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THE PRODUCT WITHOUT PHYSICAL PROTOTYPES

Digital prototype:
without physical prototypes for the product

A digital prototype is the key to safe, time-effective and resource-efficient vehicle development – without the need for physical prototypes. In our unique Zero Prototype Lab in Wolfsburg, we use the latest simulation methods to eliminate the need for real prototypes.

We integrate virtual software and hardware models using technologies and methods such as multibody simulation (MBS), software-in-the-loop/hardware-in-the-loop simulation (SIL/HIL), noise-vibration-harshness analysis and the finite element method (FEM). This enables us to predict and optimize vehicle behavior, driving performance and safety in the early development phases. Our pioneering simulator center uses driver-in-the-loop (DiL) simulation to virtually test the driving experience and incorporate subjective feedback directly into the development process.

The result: shorter development times, customized solutions and the highest quality – regardless of the season – for development without physical prototypes.

Whether you are developing autonomous driving functions, driving dynamics, vehicle movement or the human-machine interface (HMI), the EDAG Group offers customized simulation solutions. This way, we shorten your development time, significantly reduce the carbon footprint of your projects and give you a decisive competitive advantage. Place your trust in the EDAG Group, an independent development service provider with decades of experience. With digital prototypes, we work with you to realize sustainable, driver-oriented and future-proof vehicle development.

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Topic overview


Redefining the driving experience: our advanced automotive simulations

Development without physical prototypes requires an intelligent combination of various simulation methodologies. The EDAG Group uses a wide range of virtual development methods, from FEM for strength and stiffness analysis, acoustic and fluid simulations, MBS for driving dynamics, kinematics and structural dynamics, to model-based simulation platforms for simulating electrical architectures, sensors, computer systems and software components.

More in our whitepaper    More about the ZERO PROTOTYPE LAB

Digital prototypes in use: what simulators we use

In the Zero Prototype Lab, the EDAG Group relies on three state-of-the-art simulators that enable realistic and efficient vehicle development:

  • Dynamic Simulator DiM500

      The world's largest cable-driven hyperdynamic simulator offers an authentic driving experience thanks to 1:1 motion cueing and a carbon fiber hyperdock cockpit. Drivers can experience and optimize acceleration, rotation, vibrations and sounds up close, even during complex driving maneuvers.

  • Compact FSS Simulator.

      This simulator covers the entire frequency spectrum from 0.5 Hz to 20 kHz. The noise-vibration-harshness simulator (NVH) precisely simulates noise, vibrations and oscillations, which allows driving comfort and vehicle acoustics to be optimized – ideal for tests that focus on human perception.

  • Desktop Simulator (AutoHawk 24)

      This platform enables real-time simulations and hardware-in-the-loop testing. It is crucial for the seamless integration of software and hardware components into the development process.

With these simulators, the EDAG Group offers a comprehensive testing environment that covers all aspects of vehicle development – from driving comfort and acoustics to system integration.

Racing-Simulator: Solutions for motorsport

  • Customer requirement:
      • Cost savings
      • Independence from race track availability
      • Training and testing independent of the season
      • Time savings in vehicle setup
  • Solution:
      • Deployment of the unique DiM500 simulator
      • Realistic driving experience through precise reproduction of driving dynamics
      • Real-time capable driving dynamics simulation
  • Your benefits:
      • Flexibility: Any track can be virtually driven in any weather conditions.
      • Efficiency: Vehicle setups can be adjusted in seconds.
      • Cost reduction: Reduced resource consumption and less wear and tear on physical components.
      • Innovation: Vehicles that do not yet exist can be tested (e.g. race cars in early development stages). 
         
      • FOR DEVELOPMENT TEAMS: Virtually test vehicle concepts before building physical prototypes. Reduce costs, accelerate schedules and gain accurate data for optimization.
      • FOR RACING TEAMS: Perfect setups tailored to specific drivers and circuits like Portimão. Virtual testing minimizes physical component wear and maximizes efficiency of preparation regardless of circuit availability.
      • FOR DRIVERS: Familiarize yourself with new vehicles and tracks, understand setup changes and effectively prepare for upcoming challenges.

Application of digital prototypes in research

  • Customer requirement:
      • Investigation of the interaction between driver and vehicle
      • Realistic testing of various driving and traffic scenarios
  • Solution:
      • Use of simulators in the Zero Prototype Lab to answer specific research questions such as reactions to touchscreens
      • effects of not having a steering wheel
      • effects of distractions from cell phones
      • simulation of critical scenarios, e.g. fatigue or the influence of alcohol
  • Your benefits:
      • Realistic test scenarios provide valuable insights into ergonomics, safety and user experience.
      • Flexible adaptation of the simulators enables customized research results and optimized vehicle concepts.

Advantages of the Zero Prototype Lab:
Digital prototypes for vehicle development

  • Cost and resource savings: Fewer physical prototypes mean reduced development and material costs.
  • Accelerated development time: Early testing and adjustment in the virtual space shortens the time to market.
  • Year-round testing: Testing independent of the season under controlled environmental conditions, adaptable to different test tracks and conditions worldwide.
  • Flexible customization options: Modern testing enables fast and precise optimizations and simulations for hardware and software.
  • Reduced carbon footprint: Sustainable vehicle development through reduced material consumption and resource-efficient processes.
  • User-centered development: HiL simulations and ergonomic vehicle adaptations in a virtual environment contribute to comfort and intuitive operation.
  • Advanced simulation options: Realistic and repeatable testing of assistance systems and autonomous driving in a safe environment provides valuable data.

INNOVATIVE VEHICLE DEVELOPMENT

We want to work with you to implement vehicle development projects and develop optimal solutions that strengthen your competitiveness. With our many years of experience and expertise in the field of digital prototypes, we provide you with comprehensive support in the development of driving functions – from virtual product design to safe market maturity.

Let's talk about your specific use case now!

David MünzingSenior Sales Manager