ESI ITI engineering - project examples in the automotive sector

We from ESI ITI offer you our engineering services and expertise for the complete vehicle in connection with our proprietary standardised software for multiphysical simulation. This combination is unique worldwide and the reason why our engineering service projects are so successful for our customers.

Best chassis designs with ESI ITI engineering services

From drive and chassis simulation through driving dynamics and energy efficiency down to virtual testing. ESI ITI engineering services and a software for system simulation help you keep track of the huge number of variants and find efficient solutions to typical simulation tasks. Whether in automotive engineering or other industries – together with our customers we optimise gearshift comfort, ride comfort & stability, NVH (noise vibration harshness) and energy efficiency in a broad range of engineering projects.

Fuel consumption

Project example 1: Optimized fuel consumption for buses and lorries

Our customer has more than 100,000 employees and is one of the world's largest manufacturers of motor cars and utility vehicles.

Problem definition

The goal is to find optimum operating strategies to reduce the fuel consumption of buses and lorries on the basis of different driving cycles.

Problem solution

The SimulationX simulation software was used to build a model of the drive and brake system. This model allows the simulation and analysis of varying driving scenarios for each of the vehicle types. Code export and FMI make it easy to exchange the model between programs like MATLAB/Simulink. The results of each simulation are automatically recorded and available for information and review at any time.


By automating some of the work flows and creating a unique data base we were able to largely increase the efficiency of the simulation calculation.



Shifting simulator

Project example 2: Comfortable manual transmission development with the HiL shifting simulator

Our overseas customer is one of the world's leading automotive manufacturers with a staff of almost 100,000 people.

Problem definition

Gearshift comfort based on technical data and measured values is difficult to discuss between customers, contractors, development and test engineers. What makes it even trickier is that it is almost impossible to exactly repeat a shifting operation of an actual manual transmission for different persons. And the analysis of changes in geometries, parameters and environmental factors is very time-consuming.

Problem solution

In collaboration with Hoerbiger Antriebstechnik GmbH ITI has developed the HiL Shifting simulator for the comfortable design of manual gearboxes. It ensures real-time virtual simulation of the physical shifting behaviour with internal and external shift linkages down to mechanical synchronisation. Alternatively, it is possible to predefine the desired gearshift feel by characteristic force curves to provide an appropriate basis for discussion. Electric motors are controlled by a simulation model to emulate the behaviour of a real gearbox. The shifting simulator includes a shift lever to give the developer the chance to test the gearshift feel and thus check different variants for their shifting comfort already before any transmission hardware components are actually built.


Gearbox design changes can be immediately felt and experienced. Later on, the model structure can be transferred quickly and easily to similar shifting mechanisms and vehicles just by adapting the parameters.

Engine development

Project example 3: High ride comfort during cylinder deactivation

Our overseas customer employs over 100,000 people and is one of the largest automotive manufacturers in the world.

Problem definition

Downsizing is one of the big trends in engine development and cylinder deactivation (variable displacement) is one of the techniques used to achieve this. The variable cylinder engine is designed to run on all cylinders when the driver needs the full power of the engine and to switch on the electronic controller or to switch off one or several cylinders in less demanding traffic situations in order to save fuel. Erratic excitation of the engine might lead to undesirable vibrations impairing a vehicle's ride comfort.

Problem solution

The goal is to find an answer to the question how much vibration reaches the suspension rail of the driver's seat during cylinder deactivation. ITI engineers first developed a validated simulation model for the customer. For this purpose, they used the SimulationX modules of mechanics (1D and 3D), controls, and signal analysis, as well as Code Export functions. Case studies were performed to analyse and optimise the NHV behaviour.


The customer was closely involved in the modelling process and learned a lot from the expertise of the ITI engineers and became more and more experienced in using the software. Based on the simulation model, it is now possible to predict the vibration and damping behaviour of the specific case with accuracy and to optimise the NVH response. And the customer can autonomously apply or adjust and extend the simulation model to additional analysis targets.

Multiphysical simulation software at entry and expert levelsn

Are you a novice or an old hand at simulation? Are you looking for a software to match your specific needs? SimulationX is available in an entry level version and an expert version. 

Learn more

Our engineers accompany you through the entire vehicle development.

From modeling to drive and chassis simulations, to vehicle dynamics and energy efficiency to virtual testing.

Nico Krückeberg Sales
Salim Chaker Engineering
Chris Penndorf Engineering
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