Ahead of its upcoming debut, the new BMW X3 undergoes rigorous final tuning at the BMW Group test centre in Miramas, southern France. The fourth generation of this Sports Activity Vehicle (SAV) in the premium mid-range segment promises highly efficient combustion engines and an advanced plug-in hybrid drive. Engineers meticulously fine-tune all chassis control and driver assistance systems to ensure superior handling across all model variants.
Extensive testing in various conditions, including snow, ice, extreme heat, and off-road terrain, has validated the BMW X3’s versatility and performance. From urban traffic to winding roads and highways, every aspect of its suitability for daily use and travel has been refined to deliver an exceptional driving experience.
At the Miramas test track, engineers focus on analysing and optimising the BMW X3’s acceleration, suspension, steering, and braking behaviour. The vehicle’s intelligent lightweight construction and aerodynamic design, boasting a drag coefficient of 0.27, contribute to its driving dynamics and efficiency.
Compared to its predecessor, the new BMW X3 features a wider track, reduced rear axle lift, and increased body and chassis rigidity. Enhanced steering comfort and cornering dynamics are achieved through modifications to kinematics, elastokinematics, and steering ratios. Optional Adaptive Chassis with electronically controlled shock absorbers offers customisable driving modes for added comfort or sportiness.
The latest BMW iDrive system, based on the BMW Operating System 9, elevates the X3’s automated driving and parking capabilities. With standard equipment exceeding Euro NCAP safety standards, the X3 integrates seamlessly with driver assistance systems, providing precise control and harmonious interaction between driver and vehicle.
State-of-the-art sensor and software technology powers the X3’s assistance systems, enabling features like the Active Lane Change Assistant and Parking and Manoeuvre Assistant, which allows remote control of maneuvers via smartphone.
After the Taycan, the next all-electric sportscar from Porsche will be the Macan. Developed with the usual secrecy, prototypes have been running around the proving grounds of the Porsche Development Centre and the next step is to take them into the outside world for road-testing.
Real-world testing on public roads and in a real-life environment are important stages in the development of a new model. In the case of the electric Macan, due to be launched in 2023, the testing will cover at least 3 million kms worldwide in varying conditions. This will add on to the experience gained from countless previous test kilometres – driven in a virtual space.
Digital development preserves resources
Digital development and testing not only saves time and costs but also preserves resources, so it enhances sustainability. Instead of real vehicles, the engineers use digital prototypes – computational models that replicate the properties, systems and power units of a vehicle to a high degree of accuracy.
There are 20 digital prototypes for the purpose of simulation in a number of development categories, such as aerodynamics, energy management, operation and acoustics. “We regularly collate the data from the various departments and use it to build up a complete, virtual vehicle that is as detailed as possible,” explained Andreas Huber, manager for digital prototypes at Porsche. This allows previously undiscovered design conflicts to be swiftly identified and resolved.
The aerodynamics specialists are among the first engineers to work with a digital prototype. “We started with a flow-around model when the project first started about 4 years ago,” explained Thomas Wiegand, Director of aerodynamics development.
Low aerodynamic drag is fundamental to the all-electric Macan with a view to ensuring a long range. Even minor flow enhancements can make a huge difference. The engineers are currently using simulations to fine-tune details such as the cooling air ducts. The calculations not only take into account different arrangements of the components, but they also reflect real-life temperature differences.
Advanced and powerful simulation software allows almost all aspects of a new model to be viewed and tested before physical prototypes are built, saving time and money.
Virtual testing
New methods now allow very precise simulation of both aerodynamics and thermodynamics. “The digital world is indispensable to the development of the all-electric Macan,” said Wiegand. ”The electric drive system – from the battery through to the motor – requires a completely separate cooling and temperature control concept, one that is very different from that of a conventionally powered vehicle.”
While a temperature window of 90 to 120 degrees is the target for combustion engines, the electric motor, powertrain electronics and high-voltage battery require a range of between 20 and 70 degrees, depending on the component. The critical scenarios don’t occur on the road but can occur during fast high-power charging at high outside temperatures. However, the Porsche developers are able to precisely calculate and digitally optimise position, flow and temperature.
Virtual prototypes can be combined with real-world scenarios at an early stage. The best example here is the development of a completely new display and operating concept for the next generation of Macan. Using what is known as a seat box to recreate the driver’s environment, the display and operating concept can be brought to life in an early development phase in conjunction with the digital prototype.
“Simulation allows us to assess displays, operating procedures and the changing influences during a journey from the driver’s point of view,” explained Fabian Klausmann of the Driver Experience development department. “Here, the ‘test drivers’ are not just the specialists themselves but also non-experts. This allows all interaction between driver and vehicle to be studied down to the last detail, enabling selective optimisation even before the first physical cockpit has been built.”
To be the sportiest model in the segment
The first physical prototypes of the electric Macan were built using data obtained from the simulations – in some cases elaborately by hand or using special tools. These are then regularly adapted based on the virtual refinement process. By the same token, the findings from road testing are fed directly into digital development.
“Endurance testing on closed-off testing facilities and public roads in real-life conditions is still indispensable to ensure that the vehicle structure, operational stability and reliability of hardware, software and all functions meet our high quality standards,” said Member of the Executive Board Michael Steiner.
Prototype of all-electric Macan being tested at Porsche’s test track. Some cars, with camouflage over their bodies, are now being tested on public roads in different parts of the world.
The demanding test programme for the electric Macan, carried out under the extremes of climatic and topographical conditions, includes disciplines such as the charging and conditioning of the high-voltage battery, which has to meet very rigorous standards.
“Like the Taycan, the all-electric Macan, with its 800-volt architecture, will offer typical Porsche E-Performance,” promised Steiner, citing development goals such as long-distance range, high-performance fast charging and reproducible best-in-class performance figures.
Combustion engine will still be offered
While Europe is accelerating into the era of pure electromobility with all-electric vehicles, Porsche understands that the pace of change will vary considerably across the world. In some regions, there will still be demand for vehicles with conventional combustion engines. Therefore, the next Macan will continue to have a variant with a combustion engine for markets which want it.
Aston Martin has confirmed that its first SUV – the DBX – will be launched in December this year. That’s just a little over 3 months away and the engineers are busy completing what is described as the most comprehensive test regime of any Aston Martin. Extensive everyday real-world driving and high-performance track evaluation has been taking place at locations worldwide to confirm the capabilities and durability of the most versatile product in the brand’s history.
The locations include two key engineering centres – at Silverstone in the UK and the Nurburgring in Germany. While conducting durability testing at the demanding Nurburgring, the DBX has delivered cornering speeds on par with the Vantage, while achieving braking figures greater than the Super GT, DBS Superleggera. This has already seen Aston Martin’s engineering team regularly achieve sub 8-minute lap times during their regular testing of the SUV.
550 ps V8, top speed over 290 km/h
The new DBX will be powered by a 4-litre twin-turbo V8 similar to the one in the existing Vantage and DB11. However, for DBX application, the engine surpasses the performance credentials of these models, delivering 550 ps/700 Nm. High speed testing has already proven that the DBX can consistently exceed 290 km/h.
With a focus on creating a broader, more solid acoustic note, the SUV’s exhaust system has been tuned to reflect a deep bass with increasing mid-tones, creating true auditory exhilaration, particularly in more sporting drive modes.
Commenting on the test programme, Matt Becker, Aston Martin’s Chief Engineer, said: “We have concentrated our work to ensure that the calibration and tune of this 4-litre twin-turbo V8 delivers both the everyday usability and refinement expected by SUV owners. However, we have also focused heavily on matching that with the engaging driving dynamics that are commanded by our brand and inherent in every Aston Martin and early indications of the car’s overall performance have been incredibly promising.”
Hyundai Motorsport has started testing its new generation i30 TCR at Motorland Aragon in Spain. This is part of the development phase that will allow engineers to refine the car’s characteristics and make it a competitive racer on racing circuits.
Prior to the trip to Spain, the vehicle had already undergone a number of shakedowns, but the session on this track will prove invaluable to Hyundai engineers who are working around the clock to ensure that the car runs well and at a competitive pace. According to Hyundai, the sessions were completed without major reliability issues and the team even tested alternative settings as they work to develop a base set-up for the car.
The automaker considers the 5.3km track at the Aragon circuit the perfect venue for driver Garbriele Tarquini to refine the handling balance through both slow and high speed corners, as well as under heavy braking for the hairpin at the end of the long back straight.
Several different engine map settings were tested for the car’s 2.0-litre turbocharged engine to identify one that yielded the best performance figures. The engine is mated to a sequential gearbox with steering mounted paddle shifters as per racing regulations.
Speaking of the testing session, Customer Racing department manager Andrea Adamo said: “We were able to work on the balance of the car, and start developing an initial set-up that we can use in future, not only for the handling, but the important engine and differential settings. We can now use these as a base for future tests as we turn our focus to gaining the maximum performance from specific components.”
This racecar is based on the new road-going i30 but was designed and built in accordance with the TCR regulations that were first used in 2015. Currently, the TCR category is used as the platform for a number of international and national championships, as well for classes that compete at endurance events.
Hyundai’s car has been shipped back to its headquarters in Alzenau, Germany for the team to prepare it for its next test outing in the schedule. Expect more from the automaker as it gears up to take on other seasoned manufacturers in circuit racing championships around the world.
