As automakers increasingly use simulation to supplement their vehicle test programmes, just-auto spoke to Chris Hoyle, technical director of rFpro, a UK company that has modelled the Nordschleife circuit at the Nürburgring, Germany, with unprecedented accuracy.
What’s new about the approach you have taken?
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The level of accuracy in the new model is approximately ten times better than anything previously achieved. Using state-of-the-art phase-based LIDAR laser imaging technology to resolve the entire 20.8km track surface in 3D produced an accuracy better than 1mm in Z (height) and 1cm in X and Y (position). This is new territory for track surface modelling; over four man-years of effort were required just to update the graphics to support the new model.
Why do you need this level of accuracy?
One of the most important external factors affecting the performance of a vehicle model is the road surface that the tyres’ contact patches traverse. Conventional single or multi-point contact models are adequate for low frequency applications but feel too harsh to a human driver; they are fine for driver training in terms of which way the corners go but limited for use in vehicle development. Our model of the Nordschleife enables customers to carry out meaningful engineering work with a simulator, such as suspension tuning or the development of chassis systems, and arrive at the circuit with a better optimised package.
Why model the Nürburgring circuit?
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By GlobalDataIt has become a benchmark for many manufacturers, with new performance cars vying to set competitive lap times, and the variety of corners, surfaces and speeds has established it as a highly effective environment for exposing any chassis weaknesses. The circuit operators were also keen to support the modelling process, recognising that inclusion in a simulation model library is likely to stimulate additional bookings for track time. In the future, it may be that tracks which are not included in the modelling process could become less attractive and relevant to the major industrial players.
Does this mean there is a synergy between simulation and ‘real world’ testing?
Absolutely. Simulation is nothing without meaningful correlation against real test data in order to update and improve the mathematical vehicle models. At the same time, reliable simulation allows more effective preparation for the real tests so vehicle developers can achieve more during their test window; essentially the two approaches benefit each other. Back at base, on the simulator, OEMs also benefit from the ability to speed up development by testing all year round, 24 hours a day, regardless of weather or track availability, on a consistent and repeatable road surface, and from improved confidentiality through keeping secret prototypes hidden until later in the development cycle.
Can automakers make wider use of this capability?
The method of data capture, using technology mounted on a small SUV, means the process can also be applied to public roads, whether urban, rural or inter-city highways, allowing vehicle makers to simulate specific road surface types and features. With the trend towards global vehicles based on common platforms, this means new models can be evaluated over the kinds of terrain found in different continents, ensuring compatibility with individual market conditions, long before physical prototypes exist. During 2013 we built a total of 402km of digital circuit models for our simulator clients, including proving grounds, test tracks, race tracks and public roads. In total, our model library now includes over 50 circuits and test tracks and thousands of kilometres of public roads.
