EcoRacer

 

Wolfsburg, 04 July 2006 - Virtual technologies – i.e. new analytical and simulation methods – are achieving greater and greater speeds in the development of new automobiles. The results: Volkswagen can react quicker to technological trends and requirements. Shorter development times also reduce costs. At the same time, optimization of system quality and safety are declared goals. Especially challenging here is the  development of new chassis, since many safety-related subassemblies are involved. The example of the EcoRacer research vehicle – presented at the Tokyo Motorshow 2005 – clearly demonstrates the great potential Volkswagen possesses in the area of virtual processes. Background: The EcoRacer was created in record time at the computer. After just three months the first "prototype" was run through initial vehicle testing programs and exhibited remarkably good handling characteristics.


After three months the EcoRacer was drivable; after seven it was complete

A brief retrospective: The development time available for the EcoRacer, a total of seven months, was very short. In spite of this specified targets called for the design of a fully drivable vehicle with many new components. The special attraction of this program was the key characteristic to be implemented in the EcoRacer: Maximum driving fun with minimal fuel consumption. And the aspect of driving fun meant a chassis with a high level of lateral dynamic potential.

To even keep up with the tight timetable, it was clear from the outset that the body and chassis would need to be developed in parallel and had to be ready at nearly the same time. Time for any type of vehicle trials would therefore need to be kept to a minimum. For the chassis this meant that: The first shot had to be a winner. The need for a second shot would be a miss.

And the first shot was a bullseye. This was facilitated by complex simulation models of both the front and rear axles. They enabled observation of a wide variety of load situations, and analysis of kinematic and elastokinematic axle reactions. A key process here involved transferring the quasi statically determined computational results to the vehicle’s dynamic behavior. The experience of specialists in vehicle dynamics, supported by continually improving total vehicle simulations is always an indispensible component in this process.

After FEM-based mechanical design and layout of components, as mentioned above it was possible to place the vehicle on its wheels after just three months, and it immediately exhibited good driving behavior. After about one week of tuning the suspension, dampers, steering and ESP the current level was achieved. The EcoRacer demonstrates in an impressive way the capabilities that virtual technologies already offer today. Conceptually the EcoRacer – as anticipated in the target requirements – represents a futuristic synthesis of very tough economizing and superior sporty behavior. Its 230 km/h top speed, 6.3 seconds to sprint to 100 km/h and 3.4 Liter per 100 km fuel consumption say it all.