1. Development of Special-Purpose Vehicles
From the Design Sketch to the Finished Test Vehicle
From the idea ...
Special-Purpose Vehicles
u Public-authority vehicles,
e.g. police cars
u Emergency ambulances
u Fire command vehicles
u Taxis
u Driving-school vehicles
u Vehicles equipped with driver
assistance systems
Armored Vehicles
Individualization
u IAV also has a broad range
of development expertise in
Task relation to individualizing
The specific components of special-purpose vehicles must be integrated in vehicles and to armored
the existing basic vehicle in the best way possible. vehicles (armoring classes
B4 to B7).
Due to the ongoing decrease in available installation space, the package of
modern vehicles makes it very difficult to integrate additional components. Solution
This is true for visible areas, such as the instrument panel, as well as for IAV is ideally equipped to deal with
installation positions “hidden” behind cladding or panelling. these demanding tasks. We provide
a depth of competence in
Smart concepts and detail solutions are required that do not entail substantial electrics/electronics, developing
changes to the basic production version of the vehicle. Another challenge specific exterior and interior
developers are faced with is to adapt the specific components to the high- components, parts list systems as
quality interior design of modern vehicles. well as in testing and constructing
test vehicles. We use modern project
The integration of electric components into the vehicle’s production power management tools to reach the
supply system requires major interventions, especially on modern vehicles fully targets set by the “magic triangle” of
interlinked by a CAN bus. Electric components can no longer be integrated deadlines, quality/technology and
into the CAN control unit system and messages no longer be imported and costs.
exported by simply “connecting” the respective components, as in the past.
It is, for example, no longer possible to subsequently add functions to the
basic vehicle’s CAN bus without performing special measures.
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2. Development of Special-Purpose Vehicles
Concepts – Design – Product Development
Concepts
u Package layout
u Development of concept variants
u Concept visualization/design sketches (to support decisions)
Design
u Virtual and actual package analyses
u Components and assemblies design
u Preparation of drawings
Development of Power Supply System
u Concept selection
u Component selection
u System diagram
u Wiring diagram
u 3D wire routing (package)
u Electromechanical design
u Form-board drawing (production drawing)
Control Unit Development
u Feasibility analyses (CAN connection, validation, etc.)
u Algorithm definition
u Preparation and monitoring of specifications
u Algorithm integration (power supply control unit/door control
unit/steering column switch module, etc.)
u Vehicle testing (CAN/special functions)
u Preparation of drawings
u Clearance support
Comfort CAN Comfort CAN
Documentation
u Assembly instructions, installation documentation
u Circuit diagrams Power supply Door control Steering Instrument
control unit unit column switch cluster
u Support in preparing user manuals and service documents

3. Testing
u Planning and coordinating test drives
Prototype Construction
u Assembly and disassembly tests
u Construction of test and press
u Component and vehicle tests
1 Environmental simulation (cold and hot weather, paint resistance, sunlight
demo vehicles
simulation, corrosion) u Manufacturing of prototype
1 Component tests (e.g. continuous operation of doors and lids) parts
1 Misuse tests 1 Stereolithography
1 Support for vehicle endurance and fatigue strength tests 1 Selective laser sintering
u Vehicle safety 1 Fused deposition modeling
1 Offset, lateral and rear impacts 1 Vacuum casting
1 Head impact tests 1 Deep drawing
1 Airbag inflation tests
u Calibration of prototype parts
u Function tests
u Preparation of EMC measurements
u Stall-current measurements
u Start-up
System Integration
u Entering data into the database
u Definition of technical
constraints and prohibitions
u Preparing, coordinating and
monitoring clearances
u Change management
Door endurance testing
Process Integration
Depending on the client’s need, IAV's special-purpose vehicles team also takes care of
integrating these vehicles in the production or assembly processes concerned.
Here, it makes no difference to the special-purpose vehicle experts whether vehicles are
to be assembled by hand or quot;polishedquot; on the mass-production line. Support starts as
early as in the planning phase and is provided in close consultation with the Production,
Quality Assurance and Logistics departments of the manufacturing site until pre-
production and start of production. If needed, IAV also provides a task force after SOP.
www.iav.de

4. Development of Special-Purpose Vehicles
F 05/05
Further Activities
Cost Optimization
u Product management
u Project management Fierce competition and strong cost
u Marketing/sales support pressure in the special-purpose
u Procurement support vehicles sector are counteracted by
u Support in financial controlling cost-effective solutions. This includes:
u Support in quality assurance u Optimizing component costs by
way of close cooperation with
Marketing/sales support includes the evaluation of customer complaints component suppliers as early as in
and, based on the results, the preparation of model improvements, analyzing the design phase
competitors’ products, observing and introducing new technologies as well as u Adapting production processes to
helping with the preparation of marketing campaigns, service and repair
the number of units ordered
manuals.
u Optimizing production methods and
assembly processes
IAV’s scope of services may, upon request of the client, even go as far as
u Closely cooperating with the client’s
providing support in procurement processes, i.e. selecting, assessing and
monitoring suppliers and coordinating sample delivery processes, in financial Procurement and Controlling
controlling, e.g. elaborating cost-saving measures, and in quality assurance, departments
e.g. by examining and guaranteeing conformity with group guidelines,
standards, rules and laws.
… to Mass Production
Product planning
Project management
Package, concepts, design
Product development, design
Prototype construction and testing
Clearances and system integration
Process integration, production
Preproduction,
Procurement activities production
Marketing and sales
Quality assurance and measures
18-24 months of special-purpose vehicle development
Contact: torsten.masson@iav.de +49 (53 71) 8 05-12 55
Contact: markus.gellersen@iav.de +49 (53 71) 8 05-15 30
www.iav.de