press releases

System simulation: SimulationX brings practice to the model

ESI's SimulationX 4.0 simulates machines and plants not only based on nominal data, but also with tolerances, wear and faults.

Dresden, Germany – January 15, 2019 – ESI Group, a specialist in virtual prototyping software and services, today released SimulationX 4.0, the new version of its software platform for dynamic system simulation. SimulationX has proven itself for many years in industrial companies and research institutions for technical concept studies, optimization tasks and virtual system tests. Starting with version 4.0, manufacturing tolerances, aging, wear and faults can be systematically integrated into system models. The newly designed user interface allows for efficient workflows and a quick access to the world of system simulation. New model libraries including those for modeling Bowden cables and spatial vehicle dynamics make it easier for companies to reduce the number of physical prototypes through time- and cost-saving simulations.

Systematic integration of manufacturing tolerances, aging, wear and faults into system simulation

Typically, system simulation is based on nominal data (as designed). However, the behavior of the actual machine deviates from the nominal behavior to a certain extent, e.g. due to manufacturing tolerances of the individual components. In addition, aging and wear continuously change the behavior over its lifespan. Defects or malfunctions of individual components can also have a significant influence on the machine or system. Whether and to what extent such deviations affect the behavior of the entire machine depends not only on the specific component, but also significantly on the system architecture and the interaction of all components with each other. The new "System Reliability Analysis" module provides a user-friendly solution for a systematic and semi-automatic integration of both discrete and time-continuous faults in SimulationX models. This allows for analyzing the effects of such faults efficiently and reliably for different scenarios and for any period of time.


1D simulation of vehicle systems combined with spatial vehicle dynamics

The behavior of a vehicle’s powertrain, brakes, suspension and control systems (ABS, ESP etc.) is influenced by the vehicle’s spatial dynamics. In order to avoid costly revisions and delays in time-to-market, these systems must be tested under realistic conditions even before the vehicle is available as a prototype. SimulationX has proven itself for many years in the development and virtual testing of such systems and now also includes a library of multi-body vehicle models, driving maneuvers and driver behavior. This allows for the virtual representation of spatial vehicle dynamics (translatory/rotatory motion and acceleration) and for the efficient evaluation of their impact on the 1D models of the vehicle systems. These models are real-time capable and are designed to accurately represent the vehicle behavior with a minimum of input parameters.

Improved simulation performance for complex high-precision Bowden cables

The assumption that Bowden cables are simple machine elements and have little to do with high-tech is misguided. These cable systems are indeed complex components and are used for applications that require maximum precision. Endoscopes or robots for endo-surgery, for instance, require high-precision movements with precisely defined forces transmitted via such a cable. Also in cars, complex Bowden cable systems must meet the highest standards. However, mastering those cable systems reliably and under changing boundary conditions used to be a task that could only be solved with great efforts. Bowden cables change their shape and position when forces are transmitted through them. When they collide with surrounding parts, they can cause damage and undesired noises. Furthermore, the friction behavior between cable and housing, which varies with many factors, leads to unwanted effects when forces and motions are transmitted. Especially with precise movements as required in medical technology or for closing mechanisms, these non-linearities of the backlash hysteresis pose a great challenge to engineers, especially in the development of the corresponding control systems. So far, such investigations could only be performed in a virtual environment through very time-consuming and CPU-intensive finite element methods. With the new module "Bowden Cables" in SimulationX 4.0, such analyses and development tasks require significantly less time and can be realized with standard desktop computers. The simulation is not limited to the mere Bowden cable, but includes the boundary conditions, the drives and outputs as well as the control system.


For a detailed description of all the new features in SimulationX 4.0, please visit


About ESI's SimulationX

ESI's SimulationX is a software platform for modeling, dynamic simulation and analysis of technical systems. This includes vehicles, ships, industrial machinery, mining, energy technology and aerospace. Their subsystems are based on various physical domains such as mechanics, electrical engineering, thermodynamics, hydraulics, pneumatics and controls.

Using SimulationX, both the detailed behavior of the individual components and the interactions of the subsystems can be simulated. SimulationX is based on the non-proprietary model description language Modelica®. The individual parts, assemblies and subsystems are represented by model elements. Their physical behavior is defined through differential equations or can be specified with characteristic curves if required. Known for its comprehensive interfaces to various CAE (Computer Aided Engineering) solutions and data formats as well as its easy-to-use user interface, the software has been used in industry and science for over 15 years. At ESI, customers not only get the simulation platform including comprehensive analysis methods and model libraries, but also a reliable partner for engineering services for simulation tasks. For more information about ESI's SimulationX, please visit our website:


About ESI Group

ESI Group is a leading innovator in Virtual Prototyping software and services. Specialist in material physics, ESI has developed a unique proficiency in helping industrial manufacturers replace physical prototypes by virtual prototypes, allowing them to virtually manufacture, assemble, test and pre-certify their future products. Coupled with the latest technologies, Virtual Prototyping is now anchored in the wider concept of the Product Performance Lifecycle™, which addresses the operational performance of a product during its entire lifecycle, from launch to disposal. The creation of a Hybrid Twin™, leveraging simulation, physics and data analytics, enables manufacturers to deliver smarter and connected products, to predict product performance and to anticipate maintenance needs. ESI is a French company listed in compartment B of NYSE Euronext Paris. Present in more than 40 countries, and addressing every major industrial sector, ESI Group employs about 1200 high-level specialists around the world and reported annual sales of €141 million in 2016. For more information, please visit

SimulationX is a registered trademark of ESI ITI GmbH. Modelica® is a registered trademark of the Modelica Association.