In recent years, a large number of applications of virtual technologies in the commercial vehicle sector have emerged and developed. Due to its peculiarities, the commercial vehicle sector has many boundary conditions and tasks that suggest the use of a digital prototype, the virtual commercial vehicle. This whitepaper gives an overview of the use of Virtual Reality and Augmented Reality for the development, production and operation of commercial vehicles.

1. Whitepaper
Virtual Commercial Vehicle
Applications, Challenges, Results
© Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC)
Dr.-Ing. Dipl.-Kfm. Christoph Runde
Virtual Dimension Center (VDC) Fellbach
Auberlenstr. 13
70736 Fellbach
www.vdc-fellbach.de
Applications, Challenges, Results

2. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Environment commercial vehicle
Varying laws, rules, environmental
requirements
Long planning periods, changing
requirements and requests
Globalisation,
language and cultural barriers
Very high complexity:
Partially enormous sizes
Smaller batch sizes (compared to passenger
car)
Fluctuating batch sizes
High amount of variants
Changing variants and product types
Basics
2
Very high complexity:
development, production
operation, service
Changing variants and product types
Varying assembly processes and efforts
Image: LumoGraphics

3. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Virtual development
o Styling, design, interieur
o Calculation visualization
o Ergonomics
o Testing assistance systems and
human-machine-interface
Application fields
Training
o Driving and operation
o Service
Marketing & Sales
o Variant management
Basics
3
human-machine-interface
o DMU and Serviceablility
Virtual manufacturing
o Factory planning
o Assembly planning
o Manufacturing processes
o Variant management
o Sales configurators
Teleoperations
Entertainment

4. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Photorealistic illustrations
Development of alternative product
concepts
Emphasis on early development stages
Early feedback
Fast development cycles as an active
Styling, design, interieur: Design reviews
Image: LumoGraphics
Realistic design
visualizations
Virtual Development
4
Fast development cycles as an active
process element
Decide on product specifications
Realistic1:1-presentation:
real dimensions
Possibility to compare
real vehicle – virtual prototype
Image: Volvo
Image: Volvo
Large Powerwall for
1:1-visualization
Hall with the possibility
for commercial vehicles
to drive in

5. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Design reviews
Virtual Development
5
Image: Hochschule Mannheim
Design review agricultural
machine
John Deere in a CAVE (4
projection sides)

6. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Design reviews
Virtual Development
6
Image: Virtalis
Review using a Powerwall and a
Head Mounted Display at CNH

7. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Calculation visualization
Representation and interactive analysis of
the results of the simulation of CFD
(Computational Fluid Dynamics) and FEM
(Finite Element Method) data
Via VR improved spatial representation
and interaction possibility
Image: Lauer & Weiss
Load calculation
gear screw connection
Virtual Development
7
and interaction possibility
Discussion platform for interdisciplinary
cooperation
Direct display of data of physical
prototypes/ products: Augmented Reality
(AR)
Image: HLRS
Image: HLRS
Truck with AR marker
Truck with overlaid flow
simulation

8. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Ergonomics
Early verification of accessibility and
visibility of controls
Hedging visibility of safety-relevant
operating and display elements
Virtual examination of comfort
Consideration of ergonomic aspects for
Image: HS Mannheim
Examination with digital
human model plus
Motion Capturing
Virtual Development
8
Consideration of ergonomic aspects for
age groups, percentiles, somato types
(hedging product functionality for large
sections of the population)
Consideration of human as a physical
factor
Image: ESI – IC.IDO
Image: Fraunhofer IAO
Inspection of visibility and
accessibility with „seat
box“ in front of
Powerwall
Inspection freedom of
movement (model´s
right arm)

9. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Testing assistance system and human-machine-interface
Harmless testing and optimization of
assistance systems (such as brake assitant)
Testing novel human-machine interfaces
Operator interface: driver´s behavior,
driving behavior, machine simulation,
environmental simulation
Image: ESI – IC.IDO
View in driving simulator
Virtual Development
9
environmental simulation
Design information interface
Image: TU Dresden
Image: TU Dresden
Operation shotcrete
machine
Information interface in
bucket wheel excavator

10. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Digital Mock-Up (DMU) and Serviceability
Construction visualization
Geometric overall model including all
disciplines (such as electrics,
hydraulics..)
Checking serviceability and avoidance
of special tools
Image: Lauer & Weiss
Review e-machine,
gear, gear housing
Virtual Development
10
of special tools
Assembly space optimization and
simultaneous testing of mountability
and serviceability
Flexible components (hoses, cables, etc.)
can be considered
Image: Jaguar-Landrover
Image: ESI – IC.IDO
DMU review
in CAVE
Examination of hose
behavior in case of
tank disassembly

11. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Digital Mock-Up (DMU) and Serviceability
Service Engineering: Verify accessibility
visually and manually
Check accessibility of assembly units,
connecting elements, grease nipples,
etc.
- visually
Virtual Service Review
Daimler-VRSC, Brühl
Virtual Development
Image: ESI – IC.IDO
11
- visually
- manually
- using a tool
All variants can be examined
All perspectives and positions can be
considered
Image: HS Mannheim
Image: HS Mannheim
Virtual walk through
agricultural machine
Check serviceability
in front of Powerwall

12. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Digital Mock-Up (DMU) and Serviceability
Virtual Development
12
Image: Virtalis
Review using a
Powerwall at CNH

13. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Assembly planning
• Checking (dis)assembly
• Test and evaluation of assembly aids
(guide lines, bevelled corners, etc.) for
manual assembly
• Determination of mounting sequences
Collision display acoustically, graphically
Image: ESI – IC.IDO
Virtual assembly
examination of a tank in
front of Powerwall
Virtual Production
13
• Collision display acoustically, graphically
or haptically
Image: ESI – IC.IDO
Image: Haption
Ambidextrous installation/
removal examination in
front of Powerwall with
tactile feedback
Disassembly examination
with force feedback

14. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Factory planning and manufacturing processes
Geometric planning of all trades in an
overall factory model
Simulation and animation
Concurrent engineering
Virtual walkthrough
Internal logistics: additional VDC
Image: Fraunhofer IPA
View in 3D model
shell assembly
Virtual Production
14
Internal logistics: additional VDC
whitepaper
Manufacturing processes: additional
VDC whitepaper Image: TU München
Image: Visenso
Logistics: AR planning of
new conveyor technology
in existing system
Manufacturing process:
pressure die-casting tool

15. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Training – Knowledge management
Knowledge types in virtual environments:
Position knowledge: what is where?
Structural knowledge: how is something
related?
Behavioral knowledge: how does the
system behave? How do I behave?
Image: HS Mannheim
Training fire brigade using
a virtual emergency
vehicle
Training
15
system behave? How do I behave?
Procedure knowledge: which processes
cause what?
Possibilities of learning in virtual environments:
Spatial exploration
Conceptual learning
Learning motoric abilities
Procedural learning
Image: HS Mannheim
Image: HS Mannheim
Training fire brigade using
a virtual emergency
vehicle
Exploration cockpit
of an agricultural machine,
software ESI – IC.IDO

16. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Training – Simulators
Special vehicle kinematics
Special vehicle behavior
Big vehicles, high seating positions
Unclear vehicle areas
Analysis of driver postures and view
Image: GlobalSim.com
View on workplace
crane simulator
Training
16
Image: TU Dresden
Image: RIF
View on excavator on
ramp
Training: harvester

17. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Training – Simulators
Training tasks
oCoping training course
oDetection dangerous situations
oCorrect communication with
endangered persons
Avoidance of swinging load, risk of
Image: RIF
Interactive 3D model
harvester
Training
17
Avoidance of swinging load, risk of
collision
Stay of persons in danger zone
Surprising entry of people in travels Image: Fraunhofer IAO
Image: Fraunhofer IAO
Crane: underrun of
minimum distance
results in visual warning
Crane: person in danger
zone

18. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Training – Simulators
Glance into driving simulator
TU Dresden
Training
Glance into driving simulator
18
Image: TU Dresden
Image: TU Dresden
Glance into driving simulator

19. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Training – Service
Maintenance
Repair
Accessibilities
Use of tools
Processes, process knowledge, risk of
damages
Image: ESI – IC.IDO
Removal engine of a
forklift
Training
19
damages
All variants, all perspectives
Learning Concepts: demonstrate -
accompany - examine
Online assistants (e.g. with AR)
Image: BMW/Arvika
Image: BMW/Arvika
AR-view on disassembly
scenario: assembly units
and tools
AR-view on disassembly
scenario: assembly units
and tools

20. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Variant management
Long planning periods - fast technology
development
Different life cycles of product parts
Incremental and iterative development
Spontaneous request changes
Huge number of combination possibilities
Image: LumoGraphics
Representation of variants
commercial vehicles
Marketing & Sales
20
Huge number of combination possibilities
Combination restrictions
Systematic variant management very
important: unsystematic variant
management often works initially, but can
not be scaled
Image: LumoGraphics
Image: Volvo
Representation of variants
commercial vehicles
Comparison of variants in
front of Powerwall

21. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Sales configurator
Early, possibly anonymous customer
involvement
Capture customer request
Increase customer loyalty in early stages
Only product (variants) which are
possible are offered
Image: LumoGraphics
Configurator:
outside view
Marketing & Sales
21
possible are offered
Early statement on availability and
delivery date
Early statement on price, offer support Image: LumoGraphics
Image: LumoGraphics
Configurator:
inside view
Configurator menu

22. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Teleoperations
Tracking the vehicles in control center
Logistics, construction site control station
Tracking work progress
Remote control: Usage where cameras
are not possible due to environmental
conditions or signal propagation delay
Image: Financial Times
Projection in control
center Rio Tinto
Teleoperations
22
conditions or signal propagation delay
Projection screen or in case of 2D-3D task
(layout + perspective): Planning desk
Image: Financial Times
Image: Financial Times
Warning sign automated
mine in Western Australia
Unmanned trucks in mine
in Western Australia

23. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary
Teleoperations
Teleoperations
23
/ŵĂŐĞ͗ s
Perspectives of planning desk
for construction site control
station: 2D top view (for desk,
left), 3D perspective excavator
view (top right) and view from
an outside third vehicle
(bottom right)

24. Training TeleoperationsBasics Virtual Development Virtual Production Marketing Sales Entertainment Summary
Entertainment
First tests on the use of Augmented
Reality (AR) in the windscreen for
infotainment (also context-sensitive)
Use windscreen as a touch screen
Games arouse first interest in
commercial vehicles
Image: Daimler
Fading in of
information on
windscreen
Entertainment
24
commercial vehicles
Image: Aeon Project
Imageer: John Deere/Caterpillar
Interaction/ input via
windscreen
Games arouse interest in
virtual commercial
vehicles

25. Training TeleoperationsBasics Virtual Development Virtual Production Marketing Sales Entertainment Summary
Summary
Various application possibilities along the entire development process chain
Many potential benefits
Process integration is essential
Reusable 3D data is essential
Often the extension of the use of VR/ VE to more application areas is possible
Summary
25
Image: HLRS

26. VDC members and partners regarding this topic
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27. Thank you very much for your interest!
You are interested in this topic and you are looking for contact persons/
implementation partners? Please contact us.
© Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC)
Virtual Dimension Center (VDC) Fellbach
Auberlenstraße 13
70736 Fellbach
www.vdc-fellbach.de