To develop a new model, manufacturers use a digital twin. This virtual modeling makes it possible to carry out all kinds of tests before the realization of a real model. This process allows manufacturers like Renault to save time and money.
The development of a vehicle is a long process, marked by many stages. Modeling plays a crucial role in the creation of a future model and at Renault, as with the competition, to save time and money we are now going through the creation of a “digital twin”. This technology allows manufacturers to save up to a year in the design of a vehicle.
A faithful replica of the future model
Previously, to create a digital model, you had to scan a real vehicle piece by piece, down to the smallest bolt. ” Hence the term twin » explains Renault. It is now the opposite! TAll project stakeholders – from design to engineering and production – can access to this virtual model stored in the “ clouds ».
First, the design team models the car down to the smallest detail, down to the texture of the materials and the reflections on the bodywork. The engineers then take over and take care of making industrializable everything that has been imagined by the design teams.
They design the bodywork, the chassis, the electrical and electronic architecture as well as the engine. Thanks to their three-dimensional digital simulation tools, ” Iengineers are able to install a virtual occupant on board a future vehicle very early on to test positioning constraints (ergonomics) and human-machine interface (HMI) » explains Renault. Once produced, the digital twin will serve as the basis for manufacturing the physical prototype, which is always essential in the development of a vehicle.
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Saving time and money
Time is money. Extremely expensive, the physical prototypes are built in a very limited number of copies since they are made by hand. Up to two years before they are sent to the Aubevoye test center, a battery of tests is carried out with the virtual clone. ” Engineers use the entire digital twin in 3D and immersive simulation to test, for example, body aerodynamics, engine performance, transmission management or air conditioning efficiency through virtual simulation explains the manufacturer.
Unlike real models, the digital tests can be repeated as much as necessary on each element of the car, without worrying about the cost and time to achieve them. Crash tests, driving scenarios on virtual roads or passages in the wind tunnel are also simulated. Subsequently, the real prototype will enrich the digital one and vice versa. The virtual twin is also used in the mass production process of the future model. Suppliers use it to build the physical parts while the manufacturer’s factories can ” virtually develop the future assembly line, the future configuration of its machine tools or even measure future flows “.
And then ?
The life of ” digital twin » does not stop once the career of the real model is launched. ” The twins follow each other throughout their lives. explains Renault.
“Before the vehicle is manufactured, the digital twin ‘feeds’ the physical one. Out of the factory, it’s the opposite. “
The logistics, sales or after-sales professions feed the digital database of customer feedback, carry out quality monitoring or even offer updates related to the use of real models in everyday life. .
