Services

Four key benchmarking services

Technology is complex, multi-dimensional, and multi-faceted. It has become increasingly difficult (if not impossible) to view most components as single entities performing isolated functions. Many moderate- to high-impact components have multiple functions, and only by understanding the complete system can reliable comparisons be made and best practices and recommendations be established. At FEV, we decompose technology to truly understand its advantages and disadvantages. We address key questions to understand the what, the how and the why. “We not only show you how it looks, we explain why!”

Performance benchmarking

FEV’s engineering experts conduct  various vehicle performance tests using comprehensive sensor  instrumentation. Customers receive a detailed report containing our analysis and the original measurement data on topics such as energy consumption, control strategy, powertrain efficiency, charging performance, thermal management, noise vibration harshness (NVH) analysis, ADAS/AD functions, and vehicle dynamics. This benchmarking data provides valuable input for simulation tools and assists in the development of next-generation

Design benchmarking

For further in-depth analysis, vehicles undergo disassembly, focusing on major cost-driving systems such as HV batteries, fuel cell systems, electric drive units, and power electronics. All parts are documented with professional pictures and listed in a comprehensive bill of materials (BOM), that includes key part data. Exploded views clearly illustrate the structure of the components.

Our engineering experts provide detailed technical assessment from system to component level. System architecture, layouts, key design criteria, and interesting KPIs are presented in our reports and database. Additional in-depth analyses are performed upon customer request.

Cost benchmarking

The findings from the technical assessment of all components form the basis for our cost engineering experts to perform bottom-up should cost calculations. A set of boundary conditions such as production location, production volumes and supply chain assumptions are defined as the basis for the cost calculation. Leveraging a strong background in manufacturing processes, our costing experts assess material costs, manufacturing and assembly costs and evaluate relevant overhead costs. All component cost information is listed in a costed BOM and summarized in a system cost  breakdown. This cost study enhances overall cost transparency, identifies cost-driving components, and facilitates cost comparisons between different vehicles and design.

Benchmarking Academy & Innovation Lab

Within our Benchmarking Academy, we showcase components from our teardown studies in our parts exhibit and conduct valuable workshops with customers and FEV experts. Using original hardware, we explain our benchmarking results and the latest technologies in detail, generating new design and cost reduction ideas.

At the FEV Innovation Lab, we aim to push the boundaries of product and service innovation by fostering a  culture of ideation, co-creation, and experimentation using a human-centered, creative and joyful design process of new product development to solve complex problems. Our goal is to empower our clients with the right tools and

FEV Global Benchmarking Program

Vehicle overview

Level-1 Benchmark

The FEV Level 1 benchmark provides an initial vehicle overview and comparison of key performance indicators within the FEV scatter bands. We take available data from the vehicle's HMI, OBD and our installed Vbox during road and track testing. Key outputs are initial energy consumption data during WLTC, FTP and RDE cycles and charging performance figures for AC and DC charging. We also provide a nice vehicle overview with pictures, documentation of the HMI screens, information on the powertrain architecture and a subjective driving assessment.

Vehicle Performance testing

Energy Consumption

FEV's benchmarking experts investigate vehicle energy consumption in detail on legislative cycles by installing comprehensive sensor instrumentation and CAN signal reengineering. Key powertrain system components such as the HV battery, EDUs and power electronics, as well as other HV and LV components, are fitted with our sensor instrumentation to capture real data during our test procedures. On our climate-controlled chassis dynamometer, we run legislative cycles such as WLTC, FTP and RDE under different temperature conditions and display energy consumption and recuperation in energy flow diagrams. KPIs are displayed in our FEV scatterplots to compare position with other vehicles on the market.

Control Strategy

FEV benchmarking experts capture detailed measurement data during driving cycles and critical mission tests and analyze vehicle control strategies. For example, with our extensive on-board sensor instrumentation, we perform hot and cold start tests, analyze derating behavior during repetitive full load acceleration tests or generate data on regenerative braking performance. The vast amount of measured data is refined and analyzed by our engineering experts and presented in understandable graphs and FEV scatter plots so that our customers can quickly extract the results and key findings from our reports. Raw measurement data can also be provided for further analysis and simulation.  

Drivetrain Efficiency

During steady-state operation over the speed and torque range at different SOC levels, FEV engineers map drivetrain efficiency numbers. Drivetrain efficiency testing is carried out on a vehicle hub-dynamometer. Overall powertrain efficiency is measured between DC power into the inverter and mechanical power output at the wheel hubs. Optionally, a split into inverter, electric motor and gearbox efficiency can be checked. The feasibility of performing this analysis is highly dependent on the accessibility of installing a 3-phase current measurement between the inverter and the electric motor and must be checked on each specific vehicle.

Charging Performance

Equipped with a high-power DC charger in our climatized chassis dynamometer, FEV is able to test charging performance under a range of temperature conditions. During AC and DC charging cycles, we evaluate charge energy/range over time, charge efficiency and usable battery energy. With our own sensor instrumentation, we measure energy losses at various components such as OBC, HV battery and thermal management components. With our charge analyzer equipment and available CAN signals, we can also track the communication between the vehicle and the charging station.

Thermal Management

FEV engineers analyze energy consumption and control strategies for thermal management, impacting efficiency, range and comfort. We document thermal loops and operating modes during driving modes and cycles. We also identify all major system components relevant to thermal management. Based on our measurement data during vehicle testing, we analyze heating and cooling strategies, pre-conditioning and show control or target temperatures, e.g. for the EDUs and the HV battery.

NVH Performance

FEV NVH experts perform detailed measurements of noise, vibration and harshness (NVH) performance and analyze key characteristics. Using a comprehensive set of instrumentation, including an artificial head, microphones and accelerometers, we measure airborne noise and structure-borne transfer functions. Experienced engineering colleagues perform a subjective assessment against defined NVH criteria. Exterior noise is measured on a certified noise test track in accordance with the official UN-ECE R138e standard.

ADAS/AD Functions

FEV's vehicle engineering experts carry out detailed evaluations of Advanced Driver Assistance Systems (ADAS) and Autonomous Driving (AD) functions. All available ADAS/AD functions are documented and control and HMI layouts are explained. Engineering experts perform several driving maneuvers to test the performance of different ADAS/AD functions. Vehicle motion data is captured by installed sensors and cameras. The control strategy and performance during the driving tests are described in our reports.

Vehicle Dynamics

FEV's vehicle dynamics experts perform a detailed ride and handling assessment including K&C and CoG analysis. Vehicles are instrumented with e.g. steering wheel angle, pedal force and other data acquisition systems. Trained test drivers perform around 13 defined ride and handling tests on a dedicated test track. The vehicle's dynamic performance and behavior is documented by measured data and subjective evaluation. 

Design & Cost Benchmarking

Design Benchmark

FEV benchmarking experts perform detailed teardown studies and assess system architecture, layouts and key design features. The main focus is on the electric powertrain components: HV battery, EDUs and power electronics. Whole vehicle teardowns or deep dives into other components are also completed. Our benchmarking specialists produce professional photo and video documentation of the disassembly and each component. A structured bill of materials shows all parts with available information such as size, weight, material, supplier, etc. Together with our engineering experts, we carry out a detailed design assessment, describing for example system architecture, layouts, cooling circuits and key design features.

Cost Benchmark

Based on the disassembled hardware components, FEV cost engineers analyze the cost structure of defined components. Based on a defined set of calculation boundaries, a bottom-up should cost analysis is performed at different levels of detail. Key cost-driving components are calculated in more detail with a rough cost breakdown, while costs for other minor parts are taken from FEV databases or estimated by the experts. In our cost benchmark reports, we provide a full overview of the system cost breakdown and explain the key cost drivers. A costed bill of materials with one cost per line item shows all cost figures for each part. 

Benchmark Workshop

In our FEV Benchmark Centers we show original hardware from teardown studies and conduct in-depth technical workshops with our customers. Using the original hardware, our benchmarking experts explain the results of our benchmarking studies and demonstrate latest technologies and design features. In interdisciplinary workshops, we work with our customers to generate new design ideas, cost reduction ideas or new product opportunities. Our benchmark centers act as innovation labs to develop new technologies and business models. 

Component Testing

Battery Cell Analysis

FEV's battery engineering experts perform a detailed battery cell analysis, including cell disassembly, material analysis and cell performance testing. In our own battery cell laboratory, we test the electrical behavior at the begin of life, perform cell ageing analysis and assess the cell safety behavior. Our battery cell experts disassemble battery cells and separate the individual cell materials for further material analysis using high-precision microscopy.