government is a CV and combined, they underscore the need for companies combining vehicle lease, H2 fuel and all maintenance costs are in frequent and regular communication, we effectively market sub-sector, including the Department of Energy, like IAV to provide guidance on technology selection and into a single lease payment equal to the national average leverage same working methods, acquisition materials, “E-fuels would be ideal for us” 42 the National Labs and Department of Defense. And the application, as well as expert engineering support to enable of clean-diesel truck operating costs of $0.95/mile. deep technology exchange, marketing, and social media, start-up companies (aka, Innovation Companies) consti- customers to meet their objectives. and we operate inside same project management tools. A deeper look inside your vehicle 44 tute an increasingly relevant CV sub-sector, with CO2- How do you support your customers in the There are over 8,000 globally placed employees at IAV, efficent and zero emissions solutions being fast-tracked transition to new technologies? across all portfolios, and we are fortunate to have more IAV products: the easy way into to demonstration phases. This sector is characterized by than 300 CV experts interspersed among them. As a new commercial vehicle mobility 46 rapid capital infusion from the investment community, into “We have many building We have many building blocks that will make future com- result, we have options in terms of meeting customer high clock-speed teams that lack the internal resources blocks that will make future mercial vehicles more environmentally friendly. Take, for requirements globally. Support is provided bilaterally and One more thing… 48 needed to fulfil their objectives. IAV Inc. is active in all four example, our footprint in fuel cell development: IAV oper- the working relationships are very good. of these CV market sub-sectors here in the US. commercial vehicles more ates a state-of-the-art test facility for stack development. Let’s meet! 50 Now couple that block with the many that comprise IAVʼs Contact: environmentally friendly.” electrified powertrain capabilities and you see how we are [email protected] Our Mission 4 Electronics | Commercial Vehicles Commercial Vehicles | Validation 22 23 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards E-test bench a CO2-compliant fleet in 2030 10 to go Virtual trucking with IAV 15 Trucks of the future 16 Flexible, effective and econom “Don’t be afraid of unusual solutions!” 19 ical: With IAV Auros, we offer “OEMs need to achieve optimal mobile test bench automation for end-user value when selecting Innovative truck technologies” 20 electric drives and auxiliary units. Innovative truck infotainment 22 infotainment Electric mobility is picking up speed. Nearly all manufac- turers will launch new models on the market in the next E-test bench to go 23 few years. And the trend is rising. For developers, this means a growing need for suitable test benches to put Test management à la carte 25 high-voltage components and electric drives through their paces. Conventional test benches are suitable for Putting a stop to hackers 26 this purpose, but the test bench times are rare and rela- Ready for all powertrains tively expensive. In order to resolve this area of conflict, & energy types 29 uture commercial vehicle infotain- This does not always meet the requirements we have developed IAV Auros, a mobile test system for ment systems must reconcile the of customers such as freight forwarders. electric drives that is easy to transport and yet contains Digitized from scratch to delivery 30 Frequirements of OEMs, commercial “They often have several brands in their all the features required for high-voltage testing. With vehicle owners and drivers. While many fleets, for which the manufacturers each offer our system, all rooms with a voltage supply of 63 amps New momentum for hydrogen cockpits are still improvised today, the their own fleet solutions,” says Herrmann. become potential high-voltage test benches. mobility 32 future belongs to sensibly integrated solu- “But this does not help users who would tions. IAV advises vehicle manufacturers rather use a uniform system on all vehicles Despite its compact size, the mobile test bench does “Similar mindset in Gifhorn on architecture issues as well as on testing in their fleet. It would therefore be better to not compromise on performance. It can control and and in Karlsruhe” 35 and integration and user interfaces. have a connectivity interface from the OEM, monitor a single motor or two electric motors in so- to which any third-party solutions can be called back-to-back operation. Drive motors with up to IAV Teslin: Maximum efficiency Radio, navigation system, computer for logis- docked as an open platform.” 150 kW mechanical power – such as traction drives for for testing and appraisal 36 tics software: Many truck cockpits contain a hybrid or electric vehicles – can thus be tested without variety of different devices, some of which any problems. An expensive test bench, for example for Looking ahead: cost break-even originate from passenger cars. “But that’s not endurance tests, is not required. IAV Auros can be booked for new technologies 37 an ideal situation, because commercial ve- “IAV offers support as a customized service package for specific projects hicles require their own solutions – for order or purchased as a fully functional test bench solution. Mature battery system for management on the road, for instance,” says along the entire special tasks 40 Torsten Herrmann, Senior System Architect Contact: at IAV. “It would be better not to improvise development chain [email protected] Minimizing sooting of exhaust and instead to integrate everything in a gas recirculation 41 sensible way.” – from initial studies, prototypes, tests “E-fuels would be ideal for us” 42 However, the different requirements of OEMs, logistics companies and drivers must with the target A deeper look inside your vehicle 44 be reconciled. OEMs, for example, want a recognizable design and a wide range of group, HMI specifi IAV products: the easy way into variants – from a simple radio to an info- new commercial vehicle mobility 46 tainment system for coaches. In addition, cation through to a flexible architecture is required to enable One more thing… 48 the integration of modules from external HMI series develop- suppliers. This is important, for example, in Let’s meet! 50 order to log compliance with the cold chain ment and testing.” in refrigerated trucks or to be able to control structures from the cockpit. Our Mission 4 Electronics | Commercial Vehicles Commercial Vehicles | Validation 24 25 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards Test management a CO2-compliant fleet in 2030 10 à la carte Virtual trucking with IAV 15 Trucks of the future 16
ommercial vehicles are character- In the impact analyses, IAVʼs experts look “For each customer, we develop an efficient “Don’t be afraid of unusual solutions!” 19 ized by a wide variety of variants. at every change and decide whether it and effective test management system CIn light of the small quantities in- will result in new tests in line with current tailored to the identified verification and “OEMs need to achieve optimal volved, customized test management is standards – and how they can be carried validation objectives,” adds Zschoppe. end-user value when selecting therefore indispensable. IAV uses impact out most effectively: Depending on the ver- Naturally, IAV also takes account of cur- technologies” 20 analyses throughout the entire develop- ification and validation objectives derived rent standards, for instance in the field of ment process to keep the effort involved from the impact analysis, virtual methods functional safety. Following the amendment Innovative truck infotainment 22 in safety tests and vehicle validation as are often the obvious choice. Although of the ISO 26262 standard, the vehicle low as possible. they cannot replace every real test, only assembler has a greater responsibility E-test bench to go 23 a few test objectives completely exclude in this area: They must themselves car- the use of virtual methods. ry out a hazard and risk assessment and Test management à la carte 25 Different numbers of axles in the towing ve- provide their suppliers with specifications hicle, a whole range of possible superstruc- “The comparatively inexpensive and fast for their development work. “In the end, Putting a stop to hackers 26 tures or the same powertrain in different virtual methods are of great benefit, partic- the assembler must then check whether Ready for all powertrains chassis: In the commercial vehicle sector, ularly in the early phase of a development the specified targets have been met. As & energy types 29 the diversity is much more pronounced project,” says Thorsten Scheibe, head a result, functional safety is now better than in the passenger car sector. “We are of the Autonomous Driving Validation & integrated into the development process,” Digitized from scratch to delivery 30 dealing here with many more mechanical Automation department at IAV. Whatʼs more, says Zschoppe. “With our tailor-made test variants,” says Rene Zschoppe, head of the they can be easily extended to intelligently management, we support vehicle man- New momentum for hydrogen Functional Safety & Concepts department examine the parameter space under in- ufacturers, assemplers and suppliers in mobility 32 at IAV. “This means that the same basic ve- vestigation beyond its actual limits. “This complying with all specifications with as hicle can have completely different bodies means that the results cover a wider range little effort as possible,” adds Scheibe. “Similar mindset in Gifhorn such as a tipper or a crane.” At the same of applications, and thus, allow us to reduce and in Karlsruhe” 35 time, however, the development costs must the testing effort required for subsequent Contact: be spread over far fewer vehicles. What is changes in the area already investigated,” [email protected] IAV Teslin: Maximum efficiency therefore needed is a method that avoids says Scheibe. [email protected] for testing and appraisal 36 unnecessary effort and reuses existing results as far as possible. Looking ahead: cost break-even For the drivers, on the other hand, the truck software modules (e.g., logistics, body manu- of switches in the cockpit that still exist in for new technologies 37 is their living space on wheels. Driving time facturers) from the domain for entertainment. many places are thus noticeably reduced. Only carry out tests that are really is life time, and therefore, the infotainment This is the best way to meet the different In addition, the future belongs to HMIs that necessary “For each customer, we Mature battery system for system must fulfill two roles at the same requirements for safety and robustness. can be adapted to the respective needs of special tasks 40 time: On the one hand, it is an aid to work, The corresponding hardware should con- the customer. “In this area, IAV offers support This applies throughout the entire devel- develop an efficient and but at the same time it is also responsible sist of several boxes that can be combined along the entire development chain – from opment process – even shortly before the Minimizing sooting of exhaust for entertainment on the road. In individu- according to the specific requirements. This initial studies, prototypes, tests with the start of series production, when safety effective test manage- gas recirculation 41 al cases, the equipment depends on how “multi-box” design is more flexible than an target group, HMI specification through to tests and investigations for validation are much time the driver actually spends in the “all-in-one” design, given the typically low vol- HMI series development and testing,” says on the agenda. “We use impact analyses ment system tailored to “E-fuels would be ideal for us” 42 commercial vehicle – a lot in the truck on umes in the commercial vehicle sector. “We Dr Marcus Heinath, head of the UX, HMI to determine the influence of changes, for long-distance journeys, less in the vehicle advise our customers on such architectural & Instrument Cluster department at IAV. example on the safety concept,” explains the identified verification A deeper look inside your vehicle 44 for delivery services. issues, but we also undertake the testing “We are able to cover many topics from a Zschoppe. “On the basis of the results, it is and integration of infotainment systems single source, thus noticeably relieving our possible, among other things, to identify the and validation objectives.” IAV products: the easy way into Flexible “multi-box” architecture for commercial vehicles,” says Herrmann. customers of a great deal of work.” really necessary tests in the case of vehicle new commercial vehicle mobility 46 derivatives and to concentrate primarily The future therefore belongs to modular E/E In the human-machine interface (HMI), the Contact: on these in the test execution. In the case One more thing… 48 architectures that separate logical domains trend is moving towards large, freely pro- [email protected] of modified superstructures, for example, for the workplace such as Advanced Driver grammable displays – as has also been [email protected] it may be that the powertrain is adopted Let’s meet! 50 Assistance Systems (ADAS), the instrument observed in the passenger car sector in [email protected] unchanged, but we must test the changes panel and the display for the driver, as well recent years – which allow greater flexibility in braking, Electronic Stability Control (ESC) as the domain for integrating third-party and must be operated intuitively. The masses and Anti-lock Braking System (ABS) in detail.” Our Mission 4 Digitalization | Commercial Vehicles Commercial Vehicles | Digitalization 26 27 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards a CO2-compliant fleet in 2030 10
Virtual trucking with IAV 15
Trucks of the future 16
“Don’t be afraid of unusual solutions!” 19
“OEMs need to achieve optimal end-user value when selecting technologies” 20
Innovative truck infotainment 22
E-test bench to go 23
Putting a stop Test management à la carte 25 to hackers Putting a stop to hackers 26 Ready for all powertrains & energy types 29
With increasing interconnectivity, vehicles also offer Digitized from scratch to delivery 30 criminals more scope for attack. Security is therefore New momentum for hydrogen becoming an even higher priority for manufacturers and mobility 32 their suppliers. In addition, UN regulations impose new “Similar mindset in Gifhorn requirements – a challenge that IAV is tackling. and in Karlsruhe” 35 IAV Teslin: Maximum efficiency for testing and appraisal 36
o motorist wants to experience something like for attacks on vehicles are multiplying – whether via vehicle Looking ahead: cost break-even this: From the sofa, two hackers from the “Wired” keys, Wi-Fi, Bluetooth or logistics systems networked with IAV offers special for new technologies 37 Nmagazine demonstrated a remote attack on a mobile communication, to name just a few examples. And expertise and Jeep Cherokee in 2015. From a distance, the two took in the future, too, the problem is likely to grow rather than Mature battery system for control of the vehicle, switched off the engine, deacti- shrink: Already today, more and more functions are being experience in… special tasks 40 vated the brakes and intervened in the steering. How combined on domain computers. In the future, these will could this happen? The vehicle’s control unit architecture be at least partially outsourced to the cloud – and thus, Minimizing sooting of exhaust was insufficiently protected by Wi-Fi and mobile com- create new targets for attacks. • the establishment of a cyberse- gas recirculation 41 munications, and the other entrance gate to the attack curity management system was inadequately secured software updates. A series Combine security and safety • the analysis of threats and risks “E-fuels would be ideal for us” 42 of security problems enabled the two hackers to take • the creation of cybersecurity control of the vehicle via radio. How can this be prevented? An important step is to com- concepts on process, product A deeper look inside your vehicle 44 bine security and safety, i.e. cybersecurity and vehicle and information level safety. An attacker only needs to find one way to attack IAV products: the easy way into • the design of vehicle architec- Today, many vehicle manufacturers and their suppliers must a vehicle, while the developers need to know and protect new commercial vehicle mobility 46 ture with domain separation struggle with security problems: The number of known all of them. This means that the safety systems in the cybersecurity attacks has increased sevenfold between car can be infiltrated in a targeted manner by a remote • the observation of hacker One more thing… 48 2010 and 2019, according to the Upstream Security attack, as in the example above. Safety and security are progress, CVEs and CWEs Global Cybersecurity Report 2020. This is because with thus closely related – even if in the past they were usually (especially for FOSS software) Let’s meet! 50 increasing interconnectivity, the targets and possibilities considered separately. • penetration tests Our Mission 4 Digitalization | Commercial Vehicles Commercial Vehicles | Powertrain 28 29 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards UN-ECE WP.29: Ready for all a CO2-compliant fleet in 2030 10 New rules for cybersecurity (CS) powertrains & Virtual trucking with IAV 15 Cybersecurity requires the Cybersecurity requires Trucks of the future 16 vehicle to have: companies to: “Don’t be afraid of unusual solutions!” 19 • Architecture with domain • establish a Cybersecurity Manage- energy types separation ment System (CSMS) “OEMs need to achieve optimal • Security protection for critical • introduce processes and end-user value when selecting vehicle systems such as systems with responsible persons (roles) IAV’s test bench portfolio leaves nothing to be technologies” 20 an influence on: • manage security for suppliers and desired. Whether internal combustion engine, Innovative truck infotainment 22 - external interfaces service providers fuel cell drive or battery electric solution: Our • identify, assess and respond - safety (including longitudinal and experts can put all propulsion systems to the E-test bench to go 23 lateral acceleration) to risks • monitor attacks, threats and vulnera- test as they are perfectly positioned for the - availability (including theft protec- Test management à la carte 25 tion) bilities (e.g., hacking successes, future – for example, with a test cell for electric quantum computers) Putting a stop to hackers 26 - type approvals axles and a battery test bench at our E-Mobility • continuously evaluate the effective- Excellence Center in Stollberg. In Gifhorn, we - emissions ness of previous measures Ready for all powertrains have two facilities to test hydrogen drives & energy types 29 - personal data • always be ready to respond to while in Berlin, we can conduct tests with syn- (detected and threatened) attacks • Manipulation detection (intrusion Digitized from scratch to delivery 30 detection) • quickly deploy security patches even thetic fuels. • Passed penetration tests after EOP New momentum for hydrogen mobility 32
“Similar mindset in Gifhorn and in Karlsruhe” 35
The United Nations has also intervened to further improve A mammoth task for vehicle development IAV Teslin: Maximum efficiency the cybersecurity of vehicles: The UN/ECE Economic “Seamless test- for testing and appraisal 36 Commission has adopted comprehensive regulations on This is a mammoth task for all those involved – including cybersecurity and software updates that must be applied IAV. For example, all ECUs with security relevance must Looking ahead: cost break-even to the work of manufacturers and suppliers today, as they be checked, and functions such as a dedicated security ing is the key” for new technologies 37 will be relevant for type approvals from 2022 and all new module for communication (e.g., Autosar SecOC – Secure registrations from 2024. Onboard Communication) must be added. The new stan- Mature battery system for dards also fundamentally change the customer process: special tasks 40 Shared responsibility This means that a risk analysis will be central to every system and every function in the future. ndreas Geistert, Senior Vice Pres- coolant or oil conditioning – always using in other countries, we are always close to Minimizing sooting of exhaust A central point of the new regulations is that in the future ident Test Center & Powertrain state-of-the-art measuring technology. our customers. gas recirculation 41 manufacturers, subcontractors, suppliers and potential IAV is already working flat out to master this complexity ASystems Development at IAV, talks third parties will be jointly responsible for improving the and implement the new standards. For instance, the about IAVʼs test benches and the upcoming What services do you offer? How are you positioned with the “E-fuels would be ideal for us” 42 security of systems in vehicles. In doing so, all must prove company is currently redefining processes and roles – diversity of commercial vehicle powertrains. new drives? that they meet the official requirements in terms of the also together with customers. We are also expanding the We are at our customersʼ side from start A deeper look inside your vehicle 44 principles of security. In the future, vehicle architectures methodological expertise of employees through security to finish. Upon request, we can even ac- We can test all drives – powered by diesel, must be designed in such a way that by overcoming training and risk analysis are already part of our everyday What makes IAVʼs test benches stand out? company them all the way to certification. LPG, CNG, synthetic fuels or hydrogen. And IAV products: the easy way into one component it is not possible to access the next. In development work. Although there is still some work ahead First of all, we have test benches at our four This enables us to offer our customers a of course, we also have test benches for new commercial vehicle mobility 46 addition, it will be the task of companies in the future to of us in implementing the directive – the goal is clear: We locations in Berlin, Gifhorn, Stollberg and continuous service without any gaps. We battery electric drives, which we can exam- digitally monitor cybersecurity throughout the entire life do not want to give hackers a chance. Northville, MI for various components and always work closely with our colleagues ine with real batteries if desired. So we are One more thing… 48 cycle of a vehicle and to react to incidents accordingly. in many performance classes. This enables from the specialist departments to find ideally positioned for the coming variety of Contact: us to cover all our customersʼ requirements. optimal solutions – a close interaction of en- commercial vehicle drives. Let’s meet! 50 [email protected] We also combine test benches with simula- gineering and experience. This also applies [email protected] tive approaches by running real-life driving internationally: With our own test benches Contact: [email protected] profiles under real conditions with regard to in the USA and cooperation with partners [email protected] Our Mission 4 Digitalization | Commercial Vehicles Commercial Vehicles | Digitalization 30 31 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards a CO2-compliant fleet in 2030 10
Virtual trucking with IAV 15
Trucks of the future 16
“Don’t be afraid of unusual solutions!” 19
“OEMs need to achieve optimal end-user value when selecting Digitized technologies” 20 from scratch Innovative truck infotainment 22 E-test bench to go 23 to delivery Test management à la carte 25 Putting a stop to hackers 26 The digitalization megatrend is also a major topic in the Ready for all powertrains & energy types 29 commercial vehicle industry – from the development of and thus, prevent breakdowns. This enables us to plan Digitized from scratch to delivery 30 new vehicles to the driverʼs workplace and autonomous workshop stops and increase vehicle availability.” Finally, “The trend is clear: Digital future vehicles can be optimally tailored to the respective driving. IAV uses state-of-the-art digital tools and offers methods and processes New momentum for hydrogen application scenario and important questions can be an- mobility 32 its customers a modular technology kit from which tailor- swered: Which drive is optimal for the customer? Which are headed towards com- made solutions can be derived. battery size fits best? How will the vehicles be used in “Similar mindset in Gifhorn practice? Those who can answer these questions can mercial vehicles. IAV has and in Karlsruhe” 35 optimize their customersʼ TCO. a broadly diversified tech IAV Teslin: Maximum efficiency Small quantities with a high degree of variance and particu- Virtual tools for alternative drives in commercial Making the profession of “long-distance driver” for testing and appraisal 36 larly high demands on reliability and durability: Commercial vehicles more attractive nology kit that can be used vehicles are a challenge for developers – especially when in a variety of domains.” Looking ahead: cost break-even it comes to issues such as application and protection. This also applies to the installation of electric drive trains However, drivers are also affected by the digitalization of for new technologies 37 “We cannot test all vehicle variants in real-life trials with in existing vehicle platforms that were originally designed commercial vehicles. Their workplace is changing and is prototypes,” explains Matthias Schultalbers, Executive for diesel engines. Commercial vehicle platforms gener- increasingly becoming a rolling office. “In future, they will Mature battery system for Vice President Powertrain Mechatronics and CDO at IAV. ally have a service life of between 20 and 25 years – so be shown messages on their windscreen, for example to in commercial vehicles because there are clear financial special tasks 40 “Virtual development methods as well as digital twins have switching to a “zero emission” drive is still attractive even optimize route planning,” says Schultalbers. “This is part benefits here. In the “HEAT” (Hamburg Electric Autono- therefore been playing a central role for us for years.” IAV in the middle of the planned platform service life. “Here, of the generally stronger networking of driver, vehicle and mous Transportation) funding project, IAV has shown how Minimizing sooting of exhaust customers benefit from lower development costs in the too, we use digital tools, for example to integrate the new logistics planning: In order to avoid empty runs as far as an autonomous shuttle can be integrated into the traffic gas recirculation 41 medium term and consistently high quality across all powertrain, to examine the effects on the entire vehicle possible, orders and fleets will be synchronized in real of a major city. This experience can also be transferred variants, even if these cannot be built as test vehicles. and to validate the individual variants in virtual endurance time – also with the support of artificial intelligence.” This to other commercial vehicles and application scenarios. “E-fuels would be ideal for us” 42 “This is a huge issue for us right now,” says Schultalbers. runs,” reports Schultalbers. will not only improve the profitability of fleets, but also increase the attractiveness of the profession of “long- “We are currently receiving many enquiries about digi- A deeper look inside your vehicle 44 IAV engineers use digital twins, for example, to verify In the meantime, more and more fleet data from the distance driver”: The long-distance driver is increasingly talization topics and can offer solutions along the entire and validate ECUs (Electronic Control Unit) or the entire field is flowing into the development processes, where it transforming from a driver to a logistics manager, and the development chain, right up to support for operational fleet IAV products: the easy way into ECU network. But more and more activities in function supports validation and safeguarding. But it also makes it technology provides them with tools that enable them management,” says Schultalbers. “The trend is clear: Digital new commercial vehicle mobility 46 development and calibration are also being shifted into possible to provide commercial vehicle customers with to position themselves and their company in the best methods and processes are headed towards commercial virtual space. “With the electrification of commercial information on predictive maintenance. “Among other possible way within the logistics chains – an important vehicles. IAV has a broadly diversified technology kit that One more thing… 48 vehicle powertrains, this approach is becoming even things, this makes it possible to determine the severity, signal in light of the lack of new talent in this field. can be used in a variety of domains. And the response of more important,” says Florian Brandau, Director Business priority and the point of origin of a fault and, if necessary, our customers shows that we are very successful with it.” Let’s meet! 50 Development Commercial Vehicle E-Mobility at IAV. “After to predict restrictions in the availability of the vehicle,” Autonomous driving will have a major impact on the entire all, we are dealing here with a high degree of technological says Schultalbers. “A dashboard can provide the fleet logistics industry. Highly automated driving functions on Contact: novelty that we can better master with the digital tools.” operator with an overview of the condition of all vehicles, levels 4 and 5 will probably first go into standard production [email protected] Our Mission 4 Powertrain | Commercial Vehicles Commercial Vehicles | Powertrain 32 33 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards a CO2-compliant fleet in 2030 10
Virtual trucking with IAV 15
Trucks of the future 16
“Don’t be afraid of unusual solutions!” 19
“OEMs need to achieve optimal end-user value when selecting technologies” 20
Innovative truck infotainment 22
E-test bench to go 23
Test management à la carte 25
Putting a stop to hackers 26 New momentum for Ready for all powertrains & energy types 29 hydrogen mobility Digitized from scratch to delivery 30 New momentum for hydrogen mobility 32
“Similar mindset in Gifhorn he e-drive is a key instrument for reducing CO2 mobility a new boost. It can be usefully applied where and in Karlsruhe” 35 emissions. However, batteries are not yet the first battery electric drives have system-related disadvan Tchoice for many commercial applications due to tages – for example, in long-distance heavy goods traffic. IAV Teslin: Maximum efficiency their low energy density. Therefore, the future belongs Technically speaking, the hydrogen internal combustion for testing and appraisal 36 to a mix of different commercial vehicle drive systems. engine and fuel cell are ready for standard production in Hydrogen will play a key role as an energy carrier. How- commercial vehicles, and in a few years’ time parity with Looking ahead: cost break-even ever, it is important to take a cross-sectoral view and diesel should also be achieved in terms of Total Cost of for new technologies 37 make a rapid development decision. Ownership (TCO). Their impact on the environment var- ies: In terms of emissions, the fuel cell performs better Mature battery system for because it does not emit nitrogen oxides, particles and special tasks 40 In addition to diesel, battery electric drives and hydrogen hydrocarbons, and therefore does not need an exhaust will also play a key role in future commercial vehicles – aftertreatment system. However, in certain applications, Minimizing sooting of exhaust the latter either as a fuel for combustion engines or as the internal combustion engine can also show its advan- gas recirculation 41 an energy supplier for fuel cells. “The future is not black tages. This also makes it a very interesting candidate and white, but gray,” says Dr Jörn Seebode, Senior Vice for CO2-neutral commercial vehicle applications in the “E-fuels would be ideal for us” 42 President Commercial Vehicles at IAV. “In the case of short term. commercial vehicles, we are dealing with so many differ- A deeper look inside your vehicle 44 ent applications and usage profiles that there cannot be Building on existing technology one optimum drive system for all constellations. Which IAV products: the easy way into drive is optimal in each individual case is determined by Moreover, it is hardly different from a diesel engine, new commercial vehicle mobility 46 the specific load collectives based on the application and therefore does not represent a fundamentally new scenarios. This is why it is so important to approach the technology. “The hydrogen combustion engine could be One more thing… 48 topic openly with regard to technology.” brought into series production a little faster than the fuel cell, because it can make use of existing technology and Let’s meet! 50 The CO2 specifications of the European Union increase production capacities. It would also allow us to maintain the pressure on manufacturers and also give hydrogen value creation with OEMs and suppliers,” says Seebode. Our Mission 4 Powertrain | Commercial Vehicles Commercial Vehicles | Powertrain 34 35 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards “The situation is somewhat different with the fuel cell, even capacities so that the mobility sector can also be reliably a CO2-compliant fleet in 2030 10 if components could also be adopted here – for cooling supplied in the future.” Sens adds: “In this respect, IAV is or air supply, for example.” also considering solutions for decentralized hydrogen Virtual trucking with IAV 15 production, e.g. from synthesis gases, which in turn can The alternative drives for commercial vehicles would thus be produced easily from organic waste.” Trucks of the future 16 be available in principle – but there is still a lack of an ad- equate filling station infrastructure: Around 1,500 filling Cross-sector thinking required “Don’t be afraid of unusual solutions!” 19 stations would be needed throughout Germany to make the new energy source attractive. The supply of hydrogen It is therefore all the more important to think across all “OEMs need to achieve optimal from “green” sources has also been growing for years – its sectors in terms of overall systems and processes: For “Similar mindset end-user value when selecting production is ideally suited to convert excess wind or solar example, the efficiency of future electrolyzers must be technologies” 20 power into the energy-rich gas by electrolysis. However, further improved so that the maximum possible amount there is also competition for the energy carrier. “Hydrogen of hydrogen can be obtained from green electricity. IAV Innovative truck infotainment 22 is not only an energy carrier that is absolutely essential can support its customers in this and other areas: “On the in Gifhorn and in outside of mobility, but also an important raw material for one hand, we have expertise in the field of mobility and E-test bench to go 23 processes in the chemical industry,” explains Marc Sens, know the needs of fleet operators very well,” says Ralf Senior Vice President Advanced Development Powertrain Wascheck, Head of Department Fuel Cell and Hydrogen Karlsruhe” Test management à la carte 25 at IAV. “We must therefore create sufficient production Mobility. “But we also offer engineering in the areas of wind power and hydrogen production and can therefore Putting a stop to hackers 26 consider the entire value chain. This approach across all Ready for all powertrains sectors enables us to develop the ideal mobility concept & energy types 29 for every user.” Sens adds: “Such a consideration across AV and Institut für Kolbenmaschinen emission limits. One way to reduce CO2 all sectors will become even more important in the fu- (IFKM) of the Karlsruher Institut für Tech- is to use hydrogen as an alternative fuel. “Hydrogen mobility is Prof. Dr. Thomas Koch, Digitized from scratch to delivery 30 ture when legislators demand a life cycle analysis (LCA) Inologie (KIT), University of Karlsruhe, However, this presents many challenges, that takes into account all influences on the ecological cooperate in the development of hydrogen such as combustion anomalies or the devel- Head of the Institute for an important compo- New momentum for hydrogen footprint.” combustion processes. Prof. Thomas Koch opment of exhaust aftertreatment systems Piston Engines at KIT mobility 32 nent of future commer- (Head of the Institute for Piston Engines that are significantly simplified compared to cial vehicles. But there However, OEMs are also called upon to help hydrogen at KIT) and Dr Reza Rezaei (Manager for diesel engines in order to comply with Real “Similar mindset in Gifhorn mobility achieve a breakthrough. “They must offer their Advanced Combustion Development Com- Driving Emissions (RDE). What is needed and in Karlsruhe” 35 is no time to lose here, customers new concepts and sell them mobility, not just a mercial Vehicles at IAV) report on their here is a deep understanding of the internal increase engine performance and reduce vehicle,” says Wascheck. “Pioneers like Nikola or Hyundai collaboration in an interview. hydrogen combustion processes in engines nitrogen oxides. In a first step, we have de- IAV Teslin: Maximum efficiency as competition for the do just that – and such all-inclusive packages are the key and a great deal of research to optimize the veloped a concept with an injection pressure for testing and appraisal 36 to success. The examples show that the changes in the processes. of up to 50 bar. In the next step, we will jointly environmentally friendly coming years will not be linear, but rather disruptive.” IAV What exactly are IAV and KIT research hydrogen high pressure injection Looking ahead: cost break-even offers OEMs holistic consulting services to help them working on? What are the most important new with more than 200 bar and diffusive com- for new technologies 37 energy carrier hydrogen successfully manage the tough upheaval. results? bustion. Rezaei: We generally work very closely with Mature battery system for will increase.” No time to lose universities to learn the latest methods Rezaei: As part of our collaboration, we have How does the collaboration with special tasks 40 and build up know-how that we can later studied the hydrogen combustion process IAV work? “Hydrogen mobility is an important component of future use in customer projects. IAV and KIT have for a two liter heavy-duty single cylinder Minimizing sooting of exhaust commercial vehicles,” summarizes Seebode. “But there been collaborating for about two years in engine. After defining and implementing the Koch: From the universityʼs point of view, a gas recirculation 41 is no time to lose here, as competition for the environ- the field of hydrogen combustion process optimization measures to avoid knocking trusting exchange, in-depth discussion and mentally friendly energy carrier hydrogen will increase.” development for heavy-duty applications. and preignition, we were able to raise the critical analysis are very important. The en- “E-fuels would be ideal for us” 42 Wascheck, Seebode and Sens agree that decisive action To this end, we have carried out experimen- indicated mean pressure (as a measure of gineers can only draw the right conclusions is needed to exploit market potential. “If we do not bring tal investigations on a heavy-duty single- torque and power) above 19 bar. In addition, from a critical view of the analysis results. A deeper look inside your vehicle 44 any vehicles onto the market in the next four to five years, cylinder engine. a number of measures were successful- This applies to both research and devel- it could be too late,” says Seebode. “Together with our ly developed and implemented, such as opment. A similar mindset in Gifhorn and in IAV products: the easy way into customers, we therefore want to press ahead intensively Why is now exactly the right time emaciation and exhaust gas recirculation Karlsruhe helps us a lot in the constructive new commercial vehicle mobility 46 with this topic now and bring solutions into production to conduct such research? to minimize nitrogen oxides. collaboration. as soon as possible.” One more thing… 48 Koch: The political and legislative trends Koch: We are currently working on the de- Contact: Contact: in heavy-duty vehicles are moving towards velopment of hydrogen direct injection to ifkm.kit.edu Let’s meet! 50
[email protected] a further tightening of global NOx and CO2 further minimize combustion anomalies, [email protected] [email protected] [email protected] Our Mission 4 Validation | Commercial Vehicles Commercial Vehicles | Powertrain 36 37 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards IAV Teslin: Maximum Looking a CO2-compliant fleet in 2030 10 efficiency for testing ahead: cost Virtual trucking with IAV 15 Trucks of the future 16 and appraisal break-even “Don’t be afraid of unusual solutions!” 19 “OEMs need to achieve optimal end-user value when selecting for new technologies” 20 oday, various tools such as Ex- Innovative truck infotainment 22 cel, Word or PowerPoint are used Tto record data from functional or technologies E-test bench to go 23 endurance testing, before the data are stored on drives or in several databases. Test management à la carte 25 This process is not only very slow and EMs want to offer customers environmentally error-prone, it also makes it very difficult friendly vehicles and at the same time reduce Putting a stop to hackers 26 to compare different endurance runs at Otheir Total Cost of Ownership (TCO). Zero emis- Ready for all powertrains great manual effort. sion vehicles are the solution, but new technologies are & energy types 29 inherently more expensive than existing ones at first. With the TCO calculator, IAV can calculate which drive Digitized from scratch to delivery 30 IAV Teslin remedies the situation. The in- will be the cheapest option for the specific use case, telligent tool manages the data in a central and thus, present potential market scenarios. New momentum for hydrogen server database and makes them available mobility 32 intuitively on a client (Windows or Linux PC) for subsequent analysis, comparison Many drive options will be competing for the favor of buy- experts place the CO2 price per ton between EUR 60 “Similar mindset in Gifhorn and reporting. Component owners and ers in future. So the big question is: What should vehicle to EUR 170 by 2030; the median scenario is EUR 120 and in Karlsruhe” 35 diagnostic experts working for OEMs, sup- manufacturers and their customers (e.g. fleet operators) per ton. For diesel, that means: In ten years, it will cost pliers and service providers benefit from choose in the coming years in order to be able to offer between 19 and 54 cents more per liter. In the median IAV Teslin: Maximum efficiency far greater efficiency as well as improved or make use of the best TCO package? The answer to scenario, the increase is 38 cents per liter. Depending for testing and appraisal 36 evaluation possibilities during and after test this question is far from simple – because no one knows on the electricity mix, battery electric vehicles are also runs. Besides standardized data recording, exactly how, for example, the prices of individual energy affected by CO2 costs. Looking ahead: cost break-even the tool also offers flexible add-ons, de- sources and state subsidies will develop. for new technologies 37 pending on customer or project demands. The corresponding price scenarios predict electricity Furthermore, IAV Teslin produces semi- What is needed, is a tool with which different scenarios costs of 24 to 28 cents per kilowatt-hour for external Mature battery system for automatic reports in various formats and can be calculated in order to provide an objective com- sources (e.g. on the freeway) by 2030; the median forecast special tasks 40 makes it easy to compare test specimens parison. The TCO calculator from IAV does just that: here is 26 cents per kilowatt-hour. Costs for hydrogen, in different test programs, among others. As input, it requires data such as the acquisition and on the other hand, are expected to fall significantly by Minimizing sooting of exhaust Interfaces integrate the tool smoothly in distance-dependent toll costs of a truck. It can then be 2030: Today, it costs 9.50 euros per kilogram; in 2030, gas recirculation 41 existing system landscapes. used to examine various conceivable developments and the price is expected to be between 4 and 6 euros per make a product development or purchase decision based kilogram, with the median forecast being just over 5 euros “E-fuels would be ideal for us” 42 Customers in the non-automotive sector will on the best currently available knowledge. per kilogram. For comparison: In terms of energy content, also benefit from these advantages when one kilogram of hydrogen equates to around 3 liters of A deeper look inside your vehicle 44 diagnosing or assessing their products Scenarios for the CO2 price diesel, but the better efficiency of fuel cells results in a aftertests or endurance runs. lAVTeslin has rough utility factor of 4.5 liters of diesel to one kilogram IAV products: the easy way into been in productive use at IAV since 2014. A central constraint is the future CO2 price. “It depends of hydrogen. “Thatʼs why a price of less than five euros new commercial vehicle mobility 46 lt undergoes continuous optimization and above all on the legislator, so this is where political in- per kilogram of hydrogen is the magic hurdle compared has already proven its worth in numerous fluence is greatest,” says Florian Brandau, Director of to diesel,” Brandau explains. IAV bases its forecasts on One more thing… 48 customer projects. Business Development for Commercial Vehicle E-Mobility its own research from public sources. at IAV. “What is certain is that diesel will become much Let’s meet! 50 lnterested? To make swift arrangements more expensive – but nobody knows the exact course of However, other factors are also included in the TCO for an online demonstration without any events because future political currents and the global calculation. There is no difference in personnel costs obligations, simply contact [email protected]. oil price can have a major influence here.” Forecasts by for the driver for the different types of drive, while repairs Our Mission 4 Powertrain | Commercial Vehicles Commercial Vehicles | Powertrain 38 39 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards a CO2-compliant fleet in 2030 10
Virtual trucking with IAV 15
Trucks of the future 16 and maintenance are lower for battery electric or fuel cell “By working with IAV, our “Don’t be afraid of unusual solutions!” 19 vehicles. The reverse is true for the acquisition costs: Battery-electric and fuel cell commercial vehicles are customers donʼt have to “OEMs need to achieve optimal currently about three times as expensive as their diesel end-user value when selecting counterparts. “The state should therefore subsidize these start from scratch. We technologies” 20 new technologies for a transitional period to cushion the additional costs,” says Brandau. “This can be done, for have basic modules that Innovative truck infotainment 22 example, by exempting them from tolls.” However, this can only be an interim solution – in the long term, the new can serve as blueprints Holistic approach E-test bench to go 23 engines must pay for themselves even without state aid. for getting started in for active thermal Test management à la carte 25 Diesel already beaten in many applications in e-mobility.” management 2024 when it comes to TCO Putting a stop to hackers 26 Ready for all powertrains Based on the premises mentioned and the possible subsidy Thermal management is particularly im- & energy types 29 strategies of the legislators regarding acquisition and toll wagen,” Brandau is convinced. “There, according to portant in electrically powered vehicles, costs, the following possible scenario results from the the ADAC study from September 2020, the TCO is al- because the requirements for convenience, Digitized from scratch to delivery 30 current state of knowledge: Battery electric vehicles will ready lower than that of a diesel or gasoline engine.” range, charging system, operating strategy undercut diesel in many applications in 2024, with fuel It is now important to reduce the cost of drive systems and temperature control of the components New momentum for hydrogen cell vehicles doing the same four years later. The race in the commercial vehicle sector as well. “At the moment, must be harmonized. A typical example: In mobility 32 between the two alternative drive systems will also have they are simply still too high because we have a revolu- winter, the driver wants a warm cab when a clear winner within this decade: The fuel cell is likely tionary development here and everything is very new,” starting the vehicle, but at the same time “Similar mindset in Gifhorn to be cheaper than the battery electric variant on long- says Brandau. “In the case of the diesel, on the other hand, the battery should also reach the optimum and in Karlsruhe” 35 distance routes from 2029. One reason for this is energy proven basic designs are being developed further in an temperature range of 20 to 35 degrees as storage: Batteries for commercial vehicles are heavy evolutionary way, which means less effort is required.” quickly as possible. An electric auxiliary IAV Teslin: Maximum efficiency and expensive, and in addition a high variance must be heater can speed up the speed at which for testing and appraisal 36 converted to small quantities. “The fuel cell is particularly Basic modules as blueprints for development the energy storage unit warms up, but this well suited for heavy trucks in long-distance operation is at the expense of the range. Looking ahead: cost break-even when refueling en route,” says Brandau. “However, the It will be crucial for OEMs to bring the new technologies to for new technologies 37 situation is different if you generate your own electricity market quickly – otherwise they risk losing their competi- IAV approaches active thermal management or can buy electricity very cheaply: In this case, the bat- tiveness and facing competition from new players. “But by in electrically powered commercial vehicles Mature battery system for tery electric variant is cheaper.” But the important thing working with IAV, our customers donʼt have to start from with a holistic simulation approach and a special tasks 40 is that as soon as individual parameters change, the TCO scratch,” says Brandau. “We have basic modules that can large team of experienced employees – curves for alternative drives can be completely different. serve as blueprints for getting started in e-mobility. So from hardware and system development to Minimizing sooting of exhaust This is why we must constantly check all the premises customers donʼt have to do all this legwork themselves application safeguards. Using commercial gas recirculation 41 and readjust them if necessary. and together we can quickly arrive at solutions that are and proprietary tools, our experts bring new fully ready for production.” technological approaches such as phase “E-fuels would be ideal for us” 42 The figures of the TCO calculator in the current scenar- change cooling, phase change materials io show that the traffic turnaround can be achieved in Contact: or newly designed thermal management A deeper look inside your vehicle 44 the next ten years. “With cars, things will happen very [email protected] systems to series production. “The focus is quickly because of new models like the ID.3 from Volks [email protected] always on system optimization, for example, IAV products: the easy way into by using air conditioning for component tem- new commercial vehicle mobility 46 perature control,” explains Ronny Mehnert, Manager Energy & Thermal Management One more thing… 48 Powertrain at IAV. Let’s meet! 50 Contact: [email protected] Our Mission 4 Powertrain | Commercial Vehicles Commercial Vehicles | Powertrain 40 41 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards contained or removed. The results show, for example, a CO2-compliant fleet in 2030 10 that an increase in the EGR rate from 25 to 30 percent Minimizing at cold temperatures, such as in low-load operation, can Virtual trucking with IAV 15 lead to a doubling of deposits. Endurance tests can be used to determine how long the EGR components will Trucks of the future 16 Mature battery sooting of function properly under different conditions. “Don’t be afraid of unusual solutions!” 19 “Sooting cannot be completely avoided,” says Mehnert. “But something can be done about it: For example, we “OEMs need to achieve optimal system for exhaust gas can tell our customers in which engine map areas there end-user value when selecting are enough free resources for regeneration of the EGR technologies” 20 components. In this way, we can remove ten percent of special tasks recirculation the sooting. Of course, it is also possible to get to the Innovative truck infotainment 22 root of the problem and avoid particularly critical map areas by using a smart calibration.” E-test bench to go 23
Entire OEM fleets at a glance Test management à la carte 25 orking machines are often only produced in and by using several packs, the given installation space xhaust gas recirculation (EGR) is an effective and small quantities; other commercial vehicles are is always optimally utilized. The Battery Management proven way of reducing nitrogen oxide emis- IAV is already using its findings in customer projects, Putting a stop to hackers 26 Wto be retrofitted with an electric drive during System (BMS) developed by IAV is designed to enable sions from diesel engines. However, it can lead for example, for the optimum geometric and thermal E Ready for all powertrains their service life. In both cases, a modular battery and different battery topologies: Up to four batteries can be to sooting of the EGR cooler and the EGR bypass valve. design of EGR components and systems. “We also look & energy types 29 Battery Management System is required which can be optionally connected in parallel or serially in the vehicle. IAV examines and simulates this process in detail – en- at entire OEM fleets and point out to them vehicles with flexibly adapted to the respective requirements and In addition, each battery can in turn be subdivided in- abling the experts to support their customers in making particularly critical drive concepts where there is still Digitized from scratch to delivery 30 integrated without much effort. IAV has a technically ternally into four partial batteries with up to 112 battery optimum use of EGR. potential to be leveraged through the application,” says mature solution that allows, among other things, a wide cells each, thus enabling a system output of up to four Mehnert. “In this way, they can make optimum use of New momentum for hydrogen range of voltage and power levels. megawatts to be realized. exhaust gas recirculation to make their diesel engines mobility 32 Diesel engines must comply with strict nitrogen oxide even more environmentally friendly.” Fourth generation Battery Management limits in all operating conditions. Exhaust gas recircu- “Similar mindset in Gifhorn “In the case of relatively large volumes such as trucks, System available lation is a suitable alternative or supplement to SCR Contact: and in Karlsruhe” 35 OEMs cover the demand for batteries and battery man- systems because it reduces the temperature in the [email protected] agement systems themselves,” explains Dr Thomas Henke, In addition to a flexible battery topology, IAVʼs battery man- combustion chamber. In addition to slightly higher [email protected] IAV Teslin: Maximum efficiency Head of Battery System Development at IAV. “However, agement system also allows the use of interchangeable fuel consumption, however, it has another undesirable for testing and appraisal 36 such products are not available for working and special batteries: If the energy storage units are empty, they can side effect: It leads to sooting of the EGR cooler and machines. We have therefore developed a solution that be quickly and easily replaced with charged batteries at the EGR bypass valve as well as to disturbances of the Looking ahead: cost break-even allows a battery system to be integrated into a commercial a depot, for example. The BMS is also technically mature: thermodynamic processes in the engine. for new technologies 37 vehicle without much effort – either in new vehicles or as “We have been working on electrified drive trains for a retrofit solution.” around 15 years, so our Battery Management System is “The biggest problem is the long-chain hydrocarbons, Mature battery system for now in its fourth generation,” reports Henke. “In the future, which, especially at low load, encrust and stick to the special tasks 40 The battery cell modules come from established manu- we want to expand it to include additional functions, for EGR cooler,” explains Ronny Mehnert, Manager Energy facturers and are available in various voltage and power example, the determination of battery aging using artificial & Thermal Management Powertrain at IAV. “This leads Minimizing sooting of exhaust classes. They can be used to cover a wide range of per- intelligence. The aim is also to minimize the ecological to a reduction in the cross section and interferes with gas recirculation 41 formance requirements – for example, in terms of energy footprint of the IAV solution. Together with cell manufac- the control system. In the end, the component can fail content, maximum output or rapid charging capability – turers and recycling companies, the aim is to optimize completely.” Soot in the exhaust gas also leads to stress “E-fuels would be ideal for us” 42 battery production in such a way that the recycling rate for the EGR components: It deposits on the walls and increases significantly. also reduces the cross sections, impairing the function A deeper look inside your vehicle 44 “We have therefore de- of the components and reducing their service life. “Our solution is already in use in the prototype of a light IAV products: the easy way into veloped a solution that commercial vehicle, and we are in talks with other custom- Combination of test and simulation new commercial vehicle mobility 46 ers,” Henke summarizes. “We can make it ready for series allows a battery system to production in a short time, and thus, close the existing IAV wants to defuse the problem and is therefore exam- One more thing… 48 be integrated into a com- gap in battery systems for working and special machines.” ining in detail the processes involved. Measurements of hydrocarbons and soot in the EGR tract serve as Let’s meet! 50 mercial vehicle without Contact: input for precise simulations of sooting. By combining [email protected] tests and simulations, experts can predict which areas much effort.” [email protected] are particularly at risk and how the sooting can be Our Mission 4 Market | Commercial Vehicles Commercial Vehicles | Market 42 43 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards At the moment, there are also question marks over robust- question is always: How can we increase the benefit of the a CO2-compliant fleet in 2030 10 ness. But it is also important within this context to create machine for the end customer? For example, by conveniently “E-fuels would the necessary infrastructure for the supply of hydrogen. planning the unavoidable downtime for service. We can also Virtual trucking with IAV 15 provide spare parts faster if we know the condition of an What other alternative fuels are interesting engine earlier. And, of course, we are constantly optimizing Trucks of the future 16 be ideal for us” in your view? diagnostics. These are the issues we are pushing forward with the help of digitalization at Liebherr. “Don’t be afraid of unusual solutions!” 19 From the point of view of a machine and drive train manu facturer, e-fuels would be ideal, because we would only have Digitalization is also interesting for devel- “OEMs need to achieve optimal Ulrich Weiß, Managing Director at to make minimal adjustments to our engines. The space opment – especially because of the many end-user value when selecting requirements of the tanks would also be comparable – product variants. How much are you already technologies” 20 Liebherr Machines Bulle, reports in an in contrast to hydrogen or even batteries. CNG and LNG exploiting this opportunity? interview about the special features are not interesting for us because they hardly reduce CO2. Innovative truck infotainment 22 Because of the high variance, we are in a very special of the off-highway sector, possible What does Liebherr Machines Bulle think situation and have to go our own way. There are some E-test bench to go 23 alternative fuels and the importance about the digitalization of its vehicles? machines of which we only sell a few dozen – if we were to develop and validate them in-house, we would first have to Test management à la carte 25 of digitalization for his company. Our colleagues from other divisions are already working build and test these machines ourselves. Of course, that Ulrich Weiß, Managing Director on it! We as engine manufacturers contribute to this by is not possible. This is why we have developed methods Putting a stop to hackers 26 at Liebherr Machines Bulle translating our core competences and knowledge into that allow us to draw conclusions about the entire field Ready for all powertrains useful KPIs for our customers. For us, the most important and cater for many applications with just a few variants & energy types 29 using artificial intelligence. Simulations are also very important for us. Digitized from scratch to delivery 30 What are the special challenges for off- Cities in particular are driving “green” “We have developed highway vehicles? solutions. Are battery-powered off-highway The business with off-highway vehicles New momentum for hydrogen vehicles an option? methods that allow us to is becoming increasingly global. How is mobility 32 Of course, the off-highway sector is extremely different draw conclusions about Liebherr adjusting to this? from the on-highway sector, mainly due to its great diversity. There are niches where it makes sense. For example, “Similar mindset in Gifhorn There are completely different machines with completely with relatively small excavators or wheel loaders. On Liebherr is already globally positioned. We have 48,049 and in Karlsruhe” 35 different load profiles – which the engine must cater for. cordoned-off company premises, machines can be the entire field and cater employees in over 140 companies on every continent. The number of variants is almost endless, which is very operated electrically via cables, for example in recycling for many applications with We usually enter into partnerships or joint ventures to IAV Teslin: Maximum efficiency difficult to control and secure. Robustness is another is- yards. At Liebherr, we have implemented two projects, strengthen our presence in certain industries. for testing and appraisal 36 sue: We have to deal with strong braking and acceleration among others: a drilling rig weighing 55 tonnes and a just a few variants using processes, and the use of the machines in undeveloped hybrid concrete mixer in which the truck is driven by a Contact: Looking ahead: cost break-even areas also generates heavy loads. Added to this are the diesel engine and the drum is electrically driven. This al- artificial intelligence.” liebherr.com for new technologies 37 demands on service life: Our machines are in use for ten lows the engine to be switched off at the unloading point years or more, and we must guarantee service for more and work can continue without exhaust fumes. E-mobility Mature battery system for than 20 years. Downtimes are also particularly critical, as naturally plays an important role in the off-highway sector, special tasks 40 breakdowns can result in high costs for our customers although it will probably not be the central solution. and possibly also for us. Minimizing sooting of exhaust Hydrogen is considered a promising alter- gas recirculation 41 Why is a Liebherr powertrain particularly native fuel. Is it suitable for off-highway suitable for these requirements? vehicles? “E-fuels would be ideal for us” 42
Because we have many years of experience with off- Hydrogen is one of the possible energy carriers of the A deeper look inside your vehicle 44 highway machines and develop everything from the outset future for us. Liebherr is working on hydrogen combustion to meet the requirements in this area – for example, our engines in its pre-development phase, which we are al- IAV products: the easy way into engines, where we always keep an eye on the subsequent ready testing on the test bench. Among other things, this new commercial vehicle mobility 46 applications, e.g., with things like special power take-offs. involves determining the best combustion processes and Of course, there are many competitors in the on-highway achievable power densities. This is important because One more thing… 48 sector who convert their engines for off-highway applica- we must integrate the new engines into our machines. tions – but this is only possible by making compromises. We are also investigating fuel cells – but here we see cer- Let’s meet! 50 We design our engines for off-highway applications right tain limits, for example, with power outputs of more than from the outset. 150 kilowatts, where the peripherals become very complex. Our Mission 4 Services | Commercial Vehicles Commercial Vehicles | Services 44 45 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards A deeper look “Remote Service Monitoring provides detailed informa- a CO2-compliant fleet in 2030 10 tion on this: How often were they used? Are they being operated at an unfavorable operating point? Is there a Virtual trucking with IAV 15 inside your vehicle leak in the compressed air system?” Normal products for fleet management do not have such a precise view Trucks of the future 16 of the vehicle’s ins and outs. In addition, they are usually not available at all for commercial vehicles with electric “Don’t be afraid of unusual solutions!” 19 drives in niche applications: OEMs cannot integrate their standard solutions here, so fleet operators are dependent “OEMs need to achieve optimal on third-party suppliers. end-user value when selecting technologies” 20 “The DiSA Remote Service Monitor provides most of the data when the powertrain and diagnostics come from IAV,” Innovative truck infotainment 22 explains Dr Alexander Roy, Senior Technical Consultant for Advanced Diagnostics & Digital Product Life Cycle at E-test bench to go 23 IAV. This is because in this case, the messages on the vehicleʼs internal communication buses are known down Test management à la carte 25 to the smallest detail, and all available information can IAV uses data collection and Putting a stop to hackers 26 be used for detailed analysis. In the event of a technical assessment for advanced tasks: problem, a service ticket is automatically generated in Ready for all powertrains the cloud and listed in the DiSA Remote Service Center. Find out more about the use & energy types 29 Depending on the application scenario, other information of Artificial Intelligence for can be recorded in addition to vehicle data – for example, prediction and condition-based Digitized from scratch to delivery 30 images from a video camera to prevent vandalism. maintenance in this video. New momentum for hydrogen The data can be evaluated on any cloud. There applications mobility 32 from IAV are responsible for receiving and securely storing Contact: [email protected] the data, for data analytics and predictive diagnostics as “Similar mindset in Gifhorn well as for the graphical visualization of conditions and and in Karlsruhe” 35 results. Even if the vehicle is temporarily not online, the ators to reduce their TCO and avoid breakdowns. High latest data can be viewed and evaluated in the cloud: It fleet availability is in turn important for the good image of IAV Teslin: Maximum efficiency requires no up-front investment in IT technology by the innovative systems and for the operatorʼs profit.” for testing and appraisal 36 fleet operator and can be used immediately worldwide. Seamless engineering right up to standard Looking ahead: cost break-even Frontend makes information easily accessible production support for new technologies 37 any of the newly emerging, smaller commercial increase vehicle availability or to be able to better specify vehicle fleets with battery electric or fuel cell the next generation of vehicles.” Access to the information is provided by the front end, The DiSA Remote Service Monitor is already in use in a Mature battery system for Mdrive systems do not offer remote access to which flexibly displays all results via a browser and can bus fleet in Berlin that has been electrified by the “Modular special tasks 40 vehicle data. IAVʼs DiSA Remote Service Monitor bridges With IAVʼs DiSA Remote Service Monitor, this gap can be be adapted to customersʼ design specifications. For E-Powertrain for Commercial Vehicles,” a retrofittable bat- this gap: The system can be easily retrofitted and supplies bridged quickly and cost-effectively. The solution consists example, the user can immediately see where a vehicle tery-electric drivetrain developed by IAV. Other potential Minimizing sooting of exhaust important data from the field – for optimized operation of a small, interconnected control unit that is installed in is currently located, whether it has a defect and how long customers are also showing interest. “Our service is de- gas recirculation 41 of existing fleets and the development of the next gen- the vehicle and can access the vehicle data as an IoT unit until the next inspection. Based on selected aggregated signed for regular operation and is not a development tool,” eration of environmentally friendly drives. (Internet of Things). The data is then transferred to the measurement data, predictive diagnostics can also be Schröder emphasizes. “It shows that IAV offers seamless “E-fuels would be ideal for us” 42 cloud via mobile communications (3G, LTE or 5G) where performed – either on a single vehicle or on an entire fleet engineering over the entire product life cycle – from the it is processed. The user can view all information on a of vehicles. This means that any service or maintenance design right up to support for real world operation and A deeper look inside your vehicle 44 Fleet managers in logistics as well as bus operators today PC, a tablet or smartphone. requirements that arise can usually be diagnosed easily down to the very last detail.” The Remote Service Monitor use the interconnectivity of their vehicles to obtain infor- in advance. can also be used to monitor warranty claims and check the IAV products: the easy way into mation on the position and route or the “state of health” Direct access to internal vehicle quality of suppliers. Especially with innovative powertrains new commercial vehicle mobility 46 of their vehicles. “Fleets of battery-powered vehicles or communication With the help of the DiSA Remote Service Monitor, drivers and the steep learning curve of new technologies, such vehicles with fuel cell drives, on the other hand, are usually can also compare energy-conscious driving styles or information is crucial for further progress. One more thing… 48 not yet interconnected,” reports Florian Brandau, Director Whatʼs special about the IAV solution: It can “look deep determine the battery electric consumption depending of Business Development for Commercial Vehicle E-Mo- inside” the vehicle. “For example, you can immediately see on the outside temperature. “Our solution also provides Contact: Let’s meet! 50 bility at IAV. “But it is precisely with these new drivetrains whether the electric drivetrain or the brakes are working information on whether the battery is correctly dimen- [email protected] that information from the field is particularly important, perfectly,” explains Dr Thorsten Schröder, Head of the sioned – an important indication for later optimization,” [email protected] for example, to learn more about their practical use, to Diagnostic Software & IT Solutions department at IAV. says Brandau. “All these evaluations enable fleet oper- [email protected] Our Mission 4 Products | Commercial Vehicles Commercial Vehicles | Products 46 47 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
like Hamburg. The HEAT vehicle will be tested the areas of body, electrics/electronics, chas- Technology paths towards under real conditions in public spaces and sis, drive, and autonomous driving – from the a CO2-compliant fleet in 2030 10 will initially be able to drive autonomously at definition of the shuttle properties and the speeds of up to 25 km/h. system and functional requirements through Virtual trucking with IAV 15 the development of mechanics, hardware, The test track in Hamburgʼs HafenCity is software and application to validation at Trucks of the future 16 1.8 kilometers long. During its journey, the system and overall vehicle level. Within the minibus will stop at five stops, three of which consortium, IAV also makes a decisive con- “Don’t be afraid of unusual solutions!” 19 IAV products: are regular HVV stops and two of which are tribution to the specification, integration, new stops set up for HEAT. “In order to be commissioning and validation of the overall “OEMs need to achieve optimal able to drive safely on the test track, the system, consisting of shuttle, infrastructure, end-user value when selecting the easy way into shuttle uses its onboard sensors and com- control center, and high-resolution map. technologies” 20 municates continuously with the additional sensors installed along the track, the light Although HEAT is designed for autonomous Innovative truck infotainment 22 signal systems and with the central control passenger transport, it can also be adapted new commercial center HOCHBAHN,” reports Veit Lemke, to other deployment scenarios. For example, E-test bench to go 23 Executive Project Manager Project Man- the technology is also suitable for driverless agement Office. “From the fourth quarter of delivery or logistics vehicles. “HEAT offers a Test management à la carte 25 vehicle mobility 2020, HEAT will be able to carry passengers.” platform to bring autonomous driving into the commercial vehicle sector, where there are Putting a stop to hackers 26 By integrating the shuttle into the overall numerous useful application examples with Ready for all powertrains n addition to engineering services, IAV a kit of parts covers many different application In addition, IAV handles the entire engineering, system, it is possible to increase the per- a clear business case,” summarizes Lemke. & energy types 29 also offers product solutions that enable scenarios and adapts to the specific needs of for example, for communication and func- formance of the shuttle in a complex and The HEAT project also provides important OEMs and end customers to electrify each user. The kit of components suitable for tional safety of the overall system. Here, IAV “We ensure that the highly dynamic traffic environment and to insights into the mobile value chain. IAV is I Digitized from scratch to delivery 30 and automate commercial vehicles in a series production can be easily tailored to suit customers benefit from the interdisciplinary implement functions such as an automated thus acquiring the competence not only to clean-cut and tailored way. The “Modular different installation spaces and performance cooperation between the various trades and vehicle can be used intersection crossing. “HEAT has several develop autonomous shuttles but also to New momentum for hydrogen E-Powertrain for Commercial Vehicles” and requirements. This makes it an economical the consideration of all requirements through- technological unique selling propositions operate them if necessary. mobility 32 the autonomous shuttle HEAT are examples solution even for small quantities – also for out the entire product life cycle. However, the to optimum effect in in the area of autonomous travel, especially of e-mobility and autonomous driving at the retrofitting existing vehicles. expertsʼ task does not end with the delivery terms of payload or in combination with object data from the Contact: “Similar mindset in Gifhorn highest level – and are also interesting for of the parts kits for the electric powertrain: infrastructure,” says Lemke. [email protected] and in Karlsruhe” 35 small production runs. “At the start of every project, we clarify with IAV also offers its customers professional number of passen- [email protected] our customers which requirements the drive support in customer operations. This also In the HEAT project, IAV is responsible for [email protected] IAV Teslin: Maximum efficiency system must meet in practice,” reports Jens ensures that the Total Cost of Ownership gers, for example.” developing the entire vehicle. This includes for testing and appraisal 36 From consulting and engineering to the Granel, Head of Business Development Ve- (TCO) and service costs of vehicles equipped production-ready product: IAVʼs portfolio hicle Dynamics at IAV. “We then configure with IAVʼs electric drive unit are very favorable. Looking ahead: cost break-even covers all development steps in the com- the system in such a way that the user ben- for new technologies 37 mercial vehicle sector. “This enables us to efits from it to the maximum – we take into IAVʼs modular electric kit for commercial offer our customers precisely the service account, among other things, the available vehicles has recently been put into practical For more information Mature battery system for they need,” says Utz-Jens Beister, Head of installation space as well as the required drive use in sightseeing buses. Further applica- special tasks 40 Product Solutions at IAV. “OEMs and end power and range. In this way, we ensure that tions in municipal and delivery vehicles – watch our video on customers as well as bus or logistics com- the vehicle can be used to optimum effect in both as original equipment and as a retrofit YouTube! Minimizing sooting of exhaust panies can thus electrify their vehicles or terms of payload or number of passengers, solution – are planned. gas recirculation 41 implement autonomous driving functions for example.” without any major development effort. In HEAT: universal platform for “E-fuels would be ideal for us” 42 addition, future engineering projects will When it comes to the electrification of com- autonomous vehicles also benefit from our product expertise.” mercial vehicles using the modular electric A deeper look inside your vehicle 44 kit, IAV assumes the role of system inte- As part of the HEAT (Hamburg Electric Au- The Modular E-Powertrain for grator and parts supplier. This includes the tonomous Transportation) research and de- IAV products: the easy way into Commercial Vehicles: retrofittable specification, approval and procurement velopment project, IAV is breaking completely new commercial vehicle mobility 46 e-drive for different scenarios of all drive components (including electric new ground with partners such as the German machine, battery, power electronics, and Aerospace Center, Hamburger Hochbahn AG, One more thing… 48 For suppliers and municipal companies as control units) by the respective experts at the Hamburg Ministry of Economics, Transport well as bus and fleet operators, IAV’s Modular IAV. In doing so, IAV relies on cooperation and Innovation, Siemens and IKEM (Institute Let’s meet! 50 E-Powertrain for Commercial Vehicles is the with proven industrial partners to ensure both for Climate Protection, Energy and Mobility): easy way to enter the electric age. As a cus- state-of-the-art technology and optimum The aim is to integrate an autonomous shuttle tomizable solution, the powertrain offered as conditions for the components. bus into the regular road traffic of a metropolis Our Mission 4 Commercial Vehicles Commercial Vehicles 48 49 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards One more thing… a CO2-compliant fleet in 2030 10
Virtual trucking with IAV 15 selves and occupy new market segments. In the foreseeable market shakeout, the Trucks of the future 16 Fuel cells fail due to a lack winners will be those who decide early on “Don’t be afraid of unusual solutions!” 19 of infrastructure! a clear sustainability course and implement it consistently. “OEMs need to achieve optimal George: And 30 percent by 2030 is only the end-user value when selecting George: I don’t think so. It is true that there beginning. In the long term, I expect a shift technologies” 20 are only about 85 hydrogen filling stations in to a well-to-wheel approach and lifecycle Germany today. However, both the German assessments. Don’t forget: Our goal remains Innovative truck infotainment 22 government and the EU want to invest in to achieve CO2 neutrality by 2050. Innovative the transport and storage of hydrogen in products and complete solutions will then E-test bench to go 23 the future. So, over the medium term, there be even more important. Many jobs will be will be more filling stations for the energy created here in future-proof fields. In short: Test management à la carte 25 carrier. Intelligent sector coupling is likely to The CO2 legislation is an important impulse play an important role here: Local hydrogen to demonstrate the innovative ability of the Putting a stop to hackers 26 production from surplus green electricity is German and European commercial vehicle Ready for all powertrains ideal for supplying filling stations. industry at a very high level. & energy types 29 Brandau: And there is a lot happening on Digitized from scratch to delivery 30 the demand side too: Fuel cell drives and hydrogen-powered combustion engines The technological change New momentum for hydrogen could go into series production in the next will be expensive for trans- mobility 32 few years and help the energy carrier make Nobody wants to become a port companies, public a breakthrough – initially through large fleets truck driver anymore… transport and for consum- “Similar mindset in Gifhorn and hubs, which will entail the construction ers! and in Karlsruhe” 35 of filling stations. In terms of price, hydrogen remains unbeatable anyway: Due to the IAV Teslin: Maximum efficiency great demand in industry and the associ- George: This doesn’t have to be the case. At for testing and appraisal 36 ated production capacities, it will continue Brandau: That is not true. Of course, the the moment, the job is certainly very strenu- to decline and make the alternative fuel purchase price of battery electric and fuel cell ous and comparatively low paid, but this may Looking ahead: cost break-even even more attractive. That is why I expect vehicles is currently still significantly higher change in the future. Autonomous driving for new technologies 37 a sufficient network in five years, initially in than for diesel commercial vehicles. That is reduces stress because the vehicles can cities and along the freeways. why the governmant must help with incen- drive themselves even for large parts of the Mature battery system for tives to accelerate technological change. journey – but at the same time it will not com- special tasks 40 But battery electric vehicles will break even pletely replace human drivers because there in terms of Total Cost of Ownership (TCO) by are still situations that cannot be automated. Minimizing sooting of exhaust 2024. In the case of fuel cell vehicles, I expect The new CO2 legislation is gas recirculation 41 this to be achieved by the end of the decade. Töpfer: Drivers will also take on new tasks. much too strict. This endan- The lower operating costs, such as fuel and They will take care of distribution, dispatch- gers the German and Euro- “E-fuels would be ideal for us” 42 maintenance, will also contribute to this. ing and fleet management in an exciting pean commercial vehicle interactive environment, which should make industry! A deeper look inside your vehicle 44 George: In addition, the first business mod- the job much more interesting. I think that els from, e.g., Hyundai Trucks are already in the future, drivers will become transport IAV products: the easy way into in place today that enable cost-effective managers. Coronavirus has also shown that new commercial vehicle mobility 46 Töpfer: You’re not thinking outside the box. operation. Hyundai is exempt from tolls in “working remotely” is possible in many areas. Of course, the upcoming CO2 limits are a big Switzerland, and other new players offer So why not also in an autonomous truck? One more thing… 48 challenge – after all, emissions are supposed Transportation-as-a-Service, which pays to fall by 15 percent by 2025 compared to off for both users and providers. So the Contact: Let’s meet! 50 2019 and by another 15 percent by 2030. technological change is already in full swing, [email protected] Florian Brandau, Director Tom George, Director Tobias Töpfer, Manager However, this offers innovative companies a and I don’t expect it to be more expensive [email protected] Business Development Business Development Commercial Vehicle historic opportunity: They can realign them- for consumers than it is today. [email protected] Commercial Vehicle E-Mobility Commercial Vehicles Simulation & Validation Our Mission 4 Contact | Commercial Vehicles 50 “Trucks are leading technology” 6
“In these disruptive times, what we need above all are pioneers” 8
Technology paths towards a CO2-compliant fleet in 2030 10
Virtual trucking with IAV 15 Let’s meet! Trucks of the future 16 “Don’t be afraid of unusual solutions!” 19
“OEMs need to achieve optimal You will find the latest updates regarding upcoming end-user value when selecting dates for your diary on our website iav.com/events. technologies” 20
Innovative truck infotainment 22
E-test bench to go 23 Follow us on Social Media! Test management à la carte 25
Putting a stop to hackers 26
Ready for all powertrains & energy types 29
Digitized from scratch to delivery 30
New momentum for hydrogen mobility 32
“Similar mindset in Gifhorn and in Karlsruhe” 35
IAV Teslin: Maximum efficiency for testing and appraisal 36
Looking ahead: cost break-even for new technologies 37
Mature battery system for special tasks 40
Minimizing sooting of exhaust Imprint gas recirculation 41
IAV GmbH “E-fuels would be ideal for us” 42 Carnotstraße 1 10587 Berlin A deeper look inside your vehicle 44 GERMANY Tel.: +49 30 3997-80 Fax: +49 30 3997-89790 IAV products: the easy way into [email protected] new commercial vehicle mobility 46 www.iav.com
Picture credits One more thing… 48 Christian Bierwagen Sonja Hornung iStockphoto Let’s meet! 50 Max Lautenschläger Marc-Oliver Schulz Manuela Steinemann www.iav.com