AVL is the world's largest independent company for the development, simulation and testing of powertrain systems, their integration into the vehicle as well as new fields like ADAS/AD and Data Intelligence.
AVL Powertrain Engineering is an expert partner to the global automotive and mobility industry for the development of innovative powertrain systems. From diesel engines to electric drives, from alternative fuels to control software, from transmissions to batteries, we have been working in partnership with companies all over the world for more than 60 years. Unique synergies with AVL Instrumentation and Test Systems and AVL Advanced Simulation Technologies enable the development of highly creative, mature and application-specific solutions to enable our customers to meet their future market challenges.
The need for CO₂ reduction, the increasing complexity of new powertrain systems, and a requirement to achieve the highest possible level of process efficiency - along with the need to quickly launch new models - are some of the key challenges facing the automotive industry now and for the foreseeable future.
As an independent market leader in battery technology, AVL offers a full package of innovative tailored solutions to address the challenge of clean e-mobility. Our dedicated products and services cover the entire battery development process – from the assessment and selection of a single cell to SOP of a fully validated battery pack. Mechanical and thermal pack integration into the vehicle feature with low cost design, performance, serviceability, energy efficiency and recyclability. Our offering also includes: A blend of reliability and quality with reduced development times and costs High quality battery management software, tested and verified by experts Efficient and effective testing, including test-plan optimization A library of test cases for validation and verification Testing and Benchmarking Our highly instrumented cell and battery testbeds enable the testing and benchmarking of everything from high power, high energy cells to complete battery packs up to 500kW. Thermal and Mechanical Simulation The parameterization of dedicated electro-thermal models and thorough mechanical analysis, which includes strength and crash testing, obtains the battery’s best performance. Battery Design Engineering All aspects of mechanical and electrical integration are managed by AVL’s experts to ensure that the battery design meets volume production requirements. Battery Prototype Build Prototypes of any sample state, from single units to several tens of A and/or B samples, can be built-to-order during or after design engineering. Battery Management System (BMS) Development Our proprietary battery management system assures the safe operation of the battery pack according to ISO 26262, while maximizing battery performance by, for example, providing very accurate SOX values. Battery System Validation Lifetime and warranty targets are assessed by battery experts using a dedicated methodology in the areas of reliability, durability, and validation. Battery Testing and Emulation We deliver advanced battery testing tools and emulation solutions, in the form of AVL E-Storage Tester™ and Emulator™. Entire battery lab turnkey solutions are also available.
Controls are a key characteristic to differentiate the behavior of the powertrain in regards to vehicle performance, emissions, robustness of diagnostic and brand style (Brand DNA). AVL can deliver independent and modular powertrain software control solutions from prototype through to production to meet individual customer demands.
AVL designs and develops e-drive solutions which are tailored to your specific applications, including hybrids, e-vehicles or auxiliaries. We have over 15 years of experience under our belts in hybrid and e-vehicle development and have a profound knowledge of e-drive and actuators. Challenges: To reach a zero-emission mobility the electrification of vehicle powertrains will be necessary. This fact leads to new challenges for car makers and suppliers: How to make powertrain component more efficient to extend the range & reduce the charging time? How to combine compact and lightweight construction of high-power electronics under considering of passenger security? How to fit new technologies like SiC for e-Drive applications to extend functionality and maximize the performance? How to ensure safe operation in every environmental condition and for all areas of application? How to achieve a faster market entrance by efficient development? AVL offers a range of services for e-drives: Concepts – from the simulation of electric systems to the prototype Series development – design, simulation, integration, testing and verification Component development - motors, generators, power electronics and actuators E-Drive Software development for electronics EMC design and simulation Testing and validation of performance, functionality and EMC Electrification of auxiliary systems and accessories Solutions We develop single e-components but also integrated e-Drives for electric powertrains on every application of use. The AVL Abilities Methodologies & Engineering Know-How of the powertrain system integration to increase the system efficiency Enhancing the development of products and technologies through the interaction of computer-aided engineering tools to exploit feasibility Improvement loop of technical hardware innovations including the combination of hardware and software to perform high efficiency in power electronics System validation and durability tests performed by AVL’s high tech test benches Proprietary development & validation as well as cooperation with leading suppliers Your Benefits AVL designs, develops, integrates and tests your specific e-drive solution and can take it all the way to series development. Key features include: Optimal technology for your requirements: PMSM, ASM, SRM, BLDC, linear drives Electromagnetic compatibility (EMC) of all components Frontloading with innovative simulation technologies
To handle the increasing complexity in combustion engine development and avoid costly recalls, OEMs need advanced tools and smart testing methods that consider the manufacturing and assembling process. At AVL, we have the skills, experience and know-how to meet these challenges head on. Our deep understanding of the test mechanism and our leading system experience is second to none. AVL’s test systems and cutting-edge solutions for all sectors, such as light-duty, mid-duty and heavy-duty engines complete the portfolio. Our end-of-line solutions feature container systems that can be easily integrated into any existing production environment. At AVL, we take pride in being a reliable partner that delivers testing technologies for production, that combine a high degree of flexibility with precision and quality at the highest level. Examples for supported standard solutions include: End-of-Line Loaded Hot Test Systems Quality Audit (QA) / Conformity of Production (COP) Systems Qualified Hot Test Systems End-of-Line Engine Cold Test In-Process Verification Test System (IPV) AVL Guarantees Turnkey systems that suit each application and customer requirement Huge experience thanks to numerous turnkey projects globally Consistency between AVL test systems with our Integrated and Open Development Platform. High-precision measurements with reproducible results
Due to the vast amount of different transmission concepts on the market, it is necessary to consider the whole powertrain as one system. Extensive engineering experience and skills drive AVL's advanced solutions combined with efficient testing and simulation tools. Well-known manufacturers trust in AVL's individual, independent and highly innovative solutions in the area of: Passenger Car Powertrains Commercial Powertrains (on-road) Off-Road-Powertrains
The development of modern vehicles with extremely complex powertrain concepts puts high requirements on new development and validation methods with the associated tools. In order to save costs and reduce development times, road tests are increasingly being transferred to vehicle testbeds and replaced by simulation. Transferability and a balance between the individual test environments (off-line simulation, hardware-in-the-loop, component testbed, vehicle testbed, road, etc.) must be guaranteed.
Powertrains for light, medium and heavy-duty commercial vehicles use an increasing number of complex systems for engine, transmission, electric drives, exhaust aftertreatment and the respective electronic control systems. The key is to balance this complexity with the life cycle cost of the vehicle.
Powertrain solutions from conventional Gasoline or Diesel engines & transmissions up to complex Hybrids and Battery Electric Vehicles, from single components up to complete systems.
Flexible application diversity in a cost effective manner, productivity increase including precision as well as sustainability are driving the industry.
The AVL Magazine for Powertrain Development, Testing and Simulation
At AVL we understand the importance of the availability and usability of equipment and devices throughout the product lifecycle. The delays caused by operational downtime can be extremely costly. We aim to reduce the total cost of ownership and increase the availability and accuracy of test equipment. In this way AVL Customer Services for Testing Solutions helps to avoid the unplanned costs and reduces test repetitions caused by inaccurate equipment. How we do it: Worldwide, the AVL support infrastructure consists of more than 700 service employees working in more than 50 locations. 14 Hotlines guarantee access to AVL expert help and the AVL CARE™ Service Solution manages services for more than 1400 testbeds. In addition: AVL operates more than 240 of its own testbeds at 17 different locations AVL resident teams maintain, support and operate more than 1500 testbeds at customer sites AVL assistance offers application support that can reduce testing time by more than 70% by using the right calibration methodology and infrastructure. A tailored service concept can boost utilization rates to more than 80% and technical availability to more than 97% Find out more about AVL Service Modules and AVL Managed Service Contracts.
Issue July 2020
