Virtual product development
From the first idea to mass production
Virtual product development allows engineers to simulate the behavior of components and systems under various operating conditions and optimize the components before progressing to the prototype phase. First the prototypes of individual components are tested alone. In the next test step the prototype is then integrated into the system on the test bench and finally tested in the complete vehicle.
The virtual prototype is based on 3-D models
ZF engineers design components and assemblies directly using 3-D CAD programs for representation corresponding to the function and process. Design of the components is therefore accomplished hand in hand with computer-aided planning of the production, testing and assembly processes. Simulation of the function and load are also computer supported.
Component optimization with computer models
The load factors for the individual component versions are calculated using the Finite Element Method (FEM). The illustration shows the point on the housing subject to the highest load, indicated by the red area. This method eliminates tension peaks and increases the service life through optimization of the geometry.
Vehicle simulation
A software tool simulates the effects of various driving strategies or transmission configurations for each vehicle concept, providing information on the fuel consumption and performance of a new transmission design even before realization of the hardware.
Measured values under actual conditions
Real conditions and load collectives are simulated on the test bench and measurements performed on the vehicle during operation. Experimental results are generally compared with calculations to save engineering time. The knowledge gained flows into further development of the series.
