Vehicle Conversions for technical training
We convert production vehicles into training vehicles, adding test points, breakout boxes, diagnostic connections and fault simulation as needed.
Conversions are possible for petrol, diesel, hybrid, plug-in hybrid and electric vehicles. We plan the work around the vehicle itself and the intended training tasks.
Product overview as PDF
Download our brochure for an overview of the training systems and equipment options in this product area.
Different vehicle models
We are not limited to one vehicle brand. Suitable models depend on the technology and the exercises you want to offer.
Make good use of the available space
We fit test panels and fault simulation where they are accessible and appropriate for the vehicle.
From a single test point to a complete conversion
Sometimes a few additional test points are enough. Larger projects can include extensive measurement equipment, fault simulation and documentation.
Equipment that fits the vehicle
Every vehicle is different. We choose installation locations that keep test panels accessible while allowing the vehicle to remain practical to use.
Directly on the system
Measurement connections can be brought out directly at sensors, actuators and control-unit connections.
Breakout systems
Larger measurement panels can be integrated, for example, in the interior, in the rear of the vehicle or at other suitable installation positions.
Fault simulation
Defined faults can be introduced deliberately using lockable switch boxes, bridging plugs or electronic systems.
Diagnostics & evaluation
Additional diagnostic, CAN-bus, measurement and evaluation units can be integrated directly into the training vehicle.
Training vehicles with different powertrains
Whether the vehicle is petrol, diesel, hybrid or electric, we focus on the components and functions learners need to explore.
Gasoline
Engine management, mixture formation, ignition, sensors, actuators, exhaust aftertreatment and electronic engine control.
Diesel
Common-rail systems and modern exhaust aftertreatment with DPF, NOx and SCR systems as well as engine management.
Hybrid / Plug-in Hybrid
Combustion engine, high-voltage system, electric machine, power electronics, charging equipment and low-voltage electrical system.
Electric
High-voltage battery, electric machine, power electronics, charging equipment, thermal management and vehicle electrical system.
Diesel training vehicle with extensive exhaust and measurement technology
This completed vehicle shows one possible configuration of a modern diesel training vehicle. Engine management, exhaust aftertreatment, breakout measurement technology and electrical fault simulation can be examined together on the complete vehicle.
Examine modern diesel technology directly on a production vehicle
The reference setup is based on a modern common-rail diesel vehicle. Comparable training vehicles can also be implemented using other suitable vehicle models.
In addition to engine management, complex exhaust aftertreatment and electrical diagnostics can be examined together under realistic operating and fault conditions.
The number and type of measurement points, breakout systems and fault options are defined according to the vehicle and training objective.
Gasoline training vehicle with integrated breakout systems
This example shows another method of mechanical integration. Extensive measurement technology has been installed in a protected location inside the vehicle and is available for diagnostic and measurement tasks directly on the complete vehicle.
Integrate measurement technology securely into the vehicle
In this configuration, extensive breakout systems were integrated into the rear vehicle interior. This keeps the measurement panels readily accessible without filling the engine compartment with additional large control elements.
Open circuits as well as ground, positive and resistance faults can be introduced deliberately. The configuration and number of fault options can be defined for each project.
VW Golf GTE as an extensively prepared plug-in hybrid training vehicle
In a plug-in hybrid, the combustion engine, high-voltage system, electric machine, power electronics, charging function and conventional vehicle electronics come together in one vehicle. The VW Golf GTE therefore enables particularly comprehensive system, measurement and diagnostic training.
VW Golf GTE plug-in hybrid training vehicle
Like-new, fully functional VW Golf GTE with extensive didactic preparation for training and diagnostic purposes.
The vehicle includes its registration document, two keys, diagnostic-capable control units and vehicle-specific circuit diagrams on digital media.
In addition to the standard equipment, ACC and lane-keeping assist are fitted. This allows modern driver-assistance and communication systems to be included in training alongside the drivetrain and high-voltage technology.
The combination of high-voltage measurement technology, an engine-management breakout system, extensive fault simulation and CAN-bus evaluation enables diagnostic exercises across multiple interconnected vehicle systems.
Combine measurement, diagnostic and fault systems individually
Not every training vehicle requires the same level of conversion. The individual systems can be combined on a project-specific basis, making both compact conversions and very extensively equipped training vehicles possible.
Measure directly at control-unit pins
Breakout boxes enable voltage, current and resistance measurements directly in the real vehicle system.
Measurement sockets on sensors and actuators
Externally accessible 4 mm measurement sockets provide permanently available measurement points at selected sensors and actuators.
Introduce electrical faults reproducibly
Open-circuit, ground, positive and resistance faults can be introduced deliberately for defined diagnostic tasks.
Control faults via the web
Electronic fault-simulation systems can be controlled via PC, tablet or smartphone and used for flexible training and examination scenarios.
Note: AI-generated image
Hybrid vehicles for training
We can also equip other hybrid models with test points, diagnostic connections and suitable fault simulation.
Examine combustion and high-voltage systems together
Depending on the hybrid concept, the combustion engine, electric machine, high-voltage components, power electronics, energy storage and low-voltage electrical system can all be included in training.
The scope and position of additional measurement and diagnostic systems are individually adapted to the respective vehicle.
Electric training vehicles
With battery-electric vehicles, the focus shifts to the high-voltage battery, electric motor, power electronics, charging equipment and thermal management.
Depending on the vehicle and training objective, suitable low-voltage measurement points, diagnostic access, breakout systems and fault simulations can be integrated. Interactions between the high-voltage system, 12-volt electrical system, control-unit communication and charging electronics can also form part of the customized training setup.
Every training vehicle is equipped for its purpose
The conversions shown are examples. We discuss the most useful equipment for your vehicle and training subjects.
Frequently asked questions about training vehicle conversions
Which vehicles can be converted into training vehicles?
We convert suitable petrol, diesel, hybrid and electric vehicles. We assess what is possible for each model.
Can additional test points and fault simulation be installed?
Yes. Depending on the vehicle and requirements, we can add test connections, breakout boxes and fault simulation.
A training vehicle built to your requirements
Together we choose a suitable vehicle and identify the subjects the training system needs to cover.
From a handful of test points to an extensive conversion, we plan the equipment around the vehicle and the practical exercises.