Fraunhofer Institute for Industrial Mathematics ITWMDigital Twins are considered a key technology in many industrial processes, including the virtual development process for tires. Their use makes it possible to minimize tire abrasion, wear, and noise generation right from the product design stage. To further develop these technologies, we at Fraunhofer ITWM are setting up a laboratory with state-of-the-art testing facilities for tires in a specially constructed technical center building. With the support of the EU and the state of Rhineland-Palatinate as part of an ERDF program, our institute is providing the basis for precise simulations and sustainable innovations in tire research.
Schicht für Schicht setzt sich digital der Reifen zusammen. Digitale Zwillinge gelten in vielen industriellen Prozessen als Schlüsseltechnologie, so auch beim virtuellen Designen von Reifen. Ihr Einsatz ermöglicht es, Reifenabrieb, Verschleiß und Geräuschentwicklung schon beim Entwickeln des Produkts zu minimieren. Um diese Technologien weiterzuentwickeln, baut das Fraunhofer-Institut ITWM ein Technikumsgebäude mit modernsten Versuchseinrichtungen.
The tire is assembled digitally, layer by layer. Digital Twins are considered a key technology in many industrial processes, including the virtual design of tires. Their use makes it possible to minimize tire abrasion, wear, and noise generation as early as the product development stage. To further develop these technologies, we are setting up a technical center with state-of-the-art testing facilities.
Research Center – Tire Simulations for Sustainable Mobility
ERDF project »Research Center for Tire Development – REmis« Supports the Development of Digital Twins for Tires
The automotive industry is undergoing radical change, but tires will remain an indispensable part of mobility in the future – regardless of the drive system. They are the only connection between the vehicle and the road and are therefore essential for the safe movement of the vehicle, both when accelerating and braking as well as when cornering.
Tires as an Underestimated Source of Emissions: Models for Less Abrasion
When it comes to sustainability and environmental protection, current changes in the industry have so far focused primarily on vehicle propulsion systems in order to reduce CO₂ and particulate emissions. Especially in the case of electric vehicles, for which demand is growing, tires are increasingly coming into focus as one of the few remaining sources of emissions.
Reducing Rolling Resistance and CO₂ Emissions in Road Traffic
One factor that should not be underestimated is the rolling resistance between tires and road surfaces, which accounts for approximately 25 percent of CO2 emissions generated by road traffic worldwide. In terms of global CO2 emissions, this also represents a significant lever for reducing climate-damaging emissions.
Electric Vehicles and the Growing Importance of Tire Rolling Noise
The increasing use of alternative drive technologies, such as electric drives, is drastically reducing engine noise and significantly increasing the proportion of tire rolling noise in the overall noise of the vehicle. Heavier electric vehicles also require larger tires, which typically generate more rolling noise than smaller tires. As a result, minimizing tire rolling noise is becoming increasingly important for driving comfort and reducing noise pollution in residential areas.
Tire Abrasion as an Environmental and Health Risk: Facts and Regulations
According to a study by the European Union (EU), 500,000 tons of tire abrasion are generated in the EU each year. In Germany, this accounts for almost a third of all microplastic emissions. According to a study by Fraunhofer Umsicht, around seven percent of these are transported over long distances through the air and can thus enter our lungs. A much larger proportion is deposited in the vicinity of roads and some of it ends up in our waters. Only a small proportion of this is removed in sewage treatment plants. Tire abrasion therefore represents a burden on our environment and potentially also on our health. As part of regulatory measures such as the EURO 7 emissions standard, strict limits are therefore also likely to be required for tire abrasion.
Focus on Tire Emissions – Research for Clean Mobility
Our new research center is intensively investigating emissions caused by tires. The aim is to gain a comprehensive understanding of the physical mechanisms involved and thus create the scientific basis for solutions. At the same time, we are supporting the industry in further developing tires and vehicles and devising practical measures to reduce emissions – in line with the Fraunhofer Society's mission of translating research into practical applications.
We are equipping the research center for tire emissions with state-of-the-art test bench infrastructure.
This includes, among other things
- A drum test bench (ZF HSU 6.1) for testing comfort and noise emissions
- A flat belt test bench (ZF RB5) for testing rolling resistance, driving dynamics, temperatures, and the influence of realistic driving maneuvers on abrasion.
The availability of these modern, high-performance test benches beyond tire manufacturers is unique in Europe.
We use this equipment for the following purposes in our own research and to support the tire industry in developing more environmentally friendly tires:
- Characterizing and testing materials as a basis for Digital Twins
- Developing powerful simulation software for tires
- Researching tire noise emissions
- Researching tire rolling resistance
- Researching abrasion mechanisms in tire-road contact
- Developing innovative test methods for tire emissions
Research Focus of the Division »Mathematics for Vehicle Engineering«
In the research division »Mathematics for Vehicle Engineering,« we have been addressing issues related to mobility and energy efficiency for many years. One focus is on developing simulation methods and the use of artificial intelligence – for example, in the validation of sensors for autonomous driving.
In the field of activity »Tire Simulation,« we have already created a solution with the »CDTire« software tool, which is now widely used in the tire and automotive industries. In the future, the research center will contribute to making mobility more efficient and environmentally friendly.
Strengthening Rhineland-Palatinate as a Research Location: Funding and Duration
The institute is funded by the Ministry of Economic Affairs, Transport, Agriculture, and Viniculture of the State of Rhineland-Palatinate as part of the ERDF program for the establishment and expansion of application-oriented research and development infrastructures.
3D Visualization of the New Technical Center Building
In addition to tire design, the technical center will also be used for characterizing various materials and provides space for further interdepartmental research projects that are already in the planning stage.
The technical center building itself is financed by theby the Rhineland-Palatinate Ministry of Science and Health, while the aforementioned testing equipment is supported by the Rhineland-Palatinate Ministry of Economics. The latter project is scheduled to run for two years, from April 1, 2025, to March 31, 2027.