Division »Mathematics for Vehicles, Systems and Production«

In our division »Mathematics for Vehicles, Systems and Production« (MF) at Fraunhofer ITWM, we develop mathematical methods and software solutions for the virtual development, optimization, and validation of technical systems. Our research lays the foundation for realistically simulating and improving vehicles, components, and industrial processes on a computer before physical prototypes are created.

In doing so, we combine mathematical modeling, simulation, statistics, and Artificial Intelligence. Our solutions are used, among other things, in the development of vehicles, tires, cables, hoses, transportation networks, and technical systems. 
 

From Development to Flawless Production

Mathematics plays a central role not only in product development, but also in manufacturing and quality assurance. Statistical methods help realistically model usage and stress scenarios and develop test strategies for product validation. In production, models, agentic AI, and data-driven methods help detect deviations in processes early on, prevent errors, and ensure consistent quality. Modern approaches to condition monitoring and AI-supported image processing make it possible to automatically identify even the smallest irregularities and continuously optimize production processes.

By combining mathematical expertise, technical understanding, and interdisciplinary collaboration, we create solutions for the industry’s current challenges. At the same time, we are working on future-oriented topics such as data-driven modeling, Machine Learning, predictive maintenance, robotics, and hybrid models that combine physical knowledge with Artificial Intelligence methods to automate and optimize processes using agent-based approaches.

 

Our Focus Areas:

Dynamics, Loads and Environmental Data

In the department »Dynamics, Loads and Environmental Data«, we develop methods and tools for system simulation. In doing so, we take into account various environmental data, operating conditions, and individual usage patterns. In this way, we support the development of vehicles with high structural integrity, reliability, and energy efficiency, as well as driver assistance systems and automated driving functions (ADAS/AD). Our research focuses on the interactions between the vehicle, the environment, and people. We also develop tire simulation models and methods for invariant system excitation.

 

Digital Environmental Data

Statistical methods play a key role in the design process and assessment of mechanical components.

 

Load Data and Durability

Reference loads, which have been derived on system level, need to be cascaded to subsystem and component level in order to optimize and release components.

 

Dynamics and System Simulation

The fatigue life estimation of components essentially relies on the stresses and strains induced by the loads acting on the component.

 

Predictive Maintenance

With our research and project experience, we develop customized solutions for predictive and condition-based monitoring of individual special purpose machines and test benches in maintenance, their production and quality assurance.

 

Plants, Energy, and Production

Electronic, mechanical, and mechatronic systems, equipment, and machines

 

Human-in-the-Loop Driving Simulator RODOS®

We have designed an interactive motion simulator based on an industrial robot to facilitate complex simulations.

Mathematics for the Digital Factory

The department »Mathematics for the Digital Factory« coordinates its activities focused on developing software solutions for virtual product development and product creation. With our software product IPS Cable Simulation – developed in collaboration with the Fraunhofer-Chalmers Research Center for Industrial Mathematics (FCC) in Gothenburg – we support the virtual design, optimization, and validation of cables, cable harnesses, and hoses for assembly and operation. In addition, with IPS IMMA, we have developed a digital human model that enables the virtual analysis and optimization of assembly processes.

 

Digital Human Models and Human-Machine Interaction

We can perform ergonomic evaluations of people’s dynamic movements at work and in the vehicle better than before.

 

Cables, Hoses and Flexible Structures

We deal with modeling and simulation of flexible, highly deformable components and structures such as tubes, cables and hoses as well as flexible surface-like parts.

 

MeSOMICS®

We have developed a highly automated measuring machine. MeSOMICS® is short for »Measurement System for the Optically Monitored Identification of Cable Stiffnesses«.

Image Processing and Inspection Systems

Our department »Image Processing and Inspection Systems« develops mathematical models and algorithms for image analysis and implements them in software suitable for industrial use, primarily for applications in manufacturing. Our solutions help provide a better understanding of the complex geometry of materials and the relationships between structure and material properties. In this way, we open up new possibilities, such as the targeted optimization of material properties through virtual material design. To this end, we develop new methods and domain-specific machine learning techniques for the analysis of 2D and 3D image data.

 

Inline Quality Control for Production

We develop customized inspection systems and integrate them into your production process.

 

AI Applications for Industry With Little Data

Generation of synthetic data, augmentation of existing real data and anomaly detection. 

 

AI Solutions for Digitalization and Sustainability

Main emphasis is Machine Learning in Image Processing for Production and Industry.

Tire Simulation

Here at Fraunhofer ITWM, the »Digital Tire« is at the center of our extensive research activities. With the »CDTire« software tool, we have developed a simulation solution that is now widely used in the tire and automotive industries. A particular focus is on simulating tire emissions in road traffic. In particular, we investigate abrasion, particulate matter, microplastics, and CO₂ emissions. Using coupled mathematical models, we analyze the interaction between tire wear and the distribution of the resulting particles. In this way, we lay the groundwork for more precise emissions predictions and contribute to reducing environmental impact.

 

CDTire – Tire Models

CDTire is a physical tire model family with different physical models for belt, sidewall and tread and supports engineers in almost all analysis scenarios used in modern vehicle development processes from within Multi-Body Simulation tools.

 

EFRE-Project »REmis«

Research Center: Tire Simulations for Sustainable Mobility

In this project, we are developing digital twins and simulations for tire research.

 

Tire Section Scanner

Our section scanner enables high-resolution capture and AI-supported evaluation of tire cross-sections.