The development of electric gerotor pumps is a complex multiphysical optimization problem. To develop optimal systems, accurate simulation models are required to increase digital reliability. An important challenge is the accurate prediction of the pump behavior for extreme temperatures in automotive applications from $-40$ °C to 110 °C, where the viscosity of the fluid changes significantly. Therefore, simulation-based methods (numerical methods for calculating viscous friction) were developed and validated by measurements, including climatic chamber tests. The results show a strong correlation between simulated and measured performance characteristics, especially in terms of volumetric flow rate ($<5\%$), pump torque and efficiency ($<7\%$) at different temperature and viscosity conditions over a wide speed range (1000–5000 rpm) and different system pressures (0.5–5 bar). A novel method for simulating the cold start behavior of pumps (journal bearing approach for outer gear in pump housing) was introduced and validated by measurements. The methods presented significantly reduce the need for physical testing and accelerate the development process, as the pump behavior at each operating point can be accurately predicted before a hardware prototype is built. This improves the understanding of gerotor pump characteristics and provides insights to further improve the model-based development of electric oil pumps for the automotive industry.

Current research is investigating strategies, methods, and tools aimed at making vehicles more fault-tolerant and resilient. However, one level of product concretization—the level of abstract physics—was not yet in the focus of the scientific discourse. As a consequence of an increasing complexity of technical systems, the approaches fault-tolerant design and resilient design become even more important and decisive product characteristics concern the level of abstract physics. The paper analyses opportunities and approaches on this level, which are intended to allow an accommodation of faults and/or to increase the resilience of vehicle systems. Four different areas of potential improvement were identified. A systematic procedure and a conscious integration in industrial vehicle development processes were investigated. The research results were developed in several current vehicle component development processes and are explained using this basis. The presented research intends to open a new field of investigation, consequently a main emphasis is directed to future research contents and directions.