Professional Documents
Culture Documents
TMG Brochure 02 PDF
TMG Brochure 02 PDF
welcome
TO THE HOME OF HIGH PERFORMANCE
Content
Wind Tunnel & Support Services . . . . . . . . . . . 06 13
Wind Tunnels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 10
Model Shops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Computational Fluid Dynamics. . . . . . . . . . . . 12 13
Manufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 43
Rapid Manufacturing . . . . . . . . . . . . . . . . . . . . . 38 39
Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 41
CNC Production . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 43
Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 49
Driving Simulator. . . . . . . . . . . . . . . . . . . . . . . . . .46 47
Chassis Workshop. . . . . . . . . . . . . . . . . . . . . . . . . 48 49
AT A GLANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 53
OUR HERITAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Seven-Post Rig
Model Shops
Driving
Simulator
Rapid
Manufacturing
Chassis
Calculation
Composites
cfd
CNC
Production
Wind Tunnels
Engine
Design
Chassis
Workshop
car design
Accuracy
With TMGs high-speed acquisition and continuous motion systems, our two wind tunnels offer
unrivalled data efficiency and quality to enable you to extract the full aerodynamic potential.
wind tunnels
THE ULTIMATE
AERO EXPERIMENT
OUR TWO WIND TUNNELS ARE BASED ON CLASSLEADING TECHNOLOGY AND OFFER UNIQUE
INTERACTION WITH TMGS OTHER SERVICES FOR
SPEED, ACCURACY AND MAXIMUM EFFECT.
UNRIVALLED SPEED
26m
3.7m
15m
63m
11
ACCURACY IS
EVERYTHING
AN ACCURATE MODEL IS AT THE HEART OF
SUCCESSFUL WIND TUNNEL TESTING AND
TMGS HIGH-SPECIFICATION MODEL SHOPs
are READY FOR YOUR REQUIREMENTS.
Efficiency, precision and flexibility are what counts at TMG and the
wind tunnel model shops symbolises those qualities.
Located directly next to the wind tunnels, CFD and chassis calculation departments, the model shops are an integrated part of the
development process.
The models produced are based on our advanced spine which is capable of holding 512 pressure measuring channels, delivering unrivalled data acquisition and accuracy.
With two complete model struts and two pre-fit areas featuring
model hangers, the 800m TMG model shop is a high-capacity, highprecision facility dedicated to servicing our two wind tunnels.
HIGH-PERFORMANCE MODELS
VISUALISING
THE FLOW
WHETHER YOU WANT TO UNDERSTAND FLUID
FLOW AROUND A PART OR FULL VEHICLE, OUR
COMPUTATIONAL FLUID DYNAMICS EXPERTS
ARE AT YOUR SERVICE.
VIRTUAL POWER
All you need is CAD geometry of your development item and TMGs experienced engineers can create a model and begin CFD
analysis.
With a typical full-car model of 60 million
hexahedral cells, calculation, including automatic generation of post-processing movies,
can be performed within 24 hours and three
cases of this size can run simultaneously.
13
Performance
With expertise from across the automotive world, TMG offers car design consultancy
to truly bring high performance to your car or development item.
CAR DESIGN
PERFORMANCE
PLANNING
CAR DESIGN COMBINES CALCULATION, DESIGN
AND EXPERIMENTATION TO DELIVER HIGH PERFORMANCE ACCORDING TO YOUR SPECIFICATIONS.
Our calculation group will confirm structural efficiency through material and geometry
optimisation while experimentation on our
component test rigs verifies calculations or
proves prototype parts and systems, validating the achievement of performance targets
and ensuring effective development.
Supporting the design and development process, our material specialists ensure you select the best solution for your performance
and pricing specifications.
We have in-depth knowledge of high-performance composite design, including structural items and impact absorption structures,
with specialised calculation engineers to en
TMG is at the cutting edge of gearbox technology, including driveshafts and differentials, and offers a full range of developments
supported by specific tests.
We also offer a variety of specialist component solutions from carbon and metallic suspension elements to steering or brake systems development, supported by a full range
of calculation techniques, including topology optimisation, and on-site testing.
UNIFIED DEVELOPMENT PROCESS
17
chassis calculation
GETTING THE
STRUCTURE RIGHT
TMGS CHASSIS CALCULATION EXPERTS WILL
DELIVER A FULL STRUCTURAL CALCULATION
SERVICE TO OPTIMISE YOUR PARTS FROM CARS
AND BOATS TO DOMESTIC APPLIANCES FOR
EFFICIENCY AND WEIGHT REDUCTION.
19
Efficiency
With various distinct types of dynamometer and a unique range of testing systems,
TMG is the key to unlock the performance potential of your engine.
ENGINE DESIGN
All developments can be analysed thoroughly in TMGs extensive engine and comprehensive testing suite, where detailed processes
verify a complete range of specific performance parameters.
CALCULATING PERFORMANCE
The TMG engine design service looks at every detail of your project, including materials,
coatings, surface textures, fuel spray velocity, calibration, emissions and much more.
Completing our comprehensive engine design and development portfolio, the 1,100m
engine workshop features 21 assembly and
five disassembly workbenches, manned by
highly-skilled technicians.
MATERIALS MATTER
IN-DEPTH ANALYSIS
23
Engine DynamometerS
UNDERSTANDING
ENGINE PERFORMANCE
OUR ENGINE DYNAMOMETERS SUITE HAS A
PROGRAMME FOR EVERY PROJECT, FROM ROAD
CAR TO HIGH-PERFORMANCE AND HYBRID
ENGINE ANALYSIS.
Our multi-function high-dynamic dyno accurately simulates road or track driving conditions based on a defined plan, with up to
22,000rpm engine speed, 3,000rpm wheel
speed and 800kW engine power. Among its
various uses, the dynamic dyno is also ideal
for exhaust reliability studies and launch
development.
DYNO DIVERSITY
OPTIONS APLENTY
1 A SINGLE-CYLINDER DYNO
2 A TECHNICIAN MONITORS A HIGH-DYNAMIC DYNO
25
ANALYSIS IN DETAIL
UNIQUE ENGINE AND COMPONENT TESTING
RIGS PUT EVERY ELEMENT OF YOUR ENGINE AND
COMPONENTS TO THE TEST, SO CHALLENGE US
TO DELIVER THE ANALYSIS YOU NEED.
Many of our specialist test rigs have been developed in-house and can be adapted exactly
to your requirements for in-depth analysis
of fuel systems, radiator core performance,
pneumatic and steel valve spring behaviour
or clutch and launch systems.
A unique fuel system testing facility incorporates the most comprehensive analyses available, including a fuel pump test rig, fuel rail
calibration rig and single injector test and
development rig.
DETAILED INVESTIGATIONS
Heat rejection and friction analysis is a particular speciality while the latest technology
is utilised to provide incredibly detailed data
on individual components.
ULTIMATE ACCURACY
Our cam rig for air and valve spring measurement can run up to 22,000rpm engine speed
with an 110Kw electric motor. A 70-channel
measurement system, six-channel laser system and high-speed camera provide full valve
motion analysis.
The adjustable radiator wind tunnel runs at
realistic air speeds up to a maximum of 12m/s
for lifelike analysis of radiator core performance.
UNIQUE ANALYSIS
High-speed cameras and lasers deliver incredible accuracy, as does the military-grade thermal camera on our 10,000rpm clutch development rig, which requires a specific permit
from the authorities.
Additionally, we offer Horiba exhaust gas analysers, Malvern laser system for fuel spray
characterisation, fast flame ionization detection and rapid in-cylinder sampling.
27
Flexibility
TMG has a comprehensive range of over 200 specialised component test systems, whether
you need to ensure 100% reliability of safety-critical items or maximise performance.
seven-post rig
VERTICAL DYNAMIC
SOLUTIONS
OUR SPECIALISED SEVEN-POST RIG ADAPTS TO
MOST VEHICLES AND IS A FLEXIBLE DEVELOPMENT
AND PROVING TOOL FOR ORIGINAL EQUIPMENT
MANUFACTURERS AND HIGH-PERFORMANCE CAR
DEVELOPERS.
FLEXIBLE APPROACH
1
SPECIFICATIONS
Vertical actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downforce actuators. . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaluation software. . . . . . . . . . . . . . . . . . . . . . . . . .
Installed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Latest refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
MTS
TMG exclusive
2001
2009
Dedicated ground
floor facility
31
THE ULTIMATE
TEST FACILITY
WITH A HUGE CHOICE OF COMPONENT TEST
RIGS PERMITING OVER 200 DIFFERENT TESTS,
WE WILL DEVELOP AN INDIVIDUAL TESTING
SOLUTION JUST FOR YOU.
Every square metre of our extensive advanced component testing facility is accessible
by overhead crane while a modular layout
and multiple access points allow for complete confidentiality, no matter which services you require.
But it is not simply the choice of machines
and processes which sets TMG out as a class
leader; our highly-skilled technicians come
from a variety of industrial sectors and are
adaptable to meet whatever challenge they
face.
33
TMGs transmission lubrication test system provides a comprehensive analysis of internal lubricant flow.
Its six degrees of freedom at vehicle spindle gives control over vertical, lateral and longitudinal translation, brake/drive torque, camber
moment and steer moment while the 29 channels are accurate to
0.001mm and an additional four actuators can simulate downforce.
The multi-axial road simulator is the ultimate complete car and component test rig, for front and rear axle fatigue testing, full car stiffness tests and analysis of suspension sub systems.
By fully understanding lubricant flow in road/track conditions, lubrication of all internal gearbox components can be optimized for performance and total reliability. The system is also perfect for component tests to optimise items such as spray bars, oil pumps or oil
coolers.
35
MANUFACTURING
Precision
TMG is Europes leading rapid manufacturing centre and, with precise quality control
systems, you can be certain the finished product exceeds your expectation.
Manufacturing
rapid manufacturing
SPEED IS OF
THE ESSENCE
WITH ONE OF EUROPES LARGEST CONCENTRATIONS OF RAPID MANUFACTURING MACHINES
UNDER ONE ROOF, TMG IS A CENTRE OF EXCELLENCE FOR THIS CUTTING-EDGE TECHNOLOGY.
Whether for the medical, automotive, architectural or consumer sector, with 10 stereolithography machines (SLA 5000 and SLA
7000 units) and three large-frame laser sinter
machines (P700 and P360 units), TMG can
meet your demands.
FLEXIBILITY AND ADAPTIBILITY
Using their expertise and TMGs state-of-theart technology, the rapid manufacturing department can produce highly-detailed items
for any industry, no matter whether you
need small numbers of prototypes or larger
production quantities.
No matter where you are in the world, production can begin on your item at TMG within just a few hours - simply deliver a suitably-detailed 3D CAD model or STL file and we
will quickly turn your innovation into reality.
And you can be sure of a smooth and trouble-free process thanks to our modified machines, which allow round-the-clock supervision and instant reaction to any problems.
Utilising video and internet technology, we
can make your production faster and more
reliable than ever before.
39
Manufacturing
COMPOSITES
LIGHTWEIGHT BUT
HIGH VALUE
TMGS VERSATILE COMPOSITES DEPARTMENT
COMBINES EXPERIENCE AND HIGH-QUALITY HARDWARE TO CREATE BESPOKE SOLUTIONS PRECISELY
TO YOUR REQUIREMENTS.
Two large autoclaves (with 420 x 160cm curing platforms) and one smaller unit (with
200 x 80cm platform) provide the capacity to
prepare anything from small parts right up to
items the size of a complete car.
We offer a full choice of materials to suit the
precise needs of your project, from Kevlar to
glass, carbon or hybrid fibres, with a filtered,
clear-air, positive-pressure lay-up area eliminating the risk of contamination.
COMPOSITE CHOICES
REFINED PROCESSES
41
Manufacturing
CNC production
PRECISION MILLING
AND TURNING
OUR CNC DEPARTMENT IS YOUR IDEAL PARTNER
FOR DETAILED MILLING WORK AND WITH EXPERT
KNOWLEDGE OF EXOTIC MATERIALS WE HAVE THE
RIGHT CAPACITY AND EXPERTISE.
LARGE CAPACITY
FLEXIBLE SOLUTIONS
That streamlined technology also brings significant speed advantages, with a machining
strategy normally defined and ready for production within 30 minutes of 3D CAD model
delivery.
The impressive FZ 37 is a portal milling machine for very large parts, weighing up to
30,000kg, with a maximum work area of
40,000 x 5,000 x 2,500mm while the DMC
200 U offers trouble-free machining of heavy
tools weighing up to 3,500kg, with a work
area of 1,800 x 2,000 x 1,100mm.
QUALITY COUNTS
43
Facility
Diversity
Our range of machines and processes, combined with highly-skilled specialists, make TMG
the perfect place to bring high performance to your project, whatever it might be.
facility
DRIVING SIMULATOR
VIRTUAL
EVALUATION
TAKE ADVANTAGE OF THE MOST DETAILED
VIRTUAL DRIVING SIMULATOR FOR RACING
CARS ON THE OPEN MARKET FOR DRIVER-INTHE-LOOP ENGINEERING DEVELOPMENT OR
FOR DRIVER ACCLIMATISATION PROGRAMMES.
An accurate tyre model includes thermal effects, as well as a choice of weather, to cover all scenarios and provide full flexibility for
repeated tests in identical conditions.
TRACK LIST
F1 DRIVER INPUT
MULTI-PURPOSE TOOL
47
facility
chassis workshop
SPACE AND
KNOWLEDGE
TMGS SPACIOUS CHASSIS WORKSHOP CAN
HANDLE EVERYTHING FROM FEASIBILITY STUDIES
AND SPORTS CONVERSION PROJECTS RIGHT UP
TO FULL PROTOTYPE OR RACING CAR BUILD
PROGRAMMES.
Our 760m workshop and 600m of separate working space were built from new in
2000 and conform to the highest standards
of cleanliness and preparation while private
bays can be screened off to guarantee confidentiality.
Facilities include lifting machinery, a flat bed
for validation and direct HGV access.
A dedicated team of technicians bring knowledge from various road car and motorsport
disciplines to deliver the experience necessary to get the most out of any project.
DIVERSE APPLICATIONS
49
at a glance
TMG AT A GLANCE
With a comprehensive range of design,
development and production solutions,
as well as a highly-skilled staff drawn
from diverse professional backgrounds,
TMG is TRULY the home of high performance.
Around 150
1979
2000
Approx 30,000m
Approx 11,000m
Cologne Bonn (24km)
Cologne Central (10km)
A1 (2km), A4 (3km)
Website. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Telephone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
www.toyota-motorsport.com
Toyota-Allee 7, 50858 Cologne, Germany
+49 2234 1823 858
+49 2234 1823 834
contact@toyota-motorsport.com
WIND TUNNELS
MODEL SHOPS
Dimensions. . . . . . . . . . . 63 x 26 x 13m
Test section . . . . . . . . . . . 4.1 x 3.7 x 15m
Max wind speed.. . . . . . 70m/s
Fan diameter. . . . . . . . . . 6.3m
Fan power. . . . . . . . . . . . . 2.3MW
Area. . . . . . . . . . . . . . . . . . .
Measuring
equipment . . . . . . . . . . . .
Machining rooms. . . . . .
Atmospheric
control. . . . . . . . . . . . . . . .
Other services. . . . . . . . .
Rolling road
Drag . . . . . . . . . . . . . . . . . 1,800N
Side force . . . . . . . . . . . . . 1,400N
Lift . . . . . . . . . . . . . . . . . 5,200N
Accuracy. . . . . . . . . . . . . . . 0.04%
Repeatability. . . . . . . . . . 0.02%
CFD
Model cells. . . . . . . . . . . . 80million
hexahedral cells
2 x 3D ZETT MESS
Cluster . . . . . . . . . . . . . . . . 1,200 CPU
Wood and STL
Latest upgrade. . . . . . . . 2006
Processors. . . . . . . . . . . . . AMD Opteron 1172
Total dust extraction
2.8Ghz
Machining /milling
Post-processing
Carbon fibre lay-up
nodes . . . . . . . . . . . . . . . . . 4
Tyre balancing
Post-processing
Painting
RAM. . . . . . . . . . . . . . . . . . . 32GB
RAM per calculation
node . . . . . . . . . . . . . . . . . . 8GB
Ethernet . . . . . . . . . . . . . . Myricom 10GB
Software. . . . . . . . . . . . . . ProAm/STAR,
EnSight
800m2
CAR DESIGN
CHASSIS CALCULATION
Servers. . . . . . . . . . . . . . . . 2 x 64GB
Software. . . . . . . . . . . . . . Tosca,
Genesis,
ANSA,
Abaqus,
Nastran,
LSDyna (crash applications),
LMS Virtual.Lab,
LMS Imagine.Lab,
AMESim,
Matlab
ENGINE DESIGN
ENGINE DYNAMOMETERS
STANDARD/HIGH-DYNAMIC
SINGLE CYLINDER
E-motor . . . . . . . . . . . . . . . . . . 110kW
Engine speed. . . . . . . . . . . . . 22,000rpm
Channels. . . . . . . . . . . . . . . . . 70
COMPONENT RIG
E-motor . . . . . . . . . . . . . . . . . . 15kW
Engine speed. . . . . . . . . . . . . 10,000rpm
Channels. . . . . . . . . . . . . . . . . 40
SEVEN-POST RIG
Vertical actuators . . . .
Downforce
actuators. . . . . . . . . . . . .
Evaluation
software . . . . . . . . . . . . .
Installed. . . . . . . . . . . . . .
Latest refit. . . . . . . . . . .
Input motor:
Cont. power . . . . . . . . . . 700Kw
Peak/Base speed. . . . . . 22,000/ 0-17,000rpm
Output motors:
Cont. power . . . . . . . . . . 450kW
Peak/Base speed. . . . . . 3,500rpm/ 0-2,000rpm
Full-car ROAD SIMULATOR (329 Rig)
Channels. . . . . . . . . . . . . 29
Frequency. . . . . . . . . . . . 50Hz
Steering angle. . . . . . . . 44
TRANSMISSION LUBRICATION TEST SYSTEM
Manufacturing
RAPID MANUFACTURING
COMPOSITES
CNC PRODUCTION
Large autoclaves . . . . . . 2
Curing platform . . . . . . . 420 x 160cm
Small autoclave . . . . . . . 1
Curing platform . . . . . . . 200 x 80cm
Fibres . . . . . . . . . . . . . . . . . Carbon, Kevlar,
glass or hybrid
Options . . . . . . . . . . . . . . . Resin transfer
moulding
Pre-impregnated
Wet lay-up
Milling machines . . . . . . 24
Axes. . . . . . . . . . . . . . . . . . . 4 & 5
Turning machines. . . . . 2
3D QC machines. . . . . . . 8
Accuracy. . . . . . . . . . . . . . . 1micron
facility
SIMULATOR
CHASSIS WORKSHOP
Screen:
Angle. . . . . . . . . . . . . . . . . . 220 fixed
Projectors. . . . . . . . . . . . . 5
Refresh rate. . . . . . . . . . . 100Hz
Resolution . . . . . . . . . . . . 1,400 x 1,050dpi
Latency . . . . . . . . . . . . . . . ~40milliseconds
Platform:
Lateral travel . . . . . . . . . . 0.6m
Longitudinal travel . . . . 0.6m
Vertical travel. . . . . . . . . . 0.4m
Yaw travel. . . . . . . . . . . . . . 38
Roll travel . . . . . . . . . . . . . 27
Pitch travel. . . . . . . . . . . . 27
Latency . . . . . . . . . . . . . . . ~50milliseconds
OUR HERITAGE
TOYOTA MOTORSPORT GmbH HAS EXCELLED IN
A VARIETY OF DISCIPLINES AND MARKETS, FROM
TUNING ACCESSORIES FOR ROAD CARS TO THE
FASTEST RACING MACHINES ON THE PLANET.
1998
1997
1996
1995
1994
1993
1992
1991
1990
1979
2009
2008
2007
2006
2005
2004
2003
2002
2001
2000
1999
Cologne Bonn airport, the sixth largest passenger hub in Germany and its second biggest air freight terminal, is less than 25km
from TMG while Dsseldorf at 65km and
Frankfurt at 200km are also within easy
reach.
For those who prefer the train, modern highspeed rail links connect Cologne to Brussels,
Paris and Frankfurt faster than ever before
while connections to most major European
stations make a stop in the city.