Prototyping and Testing:
Prototyping and testing represent a distinctive element of expertise characteristic of Dallara’s technical identity. Over the years, we have developed a methodical and systematic approach to project validation which combines the use of cutting-edge test benches with in-depth track testing.
This expertise allows us to correlate and populate the virtual models with real data from precise, reliable and controlled measurements, helping ensure the virtual model is up-to-date, realistic and responsive in use.
It is a dual strategy which allows every aspect of the vehicle, from the structural performance to the driving dynamics, to be verified in a controlled environment before moving on to road testing.
Integrated Validation Process
The test equipment includes static and dynamic test benches which, combined with the in-depth expertise of the technical team, allow the development cycles to be accelerated significantly, while at the same time guaranteeing the highest standards of safety and reliability. This integrated validation process is divided into different complementary phases, each dedicated to specific aspects of the vehicle.
Our expertise in prototyping and testing represents a strategic asset common to all Dallara’s business units: racing, where speed of development and validation is key for success on the track; automotive, where rigorous quality and safety standards require extensive cycles of testing; and aerospace, where the reliability of components must be guaranteed in extreme operating conditions.
Test Benches
Testing on test benches allows for the simulation of extreme conditions and stresses that the vehicles will be subjected to on the road or track.
Thanks to these tests, indeed, the risk of faults due to mechanical failures or structural problems is reduced, costs and timeframes are optimized by limiting the tests performed directly on the track, and performance is improved since conditions can be replicated with great precision in the lab, allowing for accurate validation of performance.
Dynamic Test Bench: the 7-Post Rig
This is used for experimentation and development of vertical dynamics. The Post Rig is composed of seven pistons, four for the independent movement of each wheel, and three to reproduce the loads on the chassis. The pistons apply force to the vehicle, reproducing movements and acceleration generated by the track profile, aerodynamic loads, and load transfers occurring during braking, cornering, and acceleration.
Static Test Bench
This is able to measure the vertical and lateral deflection of the complete vehicle, its torsional rigidity and roll stiffness. In addition to the static test bench, equipment is also available to measure the height of the center of gravity and the moment of inertia (pitch and roll).
This test bench is also used and certified for all the FIA static homologation tests required to certify the safety of products before they are used on the track.
Fatigue Test Bench
A particular area of experimentation is the analysis of fatigue cycles on complete wheel assemblies or other components. Ever more often, indeed, the design and construction of components with service life guarantees – both in conditions of use and abuse – is required, in order to achieve ever-higher safety thresholds.
Radiator Test Bench
This is used to measure the performance of heat exchangers for vehicles. It is able to reproduce the working conditions of these heat exchangers, monitoring and measuring parameters such as operating temperature, air speed, fluid flow rate, and the pressures, in order to create a performance map of the component.
Testing does not simply mean proving what we have imagined, but transforming data into performance and performance into data.
Track Development and Testing
Carrying out tests on the track covers a key role in validation of dynamic loads, durability and thermal stresses on components. It is also key for the study of vehicle dynamics, where every technical detail is verified and optimized in order to maximize performance and guarantee vehicle safety.
Technical development and optimization
This involves evaluation of the aerodynamic modifications, engine behavior, suspension configuration and the general balance of the vehicle, with the goal of finding the ideal configuration.
Durability and reliability assessment
The strength and durability of the mechanical components is tested under real conditions, identifying any reliability issues.
Tire and brake regulation
The behavior of various types of rubber is analyzed under various track conditions (temperature, humidity) in order to find the right equilibrium between grip, durability and balance.
Driver adaptation
Become familiar with the car’s behavior, refining the driving style according to the vehicle and the track conditions.
Safety
Verification is performed of the vehicle’s reliability and its compliance with safety standards and regulations, reducing the risk to the driver.
Specialist Consultancy
Bolstered by its experience in the racing sector, Dallara provides racing teams and automotive manufacturers with specialist consultancy and professional support in carrying out and managing development programs and tests on the track or the road, as well as creating dedicated data acquisition and analysis equipment for the specific applications so as to accelerate vehicle development.
