CHALLENGE - Today the global automotive industry faces enormous challenges from A1:R81 tightening emission legislations. Regulatory differences between European, Asian and American markets and segments enhance complexity while OEMs are constantly seeking to reduce development cycle times. Consequently, there is continuous demand for increasingly efficient strategies to develop cost efficient solutions. BASF, as a leading global catalyst supplier, was approached by a commercial truck manufacturer to improve cost and performance of the current EUVI production exhaust after treatment system.
SOLUTION - Due to a very demanding timeline, the only strategic option to design suitable system proposals and to demonstrate performance under customer specific test conditions was by utilizing simulation techniques. An effective model based development toolchain was developed building upon BASF proprietary exhaust models for accurate emission prediction complemented by modeFRONTIER for multidimensional optimization purposes. Using parallel computing, the simulation of stationary and transient tests for 500 catalytic system designs was completed within two weeks. All customer targets were met and suitable prototype candidates identified.
BENEFITS - Toolchain has been successfully established as standard process for future complex system optimization tasks. Compared to experimental testing model based development saves cost, time and resources. The unique capability to design to cost and performance allows truly optimized solutions at reduced technical and commercial risk.