Moving toward Virtual Vehicle Development SAIC Tire Conference Moving toward Virtual Vehicle Development July 24, 2012 Jonathan Darab

Intro Review industry trends, tools, and key enablers such as tire data on the path to Virtual Vehicle Development The National Tire Research Center(NTRC) and Southern Virginia Motion offers the critical tools and expertise to go from vehicle and component model to winning vehicle – in one location to revolutionize component and vehicle testing, development, and integration. Workforce experience consists of 77 plus years in OEM vehicle development, race development and military (Aberdeen) development Jonathan Darab – SoVa Motion Director 12 Years GM Experience * K&C Machine Engineer * High Speed Tire Test Engineer * Lead LTR Engineer at GM * Advance Tire Development Projects * Advanced Technology Vehicle Development

Industry Trends Reduce Cost Reduce Development Time Knowledge from OEM and Race Industry, but applies to Military Reduce Cost Fewer Physical Pre-Production Properties and people Reduce Development Time Non-critical (safety) testing reduced Increase First Time Quality Conflicts with less testing Increase Robustness of Design Increase Customer Satisfaction

Enablers Reduce Cost Reduce Development Time Knowledge from OEM and Race Industry, but applies to Military Reduce Cost Increase Math Simulations in place of Physical Properties Multiple simulations can be run by one person Reduce Development Time Virtual Tests or Hardware in the Loop Tests Increase First Time Quality Virtual testing allows for multiple runs, not just one Increase Robustness of Design Optimization routines done with Math Simulations Increase Customer Satisfaction Virtual Vehicle Development Virtual and Math are interchangable

Enablers For Math/Virtual or Hardware in the Loop tests, high quality data and understanding is needed Difficult systems to model (Hydraulic – Dampers, ABS systems) are tested physically in conjunction with a math simulation – Hardware in the Loop New machines and processes are needed to produce high quality data and understanding 8 Post, Simulators, LTRe

8 Post Used to develop components to react to a vertical input Tires 8-post test rig represents the next generation in dynamic suspension testing equipment. It has several advantages over today’s 7-post rigs: Chassis actuators (aero-loaders) are electro-magnetic instead of hydraulic. Adds additional chassis actuator to produce natural roll, pitch, and warping The test rig can accommodate vehicles from a golf cart to a fully up- armored HMMWV. Does not require a fully operational vehicle Used to develop components to react to a vertical input Tires Dampers Springs Mounts Structure

Driving Simulators The driving simulator provides full-immersion simulation of the driving experience with visual, audible, tactile, and motion feedback to the driver. Component suppliers can test drive virtual prototypes such as tires or suspension components to reduce development costs associated with making physical prototypes. SoVA Motion currently has one of the only Drag Race vehicle simulations with two side-by-side simulators and realistic launch acceleration enhancements. Must have to enable subjective evaluations for Virtual Vehicle Development

Flat-Trac LTRe Testing Capability Transformational leap to establish high quality tire data for all light duty vehicles Tire size capability: Light Truck and Race High speed capability to ±200 mph (320 kph) Max Tire Width: 20in Max Loaded Radius: 21.5in Increased wheel torque capability ±7375 lb ft (10,000 Nm) is 4-5 times larger than existing Flat-Trac systems Operable over full speed range Uses high response electric motor Increased lateral force capability ±6750 lb (30,000 N) is 2 times larger than existing Flat-Trac systems High tire positioning rates for transient event simulation Improved control to make system Hardware-in-the-loop capable Designed to add wet testing capability

Tire Test Data Current Tire Test Machines have Testing Limitations Force Capability, Dynamic Response, Max Torque, Application of Torque through entire speed range LTRe was designed to eliminate all the limitations for all light duty vehicles and some heavy duty vehicles Math Modeling Due to current testing limitations, the advancement of vehicles dynamics math modeling has been slow LTRe which replicates all light duty vehicle maneuvers enables a leap in tire modeling and vehicle dynamics modeling As the vehicles move towards lighter and smaller vehicles the importance of understanding the vehicle dynamics increases, the importance of high quality tire data increases, and therefore the relevance of the LTRe

Virtual Vehicle Development Model Vehicle on 8-post Driving Simulator Tire Model Vehicle Model Driver and Environmental Inputs Tire Inputs and Body Loads Vehicle Responses LTRe Rolling Resistance Machine, and others Computer Simulation

Summary Industry trends are to reduce cost and time, while increasing quality and customer satisfaction Trends are enabled by increasing math simulation uses Math simulations need high quality data and understanding to be accurate and Hardware in the Loop for difficult systems to model High quality tire data is essential and the foundation to have an accurate math model The LTRe is a transformational leap in tire testing which will be able to reproduce all maneuvers a light duty and some heavy duty vehicles will encounter and produce the high quality tire data needed to move toward a Virtual Vehicle Development Ultimate goal is for a vehicle to be purely developed virtually, but high quality data to produce math models is needed as well as the correct tools to supplement the math data