Aerodynamics

Enhanced simulations for more efficient brakes

Faster, brisker, safer – there are many advantages to be gained from optimising the aerodynamics of a vehicle. The body is obviously important but components like braking systems also play a key role. Brake discs rotate while the vehicle is in motion, generating vortex turbulence around them. This can have an adverse effect on the overall aerodynamics and therefore on the efficiency of the vehicle. The job of our development team is to identify and prevent such problem points early on. Thanks to an improved simulation method developed by our colleague Andreas Zeller, we can now take swift action of this kind even earlier in the development process.

“I looked into the aerodynamic impact of braking systems when I did my master’s thesis at PSW. The question was how this can be included to better effect in computer flow simulations,” said Andreas. “I conducted virtual tests on a specific vehicle, investigating various possible ways of rotating a brake disc, and compared the simulation results with test data from the wind tunnel.” The new virtual simulation method allowed Andreas to predict, explain and prevent an anomaly revealed by a wind tunnel reading on a vehicle.

This methodology minimises the risk of expensive component modifications at a later stage in the vehicle development process. Should similar anomalies occur in other vehicles, the solution developed by Andreas will be used again.

“There are many interacting factors in vehicle aerodynamics, and even minor changes can have major effects,” explained Andreas. “A sound methodical approach is therefore time-consuming but necessary. My team at PSW was a great support to me, both professionally and personally.”

Having completed his master’s degree course combining work and study, Andreas is now a permanent employee at PSW and is broadening his knowledge of aerodynamics.

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