Mechatronics and optimization development for wind tunnel tests

Abstract

In the realm of the automotive industry, the development of vehicles entails the fulfillment of numerous requirements such as appealing design, comfort, safety, and efficiency. Notably, in recent years, the significance of efficiency has grown due to increasing environmental concerns regarding internal combustion engine (ICE) vehicles and limitations on the range of battery electric vehicles (BEVs).

Of the various engineering aspects, aerodynamics assumes a pivotal role in determining the performance of cars, exerting a substantial influence on vehicle efficiency. To investigate and enhance aerodynamics, automotive companies adopt a combined approach involving both digital and real-world testing. The former is accomplished through the utilization of Computed Fluid Dynamic (CFD) analyses, while the latter entails wind tunnel testing of clay car models.

This thesis covers the current approach to the study of aerodynamics, focusing on the issues that affect the existing workflow, including downtime and inaccuracies. In response to these challenges, a novel workflow based on automated mechatronics optimization is introduced and a prototype is tested, thereby showcasing a fresh and more efficient way of working with clay car models tested in wind tunnel facilities.

The proposed workflow aims to enhance the aerodynamic optimization of vehicles by implementing a scalable, plug-and-play system that expedites the process and yields advanced, efficient designs. This endeavor has brought to remarkable results, such as the development of an innovative diffuser configuration that enhances efficiency during side-wind conditions, as well as a 73.4\% reduction in time within the current wind tunnel workflow through the application of automated mechatronics.