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Virtual Testing on a New Level – Efficiency and Safety with SCALE.sdm

Reduce costs and accelerate your development cycles with Euro NCAP Virtual Testing. Fewer physical crash tests, more accurate analyses, and seamless integration into your processes – with SCALE.sdm, you can automate the entire simulation process and meet the highest standards of transparency and traceability. Optimize your vehicle development and stay ahead of the latest safety regulations.

Euro NCAP Virtual Testing enables companies to achieve significant cost savings by reducing the number of physical crash tests and accelerating development cycles. It expands test diversity, provides more precise analyses, and promotes more sustainable processes. Additionally, it facilitates early adaptation to new safety regulations and optimizes vehicle development through more efficient simulations.

OEMs face several challenges: model validation requires high-precision detailing and extensive data to accurately replicate physical reality. They must also comply with strict Euro NCAP requirements, including transparency and traceability of virtual tests. Integrating these processes into existing development workflows can be complex, especially when combining various simulation and testing methods. Moreover, acceptance of new methods within the organization and coordination with suppliers pose additional hurdles.

With SCALE.sdm, we offer a powerful software solution that automates the entire simulation process, optimizes collaboration, and ensures full transparency for all stakeholders. SCALE.sdm helps companies integrate Virtual Testing into their workflows, ensuring end-to-end automation, comprehensive documentation, and maximum transparency – ideal for meeting Euro NCAP requirements.

Complexity and Data Management in Virtual Testing

For Euro NCAP certification of the “Far Side Occupant Test” scenario, a total of eight load cases, consisting of two validation and six “Virtual Testing (VT)” simulations, must be precisely documented and stored in a traceable manner.

A crucial aspect of this process is the “static model parts” – model components that must remain unchanged across all test runs. However, this often leads to challenges: Which version is the latest? Have unintended changes been made? Are all result data sets complete for certification? Without a well-structured system, data chaos, faulty models, and excessive manual effort can severely impact development efficiency.

In addition to internal complexity, strict Euro NCAP regulations must be met: extensive result data must comply with rigorous approval criteria, and potential rating criteria should be verified before submission. The administrative workload increases – along with the risk of errors and delays.

Euro NCAP Workflow: Highest Standards for Consistency and Quality

In the eight Euro NCAP-required simulation results, most model components must remain unchanged, with only a few parameters, such as crash pulses and seat/dummy positions, being adjustable.

CAE engineers must ensure that results are complete, static model parts remain unchanged across all eight simulations, and all evaluation criteria are met.

Repeated simulations necessitate efficient automation and an optimized workflow to avoid errors and time loss.

How Virtual Testing is Managed with SCALE.sdm

Definition of Requirements in SCALE.sdm

SCALE.sdm enables the precise definition of all relevant requirements at the start of the process. In addition to specific Euro NCAP guidelines for crash pulse progressions and control parameters, Euro NCAP quality and rating criteria are also defined. This ensures that all standards for quality and data volume are met.

Efficient Model Data Management

Input data is organized in a modular folder structure, ensuring a clear separation between master data, dummy models, seat configurations, and pre- and post-processing scripts. This improves collaboration and ensures that every change is fully documented.

Automated Simulation Setup and Postprocessing

Simulation models are automatically assembled using predefined templates. LS-DYNA models are generated automatically, control values adjusted, and parameters replaced. Hash values for static model parts are calculated automatically to ensure that these components remain unchanged across all eight simulations – a key requirement for Euro NCAP data approval.

Postprocessing is also highly efficient: automatic scripts extract key figures, curves, images, and videos after each simulation run. Thanks to versioning, all steps are traceable, enabling seamless validation and audits.

Transparent Analysis and Interactive Web Reports

Instead of confusing spreadsheets, SCALE.sdm provides clear web reports that facilitate easy analysis of simulation results. A live status display shows whether all Euro NCAP requirements are met. Deviations are highlighted in color, making critical values immediately visible. Synchronized videos from predefined camera perspectives provide a precise assessment of test scenarios – a significant advantage for final Euro NCAP approval.

Secure and Efficient Data Transfer to the Euro NCAP Web Portal

Final simulation results can be automatically exported in ISO-MME format, eliminating the need for manual submission to the Euro NCAP web portal and reducing potential sources of error.

Protection Against Data Manipulation

A key concern in Virtual Testing is protecting data integrity – for both input and output data. Automated hash generation already represents a significant step toward data security. Future enhancements, such as the integration of digital signatures, will further ensure that all input and output data remain authentic and tamper-proof. This not only increases the protection of intellectual property but also enhances the credibility of simulation results.

These measures strengthen intellectual property protection and boost confidence in your simulation outcomes.

Conclusion

SCALE.sdm provides an efficient solution for automating and structuring the entire Virtual Testing process. Our platform ensures complete automation, seamless documentation, and maximum transparency – perfect for meeting Euro NCAP requirements. Enhance the quality and efficiency of your development processes with SCALE.sdm!

Want to learn more or experience a live demo? Contact us!

Virtual Testing on a New Level – Efficiency and Safety with SCALE.sdm

Complexity and Data Management in Virtual Testing

Euro NCAP Workflow: Highest Standards for Consistency and Quality