From Punch Cards to Virtual Twins: The Evolution of Advanced Simulation Technologies and Its Legacy of Innovation

Back in the 1970s, the dawn of computer-aided simulation at AVL was marked by CAE calculations and the early applications of Finite Element Methods (FEM). The first were performed in 1977 at the Fast and Innovative Key Operations Supercomputing System (Fa IKOSS)  in Stuttgart, Germany using ASKA software. Dr. Gotthard Rainer – who joined AVL in 1978 – played an important part in computer-aided simulation in AVL’s engine development. “At that time, AVL was already using CAE calculations and the first applications of Finite Element Methods (FEM) ,” says Dr. Rainer, recalling a time when creating input data was still a tedious process involving punch cards. Despite the burden of analogue processes, it ended up laying the foundation for the simulation software that has successfully changed the process vehicle development for the better.

Interactive computing was introduced in the early 1980s. Examples of this development are the installation of a TEKTRONIX 4014 graphics workstation at AVL, connected to the UNIVAC computer at the Graz University of Technology, and the setup of a VAX-11/780 computer in 1981. The following were available: GPR, CAD/CAE for hardware, and PRIME, UNIVAC, VAX as simulation software. It was now possible to operate a new computer generation via terminals with small alphanumeric screens instead of dedicating countless hours to punching punch cards manually. New supercomputers such as CONVEX or CRAY greatly expanded the possibilities for simulation. 

In the same year, engineers at AST began developing AVL FIRE™ and AVL EXCITE™. The work on FIRE had originally started in the mid-1980s and its development continued as a part of a joint research Consortium in 1989. Already in 1991, the first FIRE license was sold to Honda. Shortly after FIRE was launched on the market in 1993. The release marked a significant achievement and began establishing AST’s presence in the software solution market.

AST still remembers the 90s, back when software was delivered on magnetic tapes. Apart from FIRE, there wasn’t really any marketable software yet in 1996. That would soon change. The development of CRUISE started in 1995 in a partnership with the German automotive industry and it was launched shortly thereafter.

By the year 1996, software products and offerings from various departments within AVL had matured and found a market. Professor Helmut List had recognized the potential of the simulation software that had been developed independently across multiple divisions. He envisioned combining all of AVL’s simulation products into one business unit that would include development, sales, and service. 

The goal was to offer the simulation software products, which up to that point had primarily been used internally, to external users in order to further refine the already very precise physical models. The idea promised to be a profitable business model.

The product preceded the project: years of hands-on experience and know-how forged the path to success. AST was no longer just an idea but finally developed into an independent business unit under the leadership of Dr. Rainer.

Important driving forces for the formation of the AST division included growing applications and relevance of fluid mechanics calculations [LSA1] using FIRE and engine dynamics calculations using EXCITE. They became economically viable thanks to the new generation of computers. Particularly the software for simulating combustion processes was received outstandingly well by its users.

Dr. Rainer describes this combination of improvements as “the beginning of the democratization of the use of sophisticated simulation software.”

At the start of the new millennium, the CRUISE development project for calculating driving performance and fuel consumption was also ready for launch. EXCITE became market-leader for engine dynamics simulation.

Parallel to product development, AST expanded its presence globally. Offices were established in Slovenia, Croatia, Japan, Korea, the USA, China, Germany, India, and Russia. A key factor for this success was the growth in the Asian business. Especially Japan, which still is AST’s largest affiliate, was simulation-oriented from the beginning and quickly developed into one of its strongest markets. The portfolio expanded to include entire vehicle simulation, e-mobility, ADAS/AD, and Simulation as a Service, all integrated into a user-friendly interface. The expansion continued, beginning in Europe with the establishment of calculation and service offices in Maribor and Zagreb in May 1996.

The mechanics, flow, thermodynamics, and injection system software components were merged strategically, propelling opportunity for ever more sophisticated engines and vehicles in a rapidly developing market. The entry into real-time-enabled system simulation from around 2008 extended the application further into the testbed area.

By actively incorporating customer feedback, the software could be optimized along with significantly increasing user-friendliness. This set the strategic focus for the AST business unit, lead by Dr. Gotthard Rainer until 2018.

Roland Wanker, at the helm since 2019, envisions a future where simulation driven by AI plays a pivotal role. The Virtual Twin has become a central element in all development phases, with Artificial Intelligence also playing an increasingly important role. Both advancements align with the brand essence, which emphasizes accuracy, simplicity, efficiency, and robustness.

Whilst a lot has changed and progressed at AST, core principles of usability, modeling and numerical control have not changed. Many things are more complex today, but also more efficient and through general technological progress today hundreds of people get to collaborate on a single release.

“In the past, customers had experts who delved deeply into the structure of a piece of software. Whereas these days, software products must become increasingly user-friendly and intuitive to operate. A quantum leap in the direction of integration and user-friendliness was achieved through the complete integration of all products into a common user interface”, says Roland Wanker.

While simulation plays a crucial role in the automotive industry by addressing time and cost pressures, its benefits extend far beyond this industry. Industries such as aviation, manufacturing and healthcare are leveraging the use of simulation to innovate and solve complex challenges.

In the past, customers had experts who delved deeply into the structure of a piece of software. Whereas these days, software products must become increasingly user-friendly and intuitive to operate. A quantum leap in the direction of integration and user-friendliness was achieved through the complete integration of all products into a common user interface.

– Roland Wanker, Vice President Advanced Simulation Technologies, AVL List GmbH

For the future, Roland Wanker predicts an even more fundamental change than with the appearance of the Internet. Development in the automotive industry is under enormous time and cost pressure. In view of these drivers, simulation is becoming indispensable. Enhanced by AI, it will dominate all development phases, with the Virtual Twin at the core. As Roland Wanker asserts, "The Virtual Twin generates value before there is even a product," making it an innovation driver and catalyst in the industry.

Complex simulations (e.g., in multibody dynamics) could soon be set up and evaluated with AI support – with corresponding recommendations for design improvements. One of the central challenges of the future will be taking a leading role in the context of AI and its role in pushing simulation.