Vehicle model, especially in an early development phase, for aerodynamic analysis in a test rig and methods for providing such a vehicle model

Abstract

The invention relates to a vehicle model (2), particularly in an early development phase, for aerodynamic analysis in a test rig, with a modeled air inlet (4), with at least one modeled engine compartment replica (6) through which ambient air admitted via the air inlet (4) can flow and in which at least one modeled vehicle component (8), such as an engine, is arranged, with at least one modeled windshield (10) and with at least one water box unit (12) arranged between the modeled engine compartment replica (6) and the modeled windshield (10), which comprises at least one rapid prototyping component of the vehicle model (2) and / or at least one non-model, series-produced component of a vehicle that differs from the vehicle model (2).

Description

[0001] The invention relates to a vehicle model, particularly in an early development phase, for aerodynamic analysis in a test rig and a method for providing such a vehicle model.

[0002] In the aerodynamic analysis of vehicle models in a test rig, the aerodynamic behavior, in particular the air resistance and / or noise development, is analyzed during the driving of a later motor vehicle at an early stage of the development of the vehicle model.

[0003] For this purpose, the individual components forming the vehicle model are usually modeled solely with respect to their external geometric dimensions, without the individual components having to fulfill any real technical function. The modeled components usually only represent the external geometry of the vehicle components that they are intended to simulate in the test bench test.

[0004] When modeling the individual components that simulate the vehicle model during aerodynamic analysis on a test rig, it is often difficult to create sharp edges that the final vehicle would actually have, due to the materials selected for the modeled components. This makes it impossible, or extremely difficult, to capture the aerodynamic behavior at specific points, particularly the expected noise development, in an early development phase of the vehicle model.

[0005] One object of an embodiment of the invention is to propose a vehicle model, particularly in an early development phase, for aerodynamic analysis in a test rig and a method for providing such a vehicle model in which an aerodynamic analysis is already improved in an early development phase.

[0006] This task is solved by a vehicle model, particularly in an early development phase, for aerodynamic analysis in a test rig, with a modeled air intake, with at least one modeled engine compartment replica through which ambient air admitted via the air intake can flow and in which at least one modeled vehicle component, such as an engine, is arranged, with at least one modeled windshield and with at least one water box unit arranged between the modeled engine compartment replica and the modeled windshield, which includes at least one rapid prototyping component of the vehicle model and / or at least one non-model, series-produced component from a vehicle that differs from the vehicle model.

[0007] Because the water box unit of the vehicle model comprises a rapid prototyping component of the vehicle model and / or a non-model, production-ready component from a vehicle that differs from the vehicle model, the water box unit essentially corresponds to the water box unit later installed in the vehicle model. Since the water box unit comprises a rapid prototyping component or a production-ready component, materials are used that differ from the modeled components and, with regard to their transitions and sharp edges, correspond to the water box unit used later in the manufactured vehicle model. This allows the aerodynamic behavior, in particular the air resistance and / or the noise generation of ambient air flowing through the engine compartment replica, to be better simulated during a test bench trial.

[0008] Because the vehicle model incorporates a water box unit positioned between the engine compartment replica and the windshield, an airflow from the engine compartment replica towards the windshield can be simulated. This improves the result compared to vehicle models where the engine compartment, including the hood and windshield, is a single unit or is composed of blocks with closed surfaces.

[0009] It is conceivable to consider embodiments of the vehicle model in which the water box unit comprises at least one water box extending towards the engine compartment replica, including at least one drain, and a cover means covering the water box towards the windshield, which includes at least one opening through which a fluid, in particular rainwater, can flow into the water box through the cover means.

[0010] If the water box unit includes a water box extending towards the engine compartment replica, containing at least one drain, and a cover element that extends towards the windshield, common designs of water box units can be simulated. If the cover element includes at least one opening, further geometries that may occur and cause flow separation and / or noise generation can be represented here.

[0011] Furthermore, it is conceivable that at least one continuous recess is provided in the water tank.

[0012] In one embodiment of the vehicle model, the water tank unit can have a wall thickness that corresponds to the later real component.

[0013] Furthermore, it is also conceivable that the water tank unit, produced as a rapid prototyping component of the vehicle model, is realized in the material and outer contour of the later real component.

[0014] The results for the aerodynamic analysis on a test bench can be further improved for the vehicle model if the vehicle model includes at least one modeled hood adjacent to the water box unit and if the vehicle model includes at least one trailing edge element that can be fixed or is fixed to the modeled hood and / or the water box unit and that includes at least one rapid prototyping component of the vehicle model.

[0015] By placing a trailing edge element on the modeled hood, the simulation of flow separation of ambient air flowing around the vehicle from the direction of the hood towards the windshield can be improved. The trailing edge element can partially or completely encompass the hood on one or both sides. In particular, the trailing edge element can include an angled section, with two areas contacting the hood on two different sides.

[0016] Furthermore, the result of an aerodynamic analysis in a test rig of the vehicle model can be further improved if the vehicle model includes at least one windshield wiper element that can be fixed or is fixed to the water box unit and that includes at least one rapid prototyping component of the vehicle model and / or if the vehicle model includes at least one wiper drive by which the windshield wiper element can be moved relative to the water box unit.

[0017] By arranging a windshield wiper element, which also comprises a rapid prototyping component or a non-model, production-ready component from a vehicle that differs from the vehicle model, the influence of the ambient airflow on the water box unit in conjunction with the windshield wiper element can be better captured. If the windshield wiper element can be actuated by a wiper drive, it can be moved during the aerodynamic analysis, allowing aerodynamic behavior and / or, in particular, acoustic noise development to be captured at an early stage of the vehicle model's development.

[0018] The modeled components can be produced easily and cost-effectively if the modeled air intake, the modeled engine compartment replica, the modeled vehicle component, the modeled hood and / or the modeled windshield are made of clay, wood, metal, plastic or rigid foam.

[0019] Rapid prototyping components can be manufactured easily and cost-effectively if the water tank unit, in particular the water tank and / or the lid element, the trailing edge element and / or the wiper element, comprises a rapid prototyping component designed as a 3D printed part, a CNC manufactured part and / or a plastic injection molded part.

[0020] Furthermore, the aerodynamic analysis on a test bench of the vehicle model can be further improved if the ambient air flowing into the engine compartment replica via the air intake is already exposed to other components within the engine compartment replica. For this purpose, an embodiment of the vehicle model has at least one heat dissipation unit comprising at least one rib-like heat dissipation element, which is arranged in the air intake or downstream of the air intake and upstream of the modeled engine compartment replica, which is exposed to or surrounded by the ambient air flowing through the air intake, and which includes a non-model, production-ready component from a vehicle that differs from the vehicle model.

[0021] The heat dissipation element can comprise multiple cooling fins, which are exposed to ambient air flowing in through the air intake. The heat dissipation unit allows a cooling circuit in the engine compartment replica to be cooled by the ambient air and then returned to a vehicle component located in the engine compartment replica, such as the engine or similar.

[0022] By using a non-model, production-ready component from a different vehicle for the heat dissipation unit, particularly the fin-like heat dissipation element, a structurally delicate component of the future vehicle can be included in the aerodynamic test bench even at an early stage of the vehicle model's development. The heat dissipation elements that form the heat dissipation unit can be so intricate that they cannot be modeled using a standard component, nor can they be easily and cost-effectively provided by a rapid prototyping component. Using similar, production-ready components from other models can improve the results of the aerodynamic analysis.

[0023] Finally, the problem is solved by a method for providing a vehicle model with at least one of the aforementioned features, particularly in an early development phase, for aerodynamic analysis in a test rig, comprising the following steps: a. 100: Providing the CAD data of the modeled components, in particular the modeled air intake, the modeled engine compartment replica, the modeled vehicle component, the modeled hood and / or the modeled windshield; b. 101: Providing the CAD data of the rapid prototyping components, in particular the water tank unit, especially the water tank and / or the lid element, the trailing edge element and / or the wiper element; c. 102: Overlaying the CAD data of the modeled components and the CAD data of the rapid prototyping components; d. 103: If necessary, adjust the CAD data of the modeled components if an overlap with a rapid prototyping component is detected, especially in the area of ​​the detected overlap; e. 104: If necessary, adjust the CAD data of the modeled components at the connection points of the modeled components where the rapid prototyping component is attached to the modeled component if an overlap with a rapid prototyping component is detected; and p. 105: Providing all components and assembling them into the vehicle model

[0024] By providing the CAD data of the modeled components or the rapid prototyping components in steps 100 and 101 and superimposing them in step 102, it is possible to determine whether the subsequently manufactured parts can be joined together without any problems, especially without collisions.

[0025] Steps 103 and 104 may be performed if necessary. This is the case if an overlap with a rapid prototyping component is detected.

[0026] If no overlap is found, steps 103 and 104 do not need to be performed.

[0027] Further development of the process includes the following steps for providing all components and assembling them into the vehicle model: e. 106: Producing and / or providing the modeled air intake, the modeled engine compartment replica, the modeled vehicle component, the modeled hood and / or the modeled windscreen as solid bodies based on the CAD data, depicting the external geometry of the respective component, in particular true to scale; f. 107: Manufacturing and / or providing the water box unit, in particular the water box and / or the lid element, the trailing edge element and / or the windshield wiper element, as a rapid prototyping component of the vehicle model based on CAD data and / or as a non-model, series-produced component of a vehicle that differs from the vehicle model; and / or g. 108: Defining the water box assembly, in particular the water box and / or the cover means, and / or the trailing edge element between the modeled engine compartment replica and the modeled windscreen, defining the trailing edge element on the modeled bonnet and / or defining the windscreen wiper element on the water box assembly.

[0028] In a further development of the latter embodiment, it proves advantageous if the production and / or provision of the modeled air intake, the modeled engine compartment replica, the modeled vehicle component, the modeled hood and / or the modeled windshield includes material removal from the solid body and / or material application to the solid body.

[0029] If, for example, an overlap is detected, the modeled component can be corrected accordingly by removing material. If a gap is found between the modeled component and a component comprising a rapid prototyping part, such as the water tank unit, this gap can be closed by adding material.

[0030] Further features, details and advantages of the invention will become apparent from the attached patent claims, from the graphic representation and the following description of a preferred embodiment of the vehicle model and the method.

[0031] The drawing shows: Fig. 1 A perspective top view of an embodiment of the vehicle model; Fig. 2 A perspective view of a water tank unit of the vehicle model according to Fig. 1; Fig. 3 A schematic flowchart of a method according to the invention.

[0032] Fig. Figure 1 shows a vehicle model, designated as reference 2, particularly in an early development phase, for aerodynamic analysis in a test rig.

[0033] The vehicle model 2 comprises a modeled air intake 4 and a modeled engine compartment replica 6. Ambient air can be drawn into the engine compartment replica 6 through the air intake 4 and flow through the engine compartment replica 6.

[0034] In the engine compartment replica 6, at least one modeled vehicle component 8, such as the engine, is arranged.

[0035] Furthermore, the vehicle model 2 includes a modeled windshield 10. A water box unit 12 is arranged between the engine compartment replica 6 and the windshield 10, which includes at least one rapid prototyping component of the vehicle model 2.

[0036] At the in Fig. In the embodiment shown in 1, the water box unit 12 comprises a water box extending towards the engine compartment replica 6 and including at least one drain (in Fig. (1 not explicitly shown) and a cover means 14 covering the water box in the direction of the windshield 10. The cover means 14 comprises at least one opening 16 through which a fluid, in particular rainwater, can flow through the cover means 14 into the water box.

[0037] Fig. Figure 1 shows an embodiment of the vehicle model 2, in which two windscreen wiper elements 18 are arranged on the water box unit 12.

[0038] Fig. Figure 2 shows an isometric detail view of a cover center 14 of the water box unit 12. While the modeled air intake 4, the modeled engine compartment replica 6, the modeled vehicle component 8 and the modeled windshield 10 are formed from a material such as clay, wood, metal, plastic or rigid foam, the water box unit 12 comprises a rapid prototyping component that may include a 3D printed part, a CNC manufactured part and / or a plastic injection molded part.

[0039] Fig. Figure 3 shows a schematic flowchart of a method according to the invention. Using the illustration of the Fig. 1 and Fig. 2. The procedure is explained below: In a first step 100, CAD data of the modeled components, in particular the modeled air intake 4, the modeled engine compartment replica 6, the modeled vehicle component 8, the modeled engine hood (not shown in the figures) and the modeled windscreen 10 are provided.

[0040] In a parallel or subsequent step 101, the CAD data of the rapid prototyping components, in particular the water box unit 12 and the windscreen wiper element 18, are provided.

[0041] In step 102, the CAD data of the modeled components and the CAD data of the rapid prototyping components are superimposed.

[0042] If it is determined that an overlap between the CAD data of the modeled components and the CAD data of the rapid prototyping components is detected, the CAD data of the modeled components are adjusted in step 103.

[0043] The same applies in step 104 to the connection points of the modeled components, in the event of an overlap of the CAD data of the modeled components with the CAD data of the rapid prototyping components.

[0044] In a final step 105, all components are provided and added to vehicle model 2.

[0045] The features of the invention disclosed in the foregoing description, in the claims and in the drawing can be essential, both individually and in any combination, in the realization of the invention in its various embodiments within the scope of protection of the following claims. Reference symbol list 2 Vehicle models 4 air intakes 6 Engine compartment replica 8 Vehicle component 10 Windscreen 12 Water tank unit 14 lid materials 16 Opening 18 Windscreen wiper element 100-105 process steps

Claims

[1] Vehicle model (2), in particular in an early development phase, for aerodynamic analysis in a test rig, with a modeled air inlet (4), with at least one modeled engine compartment replica (6) through which ambient air admitted via the air inlet (4) can flow and in which at least one modeled vehicle component (8), such as an engine, is arranged, with at least one modeled windscreen (10) and with at least one water box unit (12) arranged between modeled engine compartment replica (6) and modeled windscreen (10), which includes at least one rapid prototyping component of the vehicle model (2) and / or at least one non-model, production-ready component of a vehicle different from the vehicle model (2). [2] Vehicle model (2) according to claim 1, characterized by, that the water box unit (12) comprises at least one water box extending towards the engine compartment replica (6), comprising at least one drain, and a cover means (14) covering the water box towards the windshield (10), which includes at least one opening (16) through which a fluid, in particular rainwater, can flow into the water box through the cover means (14). [3] Vehicle model (2) according to claim 1 or 2, characterized by at least one modeled bonnet adjoining the water box unit (12) and by at least one trailing edge element that can be fixed or is fixed to the modeled bonnet and / or the water box unit (12) and that includes at least one rapid prototyping component of the vehicle model (2). [4] Vehicle model (2) according to one of the preceding claims, characterized byat least one windscreen wiper element (18) that can be fixed or is fixed to the water box unit (12) and that includes at least one rapid prototyping component of the vehicle model (2) and / or that includes at least one non-model, series-produced component of a vehicle different from the vehicle model (2) and / or by means of at least one wiper drive by which the windscreen wiper element (18) can be moved relative to the water box unit (12). [5] Vehicle model (2) according to any one of the preceding claims, characterized by , that the modeled air intake (4), the modeled engine compartment replica (6), the modeled vehicle component (8), the modeled hood and / or the modeled windscreen (10) includes material such as clay, wood, metal, plastic or rigid foam. [6] Vehicle model (2) according to any one of the preceding claims, characterized by, that the water box unit (12), in particular the water box and / or the lid means (14), the trailing edge element and / or the wiper element (18) comprises a rapid prototyping component designed as a 3D printed part, as a CNC manufactured part and / or as a plastic injection molded part. [7] Vehicle model (2) according to any one of the preceding claims, characterized by a heat dissipation unit comprising at least one rib-like heat dissipation element arranged in the air inlet (4) or downstream of the air inlet (4) and upstream of the modeled engine compartment replica (6), which is open to or surrounded by the ambient air flowing in through the air inlet (4) and which comprises a non-model, mass-produced component of a vehicle different from the vehicle model (2). [8] Method for providing a vehicle model (2) according to any one of claims 1 to 7, in particular in an early development phase, for aerodynamic analysis in a test rig, comprising the steps: a. 100: Providing the CAD data of the modeled components, in particular the modeled air intake (4), the modeled engine compartment replica (6), the modeled vehicle component (8), the modeled hood and / or the modeled windscreen (10); b. 101: Providing the CAD data of the rapid prototyping components, in particular the water tank unit (12), especially the water tank and / or the lid element (14), the trailing edge element and / or the wiper element (18); c. 102: Overlaying the CAD data of the modeled components and the CAD data of the rapid prototyping components; d. 103: If necessary, adjust the CAD data of the modeled components if an overlap with a rapid prototyping component is detected, especially in the area of ​​the detected overlap; e. 104: If necessary, adjust the CAD data of the connection points of the modeled components where the rapid prototyping component is attached to the modeled component if an overlap with a rapid prototyping component is detected; and p. 105: Providing all components and assembling them into the vehicle model (2). [9] Method according to claim 8, characterized by , that includes providing all components and assembling them into the vehicle model (2): e. 106: Producing and / or providing the modeled air intake (4), the modeled engine compartment replica (6), the modeled vehicle component (8), the modeled bonnet and / or the modeled windscreen (10) as solid bodies based on the CAD data, representing the external geometry of the respective component, in particular true to scale; f. 107: Manufacturing and / or providing the water box unit (12), in particular the water box and / or the lid element (14), the trailing edge element and / or the windshield wiper element (18) as a rapid prototyping component of the vehicle model (2) based on CAD data and / or as a non-model, series-produced component of a vehicle different from the vehicle model (2); and / or g. 108: Defining the water box unit (12), in particular the water box and / or the cover means (14), and / or the trailing edge element between the modeled engine compartment replica (6) and the modeled windscreen (10), defining the trailing edge element on the modeled bonnet and / or defining the windscreen wiper element (18) in the water box unit (12). [10] Method according to claim 9, characterized by , that the production and / or provision of the modeled air intake (4), the modeled engine compartment replica (6), the modeled vehicle component (8), the modeled hood and / or the modeled windscreen (10) involves material removal from the solid body and / or material application to the solid body.

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