In the development of new vehicle platforms, weight certification compliance in early design phases is critical for regulatory approval and optimal vehicle performance. This case study describes the technical challenges and solutions for creating a robust, flexible weight certification table in concept and prototype phases. The process integrates principles of system, structural and material lightweighting to control mass uncertainties, support design flexibility and ensure compliance with global regulations.
The initial situation
The vehicle homologation and development team of an international OEM needed a structured method to define and certify vehicle mass parameters - including curb weight, gross vehicle weight and axle loads - during early concept development. The goal was to establish a standardized certification table despite constantly changing parts lists, ongoing design changes and global market requirements.
The challenge
The early development phase is characterized by high mass variability and uncertain component data, which makes it difficult to predict the total mass and distribution.
The most important technical challenges were
- Mass estimation under uncertainty
- Dynamic mass distribution
- Variant management
- Non-standardized load definitions
- Iterative structural effects
These factors jeopardized compliance with strict mass budgets, load path optimization and payload ratios.
Our approach
To solve these problems, a system-oriented, engineering-driven approach was pursued:
Centralized, version-controlled weight tracking
Real-time tracking of component masses with uncertainty factors based on the maturity of the systems.
Definition of load cases in early phases
Standardized load cases according to ISO and regulatory standards (drivers, passengers, liquids, luggage).
Lightweight construction strategies
Lightweight system construction: Modular subsystems
Lightweight structure: FEM-based optimization
Lightweight material construction: Use of aluminum alloys and ultra-high-strength steels
Interdisciplinary mass reviews
Regular coordination with purchasing, design, simulation and homologation.
Modular weight tables for variant management
Dynamic weight matrices for drivetrains, equipment and markets.
The result
- Reduction of mass uncertainty: <5 % Deviation from prototype weight at SOP
- Regulatory readiness: Uniform structure for EU and US approvals
- Greater design flexibility: Parallel development of several variants possible
- Improved mass distribution: Axle loads within ±2 % of the simulation
- Accelerated development schedule: Tables ready 3 months earlier than before
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