we drive future Profile of the Institute The Institute of Vehicle Concepts Institute brochure

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1 we drive future Institute brochure Profile of the Institute The Institute of Vehicle Concepts

2 The Institute of Vehicle Concepts The (FK) is a systems institute. It processes and coordinates technically relevant transport and traffic engineering research topics to develop new vehicle concepts and vehicle technologies. The institute s research fields address the development of future technical systems for sustainable, safe and affordable vehicle generations for road and rail transport. The institute s contributions extend from conception and design via engi neering design, calculation and simulation through to the manufacture of research demonstrators, components and vehicles. Our research fields at the institute are: - Road vehicle concepts - Rail vehicle concepts - Alternative drives - Lightweight vehicle construction The institute s guiding vision for vehicle concepts is one of successful scientific collaboration for efficient mobility, based on regenerative energy sources and energy conversion/storage of the future as well as advanced construction and lightweight engineering for road and rail vehicles. The integration of innovations in materials, processes and construction methods takes place in the network comprising of the DLR, the Helmholtz Association (HGF) and international science partners. Within the scope of the transport research programme, the works together with the Institute of Transport Research, the Institute of Transport System Technology and with around 20 other DLR institutes. The is integrated into the regional networks at the Stuttgart site and maintains a Branch Office in Berlin-Adlershof. 2 3

3 Mission The institute s mission is the research, development and evaluation of innovative vehicle concepts for road and rail transport systems. This encompasses the whole technical system, including vehicle conception and design based on the requirements of society and politics and, more recently, of the development of mobility and the corresponding development and evaluation of technical vehicle solutions. The research and development services provided are focused on application orientation and current relevance. The defining feature of the innovation builds upon significant advances in ecological or sustainability-oriented quality concepts. The mandatory requirements of safety and efficiency have to be met for all concepts. A part of the mission is also to apply the results of engineering science to continuously expand the range of teaching offered in the university sector. Exploration, development and evaluation of innovative vehicle concepts for road and rail We provide research and development services in the fields of - Raising energy efficiency - Reducing vehicle rolling resistance, and - Systemically relevant vehicle technologies Vision Our vision is focused on designing sustainable concepts for road and rail vehicles so that the future traffic requirements regarding - Sustainability - Safety and comfort - Economic efficiency can best be met in comparison with all other aspects. The institute is a nationally and internationally esteemed provider of research and development services for holistic systems concepts and selected leading-edge technologies. 4 5

4 Systems and Technology Research The research and development work on vehicle concepts and technologies is monitored by continually evaluating its economic and environmentally relevant potential and impact. The mobility determinants are processed and compared with the other traffic institutes of the DLR in order to implement the new vehicle concepts and their technologies and to shape the interactions between the traffic system and new vehicle concepts. Mobility Demands - CO 2 - Legislation - Energy prices - Availability of natural resources - Living habits Society s Needs Transport System - Requirements - General conditions - Target functions - etc. Provision of Capacity Concept Tasks Individual Solutions Vehicle Concepts - Configuration - Parameterisation - Optimisation - etc. Technology Demands Technology - Energy converter - Energy storage - Materials - Management and recycling - etc. Available or New Technologies 6 7

5 Orientation and Research Fields Concepts and road vehicles Concepts and rail vehicles Alternative drives Lightweight vehicle construction Alternative drives: Range extender technologies Systems and concept research for road and rail vehicles + Leading-edge research in selected technologies Alternative drives: Hydrogen climatic chassis dynamometer Ability to synthesise with research institutes and DLR network Lightweight vehicle construction: Dynamic components inspection 8 9

6 Research Field Concepts Road Vehicles Research Field Concepts Rail Vehicles Motivation Increasing volume transport, shortages of resources and environmental burdens as well as increasing urbanisation call for innovative systems, concepts and technologies Research Tasks - Conception and demonstration of innovative vehicle concepts - Exploration and holistic assessment of new technical solutions Key Results - VECTOR21 scenario model for motor vehicle and commercial vehicle drive systems - Next Generation Car (NGC) - HyLite fuel cell demonstrators - Light Urban Vehicle - Modularisation & platform strategies Motivation - Mass transport from the perspective megacities and energy efficiency set the general conditions for rail transport Research Projects - Innovative multiple-unit train concepts - Increasing energy efficiency Key Results - Next Generation Train (NGT) high-speed train concepts in independent running gear design - Concept commuter train NGT LINK with hybrid drive concepts - Wheel-integrated power trains - Modular lightweight honeycomb structures for car bodies with a high structural component - Software tools for evaluating high-speed traffic potentials HGV, LCA and Modelica libraries Car of the future Lightweight sandwich Chassis module High-Speed Train (HST) construction 10 11

7 Research Field Alternative Drives Research Field Lightweight Vehicle Construction Motivation - The combustion engine (hybrid) drive as the backbone for road traffic - Further efficiency increases required E-mobility plays an important role in vehicle efficiency and emissions - Innovative energy and thermal management is vital Research projects - Holistic modelling for vehicle energy architectures - Solutions for significant efficiency increases in future drives - Innovative energy conversion concepts Key Results Modelling energy flows with in-house libraries - Free-piston linear generator as a range extender - Secondary energy usage with thermoelectric generators Robust modular fuel cell systems Motivation Lightweight construction is a key technology for reducing rolling resistance and energy consumption Research Projects - Integrational processing of methods, materials and architectural concepts - Lightweight construction concepts and new technical solutions for ground-based vehicles - Functionally integrated lightweight structures Key Results - CFRP-intensive multi-material design - Adaptable crash-safe front end for alternative power trains - Rib and space frame construction method - Lightweight structures for rail vehicles - Structural sandwich components - LEICHT chassis for electric vehicles of the next generation - Shape-adaptable high-pressure CNG tank, in hybrid lightweight construction Test bed for all-wheel climatic chassis dynamometer Free-piston linear generator Carriage body Superstructure carbon-fibrereinforced polymer frame 12 13

8 Competences Skills The generates system-relevant knowledge through cross-institutional networking at the DLR and establishes the full system capacity as the Vehicle core competence. This includes the continuing development and advancement of the internal basic competences in the in-house research fields (departments) as well as the continuous close exchange with the DLR institutions and external partners at the relevant specialised level. The institute is able: - To penetrate the whole system in terms of rail and road vehicle concepts - To analyse, advance and further develop each of the system elements and their interactions - To analyse and develop new technologies, including the identification of future demands, requirements, and demands and to use these effectively and efficiently in the test beds as well as to verify these with research demonstrators - e.g. strategic approaches towards low or non CO 2 -emitting mobility through the development of technological solutions to drive forward energy efficiency and reduce vehicle rolling resistance Research Fields of the Vehicle systems and technology assessment 1 Innovative road and rail vehicle concepts Vehicle energy concepts 2 Alternative energy conversion 3 Lightweight and hybrid design methods

9 Fields of Research/ Departments Competences Work in Progress (Examples) Vehicle systems and technology assessment - Analysis of innovative vehicle systems - Analysis of innovative vehicle technologies - Scenario technology, scenario lab - Life cycle analysis - Scenario model VECTOR 21 - Life cycle analysis LCA design - Eco life cycle magnesium in vehicles Vehicle energy concepts - Drive concepts - Simulation & modelling - Energy and thermal management - Research prototyping - Drive test bed & climate rolling test bed Simulation environment MODELICA: Model Library Alternative Vehicles - Thermal management and air conditioning for vehicles - City logistics vehicle with fuel cell drive system Alternative energy converters - Development, engineering design and demonstration of electrical machines - Development, engineering design and residual energy utilisation systems - Development, engineering design and demonstration of range extenders - Test beds for electrical machines and linear range extenders - Free-piston linear generators (FKLG) - Highly integrated wheel drive systems - Thermoelectrical on-board generators (TEG) Lightweight and hybrid design methods - Material and lightweight construction methods - Lightweight vehicle concepts for road and rail - Conception, engineering design, simulation and validation of vehicle structures - Technologies for multi-material structures - Test beds for static and dynamic (crash) loads, corrosion testing - Concept lab - CFRP-intensive composite construction method - Adaptive vehicle structures for road and rail - New lightweight (sandwich) solutions - Conceptual methods and simulations - CFRP function integrated lightweight structure (ARENA 2036) 16 17

10 Equipment/ Testing Facilities The institute s equipment and facilities make it possible to conduct research on complex, technologically intensive tasks. Components - Mandatory contributions for verifying research solutions in the transport programme - Creating and consolidating unique selling points (USPs) in the development and application of new test procedures - Supporting complex technology topics with testing tasks on behalf of clients Hot gas test beds Dynamic and static load bearing test rig Subsystems Test beds for fuel cell systems Crash test bed Development Platforms Test bed for all-wheel climatic chassis dynamometer Vehicle concepts and: - Test bed electrical storage - Test bed electrical drives - etc. and: - Joining technology lab - Simulation cluster - etc

11 Sites and Branch Offices The is located at the sites in Stuttgart and Berlin-Adlershof and has a Branch Office at the STEP Engineering Park in Stuttgart. There are also plans to occupy further premises at the Forschungscampus ARENA DLR Site Stuttgart Deutsches Zentrum für Luft- und Raumfahrt e.v. (DLR) Pfaffenwaldring 38 40, D Stuttgart Branch Office Stuttgart STEP Engineering Park: Deutsches Zentrum für Luft- und Raumfahrt e.v. (DLR) Meitnerstraße 10, D Stuttgart DLR Site Berlin-Adlershof Deutsches Zentrum für Luft- und Raumfahrt e.v. (DLR) Rutherfordstraße 2, D Berlin Forschungscampus ARENA 2036 (being planned) 20 21

12 The Pfaffenwaldring Universität 14 Address and Contacts Universität Head of the Institute Prof. Dr.-Ing. Horst E. Friedrich Deutsches Zentrum für Luft- und Raumfahrt (DLR) Pfaffenwaldring Stuttgart Telephone: Contact Kristiane Schuster Public Relations Deutsches Zentrum für Luft- und Raumfahrt (DLR) Pfaffenwaldring Stuttgart Telephone: Kreuz Stuttgart 14 Meitnerstraße Wankelstraße Overview and Traffic Connections Österfeld You can reach the as follows: By car: From the motorway A8 travel towards München/Ulm or Karlsruhe, or from the A81 travelling from the direction of Heilbronn or Singen towards the motorway junction Stuttgart and then Stuttgart Stadtmitte. Take the third exit (Universität). After the exit at the third traffic light intersection, turn left over the bridge to Pfaffenwaldring (first junction on the right). You then reach the DLR on the right-hand side after around 1500 metres. Parking spaces located at the gate/barrier. By rail: Stuttgart Central Station Hauptbahnhof Stuttgart (ICE-Station), continue by regional S-Bahn (Line S1, S2, S3) towards Herrenberg, Filderstadt or Stuttgart Airport Flughafen/ Messe (Convention Center). Universität stop, follow the DLR signs; about 10 minutes until you reach the destination. By plane: Airport Stuttgart-Echterdingen, continue by regional S-Bahn to Universität stop, or take taxi (about 30 minutes)

13 DLR at a Glance DLR is the national aeronautics and space research centre of the Federal Republic of Germany. Its extensive research and development work in aeronautics, space, energy, transport and security is integrated into national and international cooperative ventures. DLR has approximately 8000 employees at 16 locations in Germany: Cologne (headquarters), Augsburg, Berlin, Bonn, Braunschweig, Bremen, Goettingen, Hamburg, Juelich, Lampoldshausen, Neustrelitz, Oberpfaffenhofen, Stade, Stuttgart, Trauen, and Weilheim. DLR also has offices in Brussels, Paris, Tokyo and Washington D.C. Profile of the Institute_GB_02/2015 Stuttgart Pfaffenwaldring Stuttgart Telephone: Telefax: DLR.de/fk/en