In the field of vehicle safety, we cover all areas typically analyzed using the finite element (FE) method. This includes all high-speed load cases such as front, side, and rear crashes. Numerous development projects with our customers have enabled us to build extensive expertise in this area.

For low-speed load cases, we have often succeeded in making optimal use of the available deformation space through innovative energy absorption concepts. In recent years, pedestrian protection has also gained increasing importance. Within various projects, we have developed concepts for bumper and front hood systems.

We use PAM-CRASH, LS-DYNA, and ABAQUS/Explicit to simulate a wide range of crash scenarios. The choice of software depends on customer requirements.

Examples:

• Head impact – makross models for grilles and control units show excellent correlation with FMVSS 201 and ECE R21 test results
• Front impact
• Rear impact
• Pedestrian protection
• Side impact
• Head impact

Using detailed simulation methods, we analyze various misuse load cases to ensure component robustness and durability under extreme or unintended conditions.

Examples:

• Infotainment display
• Glovebox latch

Dummy simulations are an integral part of most crash load cases today. When dummy load values are required in addition to vehicle parameters, we perform complete analyses including airbag systems.

For component design—such as seat development—we often use freely available rigid-body dummies. These allow an accurate representation of load introduction into the structure.

Front and rear crash analysis according to ECE-R17, as well as eigenfrequency, shaker, and noise analyses (explicit and implicit).

References:

• D4/T99 Audi
• BMW 7 Series (F01)
• Rolls-Royce (RR4)
• VW Golf / Passat / Skoda

As part of thesis projects and pre-development tasks, we have developed a calculation method that simulates the entire closing process of a door or hatch, including the lock mechanism and seal. The results provide answers to most design questions.

Collisions with other body parts and gap measurements can be evaluated. Additionally, the dynamic decay behavior and the force-time profile of the lock hook can give insights into the expected closing noise. The transient force curves also support the design of locks, hinges, and bumpers.

Another objective of this method is to assess the structural strength of the load-bearing components and attached parts. In collaboration with LMS, we developed a way to process transient element stresses in the LMS FALANCS durability program. This allows prediction of the number of door or hatch closures at a given closing speed until failure begins. Integration of nonlinear, strain-rate-dependent material behavior also enables simulation of misuse load cases.

For door or hatch closing simulations, we use PAM-CRASH, LS-DYNA, and ABAQUS/Explicit.

If nonlinearities arise in a kinematic analysis that cannot be solved using implicit dynamic methods, an explicit rigid-body simulation can be used to find a solution. This is particularly relevant when parts of the kinematics are defined via guideways with pronounced contact regions or when a fabric simulation for a soft top is to be integrated.

Static load cases with very large nonlinearities can often only be solved implicitly using significant simplifications. In certain cases, it is advisable to prioritize realistic boundary conditions over strict calculation accuracy. Examples include quasi-static roof push tests or ECE R14 analyses with seatbelts and body blocks.

In all cases, computation times are reduced so far that inertia effects no longer influence the results.

Through extensive development work, we have established a calculation method that accurately represents fabric behavior during the opening and closing of a roof system. This allows precise prediction of fabric folds and identification of potential overstretching. Areas prone to chafing or trapped fabric in the storage position can be detected.

Even before the first prototypes exist, the fabric layout can be optimized through targeted fold design.