Our services

Services2023-09-01T09:29:21+02:00

Conception

Construction Prototyping

Simulation

Testing

Trainings

FMEA

Conception

From the concept to the design and construction of the first axis modules

Starting with the proverbial blank sheet of paper

… or the available installation space, we develop individual concepts, also for test vehicles and show cars. We determine promising development approaches with the help of initial simulation calculations and CAD construction space investigations.

In addition to classic axle concepts such as McPherson front axles and multi-link rear axles, we also design new approaches in the field of e-mobility. The Schaeffler Mover demonstrates such an innovative concept. Here, the development ranged from the concept to the design and construction of the first real axle modules.

The automotive supplier Schaeffler had a vision of a flexible platform that would enable extreme steering angles of up to 90° by means of a wheel hub drive. TRE found the solution in the Intelligent Corner Module, which includes drive and brake, but also steering, suspension and damping. Here, completely new effects for driving stability and functional safety had to be taken into account.

Thanks to this chassis, the vehicle can, among other things, park sideways and turn on the spot. This results in unique application possibilities in urban areas. Depending on the desired use, bodies for passenger and freight transport can be mounted on the compact and variable “rolling chassis” without having to adapt the drive and running gear.

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Design and prototyping

from single parts to complete axis modules

Construction

We provide native 3D models and drawings for CAD software such as Siemens NX and CATIA. Of course, we take into account the OEM-specific standards for model creation. If desired, we are able to enter the data directly into the customer’s product data management system, for example via remote desktop.

In some cases, reference parts are available as hardware. We use reverse engineering to transfer these to the 3D model, where they can be redesigned to meet requirements. To achieve the weight targets, we use topology optimization. In addition, we prove the component properties with the help of extensive FEM investigations.

We design components ready for production and assembly depending on the area of application. In addition to forming, shaping and classical machining, we also design components for additive manufacturing (metal 3D printing). The design is carried out in close coordination with our long-standing suppliers (from manufacture to Tier1). Thanks to our network, we can also provide high-quality hardware at short notice.

Topology optimization

By means of topology optimization, we design components even before the actual calculation with special attention to the weight or stiffness targets. We achieve particular success with milled and cast parts such as wheel carriers, control arms and swing arms. Thus, within the available installation space, material is only used along the relevant load paths. The result is an organic functional design of the components. For optimization, we use Altair Inspire, among others.

Finite Element Method (FEM)

The finite element method (FEM) enables the simulation of material behavior within individual components. The result is proof of the component’s functionality in the desired usage scenarios or load cases. Die Lastdaten können extern oder bei TRE ermittelt werden. The model meshing, definition of boundary conditions and calculation is covered by a proven tool chain. These include Abaqus, ANSYS, FemFAT and the ANSA pre-processor.

The core objective of the investigation is to prove the strength of the components. The fatigue strength can also be determined and evaluated. Furthermore, we determine the component stiffness. The study is rounded off by various frequency analyses. We provide the output in the form of a Modal Neutral File (MNF) for further investigation in Multi Body Simulation.

Prototyping

Aggregate carrier, concept vehicles, rolling chassis

From single pieces to small series, we realize the production in our in-house workshop. With great expertise in welding technology, we manufacture welded assemblies from steel, stainless steel and aluminum – from simple sheet metal brackets to control arms and axle carriers to complete vehicle tubular frames. We adapt series parts for use in the prototype. We also handle the necessary fixture construction internally.

Composite workshop

In our composites workshop, we laminate flat components with glass fiber, carbon fiber and aramid reinforcement using the vacuum infusion process. This is how exterior and interior trim, aerodynamic components, battery housings and other parts are produced. The mold construction is realized by our long-term partners.

Axis modules

We supply you with completely assembled assemblies and axis modules. We rebuild the body of the carrier vehicle to provide functional aggregate carriers.

3D measuring systems

Measuring equipment includes a Stiefelmayer coordinate measuring machine (6m x 3m x 2m), a Romer 3D measuring arm and a chassis measuring system. With these devices we cover both tactile and optical measurement. Examples include the axle kinematics of a reference vehicle, 3D scans of components and the quality assurance of our components as measurement tasks. The PolyWorks software serves here as an interface to the CAD environment.

Simulation

Many years of experience combined
with the latest development tools

Multi-body simulation (MBS)

For more than 20 years

Chassis simulation is an important part of the virtual vehicle development process. Over the years, TRE has brought both model quality and evaluation performance to an optimal level. In their work, our engineers can rely not only on many years of experience, but also on TRE’s own toolbox as state-of-the-art development tools for simulations. This enables our experts to focus specifically on the requirements of our customers.

Vehicle handling, ride comfort, functional safety, integration of multiple controllers in dynamic and/or real-time simulation are part of our standard development process. Nowadays, this even plays a decisive role.

The bar is set high for TRE. We have our roots in racing and consistently use this knowledge advantage for series products as well.

Axle simulation

In chassis development, we always look for the optimum compromise:

  • Driving behavior
  • Ride comfort
  • Security

With the help of our simulation, we are able to investigate the elastokinematic performance of a new axle early in the development process.

For example, our simulations provide us with information about:

  • Compliance
  • Natural frequencies
  • Track change with transverse forces
  • Change of the wheelbase with longitudinal forces of the axle

As a result, we also take into account complex elements such as:

  • Leaf springs
  • Composite handlebar
  • Sword Handlebar
  • Twist Beams

Our simulation experts ensure that your new axle will perform as desired even under difficult wheel conditions. We can simulate everything from simple, kinematically defined axes to overdetermined axis systems whose properties depend on the stiffnesses of the components. For this purpose, we create realistic axis models for a wide range of installation space requirements.

Total vehicle simulations

Already during the design phase, our complete vehicle simulations provide information about:

  • Driving behavior
  • Ride comfort
  • Security

Our customers’ products can thus be optimized even before the prototype, which significantly reduces the number of test runs. In our simulations, we take into account all components of the vehicle, for example the front and rear axles, the brakes, the steering and the tires, as well as electronic control systems. The description of the rest of the vehicle is done by parameters such as:

  • Masses & Inertias
  • Elasticities of the different subsystems

For our complete vehicle simulation, we use the “plug and play” approach, which means that our models are composed of individual elements, such as:

  • Steering
  • Axes
  • Powertrain

This approach allows different vehicle variants to be quickly generated and simulated. This enables us, for example, to significantly accelerate the development of derivatives.

By simulating complete vehicles, we can already early in the project:

  • Examine axis variants
  • Select series parts
  • Create different basic tuning

Another important point of our work is the comfort studies. Transfer functions from excitations to 30 Hertz are calculated for this purpose. In addition, we can examine the handling and driving dynamics of chassis on our own 7-stamp test rig. Our simulation experts have an excellent understanding of the designers’ requirements, which guarantees an effective approach to the basic design and packaging of axis systems.

Coupling with finite element analysis (FEA)

The chassis we develop and design guarantee a high level of component safety even under the toughest conditions. We benefit from our many years of experience in defining, applying and evaluating relevant load cases.

Already during the design phase, we generate the cutting loads for the skill and stiffness calculations with our MBS models.

We perform strength verifications for the axle components using our FE analyses. Standard load cases are simulated, for example braking, cornering and vertical impacts, as well as misuse load cases, for example pothole braking and curb impressions. Our full vehicle models also offer the possibility of deriving loads from dynamic driving maneuvers.

Our designers calculate the various components in NASTRAN/PATAN using the different load cases from our simulation tool ADAMS-Car. The automatic creation of NASTRAN-compatible load case files speeds up the calculation process and avoids errors during data transfer.

Testing

Vehicle dynamics, homologation, application

Driving dynamics

Application, homologation, test drives
and tests on test benches:

Our experts deal with
with all facets of driving dynamics.

Using extensive, in-house measurement technology such as steering and braking robots, they carry out approval-relevant and manufacturer-specific tests. As part of the application, they tune the parameters for the electronic control systems as well as for spring, damper and steering systems. With our experts, we are able to supplement the objective measurements with the subjective assessment as well. We assess driving dynamics and ride comfort on the basis of our customers’ driving maneuver catalogs or TRE’s own specifications.

Within the framework of our benchmarks, we compare the products of different manufacturers and develop the basis for optimizing their chassis for our customers.

This enables TRE to take on extensive development tasks in the field of vehicle dynamics and offer its customers a one-stop service.

Driving Maneuvers Catalog (FMK)

At the end of the application, our specialists test the quality of the bedding. To this end, they conduct tests at test sites around the world according to customer-specific or TRE’s own driving maneuver catalogs – directly at the OEM or at a free test site. In this way, we ensure that the application of ESP/ESC, ABS and EPB meets the brand-specific requirements of the vehicle manufacturers.

Homologation

Steering robot

With our steering robots from ABD we perform driving maneuvers for the evaluation of the cornering behavior of vehicles and stability tests for the evaluation and verification of the ESC system (in compliance with the various legal requirements such as FMVSS126, ECE R13H Annex 9a or KMVSS Art.90-2). The tests take place at our customers’ test sites or freely available test sites around the world and form the basis for certifications. Based on the results, we make recommendations for the release of the different systems.

Not only are we proficient in all driving maneuvers, such as the Sine with Dwell, Fishhook and J-Turn, but we also use our own measurement technology to record data: With our OXTS, GPS and inertial navigation system, we can determine the vehicle response very precisely. In this way, we determine exact values with which the cornering and lateral behavior of the vehicles can be precisely evaluated and compared. Our repertoire also includes customized driving maneuvers to determine various driving dynamic variables. They are carried out by trained TRE experts in close coordination with our customers.

TRE experts also have extensive know-how in the use and adaptation of steering robots in motor vehicles. They have not only developed their own connections to the vehicle, but also mastered the handling, programming of driving maneuvers and data evaluation.

Furthermore, customer-specific driving maneuvers to determine various vehicle dynamic variables are also part of our repertoire and are performed by our trained TRE experts in close coordination with the customer.

Braking/driving robot

No matter whether Auto Motor und Sport test, ECE-R 13H Annex 9b or other approval-relevant tests: Tests with brake robots from ABD are one of TRE’s specialties. After all, many years ago we were one of the first companies ever to use them for vehicle testing. In the meantime, we have continuously developed the connection to the vehicle and the measurement technology, for example by using GPS and inertial navigation systems. This guarantees precise measured values and good comparability of the results.

With our brake robots from ABD, we can control for pedal travel, pedal force, as well as vehicle deceleration, and adjust brake pressure to within less than one bar. This gives us precise information about braking behavior in different situations – for example, depending on tires or brake pads.

Application

Spring damper systems / 7-stamp system

For the application of vertical dynamics, we use a test rig with seven hydraulic rams (7-Post Rig), which can be controlled by both force and displacement. The four wheel rams (125 millimeters amplitude) are responsible for the vertical movement of the wheels, while the three chassis rams (150 millimeters amplitude) contribute the pitch and roll moments as well as the aerodynamic forces. On the test bench, we can examine drivable and non-drivable road vehicles as well as drivable and non-drivable racing vehicles.

With our 7-post rig, we perform modal analysis (e.g., heave, pitch, roll, and torsion excitations) with and without chassis excitations, track simulations with and without chassis excitations, tests to condition virtual vehicle models, and validation tests for simulation models. However, the test rig is also suitable for complete vehicle measurements (e.g. body stiffness and frequency analyses), vertical excitation of aggregate bearings and pre-tuning of derivatives. State-of-the-art test rig technology delivers reproducible results.

TRE also has its own servo-hydraulic damper test bench (100 millimeters amplitude, six meters per second), which we can use to determine shock absorber characteristics and perform release tests. With its help, we check and modify currently installed identifiers, validate defects on the damper and offer our customers a complete service for determining all tuning variants. Our experts can draw on extensive experience with damper systems from various damper manufacturers.

Steering systems

When it comes to subjective tuning of steering systems, our many years of experience are of particular benefit to us: our application engineers are very familiar with the influence of the various parameters on driving behavior. In this way, we ensure that the calibration of various steering systems such as EPS, Servotronic or EHPS generates the desired brand-typical driving feel in terms of comfort, straight-line stability, cornering behavior, center position and torque buildup. If it cannot be achieved by purely applicative measures, we develop the necessary changes to the hardware together with our customers.

For objective measurements of temperature effects on steering behavior, we also use tests in the thermal wind tunnel at the customer’s request. There we can thermally measure the steering systems under various boundary conditions in a reproducible manner.

Brake control systems

On the road all over the world: Our application engineers test prototypes on our customers’ test sites, on the Nordschleife of the Nürburgring or on the ice of Scandinavian lakes. Thanks to our proximity to motorsport, we have a great deal of experience in the application of chassis systems of all kinds. Our test engineers have excellent skills in assessing vehicle behavior and excel in vehicle control – even at the limits of driving dynamics.

TRE not only takes care of the initial deployment, but also adapts derivatives to the requirements of different markets, for example.

When servicing brake control systems, we find the optimum compromise between driving safety and the driving behavior typical of the brand. We understand the philosophy of our customers, and our applicators ensure that the “DNA” of each manufacturer remains tangible in the chassis. This is done in close coordination with our customers and the system suppliers.

Subjective tuning

Subjective tuning puts the finishing touches on the vehicle at the end of development. In the process, we test and modify all facets of the application worldwide on public roads and under various climatic conditions – including such important vehicle characteristics as spring/damper/stabilizer tuning, elastokinematics, the combination of wheel and tire, and electronic control systems.

Thanks to their long experience, our test drivers have an extremely good feel for each vehicle and thus ensure that a chassis also exhibits the desired brand-typical handling in all vehicle derivatives.

Our experts test and apply the vehicles on proving grounds, race tracks and public roads. TRE test engineers are also trained for testing on the Nordschleife.

Trainings

Learn from our TRE specialists

cEVD – Certified Engineer Vehicle Dynamics

Practice-oriented course for driving comfort and driving dynamics

We have been offering our own state-of-the-art training courses for 10 years, incorporating our experience from 20 years supporting OEMs in vehicle and chassis development.

We make these competencies and experiences available to selected customers as exclusive advanced training. Our training courses are aimed at development engineers and employees of vehicle manufacturers and suppliers who wish to expand their experience to include subjective vehicle assessment. We also offer young engineers a quick entry into the matter, a major plus in view of the shortage of skilled workers in the automotive sector.

In small groups and under the guidance of expert TRE engineers, the following course contents are taught:

  • Theoretical concepts
  • Metrological basics
  • Simulation tools and important standards from the field of suspension tuning
  • Practical driving experience: two days at a test area
  • Participants learn on the basis of driving maneuvers how they can professionally assess and influence the tuning of suspensions
  • Subjective assessment of “comfort” and “dynamics

Our claim:

  • Learning with enthusiasm
  • Practice-oriented
  • Extremely small groups
  • Open and constructive working atmosphere
  • Experienced trainers with many years of experience in the areas of brakes, driving comfort and driving behavior (dynamics)
  • Knowledge from practitioners for practitioners

Our experienced trainers will introduce you step by step to the subjective evaluation and tuning of suspensions. In the two modules “Fundamentals” and “Advanced”, which build on each other, you will learn the most important terms, tools and methods from this demanding field. In the “Expert” module, we delve into individual topics according to customer requirements.

Upon completion of the training, you will receive a certificate from TRE as a “Certified Engineer Vehicle Dynamics”.

Fundamentals

In this two-day course, we provide a broad overview of chassis and subjective vehicle tuning.

In the Fundamentals course, our trainers work with a maximum of six participants to lay the theoretical foundations of the structure of a chassis and which aspects must be taken into account in the subjective evaluation. Subsequently, in the practical part of the course, you will evaluate the characteristics of suspensions, in terms of ride comfort and driving dynamics.

Attendees range from those unfamiliar with the field to engineers looking to advance their skills in subjective assessment or tuning.

Day 1: Laying the theoretical foundation and first practical experience

  • Introduction to the function and structure of suspensions
  • Possibilities and limits of simulation for the chassis area
  • What significance the subjective evaluation of chassis makes
  • Which aspects play a role in the subjective assessment
  • First practical work: TRE trainers show how to professionally evaluate selected chassis properties

Day 2: Subjective assessment of driving dynamics and ride comfort

  • Carrying out test drives and driving maneuvers under the guidance of a trainer
  • Getting to know braking and turn-in behavior in detail
  • There is one vehicle per two participants, so each participant drives three different vehicles for judging
  • The basis for the assessment is the grading system with ten gradations
  • Participants rate ten precisely described individual criteria in the comfort area
  • During the dynamics assessment, participants evaluate according to fifteen detailed individual criteria

The aim of the “Fundamentals” module is for participants to develop a basic understanding of the complex subject of “chassis tuning” and to become familiar with selected facets of subjective evaluation. In addition, they should also be taught how to continuously improve during everyday trips.

Advanced

Building on the “Fundamentals” course, we introduce the maximum of six participants to the fundamentals of chassis tuning in greater depth in the two-day “Advanced” module.

This course also consists of a theoretical and a practical part. Here, participants learn about measurement techniques and their standards and can also experience the effects of changes to the chassis on the test track.

Day 1: Setting up the chassis of the test vehicles

  • Explanation of special chassis measurement techniques
  • Addressing chassis components of the test vehicles, which are modified in the practical part of the course
  • B. the influence of the stabilizer is presented in theory and practice
  • Based on the standards ISO 3888-1 (test procedure for double lane change) and ISO 14512 (braking on µ-split) the participants learn the boundary conditions, the procedure and the evaluation of the tests.

Day 2: Driving tests on a test track

  • Two participants at a time experience under the guidance of a trainer what effects the changes to the chassis have on the driving behavior.
  • What happens when stabilizers are switched on and off
  • What consequences have different air pressures in the tires
  • What changes when the vehicle dynamics control (ESP) is switched off

After attending the “Advanced” module, participants will have mastered the more advanced aspects of chassis tuning, and will also have developed a basic understanding of the relevant ISO standards and the associated driving tests.

Expert

We offer our customers customized workshops on a wide variety of topics. The focus is determined by our customers themselves.

Our two-day course for a maximum of four participants is a combination of theory and practical driving tests. Our customers can determine the thematic focus themselves. We offer workshops on very different topics. In preparation for the official Industry Pool Nürburgring license, TRE has successfully trained numerous test engineers and test drivers from OEM Industry Pool members.

Possible topics are:

  • Subjective tire test: Here, participants learn to assess the effects of different types of tires on dynamics and ride comfort and become familiar with the specific terminology in this area
  • ESP: Introduction to the operation and different controllers
  • Chassis tuning using the example of changes to the shock absorber
  • Learning which effects a change of a damper map has on the driving behavior

In addition to track knowledge and an improved driving style, participants gain additional knowledge about driving dynamics, vehicle reactions and chassis evaluation.

After attending the Expert module, participants will have developed a detailed understanding of the subject. In the respective area, they can now also communicate with experts at eye level.

FMEA

Failure Mode and Effect Analysis

Risk quantification with the aim of error prevention

We have many years of experience in the areas of:

– Product FMEA design (including chassis, cooling)
– Product FMEA Customer operation/field (including powertrain, electronics, chassis)

The FMEA is created in the following six steps:

Define system boundaries – Analyze structure – Perform functional analysis – Perform failure analysis – Evaluate risk – Define optimization measures

Our services include:

– FMEA preparation
– Planning of the team meetings
– Appointment coordination
– FMEA Moderation
– FMEA postprocessing
– Tracking of the measures (on request)

For the creation of the FMEA we master the tools:

– APIS IQ FMEA
– SCIO Plato FMEA, SCIO Plato Matrix, Net-Builder

Team meetings are moderated in accordance with the current guidelines of VDA Volume 4 / DIN EN 60812.

News

Neustadt

TRE GmbH
Nachtweide 35
67433 Neustadt/Weinstraße

Contact

Phone: +49 (0) 6321 8786 – 0
Fax: +49 (0) 6321 8786 – 105
E-Mail: info |at| tre-gmbh.com

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