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The Brazilian Exhaust Gas Emission legislation established the requirement for EURO III emissions level for city busses introduction one year ahead of the remaining diesel vehicles in an attempt to improve the air quality of the populous main Brazilian cities. To comply with the new requirements Volkswagen Truck & 7-210 (front engine) and the 17-260 (rear engine) utilizing the MWM new generation 6.12 engine family equipped with the Bosch common rail electronic injection system in combination with a sort of driveline features, resulting in an extremely flexible and fuel efficient vehicle to cover a large variety of Brazilian cities routes, traffic density and loading culture, offering the best compromise of performance and fuel efficiency within all conditions.

This paper describes a new process being used by Autolatina Truck and Bus Operations, to increase productivity in the analysis and certification of vehicle structural components. It was implemented in 1993. The concept vehicle is designed using Finite Element Stress Analysis (FESA), based on historical road inputs data. Primarily the analyses pinpoint the highly stressed areas, indicating possible weak points of the new structure. These are strengthened prior to prototype build. The concept prototype is instrumented following the needs shown by the FESA. It is then run for a lap on Proving Ground and/or typical routes used by the fleets. Comparing the data acquired in the vehicle with the FESA, it is possible to better suit the design for the real application of the new product. The engineering prototypes are then built and accelerated durability certified to sign-off the released design.

An improved procedure to structurally certify medium and heavy trucks has been introduced to reduce development and certification time, as well as to increase design confidence. The new procedure is based on finite element stress analysis (FESA), laboratory tests, data acquisition, and vehicle durability tests. The vehicle structural durability test has been one of the most time demanding items of a truck program. An accelerated route has been developed, based on data acquisition and correlation analyses, halving the test time and cost.