SIMULATION
software is making P424 possible
Simulation is replacing physical testing at all levels of the racing car development process
10 years ago we could test 30% of an F1 car design exclusively in simulation. In Formula E, we can test 60% of the car in simulation. P424 will be designed and tested 95% in the virtual world and limit physical testing to the minimum.
Software reduces RnD cost significantly
Traditionally an OEM would invest 50 to 100 million USD to develop a racing car for Le Mans. With software we will reduce that cost by an order of magnitude. As an example the NIO EP9 was one of the first car of its kind entirely developed in CFD.
Software speeds up the RnD process
It takes months to build a car and put it on a track for testing. It only takes days to run digital simulations. The secret is to have the required experience to run simulations properly.
Software empowers designers and developers
Designers can now perform their own tests on their own desktop without having to involve a chain of people. Designers can get cost estimates for 3D printed parts in minutes using online quotes without waiting for a procurement team to contact their network of suppliers. Less management is needed when designers can perform their own design and testing loop.
Chassis development
Aerodynamic CFD
Full size models at various attitudes including external and internal flows (brake cooling and radiator cooling)
Structures
Linear stress analysis for stiffness and strength of metallic, plastic and composite assemblies
Nonlinear stress analysis for buckling of suspension legs
Dynamic stress analysis for crash test of safety structures
Suspension
Linear stress analysis for K&C (kinematics and compliances)
EV Drivetrain development
Battery
Thermal simulation of battery cooling inside modules
Thermal simulation of battery system in car environment during race distance
MGU
2D Electromagnetic simulation for MGU design
Thermal simulation for MGU and inverter cooling
Gearbox
Gear mesh sliding simulation for efficiency (multi-body simulation)
Oil movement simulation for churning losses and pick-up pressure effectiveness (based on a weakly-compressible SPH formulation)
Bearing life simulation based on season duty cycle
Vehicle dynamics
Lap Time Simulation
Quasi-static lap simulation using single mass point on fixed trajectory for first order design decisions
Dynamic simulation using trajectory actively optimised for second order design decisions and setup optimisation
Multi-lap simulation for energy usage optimisation during a race (very important for EV racing cars like Formula E)
Virtual 4 Post Rig
Dynamic track replay of high frequency inputs at the 4 tire contact patches
Suspension legs dynamic load calculation for strength load cases definition
Sine wave inputs for normalised damper optimisation
Driver development
Racing teams are using DIL (driver in the loop) simulators more and more to help drivers practice upcoming racing events, get used to new procedures, new steering wheel commands, work on the chassis setup with their engineers.
DIL simulators can also be used for chassis, suspension and controls developments but are not necessarily the more efficient tool for these tasks due to the ‘driver noise’ effect (repeatability not as good as simulation models for fine step gains in development).
For electronic systems, control software or suspension components, HIL simulators (hardware in the loop) are good simulation tools and are used extensively for validation of new components and code blocks before they are implemented on the racing car.
Interestingly, mass market gaming racing platforms are getting closer and closer to professional simulators. Mainstream driving simulations are nearly good enough to train professional racing drivers.
Regarding P424, a driving simulator and dynamic car model is being developed on Unity platform. The objective is to perform a ‘Virtual lap record’ on Nürburgring in a professional motion platform simulator and use the content for marketing the project and growing our community.
