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Development We develop chassis

The chassis has a decisive influence on the customer experience of the car during the ride. Driving dynamics, driving comfort and driving behaviour define the character of an automobile. Our team has long-standing experience with different systems and components.

 


However, with every vehicle generation the development faces the same challenges again:

  • Increased expectations to driving dynamics, driving comfort and driving safety
  • Cost pressure, CO2 reduction, energy efficiency

Fahrwerk Detailansicht Pano 1

Therefore we offer our competence and experience we have gathered for all assemblies of the chassis, for supplementing and supporting the customer competence:

 


 

  • Front and rear axles
  • Subframes and engine mounts
  • Wheel brakes, parking brake and brake actuation
  • Steering wheel, steering column and steering gear
  • Wheels, tires, on-board tools and vehicle jack

 


We perform the following works at chassis for passenger cars and light utility vehicles:

Driving dynamics

and axle kinematics development

The development of driving dynamics and axle kinematics defines the DNA of a chassis; for our customers this is normally a part of their own core competence.

However we are proud of being a development partner in this field, too.

 


 

  • Analysis of the market environment of the vehicle to be developed
  • Reverse engineering of competitor vehicles
  • Preparation of target vectors for the axle development
  • New and continued development of elastokinematics
  • Coupling with development and simulation of control systems
  • Consideration of package and modular system of the customer
  • Short-term mule-car build for kinematics and compliance test

Geometric integration

The geometric integration of axle components and complete axles is one of our main activities in the chassis development. For this, we are working in an autonomous, structured and documented way with our customers, suppliers and further interface partners.

 


 

  • Positioning and analysis of chassis components in moving design spaces
  • Automated package investigations in elastokinematically moved assemblies by coupling with multiple-body simulation
  • Consideration of assembly and customer service requirements

Design

The design of chassis parts is another main business area in our development.
We draft assemblies and components in early product development phases, fine-tune these in the ongoing development process up to the transfer to a nominated supplier or until after series start.

 


 

  • Design according to load, manufacturing and construction space
  • Detailing degree of the models according to the status in the product development cycle and integration of the system supplier and his manufacturing technology
  • Supplementing the special component and manufacturing competence of the system supplier by our chassis and overall vehicle know-how
  • Preparation of draft, request and release drawings and documents
  • Compliance with customer-specific standards for CAD data quality
  • Sheet steel, cast, forged, composite and plastic components

Media laying

Laying of media and cables in the overall vehicle

We apply our overall vehicle competence for the laying of hoses and lines through the vehicle package.

 


 

  • System configuration for air, negative pressure, hydraulic and electric system
  • Line laying for brake, power steering, air suspension, fuel, AdBlue, cooling system

FEA analysis

The analysis is integrated in almost all of our services as an important development step.

 


 

  • FEM linear and non-linear structural mechanics 
  • NVH, eigenmodes
  • Crash simulation (accident/misuse)
  • Component optimisation with respect to structure, shape, material strength and beading
  • Stationary and non-stationary computational fluid dynamics (CFD) 
  • Tolerance analyses on the influence on driving dynamics and costs
  • Lifetime analysis for the damage location prediction

Prototyping

of components and vehicles

Following up to the development of chassis components and systems, we offer mule and prototype vehicle build. For this, we are aware of the special requirements to chassis test vehicles.

 


Prototyping of components and vehicles:
We are specialised on the assembly of prototype vehicles with a special focus on the chassis.


Test planning

In the scope of chassis development packages, we also perform the planning and the coordination of testing with the result of a series release at due date.

 


 

  • Vehicle demand determination and planning
  • Multiple use of test vehicles
  • Planning of test tracks
  • Equipment of test vehicles
  • Logistics of vehicles and components

Chassis setup

Our chassis development offer is rounded off by the chassis setup, performed for us by experienced engineers.

 


  • Characteristics development of the chassis
  • Subjective evaluation of driving behaviour
  • Objectification by use of measuring instrumentation
  • Adjustment of tires, springs, stabilisers, shock absorbers, traction and compression stop, rubber-metal mounts
  • Definition of axle adjustment values
  • Data input into control systems

Road load data acquisition

by analysis and by measurement

The implementation of an operating load determination is important. New measuring procedures must be used because old measured values are outdated. We always strive to be up-to-date and to adapt the test load case to state-of-the-art technology.

 


Design:

  • Design according to load, manufacturing and construction space
  • Detailing degree of the models according to the status in the product development cycle and integration of the system supplier and his manufacturing technology
  • Supplementing the special component and manufacturing competence of the system supplier by our chassis and overall vehicle know-how
  • Compliance with customer-specific standards for CAD data quality

 


Calculation:

  • Structural mechanics > linear/non-linear
  • NVH
  • Crash simulation (accident/misuse)
  • Component optimisation with respect to structure, shape, material strength and beading
  • Computational fluid dynamics (CFD) > stationary and non-stationary 

 


Multiple-body simulation (MBS):

  • Axle kinematics development
  • Load data generation
  • Driving dynamics
  • Control systems

 


Tolerance analyses:

  • Identification of risks to driving dynamics caused by tolerances
  • Identification of cost reduction potentials by tolerances

 


Lifetime analysis:

  • Load data reduction
  • Damage location prediction