Vehicle Structures
In the area of vehicle structures, we focus on concept and design, calculation and testing, benchmarking, lightweight construction, passive safety and operational strength.
Concept development of vehicle structures
Based on package data, ika develops innovative vehicle structure concepts by using numerical optimisation tools in an early development phase. This enables the optimal use of the design space, even before building up the first CAD models. Right from the start, the close collaboration with the engineering teams of the chassis and the drivetrain departments guarantees the consideration of all essential boundary conditions in a coherent overall concept. The creative ideas, which are developed in interdisciplinary brainstorming sessions, set the basis for developing a convincing structural concept as a CAD model. Using numerical analysis tools, this model is refined subsequently to an innovative vehicle structure, which meets the defined requirements.
Numerical design, simulation and optimization
The virtual development process of vehicle structures at ika includes the design, the numerical simulation and the optimization on the level of components and modules as well as on full vehicle level. Based on the finite element method and on multi body simulations, analyses with regard to stiffness, strength, crashworthiness, pedestrian protection and vibration response are carried out. The simulation-based development process allows already in early development phases the verification of concepts in a very cost efficient way. For this purpose, the ika has numerous commercial CAE tools as well as powerful computing clusters for the fast execution of simulation runs.
Testing
By means of modular and multifunctional test benches ika offers an extensive testing program from component tests during the development phase to the testing of complete vehicles according to legal requirements. Thanks to the close integration of the testing and simulation processes it is possible to execute validation tests for the verification of simulation results in a fast and flexible way. Numerous measuring devices and high speed video cameras are available for data acquisition. The main test benches in the field of vehicle structures are:
- Crash test facility for component and full vehicle tests incl. a completely variable sled
- Drop towers and pendulum test bench
- Servohydralic test center and intrusion rig
- Free-motion impact test bench for pedestrian protection tests
- Test rigs for structural stiffness and modal analysis
- Testing devices for the examination of denting stiffness, denting resistance and damage caused by hail
- Measuring devices for acquisition of 3D coordinates and surface reconstruction
Development of new methods in physical testing and numerical simulation
In order to extend the application fields of numerical simulation methods and to meet special customer requirements for physical testing, ika is not only dealing with the application, but also with the further development of the corresponding methods. This includes the auto-mation of simulation tasks and post processing procedures or the coupling of several solvers for multi-disciplinary optimization. In the field of physical testing, ika has a strong com-petence in the development of structural component tests. In order to refine such component test methods, the boundary conditions of the test set-up are adjusted in a numerical repre-sentation of the test, so that the simulated component behavior corresponds with the behavior computed in the full vehicle simulation. In the end, the realization of the corresponding component test configuration on a test bench enables a significant cost reduction compared to complete vehicle tests, in particular for large test series.
Design and functional benchmarking
Design and functional benchmarking represents an important step in the development process of structural components. In addition to pure design benchmarking for complete vehicles and body and structural components, in which, among other things, construction methods, materials, masses and sheet thicknesses are determined after component disassembly, the ika also offers functional benchmarkings. In this process important component functions like torsion stiffness, bending stiffness, denting characteristics and crash behavior are determined and analyzed. If necessary, ika also develops and builds up special test benches for this purpose. The benchmarking analyses are completed by a clear and well structured documentation. Subsequently, it is possible to transfer the component dimensions into CAD data by means of digitizing techniques for further numerical simulation or optimization.
Current Projects
KI-LaSt
AI-based strategy for the optimal design of additive manufactured lattice structures for crash applications
One of the most important global goals is to significantly slow down or even stop global warming by reducing greenhouse gas emissions. In the automotive industry, the subject of "lightweight construction" …
KIZAM
Artificial Intelligence in target and requirements management
In the vehicle development process, requirements form the basis for functions, principles of operations and solutions, right up to the manufacturing and testing concepts of the later product. The efficiency …
Concept development of a steel battery housing
Development of a lightweight structural concept for a steel battery housing
The aim of the project is to design a steel battery housing with particular attention to joinability and corrosion protection. The increased use of steel poses far-reaching challenges in terms of design, …
Proactive SAFEty systems and tools for a constantly UPgrading road environment - SAFE-UP
The EU funded project “SAFE-UP” addresses the upcoming safety challenges related to Vulnerable Road Users (VRUs) and occupant protection systems in future road traffic and mobility scenarios
SAFE-UP combines the competences of 18 partners including leading universities and selected industrial partners to develop safety systems in future transport and mobility scenarios. The SAFE-UP consortium …
OSCCAR
Developing new occupant protection principles for highly automated vehicles within EU funded project OSCCAR
The new EU Horizon 2020 research project “OSCCAR - Future Occupant Safety for Crashes in Cars” develops a novel approach to improve the safety for all occupants involved in future accidents with autonomous …
Contact
Dr.-Ing. Dinesh Thirunavukkarasu
Manager Research Area
Vehicle Concepts & HMI
+49 241 80 25699
Email
Equipment and test benches
- Aldenhoven Testing Center (ATC)
- Body Components Benchmarking
- Body Stiffness
- Crash Test Facility
- Denting Test Benches
- Drop Tower Test Bench
- Optical Measuring Methods
- Pedestrian Protection Test Bench
- Roadside Infrastructure
- Servo Hydraulic Test Centre
- Test Sled Fleed
- ika test track
Presentations/Articles
- Potentials of dual-speed transmissions in electric powertrains depending on passenger vehicle segment
Wednesday, October 19, 2022 - Generic Approach to Optimized Placement of Smart Roadside Infrastructure Sensors Using 3D Digital Maps
Wednesday, October 12, 2022 - Selection of Test Cases for the Verification of Automated Vehicles
Wednesday, October 12, 2022 - Future Mobility Applications in the KoMoD-next and ACCorD Digital Test Fields
Wednesday, October 12, 2022 - Generic Approach to Optimized Placement of Smart Roadside Infrastructure Sensors Using 3D Digital Maps
Wednesday, October 12, 2022
Student theses
Currently there are no theses advertised.