Date post: | 03-Sep-2014 |
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From the idea ...
TaskThe specific components of special-purpose vehicles must be integrated in the existing basic vehicle in the best way possible.
Due to the ongoing decrease in available installation space, the package ofmodern vehicles makes it very difficult to integrate additional components. This is true for visible areas, such as the instrument panel, as well as for installation positions “hidden” behind cladding or panelling.
Smart concepts and detail solutions are required that do not entail substantialchanges to the basic production version of the vehicle. Another challengedevelopers are faced with is to adapt the specific components to the high-quality interior design of modern vehicles.
The integration of electric components into the vehicle’s production powersupply system requires major interventions, especially on modern vehicles fullyinterlinked by a CAN bus. Electric components can no longer be integratedinto the CAN control unit system and messages no longer be imported andexported by simply “connecting” the respective components, as in the past. It is, for example, no longer possible to subsequently add functions to thebasic vehicle’s CAN bus without performing special measures.
From the Design Sketch to the Finished Test Vehicle
SolutionIAV is ideally equipped to deal withthese demanding tasks. We providea depth of competence inelectrics/electronics, developing specific exterior and interior components, parts list systems aswell as in testing and constructingtest vehicles. We use modern projectmanagement tools to reach the targets set by the “magic triangle” ofdeadlines, quality/technology andcosts.
Development of Special-Purpose Vehicles
Excellence in Automotive Research and Development www.iav.de
Special-Purpose Vehicles
u Public-authority vehicles,
e.g. police cars
u Emergency ambulances
u Fire command vehicles
u Taxis
u Driving-school vehicles
u Vehicles equipped with driver
assistance systems
Armored VehiclesIndividualization
u IAV also has a broad range
of development expertise in
relation to individualizing
vehicles and to armored
vehicles (armoring classes
B4 to B7).
Concepts – Design – Product Development
Conceptsu Package layoutu Development of concept variantsu Concept visualization/design sketches (to support decisions)
Designu Virtual and actual package analysesu Components and assemblies designu Preparation of drawings
Development of Power Supply Systemu Concept selectionu Component selectionu System diagramu Wiring diagramu 3D wire routing (package)u Electromechanical designu Form-board drawing (production drawing)
Control Unit Developmentu Feasibility analyses (CAN connection, validation, etc.)u Algorithm definitionu Preparation and monitoring of specificationsu Algorithm integration (power supply control unit/door control
unit/steering column switch module, etc.)u Vehicle testing (CAN/special functions)u Preparation of drawingsu Clearance support
Documentationu Assembly instructions, installation documentationu Circuit diagramsu Support in preparing user manuals and service documents
Development of Special-Purpose Vehicles
Comfort CAN Comfort CAN
Power supplycontrol unit
Door controlunit
Steeringcolumn switch
Instrumentcluster
Testingu Planning and coordinating test drivesu Assembly and disassembly testsu Component and vehicle tests
1 Environmental simulation (cold and hot weather, paint resistance, sunlight simulation, corrosion)
1 Component tests (e.g. continuous operation of doors and lids)1 Misuse tests1 Support for vehicle endurance and fatigue strength tests
u Vehicle safety1 Offset, lateral and rear impacts1 Head impact tests1 Airbag inflation tests
u Function testsu Preparation of EMC measurementsu Stall-current measurementsu Start-up
Process IntegrationDepending on the client’s need, IAV's special-purpose vehicles team also takes care ofintegrating these vehicles in the production or assembly processes concerned. Here, it makes no difference to the special-purpose vehicle experts whether vehicles areto be assembled by hand or "polished" on the mass-production line. Support starts asearly as in the planning phase and is provided in close consultation with the Production,Quality Assurance and Logistics departments of the manufacturing site until pre-production and start of production. If needed, IAV also provides a task force after SOP.
www.iav.de
Door endurance testing
Prototype Construction
u Construction of test and press
demo vehicles
u Manufacturing of prototype
parts1 Stereolithography1 Selective laser sintering1 Fused deposition modeling1 Vacuum casting1 Deep drawing
u Calibration of prototype parts
System Integration
u Entering data into the database
u Definition of technical
constraints and prohibitions
u Preparing, coordinating and
monitoring clearances
u Change management
Contact: [email protected] +49 (53 71) 8 05-12 55
Contact: [email protected] +49 (53 71) 8 05-15 30
Development of Special-Purpose Vehicles
www.iav.de
F05
/05 Further Activities
u Product managementu Project managementu Marketing/sales supportu Procurement supportu Support in financial controllingu Support in quality assurance
Marketing/sales support includes the evaluation of customer complaints and, based on the results, the preparation of model improvements, analyzingcompetitors’ products, observing and introducing new technologies as well ashelping with the preparation of marketing campaigns, service and repairmanuals.
IAV’s scope of services may, upon request of the client, even go as far as providing support in procurement processes, i.e. selecting, assessing andmonitoring suppliers and coordinating sample delivery processes, in financialcontrolling, e.g. elaborating cost-saving measures, and in quality assurance,e.g. by examining and guaranteeing conformity with group guidelines, standards, rules and laws.
… to Mass Production
Cost Optimization
Fierce competition and strong cost
pressure in the special-purpose
vehicles sector are counteracted by
cost-effective solutions. This includes:
u Optimizing component costs by
way of close cooperation with
component suppliers as early as in
the design phase
u Adapting production processes to
the number of units ordered
u Optimizing production methods and
assembly processes
u Closely cooperating with the client’s
Procurement and Controlling
departments
Product planning
Project management
Package, concepts, design
Product development, design
Prototype construction and testing
Clearances and system integration
Process integration, production
Procurement activities
Marketing and sales
Quality assurance and measures
18-24 months of special-purpose vehicle development
Preproduction, production