Proceedings Ein stetig steigender Fundus an Informationen ist heute notwendig, um die immer komplexer werdende Technik heutiger Kraftfahrzeuge zu verstehen. Funktionen, Arbeitsweise, Komponenten und Systeme entwickeln sich rasant. In immer schnel- leren Zyklen verbreitet sich aktuelles Wissen gerade in Konferenzen, Tagungen und Symposien in die Fachwelt. Den raschen Zugriff auf diese Informationen bie- tet diese Reihe Proceedings, die sich zur Aufgabe gestellt hat, das zum Verständnis topaktueller Technik rund um das Automobil erforderliche spezielle Wissen in der Systematik aus Konferenzen und Tagungen zusammen zu stellen und als Buch in Springer.com wie auch elektronisch in SpringerLink und Springer für Professio- nals bereit zu stellen. Die Reihe wendet sich an Fahrzeug- und Motoreningenieure sowie Studieren- de, die aktuelles Fachwissen im Zusammenhang mit Fragestellungen ihres Ar- beitsfeldes suchen. Professoren und Dozenten an Universitäten und Hochschulen mit Schwerpunkt Kraftfahrzeug- und Motorentechnik finden hier die Zusammen- stellung von Veranstaltungen, die sie selber nicht besuchen konnten. Gutachtern, Forschern und Entwicklungsingenieuren in der Automobil- und Zulieferindustrie sowie Dienstleistern können die Proceedings wertvolle Antworten auf topaktuelle Fragen geben. Michael Bargende Hans-Christian Reuss Jochen Wiedemann Herausgeber
16. Internationales Stuttgarter Symposium
Automobil- und Motorentechnik
Band 1 Herausgeber Prof. Dr.-Ing. Michael Bargende Prof. Dr.-Ing. Hans-Christian Reuss Prof. Dr.-Ing. Jochen Wiedemann Forschungsinstitut für Kraftfahrwesen und Fahrzeugmotoren Stuttgart -FKFS- Stuttgart, Deutschland
ISSN 2198-7432 ISSN 2198-7440 (electronic) Proceedings ISBN 978-3-658-13254-5 ISBN 978-3-658-13255-2 (eBook) DOI 10.1007/978-3-658-13255-2
Die Deutsche Nationalbibliothek verzeichnet diese Publikation in der Deutschen Natio- nalbibliografie; detaillierte bibliografische Daten sind im Internet über http://dnb.d-nb.de abrufbar.
Springer Vieweg © Springer Fachmedien Wiesbaden 2016 Das Werk einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung, die nicht ausdrücklich vom Urheberrechtsgesetz zugelassen ist, bedarf der vorherigen Zu- stimmung des Verlags. Das gilt insbesondere für Vervielfältigungen, Bearbeitungen, Über- setzungen, Mikroverfilmungen und die Einspeicherung und Verarbeitung in elektronischen Systemen. Die Wiedergabe von Gebrauchsnamen, Handelsnamen, Warenbezeichnungen usw. in diesem Werk berechtigt auch ohne besondere Kennzeichnung nicht zu der Annahme, dass solche Namen im Sinne der Warenzeichen- und Markenschutz-Gesetzgebung als frei zu betrachten wären und daher von jedermann benutzt werden dürften. Der Verlag, die Autoren und die Herausgeber gehen davon aus, dass die Angaben und Infor- mationen in diesem Werk zum Zeitpunkt der Veröffentlichung vollständig und korrekt sind. Weder der Verlag noch die Autoren oder die Herausgeber übernehmen, ausdrücklich oder implizit, Gewähr für den Inhalt des Werkes, etwaige Fehler oder Äußerungen.
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Springer Vieweg ist Teil von Springer Nature Die eingetragene Gesellschaft ist Springer Fachmedien Wiesbaden GmbH WELCOMEINSTUTTGART What is it that has elevated the Stuttgart International Symposium – hosted by the Research Institute of Automotive Engineering and Vehicle Engines Stuttgart (FKFS) – to a real can’t-miss event for years now? Is it the broad range of current and important topics that line the agenda? The expert presentations guiding the way for the future? Or is it because the event takes place in Stuttgart, the heart of the automotive state, Baden-Wuerttemberg, and is attended by prominent participants from both the business and research sectors? The answer is: All of the above!
th For the 16 installment of the Conference, I am glad to be assuming patronage for the event and welcome all the participants and speakers. This year’s focus topic, “Global products versus non-global requirements”, addresses the challenges facing both the economy in general and the automobile industry in par- ticular: What are the consequences resulting from the contrast between global sales and adaptation to country-specific norms? How can these be overcome? The Transatlantic Trade and Investment Partnership (TTIP) that is currently being ne- gotiated between political decision makers in the US and the EU is intended to resolve exactly these issues, such as this conflict of interests in the automotive sector. One of the key intentions of this agreement is to standardize the respective national regula- tions and requirements for products sold globally on both sides of the Atlantic – such as: side mirrors, blinkers and crash tests – and introduce a unified, high standard of safety and security. This will lead to the removal of expensive duplicate standards, which, despite nearly identical safety norms, have up to now required redundant develop- ment and certification processes. Consumers ultimately stand to benefit once this burden is lifted. Such a development will likewise be significant for the automotive industry in Baden-Wuerttemberg – and for the associated machinery, metal and electronic in- dustries – in that Germany, as an export country, will be able to set the standards ac- cording to which our worldwide trading partners will have to adapt – not the other way around! Our high level of precision, reliability, quality and safety together present a strong sales argument. As such, these high standards should not be weakened in the course of the TTIP negotiations. The Government of Baden-Wuerttemberg fundamen- tally supports the TTIP agreement, but also insists that the high safety standards asso- ciated with products “made in Baden-Wuerttemberg” are not lowered in any way. I would like to thank all those who have been involved in organizing and executing this event. I hope that all the attendees will benefit from the exciting discussions, interesting presentations and also gain new ideas for their own work.
Winfried Kretschmann Prime Minister of the State of Baden-Wuerttemberg
V
AWARMWELCOME
Demands on the automotive industry in terms of research and development are con- stantly in flux. Producers and suppliers are forced to create global solutions while also considering individual customer needs as well as the legislative requirements in each market. Even emissions regulations are anything but unified globally. Starting in Sep- tember 2017, Europe plans to implement a measurement termed “real-driving emis- sions” (RDE). Evaluating pollutant emissions will be done on the street rather than at a testing station, with far-reaching consequences for engine development. Many re- gions around the globe are, at the same time, calling for localized zones with emis- sions-free traffic. This all overlaps with the ongoing process of reducing CO2 limits for vehicle fleets, with all world regions having defined various steps to achieve re- ductions in this area. This is topped by rising demands in terms of the comfort and emotionality of cars. How will the automotive industry respond to the growing con- flict between increasing globalization and maximized global product marketing, on the one hand, and diverse, particular regional requirements for vehicles, on the other? What are the technical impacts of this? Industry and research experts will report on and discuss these issues and many more at the 16th Stuttgart International Symposium for “Automotive and Engine Technology” on 15 ---- 16 March 2016. In six parallel sessions with over one hundred presentations, leading experts will ad- dress the current state of technological development, their most recent research find- ings, and concepts for the future. The program spans the entire process of vehicle cre- ation, from research and development through to production. This year, we have also been able to invite excellent keynote speakers and participants for the subsequent po- dium discussion. This will be supplemented by numerous opportunities for exchang- ing ideas, be it in relation to technical discussions, at the accompanying trade exhibi- tion, or in the social context of breaks and the evening event. We look forward to seeing you in Stuttgart, the birthplace of the automobile!
Prof. Dr.-Ing. Michael Bargende Prof. Dr.-Ing. Hans-Christian Reuss Prof. Dr.-Ing. Jochen Wiedemann
VI INDEX – Volume 1
SECTION 1
TESTING FOR WLTP Chairperson: Prof. Dr. Jochen Wiedemann
WLTP – On the increased importance of aerodynamics and 1 impact on development procedures Thomas Schütz, BMW AG
Test bench technologies for improving WLTP 19 measurement results Zdenek Mestenhauser, V. Senft, MTS Systems Corporation
On- and off-cycle energy efficiency technologies 21 of a global supplier Ulrich Schulmeister, A. Lang, M. Johannaber, D. Rieker, Robert Bosch GmbH; F. Götz, M. Rauscher, F. Schürg, Bosch Engineering GmbH
EXHAUST GAS AFTERTREATMENT Chairperson: Prof. Dr. Georg Wachtmeister
The novel SCR and PNA exhaust gas after treatment systems 31 for diesel passenger cars Nebojsa Milovanovic, S. Hamalian, MAHLE Powertrain; M. Lewander, K. Larsen, Haldor Topsoe
Experimental investigation of heat transfer characteristics 49 of UWS spray impingement in diesel SCR Yujun Liao, P. Dimopoulos Eggenschwiler, Empa – Swiss Federal Laboratories for Materials Science and Technology
From laboratory to road – Real Driving Emissions 59 Helge Schmidt, J. Badur, TÜV NORD Mobilität GmbH & Co. KG
VII INDEX – Volume 1
BATTERY Chairperson: Prof. Dr. Dr. Gerhard Hettich
Li-ion batteries for automotive applications – Quo vadis? 69 Holger Fink, Robert Bosch Battery Systems GmbH and Lithium Energy and Power GmbH
How long will an electric car’s propulsion battery last? 83 Detlef Hoffmann, SGS Germany GmbH
Increased efficiency in the calibration process of automotive 101 Li-ion battery systems Lukas Behr, U. Zimmermann, S. Trinkert, Robert Bosch Battery Systems GmbH; T. Kruse, ETAS GmbH; S. Rees, F. Bröckel, Robert Bosch GmbH; J. Xie, EWS, Universität Ulm
PHD COURSE Chairperson: Prof. Dr. Oliver Zirn
HEV concept with lean operated SI-engine optimized for 117 fuel consumption and emissions Jing Cheng, Universität Stuttgart; M. Bargende, FKFS/IVK, Universität Stuttgart; F. Altenschmidt, C. Ley, Daimler AG
Software tool to create a hybrid operation strategy 131 for simulations Dan Keilhoff, Universität Stuttgart; H.-C. Reuss, FKFS/IVK, Universität Stuttgart
Iterative refinement of the discretization of the Dynamic 145 Programming State Grid Andreas Haag, Promotionskolleg Hybrid; P. Antony, Daimler AG; F. Panik, Hochschule Esslingen; M. Bargende, FKFS/IVK, Universität Stuttgart
VIII INDEX – Volume 1
FVV PROJECTS Chairperson: Dr. Karl Kollmann
Fast predictive burn rate model for Jasoline-HCCI 155 Mahir Tim Keskin, IVK, Universität Stuttgart, M. Grill, FKFS; M. Bargende, FKFS/IVK, Universität Stuttgart
Transient simulation of nitrogen oxide emissions on 171 diesel engines Benjamin Kaal, M. Grill, FKFS; M. Bargende, FKFS/IVK, Universität Stuttgart
Renewables in transport 2050 – Empowering a 185 sustainable mobility future with zero emission fuels Patrick R. Schmidt, W. Zittel, W. Weindorf, T. Raksha, LBST – Ludwig-Bölkow-Systemtechnik GmbH; D. Goericke, FVV e.V.
LIGHTWEIGHT CONSTRUCTION II Chairperson: Dr. Marco Schneider
Quality management of CFRP-components in the 201 automotive production Manuel Schuster, M. Soutschek, A. Hansmersmann, Fraunhofer IPA
High volume production of lightweight automotive structures 213 Clemens Buschhoff, C. Brecher, M. Emonts, Fraunhofer IPT
Thermoplastic composites for high volume production 227 Stefan Epple, C. Bonten, IKT, Universität Stuttgart
IX INDEX – Volume 1
SECTION 2
RDE I Chairperson: Prof. Dr. Michael Bargende
Mercedes-Benz diesel technology OM654 near-engine-mounted 239 SCR system for WLTP and RDE Tillmann Braun, P. Lückert, F. Duvinage, A. Mackensen, Daimler AG
The gasoline engine and RDE challenges and prospects 257 Günter Fraidl, P. Kapus, K. Vidmar, AVL LIST GMBH
Solutions to fulfill “Real Driving Emission (RDE)” with 285 diesel passenger cars Dirk Naber, A. Kufferath, M. Krüger, S. Scherer, H. Schumacher, M. Strobel, Robert Bosch GmbH
VEHICLE TECHNOLOGY Chairperson: Prof. Dr. Thomas Maier
A multiscale approach to virtually render fluid dynamics 287 on overall vehicle level Frank Hermsdorf, C. Jahn, G. Prokop, TU Dresden
Investigation of visibility properties through wetted glass 301 planes on vehicles Thomas Landwehr, IVK, Universität Stuttgart, T. Kuthada, FKFS; N. Widdecke, J. Wiedemann, IVK/FKFS, Universität Stuttgart
The new Porsche 911 Carrera – Evolution in aerodynamics, 315 thermal management and heat protection Matthias Klingbeil, J. Weissert, M. Yilmaz, Dr. Ing. h.c. F. Porsche AG
X INDEX – Volume 1
ELECTRIC POWERTRAIN Chairperson: Prof. Dr. Nejila Parspour
Holistic approach for the design of electrical powertrains 331 for electric and plug-in-hybrid vehicles applying the methodology Multi-Objective Optimization Adam Babik, T. Reuschlé, A. Schönknecht, Robert Bosch GmbH
Electric drivetrain modular layout based on range 349 specifications Markus Orner, T. Riemer, FKFS; H.-C.Reuss, FKFS/IVK, Universität Stuttgart
Combined power train and thermal management 367 optimization using an extended dynamic programming Mike Liebers, R. Kloß, B. Bäker TU Dresden
Analysis of the effects of high coil temperatures on 383 performance and drivability of electric sports cars Tobias Engelhardt, A. Heitmann, S. Oechslen, Dr. Ing. h.c. F. Porsche AG; H.-C. Reuss, FKFS/IVK, Universität Stuttgart
TIRES Chairperson: Prof. Dr. Thomas Vietor
Experimental validation of the Maxwell model for 401 description of transient tyre force Andreas Hackl, W. Hirschberg, C. Lex, TU Graz; G. Rill, OTH Regensburg
Measuring a reference friction potential by anti-lock 419 braking tests Thorsten Lajewski, J.Rauh, Daimler AG; S. Müller, TU Berlin
Parametrical approach for modeling of tire forces and torques in TMeasy 5 435 Ronnie Dessort, C. Chucholowski, TESIS DYNAware GmbH; G. Rill, OTH Regensburg
XI INDEX – Volume 1
SOFTWARE AND DEVELOPMENT Chairperson: Prof. Dr. Tobias Flämig-Vetter
Software-in-the-Loop at the junction of software 451 development and drivability calibration René Linssen, F. Uphaus, Daimler AG; J. Mauss, QTronic
Continuous delivery for simulation-model development 467 Marius Feilhauer, J. Häring, J. Buchner, ETAS GmbH
Generic development of software components and reuse 479 for projects and variants Walter Nagler, ZF Friedrichshafen AG
Agile processes in automotive industry – Efficiency and 489 quality in software development Axel Schloßer, J. Schnitzler, T. Sentis, J. Richenhagen, FEV GmbH
ARENA2036 Chairperson: Peter Froeschle
ARENA2036 – DigitPro: Development of a virtual 505 process chain Peter Middendorf, D. Michaelis, P. Böhler, J. Dittmann, F. Heieck, IFB, Universität Stuttgart
Highly versatile plug&produce assembly systems 517 Stefan Junker, M. Vorderer, Robert Bosch GmbH
Digital reality – A revolution for planning and scheduling 535 of the smart factory Bernd-Dietmar Becker, D. Wohlfeld, FARO
Linked logistics concepts for future automobile manufacturing 537 using innovative equipment Karl-Heinz Wehking, J. Popp, IFT, Universität Stuttgart
XII INDEX – Volume 1
SECTION 3
RDE II Chairperson: Prof. Dr. Peter Eilts
Analytical challenge on Real Driving Emission 547 Hiroshi Nakamura, HORIBA Ltd.
Introducing a method to evaluate RDE demands 549 at the engine testbench Jan Gerstenberg, H. Hartlief, S. Tafel, Bosch Engineering GmbH
Model supported calibration process for future 565 RDE requirements Dirk Neumann, M. Steinbach, T. Kutzner, A. Lehmann, V. Kassem, M. Dreiser, IAV GmbH
VEHICLE CONCEPTS Chairperson: Prof. Dr. Lutz Eckstein
Methodological development from vehicle concept to modular 581 body structure for the DLR NGC-Urban Modular Vehicle Marco Münster, M. Schäffer, R. Sturm, H. E. Friedrich, DLR Institut für Fahrzeugkonzepte
Quantification concept for vehicle packaging 597 Arthur Frick, R. Müller, T. Blauß, Daimler AG; D. Schramm, Universität Duisburg-Essen
Analysis of hydraulic brake systems with regard to 607 the requirements for future vehicle concepts Christian Riese, Robert Bosch GmbH; F. Gauterin, Institut für Fahrzeugsystemtechnik (FAST) KIT
Formula Student – A successful part of engineering education 619 Helena Ortwein, S. Heußner, Rennteam Uni Stuttgart e.V.
XIII INDEX – Volume 1
ELECTRIC VEHICLES Chairperson: Prof. Karl-Ernst Noreikat
Electromobility in daily life – Are you still exploring 629 or riding already? Matthias Vogt, bridgingIT GmbH
System-integrated data acquisition in validation and 643 operation of electric vehicles Katharina Bause, F. Munker, N. Reiß, M. Behrendt, A. Albers, IPEK, Karlsruher Institut für Technologie (KIT); A. Rupalla, RA Consulting GmbH
Optimized operating strategies for electrified taxis 659 by means of condition-based load collectives Raphael Pfeil, M. Grimm, FKFS; H.-C. Reuss, FKFS/IVK, Universität Stuttgart
Vehicle simulation of an electric street sweeper for substitution analysis 673 Rene Budich, M. Hübner, HTW Dresden
ENGINE PROCESS I Chairperson: Prof. em. Dr. Günter Hohenberg
Reliability-oriented simulation in the engine development process 691 Stefan Jetter, F.-O. Müller, R. Weller, M. Zöllner, Daimler AG; B. Bertsche, IMA, Universität Stuttgart
Variable valve timing of intake valves of a heavy-duty Diesel 705 engine as a way to improve fuel consumption Simon Schneider, S. Naujoks, MAHLE International GmbH
New product aimed to optimize air intake system for low end torque enhancement 721 Vincent Raimbault, J. Migaud, MANN+HUMMEL France SAS; D. Chalet, Q. Montaigne, A. Bouedec, École Centrale de Nantes, LHEEA Lab. (ECN/CNRS); H. Buhl, H. Fuchs, MANN+HUMMEL GmbH
Real-time simulation of the effects of catalyst on automotive engines performance 737 Agostino Gambarotta, M. Crialesi Esposito, University of Parma; P. Dimopoulos Eggenschwiler, F. Lucci, Empa – Swiss Federal Laboratories for Materials Science and Technology
XIV INDEX – Volume 1
STEERING Chairperson: Prof. Dr. Clemens Gühmann
A PID and state space approach for the position control 755 of an electric power steering Vivan Govender, G. Khazaridi, T. Weiskircher, D. Keppler, Daimler AG; S. Müller, TU Berlin
Identification and evaluation of the real temperature loading 771 of steering electronics Ulrike Weinrich, G. Baumann, FKFS; H.-C. Reuss, FKFS/IVK, Universität Stuttgart; S. Walz, Robert Bosch Automotive Steering GmbH
Fully automatic and haptic test of electric power steering 787 in a virtual environment Jörg Paschedag, M. Scherer, ITK Engineering AG
ERGONOMICS IN AUTOMOTIVE PRODUCTION Chairperson: Urban Daub
Ergonomical sequencing with state of the art tube lifters 797 Tilmann Hilbert, J. Schmalz GmbH
Future ergonomicVtools – )rom the prototype to the 807 serial product by comprehensive product optimization Tanja Schembera-Kneifel, M. Keil, $8',AG
Loading of the musculoskeletal system in automotive assembly – 817 The potential of an applied biomechanics analysis concept Christian Lersch, Velamed GmbH; L. Hausmanninger, AUDI AG; W. Potthast, Deutsche Sporthochschule Köln
New approaches for analysis in ergonomics: From paper and pencil methods to biomechanical simulation 821 Florian Blab, O. Avci, U. Daub, U. Schneider, Fraunhofer IPA
XV SPEAKERS, CHAIRPERSONS – Volume 1
Adam Babik Ronnie Dessort Robert Bosch GmbH TESIS DYNAware GmbH Prof. Carla Bailo Prof. Dr. Klaus Dietmayer The Ohio State University Universität Ulm Prof. Dr. Michael Bargende Prof. Dr. Lutz Eckstein FKFS/IVK, Universität Stuttgart RWTH Aachen University Katharina Bause Prof. Dr. Helmut Eichlseder IPEK/Karlsruher Institut für Technologie TU Graz (KIT) Prof. Dr. Peter Eilts Dr. Bernd-Dietmar Becker TU Braunschweig FARO Tobias Engelhardt Lukas Behr Dr. Ing. h.c. F. Porsche AG Robert Bosch Battery Systems GmbH Stefan Epple Prof. Dr. Christian Beidl IKT, Universität Stuttgart TU Darmstadt Marius Feilhauer Florian Blab ETAS GmbH Fraunhofer IPA Dr. Holger Fink Prof. Dr. Stefan Böttinger Robert Bosch Battery Systems GmbH and Universität Hohenheim Lithium Energy and Power GmbH Tillmann Braun Prof. Dr. Tobias Flämig-Vetter Daimler AG Duale Hochschule BW Stuttgart Dr. Bernhard Budaker Dr. Günter Fraidl Fraunhofer IPA AVL LIST GMBH Rene Budich Arthur Frick HTW Dresden Daimler AG Clemens Buschhoff Prof. Dr. Horst E. Friedrich Fraunhofer IPT DLR Institut für Fahrzeugkonzepte Jing Cheng Peter Froeschle Universität Stuttgart ARENA2036 e.V. Urban Daub Prof. Agostino Gambarotta Fraunhofer IPA University of Parma
XVI SPEAKERS, CHAIRPERSONS – Volume 1
Prof. Dr. Frank Gauterin Dr. Stefan Kampmann Karlsruher Institut für Technologie (KIT) Robert Bosch GmbH Prof. Dr. Bernhard Geringer Dan Keilhoff TU Wien Universität Stuttgart Jan Gerstenberg Mahir Tim Keskin Bosch Engineering GmbH IVK, Universität Stuttgart Vivan Govender Matthias Klingbeil Daimler AG Dr. Ing. h.c. F. Porsche AG Prof. Dr. Clemens Gühmann Prof. Dr. Thomas Koch TU Berlin Karlsruher Institut für Technologie (KIT) Andreas Haag Dr. Karl Kollmann Promotionskolleg Hybrid Silke Krebs Andreas Hackl Staatsministerium Baden-Württemberg TU Graz Prof. Dr. Karl-Ludwig Krieger Prof. Dr. Horst Harndorf Universität Bremen Universität Rostock Prof. Dr. Ferit Küçükay Frank Hermsdorf TU Braunschweig Technische Universität Dresden Thorsten Lajewski Prof. Dr. Dr. Gerhard Hettich Daimler AG EAST Consulting Thomas Landwehr Tilmann Hilbert IVK, Universität Stuttgart J. Schmalz GmbH Christian Lersch Detlef Hoffmann Velamed GmbH SGS Germany GmbH Yujun Liao Prof. em. Dr. Günter Hohenberg Empa – Swiss Federal Laboratories for IVD Prof. Hohenberg GmbH Materials Science and Technology Stefan Jetter Mike Liebers Daimler AG TU Dresden Dr. Stefan Junker Dr. René Linssen Robert Bosch GmbH Daimler AG Benjamin Kaal Prof. Dr. Thomas Maier FKFS Universität Stuttgart
XVII SPEAKERS, CHAIRPERSONS – Volume 1
Gian Mauro Maneia Vincent Raimbault Ce.S.I. Centro Studi Industriali Srl MANN+HUMMEL France SAS Zdenek Mestenhauser Prof. Dr. 'UWolfram Ressel MTS Systems Corporation Universität Stuttgart Prof. Dr. Peter Middendorf Prof. Dr. Hans-Christian Reuss IFB, Universität Stuttgart FKFS/IVK, Universität Stuttgart Dr. Nebojsa Milovanovic Christian Riese MAHLE Powertrain Robert Bosch GmbH Marco Münster Prof. Dr. Hermann Rottengruber DLR Institut für Fahrzeugkonzepte OvGU Magdeburg Dirk Naber Prof. Dr. Eric Sax Robert Bosch GmbH Karlsruher Institut für Technologie (KIT) Walter Nagler Markus Schäfer ZF Friedrichshafen AG Daimler AG Dr. Hiroshi Nakamura Tanja Schembera-Kneifel HORIBA Ltd. AUDI AG Dr. Harald Naunheimer Dr. Axel Schloßer ZF Friedrichhafen AG FEV GmbH Dirk Neumann Helge Schmidt IAV GmbH TÜV NORD Mobilität GmbH & Co. KG Prof. Karl-Ernst Noreikat Patrick Schmidt NorCon LBST – Ludwig-Bölkow-Systemtechnik GmbH Markus Orner Dr. Marco Schneider FKFS Fraunhofer IPA Helena Ortwein Dr. Simon Schneider Rennteam Uni Stuttgart e.V. MAHLE International GmbH Prof. Dr. Nejila Parspour Ulrich Schulmeister Universität Stuttgart Robert Bosch GmbH Dr. Jörg Paschedag Manuel Schuster ITK Engineering AG Fraunhofer IPA Raphael Pfeil Dr. Thomas Schütz FKFS BMW AG
XVIII SPEAKERS, CHAIRPERSONS – Volume 1
Dr. Michael Steiner Ulrike Weinrich Dr. Ing. h.c. F. Porsche AG FKFS Prof. Dr. Thomas Vietor Prof. Dr. Jochen Wiedemann TU Braunschweig FKFS/IVK, Universität Stuttgart Matthias Vogt Johannes Winterhagen bridgingIT GmbH Redaktionsbüro deltaeta Prof. Dr. Georg Wachtmeister Prof. Dr. Oliver Zirn TU München Hochschule Esslingen Prof. Dr. Karl-Heinz Wehking IFT, Universität Stuttgart
X,;
INDEX – Volume 2
SECTION 1
HYBRID I Chairperson: Prof. Dr. Christian Beidl
The potential of 48V HEV in real driving 1 Mark Schudeleit, C. Sieg, F. Küçükay, IfF, TU Braunschweig
Online optimization based energy management of 19 hybrid electric vehicles using direct optimal control Raja Sangili Vadamalu, C. Beidl, TU Darmstadt
Rapid multi-physics approach to the development of 37 electric drive systems for hybrid and electric vehicles Christoph Leser, V. Aronovich, R. Hejny, J. Wattleworth MTS Systems Corporation
LIGHTWEIGHT CONSTRUCTION I Chairperson: Prof. Dr. Horst E. Friedrich
Material+energy efficient processing of composites for 45 automotive lightweight parts Jens Klug, M. Schuck, HBW-Gubesch Thermoforming GmbH
Forta H-Series – Ultimate lightweight solutions with 55 high strength austenitic materials Stefan Lindner, Outokumpu Nirosta GmbH
Fiber reinforced ceramic composites for hot gas and 65 fire retardant applications in automotive Patrick Weichand, R. Gadow, M. Jiménez, IFKB, Universität Stuttgart
VII INDEX – Volume 2
CHARGING OF ELECTRIC VEHICLES Chairperson: Prof. Dr. Eric Sax
Future generations for DC fast charging systems 73 Ursel Willrett, IAV GmbH
Regression test requirements for the charging communication 89 of electric vehicles Johannes Unser, Vector Informatik GmbH
Automated robot-based charging system for electric vehicles 101 Bernhard Walzel, C. Sturm, J. Fabian M. Hirz, TU Graz
ENGINES COMPONENTS I Chairperson: Prof. Dr. Bernhard Geringer
Inlet swirl throttle for passenger car engines 115 Wolfgang Wenzel, U. Hanig, J. Song, BorgWarner, Inc.; B. Bareis, BorgWarner Emission Systems; M. Miclea-Bleiziffer, BorgWarner Turbo Systems
Crank angle resolved floating-liner friction measurements on 133 microstructured cylinder liner surfaces Henning Pasligh, K. Oehlert, F. Dinkelacker, ITV, Leibniz Universität Hannover; H. Ulmer, Bertrandt Ingenieurbüro GmbH
Technology change towards fully synthetic air filter elements 147 in engine air filtration Thilo Müller, T. Batt, M. Heim, A . Pelz, G.-M. Klein, MANN+HUMMEL GmbH
VIII INDEX – Volume 2
THERMAL MANAGEMENT I Chairperson: Prof. Dr. Frank Gauterin
Residual heat utilization in vehicles by thermochemical 161 energy storage Peter Hofmann, M. Jakobi, IFA, TU Wien
Holistic thermal management in electric vehicles 181 Srÿan Milakoviü, FKFS, J. Wiedemann, FKFS/IVK, Universität Stuttgart; J. Haug, MAHLE Behr GmbH & Co. KG; M. Hartinger, Robert Bosch GmbH; J. Maué, Daimler AG; J. Rothfuss, sitronic GmbH & Co. KG
Thermal simulation of an electric motor in continuous 205 and circuit operation Stefan Oechslen, A. Heitmann, T. Engelhardt, Dr. Ing. h.c. F. Porsche AG; H.-C. Reuss, FKFS/IVK, Universität Stuttgart
AMBER-ULV – A STORY OF FUTURE LIGHT URBAN ELECTRIC VEHICLES Chairperson: Gian Mauro Maneia
Introduction to AMBER-ULV and its different business models 219 Michael Stie Laugesen, NTU International A/S, G. M. Maneia, Ce.S.I. Centro Studi Industriali Srl
An innovative energy management system acting on 235 multiple battery packages. TBA
Achievements with model-based development on the innovative 237 traction system of the AMBER-ULV Car Claudio Rossi, D. Pontara, University of Bologna; A. Galli, EOS; P. Fiani, Sherpa Engineering; M. Alirand, Siemens Industry Software
Crash structure design, modelling, virtual sign-off 253 for physical crash testing Gian Mauro Maneia, Ce.S.I. Centro Studi Industriali Srl, R. Papalia, NOVA SRL
IX INDEX – Volume 2
SECTION 2
HYBRID II Chairperson: Prof. Dr. Michael Bargende
48 volt technology – More than a mild hybrid 255 Bernd Mahr, Continental
Plug-in hybrid by Mercedes-Benz – The technology kit for 265 future consumption targets Daniel Görke, S. Schmiedler, J. Strenkert, Daimler AG
Development of simulation test bench (HV-HIL) to calibrate and 281 evaluate hybrid vehicle components without real engine or car Hikaru Mizuno, R. Elbers, P. Pfeilmaier, Toyota Motorsport GmbH; T. Naono, H. Oyobe, H. Hanada, K. Shirota, Toyota Motor Corporation; J. De Smet, Toyota Motor Europe
Concept solution for efficiency improvement of a powertrain with 295 P2 hybrid technology by an intelligent hybrid control unit Shen Wang, T. Kersting, M. Rohe, Schaeffler Engineering GmbH; B. Pennec, Schaeffler Trading (Shanghai) Co. Ltd.
ADAS Chairperson: Prof. Dr. Klaus Dietmayer
Validating advanced driver assistance systems (ADAS) using 307 comprehensive, loss-free in-vehicle measurements Joachim Löchner, J.Wagner, M. Wolter, $)HUQDQGH] ETAS GmbH
Predictive motion cueing algorithm for development of interactive 319 assistance systems Jürgen Pitz, T. Rothermel, M. Kehrer, IVK, Universität Stuttgart; H.-C. Reuss, FKFS/IVK, Universität Stuttgart
Safety and security requirements engineering 335 Christof Ebert, Vector Consulting Services GmbH; M. Brasse, Hella; E. Metzker, Vector Informatik GmbH
X INDEX – Volume 2
DRIVING DYNAMICS Chairperson: Prof. Dr. Ferit Küçükay
Improvements on availability and comfort of electric drives for 347 electric power steering application Nick Trmmel, T. P|tzl, Robert Bosch Automotive Steering GmbH; H.-C. Reuss, FKFS/IVK, Universität Stuttgart
Creation of driving cycles with lateral and longitudinal dynamics 363 for analyzing energy losses in chassis Andreas Schultze, M. Hauck, M. Lienkamp, TU München
Development of objective criteria to assess the vehicle performance 377 utilized by the driver in near-limit handling conditions of racecars Florian Goy, IVK, Universität Stuttgart; J. Wiedemann, FKFS/IVK, Universität Stuttgart; T. Völkl, G. Delli Colli, AUDI AG; J. Neubeck, W. Krantz, FKFS
ENGINE PROCESS II Chairperson: Prof. Dr. Horst Harndorf
Investigation of the mixture formation process with combined 397 injection strategies in high-performance SI-engines Daniel Koch, G. Wachtmeister, LVK, TU München; M. Wentsch, M. Chiodi, FKFS; M. Bargende, FKFS/IVK, Universität Stuttgart; C. Pötsch, Volkswagen AG; D. Wichelhaus, Volkswagen Motorsport GmbH
Online-methods for engine test bed measurements considering 415 engine limits Benjamin Hartmann, P. Heuser, Bosch Engineering GmbH; E. Kloppenburg, R. Diener, Robert Bosch GmbH
Simulative development of thermal management for warm-up 429 Björn Meyer, IVK, Universität Stuttgart; M. Bargende, FKFS/IVK, Universität Stuttgart; I. Kutschera, M. Gruber, S.-F. Haas, AUDI AG
Analysis of working processes and efficiency assessment 445 of hand-held power tools Stephan Meyer, A. Kölmel, T. Gegg, U. Dawin, ANDREAS STIHL AG & Co. KG; P. Piecha, A. Trattner, S. Schmidt, R. Kirchberger, IVT, TU Graz
XI INDEX – Volume 2
INJECTION Chairperson: Prof. Dr. Hermann Rottengruber
Experimental study on the impact of the jet shape of an 459 outward-opening nozzle on mixture formation with CNG-DI Dimitri Seboldt, D. Lejsek, Robert Bosch GmbH; M. Bargende, FKFS/IVK, Universität Stuttgart
3D-CFD analysis on scavenging and mixture formation for 479 CNG direct injection with an outward-opening nozzle Marlene Wentsch, M. Chiodi, FKFS; M. Bargende, FKFS/IVK, Universität Stuttgart; D. Seboldt, D. Lejsek, Robert Bosch GmbH
Penetration path analysis of diesel sprays via spray force 499 measurements Hans Römisch, T. Hergemöller, F.-P. Gulde, Daimler AG; M. Bargende, FKFS/IVK, Universität Stuttgart
Effects of new nozzle hole configurations on air utilization 515 and soot emissions of diesel engines Klaus Hielscher, R. Baar, TU Berlin; M. Brauer, IAV GmbH
AUTOMOBILE & BIG DATA Chairperson: Dr. Bernhard Budaker
IT architectures for Big Data in the automotive field 535 Jens Jäger, Fraunhofer IPA
Digital realms in production planning – 6afety through 537 virtualization Ulrich Odefey, M. Pfeil, V. Fäßler, TWT GmbH Science & Innovation; T. Bär, Daimler AG; H. Zipper, Institut für Automation und Kommunikation e.V. Magdeburg
Big Data in automotive production – Concepts and experiences 549 Thomas Bauernhansl, Fraunhofer IPA
XII INDEX – Volume 2
SECTION 3
CHASSIS OF THE FUTURE Chairperson: Prof. Dr. Jochen Wiedemann
Honda’s philosophy on vehicle dynamics performance and 551 future technology direction Yasunori Oku, Honda R&D Europe (Deutschland) GmbH
E-Mobility and driver assistance: Will driving dynamics and 567 driving pleasure stay behind in the future? Peter Schäfer, U. Reuter, C. Hoffmann, Dr. Ing. h.c. F. Porsche AG
Automotive game-changers and their challenges from a 583 chassis perspective Andreas Wagner, AUDI AG
AUTOMATED DRIVING Chairperson: Prof. Dr. Hans-Christian Reuss
Safety argumentation for automated driving systems 601 Michael Helmle, P. Sautter, F. Hauler, F. von Zeppelin, Robert Bosch GmbH
The Connected Car – A system-of-systems: Exploration of 603 challenges in development from experts view $UPLQ.XUUOH$$OEHUV, S. Klingler, IPEK, Karlsruher Institut für Technologie (KIT)
Connected efficiency – A paradigm to evaluate energy 615 efficiency in tactical vehicle-environments Jochen Kramer, M. Hillenbrand, K. D. Müller-Glaser, FZI Forschungszentrum Informatik; E. Sax ITIV, Karlsruher Institut für Technologie (KIT)
XIII INDEX – Volume 2
THERMAL MANAGEMENT II Chairperson: Prof. Dr. Stefan Böttinger
Optimization of an engine coolant radiator for vehicle 629 thermal management Lothar Seybold, I. Lazaridis, A. Seryi, W. Filsinger, Adam Opel AG; F. Gruber, B. Taxis, MAHLE Behr GmbH & Co. KG
Simulation in thermal management – Looking back, status 647 and outlook of an exciting discipline Andreas Koller, Dr. Ing. h.c. F. Porsche AG
Design and development of a component test bench 659 for the investigation of automotive ORC systems Holger Mai, D. Nascimento, Kratzer Automation AG; H. Rätz, H. S. Kunte, O. Willers, J. S. Seume, TFD, Leibniz Universität Hannover; S. Weigl, UFT GmbH
ENGINE CHARGING Chairperson: Prof. Dr. Helmut Eichlseder
The hot side of the new 4-cylinder diesel engine from 679 Mercedes-Benz Jochen Schmid, Daimler AG
Experimental investigation of operating parameters 687 on constant-tone-noise of turbochargers Marco Leonetti, FKFS, M. Bargende, FKFS/IVK, Universität Stuttgart; D. Filsinger, M. Kreschel, IHI Charging Systems International; C. Meier, H. Schulze, Mercedes Benz
Concept for lower raw engine emission covering full 707 engine map operation Mike Lau, R. Suteekarn, Eaton Germany GmbH; G. Lautrich, M. Pannwitz, T. Tietze, IAV GmbH
XIV INDEX – Volume 2
ENGINES COMPONENTS II Chairperson: Prof. Dr. Thomas Koch
Fritz Winter ecoCasting: Development of light-weight cylinder 727 crankcases of cast iron Wilfried Wolf, W. Steinberg, Fritz Winter Eisengießerei GmbH & Co. KG
Tailored crankshaft design from early development phase on 739 Julius Perge, VKA, RWTH Aachen University; R. Beykirch, J. Lehmann, M. Gast, FEV GmbH; A. Piccaglia, A. Almini, N. Parenti, VM Motori FCA
Concept for Diesel Particulate Filter monitoring based on 759 BOSCH Particulate Matter Sensor (PMS) Jörg Linke, D. Konrad, Bosch Engineering GmbH
E/E-ARCHITECTURE Chairperson: Prof. Dr. Karl-Ludwig Krieger
A method to control distributed cause-effect chains of 769 electrical and electronic systems in the field of driving dynamics and driver assistance Matthias Wiese, W. Schrüfer, H. Kerscher, M. Hambauer, A. Kron, BMW Group
Cross-domain vehicle control units in modern E/E architectures 783 Waldemar Haas, P. Langjahr, Bosch Engineering GmbH
Intelligent sensor layout of PVDF structure-borne sound sensors 793 to gain signals mechanically .ODDV+auke Baumgärtel, K.-L. Krieger, ITEM, Universität Bremen
XV SPEAKERS, CHAIRPERSONS – Volume 2
3URI&arla Bailo Prof. Dr. Frank Gauterin The Ohio State University Karlsruher Institut für Technologie (KIT) Prof. Dr. Michael Bargende Prof. Dr. Bernhard Geringer FKFS/IVK, Universität Stuttgart TU Wien Prof. Dr. Thomas Bauernhansl Daniel Görke Fraunhofer IPA Daimler AG Klaas Hauke Baumgärtel Florian Goy ITEM, Universität Bremen IVK, Universität Stuttgart Prof. Dr. Christian Beidl Prof. Dr. Clemens Gühmann TU Darmstadt TU Berlin Prof. Dr. Stefan Böttinger Waldemar Haas Universität Hohenheim Bosch Engineering GmbH Dr. Arnulf Braatz Prof. Dr. Horst Harndorf Vector Consulting Services GmbH Universität Rostock Dr. Bernhard Budaker Dr. Benjamin Hartmann Fraunhofer IPA Bosch Engineering GmbH Urban Daub Dr. Michael Helmle Fraunhofer IPA Robert Bosch GmbH Prof. Dr. Klaus Dietmayer Prof. Dr. Dr. Gerhard Hettich Universität Ulm EAST Consulting Prof. Dr. Lutz Eckstein Klaus Hielscher RWTH Aachen University TU Berlin Prof. Dr. Helmut Eichlseder Prof. Dr. Peter Hofmann TU Graz IFA, TU Wien Prof. Dr. Peter Eilts Prof. em. Dr. Günter Hohenberg TU Braunschweig IVD Prof. Hohenberg GmbH Prof. Dr. Tobias Flämig-Vetter Jens Jäger Duale Hochschule BW Stuttgart Fraunhofer IPA Prof. Dr. Horst E. Friedrich Dr. Stefan Kampmann DLR Institut für Fahrzeugkonzepte Robert Bosch GmbH Peter Froeschle Jens Klug ARENA2036 e.V. HBW-Gubesch Thermoforming GmbH
XVI SPEAKERS, CHAIRPERSONS – Volume 2
Daniel Koch Holger Mai LVK, TU München Kratzer Automation AG Prof. Dr. Thomas Koch Prof. Dr. Thomas Maier Karlsruher Institut für Technologie (KIT) Universität Stuttgart Andreas Koller Gian Mauro Maneia Dr. Ing. h.c. F. Porsche AG Ce.S.I. Centro Studi Industriali Srl Dr. Karl Kollmann Björn Meyer IVK, Universität Stuttgart Jochen Kramer FZI Forschungszentrum Informatik Dr. Stephan Meyer ANDREAS STIHL AG & Co. KG Silke Krebs Staatsministerium Baden-Württemberg Srÿan Milakoviü FKFS Prof. Dr. Karl-Ludwig Krieger Universität Bremen Hikaru Mizuno Toyota Motorsport GmbH Prof. Dr. Ferit Küçükay TU Braunschweig Thilo Müller MANN+HUMMEL GmbH Armin Kurrle IPEK / Karlsruher Institut für Technologie (KIT) Dr. Harald Naunheimer ZF Friedrichhafen AG Mike Lau Eaton Germany GmbH Prof. Karl-Ernst Noreikat NorCon Michael Stie Laugesen NTU International A/S Dr. Ulrich Odefey TWT GmbH Science & Innovation Marco Leonetti Stefan Oechslen FKFS Dr. Ing. h.c. F. Porsche AG Dr. Christoph Leser Yasunori Oku MTS Systems Corporation Honda R&D Europe (Deutschland) GmbH Stefan Lindner Prof. Dr. Nejila Parspour Outokumpu Nirosta GmbH Universität Stuttgart Jörg Linke Henning Pasligh Bosch Engineering GmbH ITV, Leibniz Universität Hannover Joachim Löchner Julius Perge ETAS GmbH VKA, RWTH Aachen University Dr. Bernd Mahr Jürgen Pitz Continental IVK, Universität Stuttgart
XVII SPEAKERS, CHAIRPERSONS – Volume 2
Prof. Dr.'U Wolfram Ressel Nick Trümmel Universität Stuttgart Robert Bosch Automotive Steering GmbH Prof. Dr. Hans-Christian Reuss Johannes Unser FKFS/IVK, Universität Stuttgart Vector Informatik GmbH Hans Römisch Prof. Dr. Thomas Vietor Daimler AG TU Braunschweig Claudio Rossi Prof. Dr. Georg Wachtmeister University of Bologna TU München Prof. Dr. Hermann Rottengruber Dr. Andreas Wagner OvGU Magdeburg AUDI AG Prof. Dr. Eric Sax Bernhard Walzel Karlsruher Institut für Technologie (KIT) TU Graz Markus Schäfer Shen Wang Daimler AG Schaeffler Engineering GmbH Dr. Peter Schäfer Patrick Weichand Dr. Ing. h.c. F. Porsche AG IFKB, Universität Stuttgart Jochen Schmid Marlene Wentsch Daimler AG FKFS Dr. Marco Schneider Dr. Wolfgang Wenzel Fraunhofer IPA BorgWarner, Inc. Mark Schudeleit Prof. Dr. Jochen Wiedemann IfF, TU Braunschweig FKFS/IVK, Universität Stuttgart Andreas Schultze Dr. Matthias Wiese TU München BMW Group Raja Sangili Vadamalu Ursel Willrett TU Darmstadt IAV GmbH Dimitri Seboldt Johannes Winterhagen Robert Bosch GmbH Redaktionsbüro delta eta Lothar Seybold Wilfried Wolf Adam Opel AG Fritz Winter Eisengießerei GmbH & Co. KG Dr. Michael Steiner Prof. Dr. Oliver Zirn Dr. Ing. h.c. F. Porsche AG Hochschule Esslingen
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