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The development of entire car bodies benefits from simulations, especially if they are performed at an early stage of development. Simulations lower the costs for required car body modifications. This paper focuses on dip painting simulation and describes the simulation process by detecting badly painted areas and liquid carry overs. A new hydrodynamic method has been benchmarked to CFD and real-life results. Results will be shown together with case examples. The solver is similar to, and as accurate as, standard CFD solvers; it is faster in its computation speed by a factor of at least 1000. The electrophoretic deposition (ELPO) of an entire car body can be simulated overnight with ALSIM. How is this possible? This paper points out the reason for all of this.

Simulations need high quality mesh representations as input which are often manually prepared. The fully automatic mesh preprocessor software MERGE avoids this time consuming task. The software CAD or STL data as input, repairs invalid meshes and merges the input objects together. Small gaps between the input objects are automatically closed. The output surface mesh can be supplied in two different flavors, either as a mesh that minimizes the number of elements or as a mesh consisting of high quality triangles, ready for 3D meshing. A closed and connected surface mesh of an entire car body can be prepared overnight in a fully automatic manner.

Liebherr Machines Bulle SA has chosen a technical solution for their 4 cylinder engines on the basis of cooled EGR and a closed DPF system including a fuel dosing unit to achieve Stage IIIB / Tier4i Emission Standards. Main portions of the development, especially the engine and after treatment calibration was performed together with Engineering Center Steyr. The calibration was done under consideration of best fuel consumption, optimized combustion acoustics, satisfying vehicle dynamics as well as fulfillment of legislative regulations, engine and vehicle boundaries. The usage of complex software functionality, a sophisticated calibration process as well as a high end 2000bar injection system was mandatory.

In 1991, Hino Motors, Ltd. (Hino) launched the world's first hybrid city buses in the market. Thereafter, Hino has improved its hybrid vehicle technology and applied it to various commercial vehicles including city buses, sightseeing buses, medium-duty trucks and light-duty trucks. Presenter Shigeru Suzuki , Hino Motors, Ltd Shigeru Suzuki , Hino Motors, Ltd

Main topics are the development and the build-up of an 18ton hybrid truck with a parallel hybrid drivetrain. With this truck it is possible to drive up to 3 kilometers in the pure electric driving mode. In this R&D Project the Engineering Center Steyr, a company of MAGNA Powertain has developed a hybrid truck with an integrated motor generator (IMG) including a clutch system for pure electric driving. Also a Li-Ion power battery, electrified traction voltage auxiliaries (steering pump, air compressor and climate compressor) and a cooling system for the new power electric components. The beginning of the paper shows a detailed layout of the developed hybrid truck. Chapter two shows the developed simulation model which is used for the dimensioning and for detailed simulations of hybrid drivetrains. To simulate thermal effects, a co-simulation environment between a longitudinal dynamics and thermal management software is applied.