Japanese OEM gains ground with Cosworth motion controller

16 October 2019

A major Japanese car manufacturer has made important gains in vehicle development thanks to implementation of a new Cosworth Motion Controller (CMC) system, which has improved the speed, accuracy and value of its windtunnel work.

The CMC, which had previously been deployed on scale models at the Penske Technology Group (PTG), augments Cosworth’s Diablo suite, which is designed to enhance productivity and repeatability in the windtunnel environment.

The CMC provides dynamic and precise attitude control of vehicles, leveraging the speed and accurate timing of EtherCAT®. The solution uses real-time, closed-loop control, based on measured axis feedback, to compensate for vehicle or motion system deflections. The result? Optimised repeatability.

In this latest commission, the CMC allows the manufacturer to control full-size vehicles that sit on a moving belt on standard, flexible tyres. The size and mass of the cars, plus their elastic link to the road create unique challenges for accurate, fast positioning as oscillations may set in.

The CMC has been tuned to prevent such oscillations from occurring. Modifications allow for the large, undamped mass of a car on flexible tyres, with a non-linear suspension. Out of the box, the CMC has provided a significant improvement in positioning accuracy, 0.1m vs. 0.4mm, as well as a 40% reduction in test time.

More importantly, the CMC introduced continuous motion playback to full-size car testing, which allows for even greater efficiency and gathering of richer data. In this mode, a long motion profile is predefined, through which the vehicle moves continuously with concurrent data acquisition. It also greatly reduces vehicle set-up time by removing the need to conduct a time-consuming motion calibration prior to running.

“This second deployment of the CMC demonstrated its capability to control the attitude of full size vehicles in a wind tunnel very accurately, successfully coping with flexible tyres and no damping,” said Cosworth. “Support for conventional point-to-point motion and continuous profile playback led to reductions of test time in excess of 40% out of the box, with potential for further improvements. The CMC’s ability to cope with non-linear suspension systems with no need for prior calibration saves a significant amount of vehicle setup time, greatly improving productivity.”


Latest issue

FREE Newsletter

Stay up to date and a chance to win 1 Years Subscription*

  • This field is for validation purposes and should be left unchanged.

Latest Tweets

Stay up to date with our social world

RACE TECH magazine @RaceTechmag
17 May
McLaren to attract more fans to Formula E -
RACE TECH magazine @RaceTechmag
11 May
🏎 FORMULA E GEN3 @ScarbsTech reports from the launch of @FIAFormulaE controversial #Gen3 racecar 🏎 A TEMPLATE FOR G…
RACE TECH magazine @RaceTechmag
27 Apr
Ferrari tests its 296 GT3 ahead of 2023 debut #Ferrari296GT3 @FerrariRaces #Ferrari #FerrariCompetizioniGT…
RACE TECH magazine @RaceTechmag
27 Apr
F1 2022 THAT’S BETTER! Is this order the ‘new normal’, or is porpoising masking the cars’ true pace? @ScarbsTech ex…
RACE TECH magazine @RaceTechmag
27 Apr
Ferrari tests its 296 GT3 ahead of 2023 debut -
RACE TECH magazine @RaceTechmag
20 Apr
Read our digital April issue for free (limited time only) Want to launch your #electric racing career? Is this the…
RACE TECH magazine @RaceTechmag
13 Apr
Easter Offer! Get a 30% discount off a RACE TECH subscription - limited time only #Easter2022 #Easter
RACE TECH magazine @RaceTechmag
12 Apr
Latest issue of RACE TECH out now. Don't miss #NASCAR #LeMans24jp the unmissable World Motorsport Symposium +…