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The big figures behind a family of giants: check out the backstage of creation of the new heavy-duty VW

September 01 2020
  • Tests: new heavy-duty vehicles had the largest data acquisition campaign from VWCO;
  • More than 20 prototypes were used in the development of the new heavy-duty VW in Brazil;
  • Development involved customers from the first stage of field validations.

Two vehicles with 300 monitoring points consolidate the largest data acquisition campaign of Volkswagen Caminhões e Ônibus in tests. From a whip script support to an entire axle, nothing escaped the careful analysis of the automaker's engineers to prove the robustness and durability of the components of the new VW heavy-duty family.

In this measurement campaign, Meteor vehicles crossed six Brazilian states on road routes that have traditionally been a symbol of soy transportation in Brazil. Mato Grosso, Mato Grosso do Sul, Goiás, Minas Gerais, São Paulo and Rio de Janeiro were on the route of these highways.

Sensors and special instruments were installed throughout the vehicle, subjected to the most adverse highway conditions, whether in real operation, special tracks, roads or the VWCO proving ground in Resende.

In the VW Constellation model, with its already known cabin, the tests involved application to customers, who actively participated in the development of the vehicle and contributed with improvements to ensure that the novelties were 100% aligned to the day-to-day demand.

Over two years, the models were part of the fleet of customers in the sugar cane segment in the interior of São Paulo and Minas Gerais, in severe condition, carrying up to 125 tons. This was the first time that VWCO provided models still in the prototype phase for this type of evaluation.

Be it in the off-road or on road application, the models have overcome diverse track and climatic conditions, even facing quagmires loaded with 74 tons, to validate their configuration and the traditional VW reliability before they reach the market.

Structured tests of accelerated durability were conducted in the VWCO proving ground, based on the information gathered in real applications, establishing an agile and efficient development process to deliver to the market an extremely robust product, tailored to operate in the most diverse applications of the heavy-duty segment.

Cabin tests - The cabin underwent several tests, including the cab shake, in which the cabin is subjected to abrupt movements in a laboratory test. There was a simulation of kneading of the cabin and even tilting so that the final result is the least possible effort for the driver. In addition, the cabin was subjected to thermal aging tests in a climatic chamber, which promoted abrupt highs and lows in temperature and humidity to gauge the durability of internal and external finishing components.

The work included defrosting and defrosting tests, carried out at low temperatures, with the objective of validating the capacity of the air conditioning and ventilation systems in extreme conditions, in which safety can be compromised by low visibility.

Simulations for the best operating cost - In vehicles that are launched now, customers will notice this equation of simulations and evaluations in real conditions. This translates into the best operating cost, since the final design of each component is optimized for maximum durability, safety, comfort and productivity of the models.

Technical validation was carried out on the new VWCO test track in Resende, the most advanced in Latin America, and also in the field in partnership with customers, engaging them in this development.

In line with what is most modern in project management, this launch involves integration teams between different departments of the company, in addition to a wide range of virtual simulations to speed up vehicle evaluations and reduce development costs, done with components dynamically, and even creating new testing procedures in the company.

At the same time, the VWCO team of professionals also prepared an extensive study of the heavy-duty operations in Brazil to ensure that the configuration of the vehicles met the reality of operation in the country, maximizing the operational results of the customers.

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