Beruflich Dokumente
Kultur Dokumente
MARCH 2010
Model behavior
Few have more experience
in developing hot hatches
than Renaults senior vice
president of pre-engineering
Simulation gets taken up a notch at Fords
Numerically Intensive Computing Center
www.AutomotiveTestingTechnology International.com
Silencing noise and perfecting sound
Increase the acoustic performance of your vehicle
References on www.lmsintl.com/acoustic
$G$77,0DU$FRXVWLFVLQGG
CONTENTS
COVER STORY
056
038 Wind tunnels
Impressive advances are taking place
at wind tunnel facilities around the world
004 032
WHATS NEW
004 Audi A8
Audis flagship model has evolved
to become a benchmark in comfort
008 Jaguar XJ
Jaguar has stopped looking back
with the new, futuristic XJ
010 Chevy Spark
It may be small, but it is all-new
and hopes to take over the world
012 Automotive Testing Expo India
The inaugural event showed that Indias
automotive development industry is going
from strength to strength
014 Supplier Interview: FEATURES
Applus IDIADA
Carlos Grasas, CEO of our Company of the 032 Automotive Center of Excellence
Year, explains his philosophy for the future An advance preview of the wind tunnel
facility at the GM-backed Automotive
016 Automotive Testing Technology Center of Excellence in Ontario, Canada
International Awards
The winners give their reactions 044 Proving grounds in 2020
What will proving grounds look like in
030 Proving grounds a decade? The experts gaze into the future
Keith Read brings you the latest proving
ground news from around the world 050 Renault
Michel Balthazard, vice president of
pre-engineering at Renault, discusses
his passion for hot hatches
056 Simulation
Steve Kozak from Fords Numerically
Intensive Computing Center and industry
veteran Hans-Hermann Braess explain
the virtual world
062 Mustang tour
050 044
Jim McCraw enters the world of
dynamometers at Mustang Advanced
Engineerings headquarters
018
REGULARS
Theodore
Editors note
Eagle-eyed readers may So what can be done? Clearly,
Lessons from Avatar
have noticed some vehicle Toyota is doing all it can to rectify
020 Read development stories in the news the physical problem. However,
Can testing cover everything? of late. Yes, the Toyota saga with a tumbling share price, a
continues. knock to the companys image that
024 10 questions The media, and consequently will take some time to recover from,
Massimo Fulfaro from Fiat Powertrain the public, seem to have become and a general feeling of betrayal
Technologies, program manager of our quite hysterical over the Toyota (even the angle of Akio Toyodas
Engine Development Team of the Year, recall dbacle that is dominating bow when apologizing is now
headlines. But serious recalls being criticized for heavens sake),
tells us what drives him
happen all the time. Indeed, if the it will have to be something big.
026 Ask the experts scaremongers were to combine Perhaps greater investment in
The panel is given a tough choice Fords recall figures of late (over test procedures, to match its
14 million, trivia fans), and those (until recently) ever-expanding
028 Ask Alex of Ford and GM over the years, they sales volumes? Perhaps a proactive
Our resident automotive lawyer contemplates would fi nd Toyota humbly taking agreement with the NHTSA to aid
the legal status of a recalled vehicle not second, not third, but sixth its fairly toothless efforts to enforce
place overall. Surely a sticky pedal safety concerns?
028 Recall roundup or a curling floormat are not worthy In the meantime, a number of
The latest vehicle roundup news of sharing airtime with the exciting, unscrupulous drivers who have
from the first quarter of 2010 headline-grabbing risk of fi re? been involved in speed-related
Apparently they are and then accidents when driving a Toyota
084 Testbed legends some. Im not making light of the have found not only a convenient
A tribute to the Aurora, an ugly concept Toyota issue without a doubt excuse, but also an opportunity
with a good soul, and a hell of a story there is a serious safety problem, to blame the wealthy Toyota. Such
but weve had worse before. behavior is unspeakable when
Could it be the Toyota association some have genuinely suffered
PRODUCTS AND SERVICES that is creating the interest? through an engineering fault.
Good old Toyota. A solid The only upsides are a greater
066 Cross-drive transmission test bench brand that buyers can rely on. public interest in vehicle quality
068 Full-scale commercial rolling No nonsense, no ego, no opinion- and durability, and greater scrutiny
road wind tunnel dividing styling, just good, well- of supplier-sourced components
designed, impeccably engineered and units. Because lets not forget
070 Putting the human touch
and manufactured cars for the that Toyota doesnt actually
in automotive testing
masses. Dont know about cars, manufacture the pedal assemblies
072 Optimized combustion: increasing but want something decent and in question, though admittedly
diesel efficiency reliable? Buy a Toyota. Theyre it should adopt stricter test
074 Success reported in exhaust gas unstoppable apparently. procedures for components if it
measuring system For many Toyota owners, a safety is to escape further headlines. As
075 Complex test system realized issue on their faithful mode of should all OEMs: with such public
077 Products and services directory transport is akin to discovering and media interest, someone else
that their faceless mailman might suffer the limelight soon.
of many years is a serial killer. Adam Gavine
A8 by numbers
Audi A8 4.2 TDI
Engine: 90 4134cc V8
Power: 350bhp@4,000rpm
Torque: 800Nm@1750-2750rpm
Transmission: Eight-speed tiptronic
Performance: 0-62mph in 6.6 sec,
155mph (249km/h) top speed
(governed)
Economy/emissions: 37.2mpg
combined cycle/199g CO2/km
Suspension: Five-link front,
trapezoidal rear, air suspension
Curb weight (DIN): 1995kg (4398 lb)
Vehicle length: 5137mm
Vehicle width: 1949mm
Vehicle height: 1460mm
Audi A8
In a segment with some of the most demanding customers, the new A8 has
some tough demands to meet. Whether in the front or the back, customers can
enjoy the comfort of this model
WORDS BY ADAM GAVINE
Lightweight contender
Audi has increased the strength strength of more than 250N/mm2 five
of the higher-strength body complete A8s could be suspended from
components (up to 25% stronger) in a strip of this material only 13mm (0.51
the A8, reducing material thickness in) thick and 30mm (1.18 in) wide.
and weight by up to 20%. This There is a cover layer on both sides, Inertial / GPS System for
achievement is due, in part, to and each of the cover layers represents
an innovative composite material for approximately 10% of the total
Vehicle Dynamics Testing
the aluminum sheets called a fusion thickness. With a conventional
alloy, which alone saves 6.5kg (14.33 aluminum sheet, this is roughly 0.2mm
lb). For the load-bearing parts of the (0.01 in) for both together. The cover
GPS synchronized
structure, 15 fusion panels are used. layer helps to ensure that the panels easy to use
The core layer of the new material can be shaped easily in the press,
is made of an alloy having a tensile despite the high-strength core. fast set-up
maintenance free
low data latency
Torsional stiffness has increased by
25% compared with its predecessor
The biggest revelation with the new model is the adaptive GeneSys
air suspension. There was some criticism of the D3 as the Elektronik GmbH
Expertise in
GPS and Inertial
Metrology
WHATS NEW
g
Jaguar XJ
The lynchpin of Jaguars renaissance is finally although well over 1.5 million
miles were clocked-up virtually.
get to a car. In reality, the car
is just the confirmation.
ready, and for once, the XJ is not looking back We no longer tend to focus When it came to emissions
WORDS BY KEITH READ on bogey mileages, says Atkin. compliance testing, Jaguar opted
Its more about the robustness for a mixture of simulation and
Increased simulation ABOVE: The XJ has eschewed traditional of the engineering standards in driven tests. For durability, it
and virtual evaluation is styling in favor of flair and technology the tests and to what extent we employed its new rig facility at
BELOW: Jaguar evaded the car spies
changing vehicle development throughout the testing program by various can do them on a computer. We its Gaydon, UK facility, where
and this is graphically illustrated means, such as vinyl wrapping to have many variables and do lots a vehicle, stripped of wheels
by Jaguars test program for its resemble a BMW prototype and lots of tests before we even and transmission, has torque
new, all-aluminum-body XJ
sports sedan. The car, revealed Domesticated cat
last year and due on sale very
soon, marks a step-change for Every test program has its achieved its objective with We had very long debates
Jaguar, and following XK and challenging aspects. Not all are an all-enveloping plastic about the air management
XF, completes the introduction as unusual as those identified by camouflage. XJ completed paths for the speakers that
Rob Atkin during development of its testing, and arrived at its actually drove some changes
of three key model ranges. the new XJ The car was to be unveiling still a total surprise. in things like doors and the
Rob Atkin, vehicle such a change for Jaguar that the The other most challenging detail of the parcel shelf.
engineering manager for the camouflaging on prototypes aspect, Atkin explains, was
XJ program, estimates that had to be impenetrable. integration of the audio
increased simulation which We had to conceal the true system. With XJ we wanted
reduced development times lines and aesthetics of the to do something different and
meant 60-70% of XJs testing car without impeding vehicle something special with the
dynamics or NVH, says Atkin. audio. We really wanted
was virtual and undertaken
It was a challenge. to meet customers
before any prototypes were built. Fortunately for him, since expectations based on
Actual cars were test-driven vehicle security was one of their expectations of
a relatively modest total of his responsibilities, Jaguar their home systems.
approximately 500,000 miles,
Chevy Spark
The Spark may be small but it has big plans for the world
WORDS By adam gavine
Automotive
Testing Expo India
Having established itself as a leading trade fair in Germany, the USA
and China, Automotive Testing Expo opened in India with great success
WORDS By dean slavnich
Experts in the financial Japan, and South Korea dont While western OEMs are plans to hit the US market
world say that Indias simply use India as a cheap clamouring to get in, Indias within the next two years,
economy will grow up to 8% manufacturing base as they domestic car companies are and last year, India overtook
over the next year currently, do in the case of some other looking outwards. Tata Motors, China to become Asias fourth-
one of the fastest growth rates BRIC nations. No, India is fast part of Tata Group, worth the largest exporter of cars.
worldwide. Having spent becoming a development hub for better part of US$71 billion, In fact, the Indian players
a week in Hyderabad covering companies such as Ford, Nissan, completed the takeover of Jaguar themselves are pouring vast
Automotive Testing Expo India, Hyundai and GM. The message Land Rover in 2008, signaling sums of money into R&D,
its easy to see why the country is clear: theres far more to India the start of companies in ensuring that the countrys
is accelerating its way out of the than just cheap manufacturing. developing economies acquiring automotive industry is not
financial meltdown that plagued OEMs and suppliers are moving big western OEMs. Mahindra & following its competitors, but
so many nations in 2009. to the country for skilled R&D. Mahindra has already confirmed leading the way when it comes
The Indian market might to innovation. Tatas Nano is
just become the automotive one thing, but lets not forget
industrys great savior. SiTia moves into the Indian market Revas electric powertrain
Depending on who one talks to, expertise, Mahindras diesel
its estimated that only 1-4% of SiTia, a high-tech solutions developer based in Nantes, hybrid commitment, and
France, is regarded as a specialist in test bench development
Indians own a car this from Maruti Suzukis efficient
by suppliers and OEMs around the world, providing endurance
a population of over one billion. test benches, characterization and measurement benches, manufacturing. Little wonder
The potential is huge. HIL benches, quality control benches, and customized solutions. Volkswagen is keen to secure
But India is far from being We have standard products, but we can also customize a large stake in Suzuki.
just a numbers game. The our test benches on demand, explains general manager Im aware that my words
country is also a fertile ground Fabien Arignon. Working with many different suppliers and car here paint an almost perfect
for highly skilled engineers and makers means we have to be able to adapt our machines. picture of India. However,
innovative engineering solutions. New to SiTia is a universal test bench digital controller that like most countries, India has
is adaptable to all actuator technologies, including hydraulic,
Along with South Korea and pneumatic, and electric. The Universal digital controller offers
its problems. However, the
Japan, the country has fast flexibility and ease of use, together with real-time performance. growth potential is there to
become a leading light in The SCS software installed in the controller allows control of be seen, and India stands out
developing fuel-efficient small 16 actuators in real time, both independently and synchronized, from the other blossoming
vehicles for a world thats and features a multiaxial complex endurance analysis function. economies with its rich pool
increasingly concerned about It can also launch several tests independently, and create any of engineering talent that
fuel economy and emissions. test procedure. It monitors tests with automatic thresholds and will make the country a leader
can calibrate measurement channels such as gain and offset.
The Tata Nano expected to get in automotive development.
Having customers such as Autoliv, Delphi, Valeo, PSA, Renault,
Indians moving on a mass scale Michelin and Visteon is not enough for SiTia, says Arignon: Just wait and see.
embodies Indias highbrow Our goal is to establish ourselves in new and developing To read about some of the
engineering approach. markets such as India. I believe that the market has great technologies launched at the
But theres more. The larger potential and we are fortunate to be part of it. expo, visit www.testing-expo.
players from Europe, the USA, com/india/review_10.php.
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WHATS NEW
Applus
IDIADA
Having won the Company of the Year Award,
Carles Grasas, CEO of Applus IDIADA,
explains his philosophy for the future
WORDS By ADAM GAVINE
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WHATS NEW
Engine Development Team of the Year Chief Program Engineer of the Year
Fiat Powertrain Technologies Joachim Lindau, Mercedes-Benz
Picking up this award in recognition of the Joachim Lindau, from Mercedes-Benz, was named Chief Program
innovative twin-cylinder MultiAir engine, Engineer of the Year due to his sterling efforts in developing the
Franco Bay of Fiat Powertrain Technologies E-Class range. The variety of models required some 700 prototypes
stated: We are delighted to receive this award and 36 million test kilometers (22.4 million miles)
that confi rms the quality and importance of the highest ever for a Mercedes-Benz car as well
MultiAir and emphasizes the efforts we made as 150 crash tests and 17,500 virtual crash tests.
to introduce such a breakthrough technology. Lindau was humble when accepting his
In the 1990s, we were the fi rst to introduce the common-rail award: Im very proud to work in a team
technology that is now the worldwide standard in diesel technology, of such talented engineers. I`m a small part
and we hope that MultiAir will soon become the key technology for of a big machine in every sense, and I love
gasoline engines. The team that developed MultiAir is very proud my work, and what we achieve. It is very
to receive this award as a recognition of the hard work carried flattering to accept this award on behalf
out over years of research. of the department.
On winning the Vehicle Development Program of the Year Having dressed for the
category for the Panamera, a delighted Andreas Prbstle, occasion to collect the
project manager, chassis product line, Panamera, said: trophy for Luminyss fl icker-
Im very pleased to have been given this award and accept free SunSource lighting
it on behalf of the whole team here at Porsche. As a dynamics engineer, its a great privilege to work at technology, chairman and
Porsche given the companys focus on the driving experience, and the Panamera was a challenging and CTO David Pringle said: This
rewarding project. Our experience enabled us to approach the development of a four-door luxury saloon award is the culmination of
from the perspective of a sports car manufacturer with this unique wide range from comfort and sport. a three-year effort to adapt
We used lightweight suspension techniques and materials, innovative technical solutions, and a Porsche- our unique technology to
typical setup, together with efficient aerodynamics and a low center of gravity to deliver benchmark the needs of the crash-test
performance. To see the Panamera trophy for yourself, visit the Porsche museum in Stuttgart, Germany. industry. We are excited and
grateful for this recognition
from the industrys leading
Dynamics Development of the Year publication a terrific
companion for our Oscars
Anthony Best Dynamics and Emmy!
Kinematics and
Innovation of the Year
Compliance test
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OPINION
01
How long have you been in the
industry, and how did you end
massimo
up working with automobiles?
I graduated in aerospace engineering in 1999 and started
working with Fiat Group in September 1999 as a system
fulfaro
design engineer in charge of developing the 1.4 16V FIRE
engine. I then moved to Fiat Powertrain Technologies and
was in charge of the product engineering department as
the system chief engineer for FIRE petrol engines.
02
What are the best and worst
program manager, elements of your job?
Fiat Powertrain Technologies I like being involved with all the functions of the
company, from problems in the assembly line, to the financial
aspects where we make cost benefits for the customer, and
the company. I am not just involved in the company 360
N 16
a small CEO of product, and it is exciting and challenging.
I like almost everything about the job, though sometimes
ISN G E
I have to spend more than 12 hours in the office. The job is
PA
W EE not about money its about reaching a goal. This is the driver
for the team and it makes us very happy.
03
What is your proudest career
Program manager of our Engine achievement to date?
Development Team of the Year I graduated with the highest distinction and
management decided to fast-track me. I asked for the chance
shares his thoughts to introduce new engine technologies, but the managers said
$URABILITY AND 0ERFORMANCE
4HE MOST COMPLETE RANGE OF ADVANCED PRODUCTS FOR WHEN FAILURE IS NOT AN OPTION
MEASURE AND PREDICT WITH CON DENCE
10 QUESTIONS
they wouldnt go into production because they would rather challenge. It also means you have to stay in the office very late!
follow someone else. We were the master engineers in all of But it works: if you give people easy targets, they are not
GM, and to follow others seemed stupid. This has changed. challenged. But if you work towards that goal, you will reach it.
Our new technology is like our revenge, and the market will Once you know you are able to do it, you can do it again.
appreciate our technology in diesel, petrol, and flexfuel.
07
How confident would you feel about
04
Whats happening at Fiat? developing a car purely in the lab?
A huge company like Fiat has rules and Validation is becoming virtual, and time to market
processes, and not all suppliers have the is shortening due to CAD and FEM applications. This is
knowledge to interact with us, so we sent some specialists something that will shorten development times, but we cannot
to suppliers. This would never have been done in the past. live without vehicle tests and bench tests.
We now have Fiat people moving worldwide between Fiat,
08
Ferrari, and Maserati to spread confidence and make a truly
worldwide company. What are your goals for the next five
years?
05
What could legislators do to make We have strong ideas that will come on the
your working life easier? market in the near future, from passenger and industrial
applications, to lower emissions.
The new Euro 6 limit takes a huge effort to achieve.
09
With companies such as Fiat with small displacement cars, they
should weigh the percentage of fuel consumption in relation to Whats your advice for engineers?
your fleet on the market. It is easier for BMW or Daimler to reduce If you invest money you see the effect on vehicle
CO2 by 10% over the next three years than it is for us. It makes no sales, the engines, and the business. If we have
sense that they dont consider this difference. As it is, we would a problem with an engine, we have to make sure we have the
have to invest 10 times more than BMW to cut 10% from our fleet. right equipment in the plant to avoid mistakes.
Carles Grasas Andrew Eastlake are fully integrated into the design
CEO Head of laboratories process, but there are still areas, such
Applus IDIADA Millbrook as EMC modeling, where the science
is there, but its less mature, so we
Computer technology has Id like to include hills in the can expect the overall picture to
provided not only an effective list of must-haves, because evolve further.
way to catch and deal with they produce revealing data
test results, but also the in areas such as drivability, Gregor-Fritz Gongoll
opportunity to test virtually, which cooling, and the performance of engine Head of project development
means avoiding carrying out tests that are mounts, which cannot be achieved
Audi
not necessary. For example, every time cost-effectively in any other way.
the experiment does not differ much Expertise in using virtual
from the original, it can be simulated. Dave Havergill methods. Trial and error
Senior manager, is expensive, where you
Judith Curran vehicle & systems engineering build cars, change them,
Director of vehicle evaluation & verification MIRA change the tooling, and try again.
This is finally history. It helps us
Ford
CAE has had the biggest a lot to know in advance what we expect
CAE. We are doing more impact and its influence the car to do, so we can have a small
modeling, to the point where will continue to grow as number of mules and prototypes.
its driving our prototypes techniques mature. In many There is a commitment with our top
over the past three years, weve areas of vehicle engineering, simulation management that it is better to invest
had a 50% reduction in the number of has changed the underlying purpose in simulation technology than on tooling.
prototypes weve had to produce. The of testing away from finding out if Simulation is very important, and behind
same program three years ago would something works, to model validation. a good simulation program, you need
have required twice as many vehicles. Techniques such as FEA and CFD good engineers.
ALEX GEISLER
Ask Alex
3ATISlEDCUSTOMERSBECAUSEOF
sINNOVATIVEDESIGN
sRELIABLETECHNOLOGY
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7EAT2%.+4EST3YSTEM'MB(MADEQUALITY
OURMOSTIMPORTANTMAXIM
Shift to best
in technical performance
We provide test conditions for shared success
Probedruck
PROVING GROUNDS
Charging ahead
ARVIDSJAUR Arctic Falls
invested more than US$2.75 million
in new and improved facilities
during the first nine months of
last year in readiness for the
2009/2010 season. It is the biggest
investment since the company
was established, 22 years ago, to
become Swedens first permanent
winter test proving ground.
A major element of the of the project was the design and
investment is a new facility for development of a Chargelyzer to
tire testing for an unnamed measure and analyze the charging
Bullets in Vegas
customer. This has had the effect phase. Chargelyzers are currently
of increasing capacity on its two under evaluation and will be fully
other tire test tracks, which are operational next season.
available to all customers. The car industry and its
With an eye on the growing suppliers worldwide are still going
Nevada
Organizations If constructed, the proving requirements for cold-weather through a tough period, says CEO
advocating high-speed rail ground is likely to be testing testing of electric vehicles, Arctic Jonas Jalar (pictured above). But
links to connect Las Vegas with advanced maglev systems, as Falls entered into a project with a we are convinced that an upturn
southern California and other well as more conventional high- partner to develop specific testing is not far off, which is why we have
codes for electrical vehicles. Part dared to invest this heavily.
regions and cities want to speed rail systems, in extreme
build an R&D center and desert conditions. Promoters of Swedish-Indian agreement
proving ground on public the proving ground say the time
land to the north of Las Vegas. is ripe, since high-speed rail NEW DELHI Following Shrikant R. Marathe, director
Experts in high-speed rail technology is rapidly changing a fact-finding trip to the of ARAI, says the move was
systems including the with next-generation systems Arctic region of northern essential in order that Indian-
company operating Japans being introduced. They want to Sweden, ARAI the Automotive produced vehicles could
Research Association of India perform satisfactorily in global
Shinkansen Bullet train move quickly because President
has signed a memorandum of markets. Tata, Hyundai, and
have made presentations at Obama has cited high-speed understanding with the Swedish other OEMs are marketing
a forum held at the University mass transportation as a government. It opens the door products overseas. This facility
of Nevada, Las Vegas. priority for his administration. for cold-weather testing of new will help them ensure that their
models designed and built by vehicles are reliable, durable,
manufacturers in the sub- and perform well in adverse
Suzuki to establish R&D center in India Continent. conditions, he added.
ROHTAK Work on construction of the only Suzuki R&D center
outside Japan has got the green light with allocation of 700
acres of land by the Haryana State government in India. It will
enable Maruti Suzuki to establish a state-of-the-art proving ground
complete with crash laboratories and wind tunnels.
Arizona welcomes all
Maruti Suzuki is Indias largest passenger car producer, and WITTMANN The former Volvo
has made Haryana a global manufacturing hub. With the proposed Proving Ground has a new name
proving ground and laboratories close to the city of Rohtak, the plate at the main gate. Now called
company is aiming to create a global R&D hub in the same region. simply the Arizona Proving Ground
Following signing of the land pledge, Shinzo Nakanishi, chief (APG), and benefiting from millions
of dollars of investment by Ford, a
executive of Maruti Suzuki, said: Six years ago, Osamu Suzuki,
neutral name was chosen in order
chairman, Suzuki Motor, Japan, promised the people of India that
to promote its open-to-all status.
he would make Maruti Suzuki the R&D hub for Asia. Today, we Volvo still has a year-round
have taken a step further in realizing this promise. presence at APG, but non-Ford
Development of the site will be in phases with test tracks in family vehicles are just as likely
phase 1 due for completion in 2012. Phase 2 will see the R&D to be testing on its tracks under
facilities completed by 2015. the new regime.
Aero-acoustic
wind tunnels
Anechoic
test chambers
Reverberation
rooms
Silencers
Soundproong
walls
Sound enclosures
Architectural
acoustics
Noise calculations
North
wind Ontarios provincial government,
a university, General Motors, and others
are combining to create a one-stop
testing shop in the Great White North
Words By jim mccraw
Building a bridge across the Atlantic Ocean might includes a solar array and a Mustang input dynamometer;
be easier than the project currently being built in and one smaller chamber (9 x 6.4 x 5.6m), with a -40C to
the Canadian province of Ontario, where a +60C temperature range and soak capability with 5-95%
dedicated group is finishing what they hope will be the humidity so that, potentially, three different companies can
most capable environmental wind tunnel complex to date. be running three different climatic tests at the same time.
The C$123 million five-story complex, the first of its The building also houses a climatic variable-wheelbase
kind in the world, is currently in its final construction stages four-poster shaker chamber used for squeak/rattle/durability
and will be going through the commissioning process this testing, with the same temperature and humidity capabilities
summer. The facility has been designed to offer automotive as the others. Next to that is a very large multi-axis semi-
and truck OEMs, Tier 1 suppliers, and other interested groups anechoic simulation table (MAST) that can perform three-
an independent climatic wind tunnel. It will be the main axis shaking tests. There is a vehicle preparation center, a
part of the Automotive Center of Excellence (ACE) at the vehicle diagnostic center, a garage facility complete with
University of Ontario Institute of Technology (UIOT) near hoists, a complete machine shop, a kitchen, and four levels
Oshawa, Ontario, and a mere stones throw from the General of research laboratories and office space for permanent and
BELOW: The Motors assembly complex there. General Motors Canada is visiting staff. All of this is right next to a university full of
centerpiece of the a major sponsor of the center, and other partners include students, faculty, and lab technicians, all ready and willing
facility. The rotor and
blade together weigh
the national government, the provincial government, and to help with projects.
more than 6,000kg Partners for the Advancement of Collaborative Engineering The climatic wind tunnels specifications are awesome.
BOTTOM: Early Education (PACE). The variable nozzle can be adjusted from 7-14.5m 2 in size.
stages in the In addition to the climatic wind tunnel, the facility will The main room measures 20m-long by 13.5m-wide by 7.5m-
construction include two environmental test chambers: one being a large high to accommodate anything from an A-size car to a
of the climatic
wind tunnel
chamber (20 x 6 x 5.5m) for vehicles up to coach size, which transit bus or a tractor/trailer combination. The temperature
in the room can be adjusted from -40C to +60C with The UIOT/ACE climatic wind tunnels dynamometer can
humidity from 5-95%, with rain, snow, and a diurnal solar be used for two-wheel-drive or four-wheel-drive applications,
array that is capable of simulating the travel of the sun over motoring at 197kW or absorbing 168kW at both ends at
the vehicle. speeds between 57mph (92kph) base and 155mph (250kph).
The floor of the main room contains an infinitely Its rated weight limit is 20,062 lb (9,100kg) per axle. The
adjustable turntable with a built-in Burke Porter Model 4810 entire dynamometer unit is mounted on air bearings so
dynamometer to enable vehicle testing at various angles of that, eventually, it can be moved in and out as needed. The
yaw. The dyno can measure up to 3,000hp, and can absorb dynamometer installation can also test an electric or hybrid
900hp on each axle of a four-wheel-drive vehicle with vehicles regenerative braking system.
speeds up to 155mph (250kph). Vehicles can range between The sunlight simulation equipment can replicate sunrise
88-118 inches (223-300cm) in wheelbase. to sunset light loadings, and is based on an array of 21 metal
The fan and motor assembly in the new climatic wind halide lamps with a maximum intensity of 1,200kW/m 2,
tunnel are equally impressive. The motor can run at speeds and a minimum of 600kW/m 2, with uniformity of cover
over 600rpm, with 2,500kW of power. The rotor and blade rated at plus or minus 10% and lighting stability of plus or
together weigh more than 6,000kg, and the whole assembly minus 5%. For rain, the tunnel has an array of 12 variable
can run up from zero to 40% power in six seconds, from 40 nozzles at the exit of the main nozzle, designed to shower
to 100% in 15 seconds, and from 100% back to zero in a 15- the vehicle at 93mph (150kph) at a temperature of +20C,
second wind-down. with freezing rain capability down to -5C. The twin snow
Airflow is rated at 888m 3/sec, 293m 3/sec with the large guns fitted in the chamber can shoot snow at 31-62mph
nozzle opening, and at 470m 3/sec with the small nozzle (50-100kph) at temperatures ranging from -30 to -10C.
opening. The maximum wind speed rating for the tunnel is There is a built-in facility to do under-vehicle infrared
240kph or just under 150mph. photography for heat studies, and the facility can handle
Moving forward
The automotive testing industrys most reliable
sensing source for more than 60 years.
> NEW! Extensive replacement sensor program, with 15% competitor
trade-in allowance
> Vehicle and powertrain NVH
> Modal and structural analysis
> Crash and crush testing/ATDs
> Automotive component and system performance/test cells
Shock and crash testing (7264G) High temperature (65HT) Crush zone testing (7286/7287)
> Damped with DC response > Continuous operation to +175C > Low-cost for one-time use
> 2000 g full-scale range > Compact (10 mm) and lightweight (5 gm) > 2000 g full scale, DC response
> Rugged to 10,000 g shock > Triaxial, low impedance design > Compact, rugged and lightweight
1-949-493-8181
www.endevco.com www.meggitt.com
WIND TUNNELS
in the room can be adjusted from -40C to +60C with The UIOT/ACE climatic wind tunnels dynamometer can
humidity from 5-95%, with rain, snow, and a diurnal solar be used for two-wheel-drive or four-wheel-drive applications,
array that is capable of simulating the travel of the sun over motoring at 197kW or absorbing 168kW at both ends at
the vehicle. speeds between 57mph (92kph) base and 155mph (250kph).
The floor of the main room contains an infinitely Its rated weight limit is 20,062 lb (9,100kg) per axle. The
adjustable turntable with a built-in Mustang dynamometer entire dynamometer unit is mounted on air bearings so
to enable vehicle testing at various angles of yaw. The dyno that, eventually, it can be moved in and out as needed. The
can measure up to 3,000 horsepower, and can absorb 900 dynamometer installation can also test an electric or hybrid
horsepower on each axle of a four-wheel-drive vehicle with vehicles regenerative braking system.
speeds up to 155mph (250kph). Vehicles can range between The sunlight simulation equipment can replicate sunrise
88-118 inches (223-300cm) in wheelbase. to sunset light loadings, and is based on an array of 21 metal
The fan and motor assembly in the new climatic wind halide lamps with a maximum intensity of 1,200kW/m 2,
tunnel are equally impressive. The motor can run at speeds and a minimum of 600kW/m 2, with uniformity of cover
over 600rpm, with 2,500kW of power. The rotor and blade rated at plus or minus 10% and lighting stability of plus or
together weigh more than 6,000kg, and the whole assembly minus 5%. For rain, the tunnel has an array of 12 variable
can run up from zero to 40% power in six seconds, from 40 nozzles at the exit of the main nozzle, designed to shower
to 100% in 15 seconds, and from 100% back to zero in a 15- the vehicle at 93mph (150kph) at a temperature of +20C,
second wind-down. with freezing rain capability down to -5C. The twin snow
Airflow is rated at 888m 3/sec, 293m 3/sec with the large guns fitted in the chamber can shoot snow at 31-62mph
nozzle opening, and at 470m 3/sec with the small nozzle (50-100kph) at temperatures ranging from -30 to -10C.
opening. The maximum wind speed rating for the tunnel is There is a built-in facility to do under-vehicle infrared
240kph or just under 150mph. photography for heat studies, and the facility can handle
Moving forward
The automotive testing industrys most reliable
sensing source for more than 60 years.
> NEW! Extensive replacement sensor program, with 15% competitor
trade-in allowance
> Vehicle and powertrain NVH
> Modal and structural analysis
> Crash and crush testing/ATDs
> Automotive component and system performance/test cells
Shock and crash testing (7264G) High temperature (65HT) Crush zone testing (7286/7287)
> Damped with DC response > Continuous operation to +175C > Low-cost for one-time use
> 2000 g full-scale range > Compact (10 mm) and lightweight (5 gm) > 2000 g full scale, DC response
> Rugged to 10,000 g shock > Triaxial, low impedance design > Compact, rugged and lightweight
1-949-493-8181
www.endevco.com www.meggitt.com
WIND TUNNELS
hydrogen fuel directly in the chamber or indirectly outside ACEs operations manager John Komar says: The nice
the chamber in complete safety. And, while the facility is thing about a climatic wind tunnel is that you can have a
intended for automotive, truck, and coach use, it can also be snowstorm in July or a hot, sunny desert breeze in the
used to test locomotives, aircraft components such as wing, middle of January without ever having to go outside.
aileron and stabilizer sections, and of course, wind turbines Komar, who also manages the renowned Kapuskasing
for energy generation. cold-weather testing complex in northern Ontario, says:
It can also be used for small product testing where the This is a unique tunnel because it has a variable-nozzle
extremes of heat, cold, and humidity conditions are expected design, going from 7m to 9.2-12m, with larger sizes possible
during the product lifecycle. after some conditioning. Its a programmable nozzle, so its
The huge complex had its beginnings in 2002, with the infinitely variable, which is a feature not seen in any other
idea of providing a highly capably and efficient independent wind tunnel in the world.
testing facility to the Canadian industry, which is mostly BELOW: A rendering Komar says that General Motors has built a number of
based in Ontario (Ford, GM, Honda/Acura) and to the of how the Diamond + wind tunnels with a lot of different partners in the past, and
American industry, which is based in the nearby states of Schmitt Architects- has developed specifications that are leading-edge. In this
designed facility will
Michigan, Ohio, Indiana, Illinois, and Kentucky, all within look when complete project, General Motors is providing a lot of benchmarking
a half to a days drive of the center. later this year and technical expertise, which means that the UOIT and the
Canadian government are not acting alone. They have a very
experienced partner in GM.
He says the project was a collaboration between GM, the
university, facility designer Aiolos, the architects Diamond
& Schmitt, general contractor Vanbots, and hundreds of
individuals from construction, electrical, and engineering
companies, all reporting to a third-party project manager
and heading toward commissioning in the autumn of 2010.
He says that the ongoing staff employment for the facility
will include about 35 specialists. If the business booms, the
center is prepared to work around the clock.
Komar says: Engineers are going to be thrilled to come
to this site, because they are going to be able to get in there
and get their hands dirty, do the things they need to do, and
get out. They will have access to those resources in one
place, instead of booking a wind tunnel here, a shaker there.
There are no logistics. You just wheel it around inside the
facility. No longer do you have to coordinate with different
institutions to carry out a wide range of physical testing or
LEFT: The chamber advanced development technology work.
that houses the four- Komar says that the facility will evolve to include a future
poster shaker, which
will be used to test for emissions testing facility. It has been designed to incorporate
structural durability an aero rolling-road facility in the future, which would cost
and noise an additional C$24 million, but is not currently funded.
The OEMs are used to working in a facility like this.
They have them all around the world. But its that small
entrepreneurial or industrial company that needs access to
these kinds of tools. Heres a facility they can get in. Many
companies might only have a product development cycle
every four years, and for that, you cant build a facility like
this. But they still need three or four weeks, maybe a month
or two, to do the work that needs to be done. We might be
able to support 200 companies over a five-year forecast. The
idea is to drive innovation into that industrial base. And
even better, its near the largest city in Canada, with all the
technology thats available, not just sitting out there in the
middle of nowhere.
Road ready
Looking to include ground effect in your aerodynamic tests?
The National Research Council Canada (NRC) has added a full-scale, commercially available rolling
road test facility to our 9-metre x 9-metre wind tunnel.
This new facility adds rotating wheels on a rotating plane to our already impressive list of capabilities,
including test design and model construction, instrument customization, data acquisition, report
generation, and expert advice. All services are available for full-speed single or multiple vehicle set-ups.
Put us to the test. NRC has the expertise and technical support you need.
Tel: +1 613 990 0765 www.NRCaerospace.gc.ca/atti-rolling
Vous trouverez ces mmes renseignements en franais sur le site Web indiqu.
WIND TUNNELS
Air force
RUAG and Windshear have been making impressive upgrades to their wind tunnel
facilities to meet the ever-changing needs of automotive and motorsport customers
Words By gwyneth jones
Y
and emissions test cells, aerodynamic, acoustic, and climatic wind tunnels,
CM
altitude chambers, and engine and powertrain test cells. The latest release of
our automated test measurement and control software, Test SLATE, offers a
MY
proven solution for integrating diverse hardware and subsystems, managing test
CY
(formerly Jacobs Sverdrup)
configurations, maximizing test productivity, and transforming test data into
600 William Northern Blvd. meaningful results.
Tullahoma, TN 37388
CMY
K
Phone: 931-455-6400
Fax: 931-393-6211
www.jacobstechnology.com
Too much drag? RUAG wind tunnel testing helps you do better.
RUAG Aviation
Please visit us and our
Aerodynamics Center P.O. Box 301 6032 Emmen Switzerland partner HBM at Aerospace
Legal domicile: RUAG Switzerland Ltd Seetalstrasse 175 P.O. Box 301 6032 Emmen Switzerland Testing in Hamburg: Booth B 30
in Hall B 4 upper level
Tel. +41 41 268 38 01 Fax +41 41 268 38 97 aerodynamics@ruag.com www.ruag.com
WIND TUNNELS
The Aerodynamics Center at RUAG Aviation meaning it can offer optimized solutions for data acquisition,
started operation in E
mmen,
Switzerland,
during balances, and model manipulators in its own tunnels.
the mid-1940s researching military aerodynamics. The wind tunnel facilities have been constantly upgraded
Soon, development of wind tunnel-associated equipment since their introduction. In fact just recently, several control
began, and international military and civil aviation projects systems and the video system in both the AWTE and the
were acquired. In the 1980s, the first wind tunnel tests with LWTE were replaced. Then the master control system was
a moving ground were performed for motorsport projects, replaced, which means the facility can offer more automatic
and a long and important involvement in the automotive and flexible operation.
field began. The AWTE, measuring 2.45 x 1.55m, is equipped with
The main location of RUAG Aviation is in the central part moving ground systems and is mainly used for automotive
of Switzerland near Lucerne. The company is still rooted, as testing. The LWTE, measuring 5 x 7m, is used 30% of the
the name suggests, in the aerospace business, and operates time for automotive testing, for example for soiling tests and
several wind tunnels for aviation, but also serves automotive occasional load tests for trucks, cars, and motorbikes. The
development. The model wind tunnel is almost exclusively AWTE is also used extensively for motorsport projects.
used for automotive purposes for race and production cars; The AWTE features an open test section and is of the
the tunnel derives its name from this focus: the Automotive closed-return type. This design allows for relatively large
Wind Tunnel Emmen (AWTE). models up to 50% and extremely easy model access; this
RUAG Aviation has been involved in the international is important for time-efficient wind tunnel testing, as cost
aerodynamics business for more than 60 years, and derives plays a large role during aero developments.
much of its automotive know-how from this experience. The often-heard complaint about correlation problems
The combination of aerospace and automotive projects is with open test section data especially for race cars does
natural and synergetic. Although aerodynamic optimization not hold true anymore, as efficient, precise, and sound wind
processes and the duration of the impact of wind tunnel tunnel correction methods are readily available that limit
results differ in these two fields, the aerodynamics is based this shortcoming of open test sections compared to their
on the same physical principles, and the technologies used closed counterparts.
for testing and
the end product are similar. This situation is The AWTE runs at up to 60m/s and features a moving
helped by the fact that RUAG Aviation is a provider of wind belt and an active boundary layer treatment system to
tunnel services and a supplier of wind tunnel equipment, realistically simulate the road. RUAG Aviation was one of
Formula 1 teams
return to Windshear
Windshear is expecting Bordner is particularly keen to
a successful year after F1s start testing F1 cars again, saying:
regulatory body, the FIA, lifted The Windshear team stands ready
its ban on full-scale wind tunnels. to provide the same high-quality,
Under the ban imposed in 2008, productive testing that F1 teams
F1 teams could only perform came to expect in 2008. He adds:
a limited number of tests on scale Several F1 teams have contacted us
models less than 60% of full size. already about testing early in 2010.
However, following changes to F1s Anticipating the FIAs decision,
Sporting Regulations in December Windshear has made investments,
2009, the teams can now perform including wheel side-force
up to six one-day aerodynamic measurement technology
tests at an FIA approved test and improved temperature
track or a full-scale wind tunnel compensation. The new wheel side-
test facility. force system will enable operation
Windshear stands to benefit from while vehicles run at speeds up ABOVE: Formula 1 as a 20% improvement in test
the new rule. Its tunnel is said to to 180mph on the rolling road. cars and IndyCars productivity. A typical customer
be the first full-scale, single-belt, An additional benefit will be have made regular could see an additional two
180mph rolling-road wind tunnel reduced tares and the ability to appearances at hours of test data in a given day.
to be 100% commercially available. measure chassis lateral forces with Windshears full- On the heels of that project,
scale, single-belt,
Asked about the lifting of the ban, and without wind. The end result Windshear implemented a new
180mph rolling
Windshears site manager, Jeffrey will be a more accurate side-force road wind tunnel process of database management
Bordner, says: We are delighted measurement capability and an that reduces the time to collect
with the FIAs decision. Our facility increase in the number of data test data. The process has already
delivers accurate, repeatable data runs available within a given been shown to reduce data
that is essential to F1 developers. test period. processing time by more than
Furthermore, we already have The temperature compensation 30% meaning a large reduction
security and privacy systems in system for downforce measurement in the time spent managing data,
place to meet all F1s requirements eliminates the need for run-to-run and an increase in the number
for highly confidential testing. warm-ups, translating to as much of test runs.
Constant? Dynamic?
SINGLE high-performance temperature
control and cooling systems use liquid
media for either maintaining constant
operating temperatures or for running
dynamic temperature profiles on test
benches. Distinguished by their high
reliability and precision, these systems
control either the flow rate or the oper-
ating pressure and cover temperatures
of between -40 and +350 C: tailor-made
temperature control technology for oper-
ating and safety tests of engines, pumps
or heat exchangers.
ABOVE: The AWTEs the pioneers in ground simulation when it introduced the
open test section rolling road system into the AWTE in the 1980s, and since
allows for easy access
to relatively large
then has installed its second moving-belt system.
vehicle models The model and wheel manipulators lead to precise and
automatic ride height, yaw, roll, and longitudinal position,
as well as steer control of the model. To further improve
realism, RUAG Aviation has developed equipment and
procedures to rapidly move (race) car models with respect
to ride height during measurement so that the dynamic
Pressurised water unit
phenomena taking place can now be studied under the
up to 200 C laboratory-like conditions of the wind tunnel instead of the
complex and inconsistent environment of the track. Because
of this factor, the AWTE was recently upgraded to allow full
dynamic loads on the wind tunnel structure.
SINGLE at o 2010:
to m o ti ve Testing E xp AWTEs facilities have served a number of teams from
A u F1, as well as teams from other formulae, Le Mans projects,
d 1268
Hall 1, stan DTM, and motorbike race teams seeking privacy. One of the
most prominent users was the former Formula 1 Sauber
Team, which made its best appearance in the constructors
www.single-temp.de championship with a car that was optimized in the AWTE.
Over the years, the core business at the Aerodynamics
SINGLE Temperiertechnik GmbH Center has evolved from being purely a wind tunnel operator
Ostring 17-19, 73269 Hochdorf, Germany
Phone +49 7153 30 09-0, Fax: +49 7153 30 09-50
with activity in experimental aerodynamic development, to
info@single-temp.de offering equipment and model design and CFD.
02 0
PROVING GROUNDS
2 vision
It is hardly surprising that those who responded were Coverley expects investment to enhance facilities such ABOVE: Cold testing
unanimous on many counts evidence that proving ground as the hill route and other areas of Millbrook with the in areas such as
Swedish Lapland
bosses have to look at how automotive technology is infrastructure necessary to test these systems. At the same could become an
developing in order to predict what facilities will be sought time, he expects Millbrook to move towards higher levels of outsourced task
to test those developments. Top of the list among features automated data capture to speed up customers test
that will be available to clients at proving grounds 10 years programs: Automated data capture is happening on a small
from now is a full range of fuels and energy sources, scale at proving grounds now. But, looking at F1 as an
including those we currently call alternative such as example, we can see how this works on a wider level and
hydrogen but may well be commonplace in 2020. allows the vehicle to talk directly to analysis technology,
One of those energy sources is electricity and at the thereby cutting out all need for data input. When dealing
Arizona Proving Ground until recently known as the with large amounts of data, this will reduce download time,
Volvo Arizona Proving Ground, where Ford has spent and means engineers can give customers results almost
millions of dollars on a wide range of tracks and facilities immediately upon completion of testing.
Bjorn Bondo, was emphatic: We need to switch over to Asked what new facility he would ideally create for use
charging stations versus fueling stations, he says. in the future regardless of cost Coverley does not hesitate.
And while Ford will be installing those facilities at its The UK needs a black lake, he says. We desperately need
desert proving ground, Jonas Jalar, CEO of Swedens Arctic a very large area of flat tarmac that will allow for a wide
Falls winter testing center, will be doing the same: We will range of testing, from basic vehicle handling through to the
have to meet the demand of alternative fuel which we are ITS technologies we know are coming. But he does not see
doing for electrical vehicles and also for other new systems such a black lake as a Millbrook-only facility. On capital
and techniques. We are already a partner on a project to cost and environmental grounds, he advocates collaboration
develop specific testing codes for electrical vehicles. between proving grounds, OEMs, component manufacturers
But it is in the way that Arctic Falls is likely to be used by and, most importantly, the government.
OEMs and component-makers in 10 years time that could Sharing Coverelys desire to see a black lake vehicle
be different. I think, and hope, that in 10 years, we will be dynamics area (VDA) is Mat Hubbard, technical director of BELOW: We will see
a strategic partner that performs a significant volume of Anthony Best Dynamics, a company that designs, develops, far more robot drivers
taking to the tracks in
winter testing, says Jalar. This move will be a cost-efficient and manufactures a range of products used by proving the future, according
solution, as the industry will not have to send as many grounds and their customers. For vehicle dynamics testing, to Anthony Best
people to our region. Instead, they will give us a specification its always nice to use a large diameter VDA that allows tests Dynamics
of tests required, and we will undertake them.
Many proving grounds are built on flat or near-level
ground, where any gradients are artificial and man-made.
One exception is Millbrook, originally established in the
UK by General Motors for its nearby Vauxhall factory, but
now used regularly by many different OEMs and component
companies. On one side of the Millbrook site is a steep
natural escarpment, home to its famous hill route, and an
area with huge potential when it comes to ITS, according to
director Mark Coverley.
One of the main areas of development that will lead to
the need for new facilities at proving grounds is ITS both
intelligent infrastructure systems and intelligent vehicle
systems, he says. With hybrid and electric vehicles, for
example, ITS developments are working towards the car
understanding when it needs to boost and conserve power.
One such aspect relates to traveling up and down gradients,
when power can be readily consumed knowing that there is
opportunity for regeneration. This is hard to accurately
simulate on a flat road, but our hill route will be vital.
Colmis Proving Ground is located in Arjeplog in the Colmis Proving Ground is your total service provider.
north of Sweden up against the Arctic Circle. Q Tracks Lake tracks and Land tracks.
Q Workshops and Offices.
Q Arjeplog is known as The Winter Testing Capital Q Accommodations.
Q Colmis Proving Ground is certified according to Q Durability drivers
ISO 9001 and 14001 Q Just one phone call away. +46 961 720100
All tracks, Workshops and Offices are located within the fenced area of Colmis Proving Ground.
www.colmis.com info@colmisab.se
INTERVIEW
In the world of hot hatches, many agree that one Ring record
marque is king: Renault. And within Renault, few Before launching the third-
know more about the hatchback sector than generation Mgane, the
Michel Balthazard, senior vice president of pre-engineering engineers at Renaultsport
and member of the management committee. decided to give the R25 a final
Balthazard has been a Renault man since graduating send-off. The stripped-out R26.R
from the cole Centrale de Lyon in France. I started at model was 123kg lighter than
Renault in 1977 and worked for three years in safety and the regular model which,
combined with 230bhp and
structural projects, working on seats and seatbelts mainly 310Nm torque, resulted in
front-impact work, he explains. a dramatic final hurrah at the
After this, Balthazards love of the hot hatch began, when Nordschliefe. Its lap time of
he was put in charge of the second-generation R5. I developed eight minutes and 17 seconds
the GT Turbo and Cup versions with RenaultSport. The GT was not just quick: it was the
Turbo had a turbocharged version of the engine from the quickest-ever time set by a
current car, with specific developments to the rear axle and production front-wheel-drive
car. And even quicker than
chassis. We also made the Turbo2 for rallying. Even when
an E46 M3 or Lotus Exige S!
we sold some Turbo2s for the road, it was still a car designed
for rallying. This kind of car had a very specific chassis,
though the body looked like a normal car.
The Turbo2s roots were planted when Renault created the
worlds first hatchback, the R16 (see page 53). There is a gulf
in performance between the two, but the basic principle is
the same. Hatchbacks are not so much low cost as cost-
efficient, says Balthazard. They are a little more expensive
to make because a sedan is very simple, and a hatchback is
more complicated. But if you take into account the volume
of the car, you need a longer car to get the same volume with
a sedan. A hatchback is more space-efficient.
So why is France so good at creating hot hatches? It is
difficult to explain, says Balthazard. For many years,
customers liked these cars because they are practical, and
there is a good ratio between roominess and the ability to
drive it on the track. Also, the styling of the car is sexy. It is
a good choice for a customer: it is practical, efficient, usable,
and offers nice styling. For a car manufacturer, it is cost-
efficient because you have roominess in a short car you
dont need a long car to have a large luggage compartment.
It started with the R11 in the early 1980s. We took the
R9, which was a classic sedan, and made the R11, which
was a hatchback. That was the first fast hatchback in the
segment, and soon 80% of our sales were for the hatchback
as people liked the roominess and practicality. We made
our first sporty hatchback with the R11 and now there is a
customer base in France for these cars. The R11 was swiftly
followed by a car that influenced modern hot hatch design,
and was the first of a breed: the Renault 5 Gordini.
For the Frenchman, the recipe for a hot hatch seems
refreshingly simple: There is no real difference in handling
Hatch made
in heaven
The publics love of high-performance hatchbacks can be traced back to one
company. Renaults Michel Balthazard explains how to heat up a hatch
Words By adam gavine
For more than 40 years, MTS has been providing the products and services that vehicle
test labs around the world need to operate with greater speed and confidence.
Whether your testing involves materials, components, subsystems or the full vehicle,
we offer the proven solutions you need to succeed. Contact us today to discover how
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performance between a sedan and a hatchback. However, BELOW: While modifications. For example, with the Clio, they change the
the hatchback does have body stiffness problems as there is Balthazard loves hot rear axle, increase the width, and modify the road handling.
hatches, he chose
a big hole in the back and this can lead to deformation. a four-wheel-steer
They then do some chassis tuning without completely
With hatchbacks, we make sure that the rear of the car Laguna V6 diesel redesigning the front axle, and they have specific engine
is stiff enough to minimize body deformation. You have to make coup as his development they use the two-liter engine, which is tuned
sure you have no deformation of the body to manage a good company car to 205bhp. The Twingo RS is a classic Twingo with specific
engine. If you have deformation it is difficult to precisely manage modifications.
the way the tire and rear axle connects to the road. Then For the Mgane, it is different because it has heavier
you have to reinforce the stiffness of the car, which is difficult modifications on the chassis, with specific rear and front
with a hatchback, since you need steel bars and additional axles completely redesigned by Renaultsport it is really a
structural parts. But in saying that, there are no real issues specific chassis, more orientated to being a sports car. The
with hatchbacks. The weight balance between front and front axle is independent and the engine is more powerful
back is good, though you have to develop good front and with around 250bhp and a turbocharger. The general shape
rear axles to manage the way the tires stick to the road. of the body is the same, with some developments to make it
Getting to specifics, Balthazard mentions some recent look like a Renaultsport car. We have three versions with
projects: There are two ways of working on a sports hatch. different engine power and chassis tuning. When you get to
For a Clio or a Twingo, we use the current production car the latest version, the R26, it is really designed for racing,
and the Renaultsport technology team makes some specific even though it can be driven on the road. It is a very efficient
chassis that benefits from our motorsport experience. A lot Renault fans will recall the hot is making a comeback, with
of improvements come from motorsport, and we improve Gordini models of the 1960s, special Gordini editions of the
the chassis all the time based on experience during racing. recognizable by their blue Twingo and Clio. Unfortunately
paintwork and twin white these editions offer little more
Special editions, including the R26, come from the track.
stripes. For those who dont than a cosmetic difference from
Getting engine and handling performance into a hatch is remember, this important part the Renaultsport cars on which
one thing, but one must remember the other great benefit of of Renaults sporting heritage they are based.
the hot hatch: low price. To keep prices low, development
costs are kept as low as possible.
We have developed a CAD system, which we use to ABOVE LEFT: Cars time reductions 24 months will be the realistic minimum,
predict the car numerically. Now, for example, we are testing like the Twingo RS though I think we can still improve this time slightly through
are keeping low-cost
the crash behavior of a car through simCAD systems front, thrills within the grasp
technical standards and more accurate calculations, etc.
rear, side impact everything is calculated. of young drivers Perhaps we could save one or two months.
We are increasingly managing the definitions of the car For Balthazard, the time saving doesnt end there. The
by making calculations and reducing the number of tests real question is how long it will take to manufacture the
we have to do on real cars. We no longer use prototypes tools for production. Many Japanese companies Toyota,
the first car we use is manufactured with the production for example have done a lot of work on tooling planning.
tooling. We start physical tests on a car a year and a half I want to decrease the time to manufacture tooling, as that
before production. We develop more calculations for each is a real issue for bringing cars out more quickly.
car we develop, and we also reduce development time and But can the speed of Renaults development programs
costs with each new generation. We developed the new ever match the speed of its hot hatches? There is an
Mgane hatch in 32 months and the new Scenic took 29 interesting side to being as quick as possible. Because the
months. The Laguna took 35 months to develop, so with amount of planning is decreasing and we are spending less
each project, through calculation and simulation, we reduce on development, we can launch cars more quickly which
testing time and costs. means we are closer to customer expectations. For example,
These timescales are even more impressive when you a lot of luxury cars came out during a recession in 2009,
consider that Balthazard is counting this period from the following three years of development. It is good to be as
design freeze stage. But we are nearly at the limit of possible quick as possible, but there is a minimum.
Test
test by nu
numbers
Simulation of vehicle crashing is taking up vast amounts
of number-crunching power at Fords NIC Center
WORDS BY MIKE MAGDA
Accidents happen
With the introduction of more
sensitive airbag pressure sensors
on the 2010 Taurus and 2009
F-150, Ford engineers developed
a series of side-impact tests to
calibrate their sensitivity. The
airbag sensors use pressure
pulses from the side impact to
deploy up to 30% faster than an
older system using acceleration-
based sensors.
However, everyday mishaps,
such as a shopping-cart collision
or a runaway bicycle could trick
the sensors. Tests include using
a lab robot to push a shopping
cart loaded with a 110-pound
weight into door at 10mph.
Another test simulates the
impact of a bicycle wheel.
Ford says the pressure-based
sensors help the vehicles perform
better in federal side-impact
tests, are less likely to be affected
by design differences, and give
designers more flexibility because
of tighter packaging.
EMC-testing
Radio parameters
Electrical safety tests
Environmental simulation
Metrology testing
Automotive testing
Wild horses
HEADQUARTERS: Brel & Kjr Sound & Vibration Measurement A/S DK-2850 Nrum Denmark
Telephone: +45 77 41 20 00 Fax: +45 45 80 14 05 www.bksv.com info@bksv.com
Local representatives and service organisations worldwide
PRODUCTS AND SERVICES
Cross-drive transmission
test bench Mustang Advanced Engineering
Mustang Advanced Engineering has designed, built and delivered Tel: +1 888 468 7826
Email: sales@mustangae.com
a state-of-the-art cross-drive transmission test bench for testing Web: www.mustangae.com
Abrams M1A1 and M1A2 Battle Tank X1100-3B transmissions
501
ONLINE READER ENQUIRY NUMBER
Mustang Advanced specifically for adjustable- transmission. The control The power unit consisted
Engineering (MAE) speed service, the AC motor system allows the of a motor drive, electric
proposed a custom combines optimum measurement of the prime mover, and an
cross-drive transmission proportions of copper and iron dynamometer applied torques enclosure. The prime mover
dynamometer to meet the with unique rotor slot designs as well as the induced was an electric motor that is
application and test to deliver power-matched acceleration torque applied rated for multidirectional and
requirements of a cross-drive performance on adjustable by the mass of the power reliable variable speed control.
transmission test bench for frequency PWM power. absorbers inertia. This is The motor is guarded drip-
testing X1100-3B Mustangs design allowed required to accurately measure proof force vent, rated for
transmissions in accordance the furnished pair of power during transient 429HP continuous, 643HP
with NMWR 9-2520-276 dynamometers to be cradle- testing. The furnished pair intermittent, with a base
volumes 1-3. Having recently mounted with a load cell of air-cooled eddy current speed of 1,485rpm and
delivered a containerized and speed encoder to actively dynamometers were supplied maximum speed of 2,965rpm.
version of a similar system measure the output torques with a fast responding The prime mover possesses
to support Operation Iraqi and speeds of the transmission controller, which delivered low inertia to more accurately
Freedom, MAE built on many to instantaneously determine a very fast response and simulate the inertia values
years of experience to deliver the output power of the ideal settling times. seen by the transmission
a custom solution.
The system was designed
to simulate engine input
speeds and vehicle loads for
heavy-duty transmissions.
The system can control the
transmissions input speed
and output loads, allowing the
operator to apply loads to the
transmission as though it is
in the vehicle.
In order to facilitate proper
transmission testing, a low-
inertia motor is required so as
to produce similar acceleration
rates as seen with an engine.
The furnished AC motor is
a definite purpose, adjustable-
speed motor designed for
optimum performance in
demanding constant torque
and constant horsepower
applications. This design is
based on years of experience
in producing variable-speed
motors. When matched with
a high-performance AC
variable-frequency drive, it
provides the ideal solution for
the toughest industrial speed
drive requirements. Designed
Full-scale commercial
rolling road wind tunnel Windshear Inc
Testing engineers and Formula One race teams are visiting Tel: +1 704 788 WIND (9463)
Email: info@windshearinc.com
the worlds first commercial full-scale rolling road wind Web: www.windshearinc.com
tunnel to gain a competitive advantage
502
ONLINE READER ENQUIRY NUMBER
As the company art open-jet wind tunnel configured so that no two have been in high demand
behind the first 100% design from Jacobs customers will see the others from the very beginning.
commercial full-scale Technology with the latest vehicles at any time. Also, Its first commercial customer,
rolling road wind tunnel, developments in wide-belt all Windshear employees a Formula One team, traveled
Windshear Inc understands rolling road systems. This and contractors sign non- from Europe to use the
the necessity of staying at the makes Windshear a source disclosure agreements and latest technology to get
leading edge of the science and for highly accurate, repeatable are bound by strict privacy a competitive advantage on
technology of experimental aerodynamic data, which guidelines. Card keys are the racetrack. The customer
aerodynamics. The company, gives a competitive advantage issued to all customers, base quickly grew from there,
based in Concord, North on the racetrack or in the limiting areas and times of and now includes most top
Carolina, is now headed into global marketplace. access, and unauthorized NASCAR and Indy car race
the third year of its operation, To ensure absolute personnel are prohibited teams, as well as numerous
and customer demand for its confidentiality with all of from customer areas. other customers from a wide
highly accurate aerodynamic its clients, Windshear Inc Windshears test services range of markets, including
simulation is stronger than maintains a high standard everything from road racing
ever. of security. All test data files to television and video
Test vehicles are placed are erased from Windshears entertainment. Windshears
on the rolling road and tested servers once a customers BELOW: The rolling road is 10.5ft-wide
services are available around
at speeds up to 180mph and testing is complete, and by 29.5ft-long, and can accommodate the clock if necessary, to
yaw angles up to 8 degrees. the facility is physically a wide range of test vehices meet customer demand.
Windshears main fan consists
of 29 carbon fiber blades
reaching 22ft in diameter,
and is powered by a 5,300
horsepower electric motor.
The system can accelerate
from 0 to 180mph in less
than a minute.
Windshear also boasts
an integrated temperature
stability system, which can
control air temperature to
standard day conditions,
plus or minus 1F. The high-
tech rolling road is 10.5ft-
wide by 29.5ft-long, easily
accommodating a wide
range of test vehicles.
During testing, through-
the-belt sensors measure the
aerodynamic downforce under
each tire, while biaxial load
cells integrated into the
restraint system register the
aerodynamic drag and side
force. The technology available
at Windshear is the successful
union of the latest state-of-the-
Take cutting-edge wind tunnel technology. Add a 180 mph rolling road.
created the worlds first and finest commercially available full-scale testing
environment of its kind, we did much more than create a new wind tunnel.
Human and den Dijssel, test & simulation initial automotive-system and repeatedly. If a component
hardware in the systems manager, Moog. development can be brought does not respond well on a
loop (H2iL) testing Lab testing, with the into the laboratory, delivering certain part of the track, just
is used in the aerospace driver included, ensures more a range of important benefits that part of the track can be
industry, and can reduce R&D consistent test conditions, compared to HIL testing. evaluated repeatedly and the
time, as well as budgets (see creating a more controlled test Driver response and results recorded to provide
Human in the Loop, May 2009 and improved results; unlike feedback is immediate and detailed results for improved
issue, p30). That article, by track testing where conditions enables qualitative feedback. driver evaluation, which is
Moog, presented the case that continually change. Multiple driver experiences particularly beneficial in
there is also a clear fit for H2iL In a traditional HIL testing can be incorporated and race car test scenarios.
in the automotive industry, configuration the powertrain different driving habits The system also helps
given the growing need for is still driven (or tested) by and road conditions can reduce track time as driving
more sophisticated testing a dynamometer. This is be recorded and evaluated, scenarios can be created
technology. transformed into an H2iL providing objective and and recorded for playback
This follow-up article looks simulation when the simulated instant metrics on the without leaving the lab.
at some of the benefits and the driver input is replaced specimen under test. Virtually any road or
specific details of what H2iL with a full 6DOF motion Designers often need climatic conditions can
brings to automotive testing. simulator and an actual to analyze vehicle response be simulated such as track
HIL testing involves vehicle human test driver in the to one specific road condition. surfaces, ambient conditions
hardware components loop simulation. With H2iL the same road and vehicle models, adds
being tested in a simulated In this H2iL testing section and conditions can van den Dijssel. Development
environment. The interface scenario, the driver of the be replayed while making time and test time are
can be hydraulic, electric, motion simulator drives subtle system and component dramatically reduced and
or mechanical, and may also a vehicle model on mapped changes; that enables fast controlled because automotive
include use of environmental proving-ground roads while repeatable A-B-A testing. designers no longer require
chambers to simulate the powertrain operates H2iL allows for highly access to the track or proving
temperature, humidity on the dynamometer, which sophisticated replication grounds and do not have
or air, or even air pressure. is now coupled to the motion techniques that aid and to wait for the right climatic
Practically all driver feedback platform. This means that improve driver performance conditions.
is gathered from the test track, or train drivers to perform H2iL also increases safety
which is timely and expensive. specific maneuvers. Lap levels as dangerous road
H2iL testing brings the performance can be recorded conditions can be tested
driver into the simulated and any deviations caused in a safer, more controlled
environment or loop, which by hardware modifications laboratory environment.
can reduce the number of or replacement can be Drivers are not subjected to
prototype vehicles required observed. Moreover, laps can dangerous road or ambient
and the number of hours be superimposed on screen conditions since they will
spent on race track or proving so a driver has simultaneous be operating the simulator.
ground testing, says Pim van reference to previous Although track scenarios
performances, which can may be taken to the very
RIGHT: 7DOF driving help the driver operate the limits of performance on
simulator with a lateral rail simulated vehicle on the new design, the integral
a certain part of the safety management systems
track consistently built into the simulator
will protect the driver,
and even the test parts,
from uncontrolled and
excessive responses.
AOS Technologies AG
Taefernstrasse 20
CH-5405 Baden-Daettwil
Phone +41 56 483 34 88
Be smart with high-speed cameras from www.aostechnologies.com
AOS Technologies! info@aostechnologies.com
PRODUCTS AND SERVICES
Optimized combustion:
increasing diesel efficiency
Hottinger Baldwin Messtechnik
Automotive manufacturers are continuing to improve and Tel: +49 6151 803559
Web: www.hbm.com
increase combustion engine efficiency by focusing on overall
efficiency and enhanced diesel engine fuel injection
504
Ideal for:
Powertrain development
Steering column testing
Drive cycle development
Component development
Brake testing
Series 8179
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PRODUCTS AND SERVICES
506
of the testbed is technically
demanding.
At maximum rigidity, the
system allows for movements
in six degrees of freedom at
the same time. Experienced
FGB engineers and
technicians will design
and produce the testbed
components.
The testbed is used to test
complex compound materials
at realistic load conditions.
ABOVE: The Hexapod testbed
Specimens weighing over airplane galleys) and bracing The Hexapod, the allows for movements in six degrees
a ton are tested with many tests (force-controlled even mechanic parallel structure, of freedom at the same time
types of multiple-axis load for strongly non-linear is operated in freely selectable
conditions. The modular components) are implemented force/distance control.
design of the test system for large specimens. The software from FGB
allows for versatile test Below the platform, tests used for testing contains
options. on smaller components (e.g. all required functions for
In the upper test bench air springs) are implemented operating the Hexapod
(above the platform), both at maximum rigidity of the testbed. It contains a
vibration tests (e.g. for test system. de-coupled, hybrid force/
distance control, which allows
Performance data: the user to specify distance
or force data for movements
Individual forces: z axis up to 500kN, x/y axis up to 200kN
in any space direction of
Individual torques: 40kNm the coordinate system.
The signals are
Distances and angles implemented on the individual
Combined distances: 150mm
Combined angles: 5
hydraulic cylinders within the
software as well, without the
Dynamics user having to intervene.
Speeds: up to 1m/sec Along with the control mode
Accelerations: up to 6g
Operating frequency: up to 30Hz
pseudo-force control, an
iterative real-time control
Hydraulics (linear/non-linear) is also
Hydraulic oil supply: 1,000L/min contained within the
Operating pressure: 280bars
functional scope and can
be adapted by the user.
Colmis AB D2T
Tel: +46 961 720 100; email: info@colmisab.se; web: www.colmis.com Tel: +33 130 1307 07; email: sales@d2t.com; web: www.d2t.com
w w w. a u t o m o t i v e i n t e r i o r s e x p o . c o m
Racelogic
Tel: +44 (0)1280 823803; email: sales@racelogic.co.uk; web: www.racelogic.co.uk
ADAS testing
New developments appearing in
518 advanced driver assistance systems
(ADAS) technology are prompting
increasingly stringent testing requirements. This
has led to the need for an accurate and flexible
way of verifying ADAS systems. Answering this
demand, the VBOX ADAS solution (with users
including Jaguar, Land Rover, Continental,
and Peugeot) enables developers to easily
test systems at sub-2cm positional accuracy.
This is useful for a wide range of applications,
including testing lane departure warning,
collision mitigation, and adaptive cruise control.
At the core of the system is a VBOX 3i data
logger connected via telemetry to an RTK base
We do not know
EFFECT 1
station. GPS and CANdata can be viewed real-
time and logged for analysis. A Video VBOX has proved very useful. We even use the system whether you see grey
enables recording synchronised with the data, in client demos, which gives a great illustration dots in the corners
which can be graphically overlaid on the video in of the accuracy of our products against the VBOX
real time for enhanced analysis and verification. benchmark. I especially like its ability to be of the squares... But
Rob Cavanagh, lead ADAS engineer at installed in two vehicles, zero the distances when it comes to the design of
Continental, comments, The VBOX ADAS system out, and be testing in just 15 minutes.
a coupling for your transmission
system, you will not be fooled.
Renk Test System GmbH
Tel: +49 821 5700 408; email: info.testsystem@renk.biz; web: www.renk-testsystem.eu Competency in power
transmission applications
Customized test systems since 1946
Renk Test System GmbH (RTS) has systems and one 72 in chassis dynamometer In-house research,
519 been engineering and manufacturing for a renowned supplier of the Chinese heavy-
development and design
turnkey test systems for the duty industry. Each transmission test stand is
automotive, aerospace and rail-vehicle industries equipped with a shiftable planetary adaptation-
and their suppliers, mainly for R&D purposes, for gearbox which enables loading the specimen
In-house torsional
more than 20 years. The company offers its own up to 800kW and 10,000Nm. The maximum vibration-calculations
hardware and software concepts, engineering speed for the output-motor reaches 3,400rpm. of multimass systems
and maintenance services. An integrated shifting-robot enables around-
RTS is among the worldwide leading suppliers the-clock testing for durability- and efficiency- In-house elastomere
for customized chassis dynamometers and test purposes.
drivetrain-components test equipment for well- The one-axle chassis dynamometer is able to
development , In-house
known manufacturers of passenger cars and apply 100,000N tractive force to the trucks being mould construction
heavy-duty-vehicles all over the world. In 2010 tested. All three turnkey systems will be installed
RTS started assembly of two transmission-test at the suppliers R&D center in June 2010. In-house rubber production,
mechanical machining
Re-Sol, LLC and test benches,
Tel: +1 248 219 5256; email: info@re-sol.com; web: www.re-sol.com customised solutions for
Mobile multifuel flow-measurement system prototypes, small- and large-
scale production series
Re-Sol introduces its new RS474-250 An electronic pressure control maintains the
520 mobile multifuel flow-measurement engine supply pressure within +/- 0.2kPa in
visit us in
system. It was designed to measure the range of 100-700kPa. This is beneficial
engine-fuel consumption in the range of 0.25- when running engines without fuel return. Stuttgart
250kg/h. The system handles a variety of fuels, Fuel returning from the engine is temperature- Stand 1835
such as gasoline, alcohol and alcohol mixtures, controlled in the range of 5-50C. Solenoid
diesel, and bio-diesel. The integrated Coriolis valves are installed to disconnect the engine
mass-flow meter provides instantaneous direct from its fuel supply. Fuel-related electrical parts Dipl.-Ing. Herwarth Reich GmbH
mass flow, volume flow, temperature and density meet x-proof or intrinsic safety requirements. The
in a variety of engineering units. Start/stop mobile design and the small footprint (61cm x E-Mail: mail@reich-kupplungen.de
commands activate the internal totalizer. 61cm) enable the system to be very close to the Phone: +49 (0) 234 9 59 16-0
A variable-speed drive controls the engine engine. Ethernet communication is standard and
supply flow rate in the range of 45-450 liters/h. serial communication and analog are optional. www. -Kupplungen.de
INDEX TO ADVERTISERS
A & D Technology Inc ............................. IBC D2T ..........................................................19 MOOG ......................................................13
Affiliated Construction Services ..............25 Darchem Engineering ..............................37 MTS Systems Corp ..................................52
AFT Atlas Fahrzeugtechnik GmbH ...........59 Dewetron GmbH.......................................55 Mustang Dynamometer ...........................15
To request a free subscription Anthony Best Dynamics Ltd .....................17 FAIST Anlagenbau GmbH .........................31 National Research Council Canada ..........37
AOS Technologies ....................................71 FGB Fertigungsgeratebau A nCode International..................................24
to Automotive Testing Technology Application Engineering Inc .....................54 Steinbach GmbH ..................................43 PCB Load & Torque, Inc ...........................73
International go online to: Applus IDIADA Group ...............................27 FUNDACION CETENA-CITEAN .................65 Peak Solutions GmbH ..............................46
Arctic Testing Services Oy .......................46 GeneSys Elektronik GmbH .........................7 Race Technology Ltd ................................26
automotivetestingtechnologyinternational.com Automotive Interiors Expo 2010...............80 HBM Hottinger Baldwin Reich Kupplungen ....................................81
Automotive Testing Expo Messtechnik GmbH .............................. 11 Renk Test Systems GmbH ........................29
Europe 2010 ..................................21, 22 IMTECH Deutschland GmbH & Co KG.......29 Re-Sol, LLC..............................................21
FREE ONLINE READER Automotive Testing Technology International
Online Reader Enquiry Service......82, 84
Jacobs .....................................................40
KMT Kraus Messtechnik GmbH ..............9
Rototest AB ..............................................78
RUAG Schweiz AG ....................................40
ENQUIRY SERVICE AVL List GmbH ......................................OBC
Battery Show ...........................................83
LMS International ...................................IFC
MAHA-AIP GmbH & Co KG .......................31
Seoul Industry Engineering Co .................71
Signal Group ..............................................3
ALSO AVAILABLE Brel & Kjr .............................................65 Matter Engineering ..................................76 Single Temperiertechnik GmbH ...............42
Colmis Proving Ground.............................49 Meggitt Endevco ...................................35 Virginia Panel Corp...................................73
Continental Tire North America Inc ..........53 Mikes-Testing GmbH................................61 Wind Shear Inc .........................................69
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TESTBED LEGENDS
A tribute to historys most forward-thinking concept cars,
which have formed testbeds for technologies of the future
Concept of money
The Aurora project was plagued
by financial problems. The
US$30,000 cost to build the
prototype cleaned out Juliano
and the parishioners who
helped finance the build.
The IRS then became
involved, and found Juliano
guilty of misappropriating hands and fell into a state of
church funds. He claimed that disrepair until car enthusiast
Aurora
GM was out to stop his project, Andy Saunders acquired it in
but ultimately had to declare 1993 and spent the next 10
himself bankrupt, and leave years restoring it.
the church. The car may now be seen at
The Aurora concept may have been created
Sadly, to settle a debt to a high-profile events such as the
with the best intentions, but it needed divine repair shop, Juliano had to give Goodwood Festival of Speed,
intervention to become a reality. Unfortunately it his beloved prototype. The car and on display at the National
no such intervention arrived for Father Alfred A. then passed through several Motor Museum at Beaulieu, UK.
Juliano, a Catholic priest and the creator of the
Aurora, which was claimed to be the worlds first
experimental safety vehicle. His second-biggest ABOVE: The Aurora may
have attracted interest
belief was that cars could be much safer. at its ill-fated launch, but
The styling found few fans, and with a price no orders were placed
of US$13,000 when it was released in 1958, it
was only $1,000 less than the most expensive
car on the US market, the Cadillac Eldorado
Brougham. Juliano was further cursed when the
prototype broke down no fewer than 15 times
on its journey to its unveiling due to fuel problems
in the untested, aged drivetrain. Arriving hours
late for its own launch, the Aurora failed to attract LEFT: The bulbous
windshield design
a single order.
did not require wipers
Reality check
The vehicle did have a basis in the frame, which could be The curiously shaped interior metal shades
in reality, as its chassis operated from the dashboard windshield was no mere to block out the sun.
was that of a salvaged 1953 to aid tire changing. The styling detail. It was A remarkable feature that
Buick. The intention was spare tire, mounted under designed to enhance has never seen production
to offer a choice of Chrysler, the front of the car, would driver visibility and its reality was the swivel-
Cadillac, or Lincoln engines be automatically lowered shape negated the need mounted front seats. If
to power the car. to the ground. for wipers. In addition, the a frontal collision looked
The prototype took two The spare tires position shape of the shatterproof imminent, the occupants
years to design and three was also designed to resin meant that, in the could swivel around and
to build, and was said to absorb impacts, which event of a frontal impact, be protected by their high-
be high-quality work. complemented other safety there would be more room backed seats.
The fiberglass body was features such as seatbelts, between the windshield The large mouth at the
designed to be dent-, side-impact bars, a rollcage, and the occupants heads. front not only scooped
rust-, and corrosion-proof. a collapsible steering The tinted, transparent up air, but was foam-filled
A clever feature was a series column, and a padded astrodome roof also aided to cushion any impact
of hydraulic jacks mounted instrument panel. visibility, with adjustable with a pedestrian.
We are A&D Technology. A leading supplier of integrated powertrain test cells and high-tech development tools for a
wide range of applications, from conventional engines and transmissions to alternative fuels and hybrid technology.
With a complete suite of products, an experienced team, and best-in-class partners, we provide innovative solutions
that reduce test time, increase test coverage, and utilize new methods and tools to effectively manage todays and
tomorrows complex and evolving test requirements.
Test us.
www.aanddtech.com
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AVL EMISSION MEASUREMENT SYSTEMS.
EASY-TO-USE. ScALEAbLE. ExTENSION cApAbILITY.
Successfully installed and commissioned Euro 5&6
and EPA1065 compliant engine and vehicle testbeds.