Moog develops customised simulator for Scuderia Ferrari

Moog Industrial Group, a division of Moog Inc, has delivered a new testing simulator to Scuderia Ferrari in the Gestione Sportiva at Maranello, Italy. Two years in development, the new Ferrari F1 dynamic driving simulator features a customised motion control system with combined motion mechanism, control loading system, software, cockpit and dedicated operator workstation. A crucial requirement was that the system needed to operate at a higher frequency bandwidth compared to conventional systems.

Ferrari selected Moog to provide an integrated, versatile motion control and testing system to meet specific and highly demanding requirements. The project development entailed a bilateral exchange of expertise to overcome technical challenges. In particular, addressing the latency and high-bandwidth requirements of the simulator led to advances in the use of carbon-fibre composite materials in the structure to increase stiffness and reduce weight.

Marco Fainello, Head of the Car Performance Department for Scuderia Ferrari, states: "The dynamic driving simulator completely meets our specifications and expectations for a system that can test car designs as well as train drivers. Working closely with Moog during the two years of development on this system has helped us realise the maximum benefit from high-performance simulated motion control."

Driving reality

Ferrari test-drivers are already using the new simulator, which offers them a heightened sense of driving reality as well as highly responsive and immediate feedback on their actions.

Fainello continues: "The driving simulator is being used to test current and future car designs and train new drivers on multiple F1 circuits. In both these training scenarios we cut track time and can plan training with more certainty without wondering about weather forecasts."

The driving simulator simulates real race track conditions and is used to test different aspects of the car such as wings and brake settings that affect performance. The high fidelity of the simulator enables the driver to feel the difference that modifications to a part or component of the car can produce without the high acceleration of a real-test drive. Moreover, driver training is no longer restricted, which saves both time and money while respecting new regulations.

Pim van den Dijssel, business manager Europe for Moog, adds: "We worked closely with Ferrari's engineering team during the development of the driving simulator in our facility and we are delighted to hear positive feedback from Ferrari's drivers now using the system."

Accurate feel

Ferrari required the simulator to run at mechanical frequencies high enough to help drivers get the most accurate feel of the car's behaviour and create much higher velocity and acceleration than standard systems. This represented one of the most challenging aspects of the project and resulted in Moog designing new actuators in order to deliver the desired strength and stiffness at lower weight. Low weight, stiffness and rigidity of the cockpit cabin were also important.

High bandwidth and less latency make brake and steering more responsive, creating the high fidelity that test-drivers need to feel and assess the car's behaviour correctly.

The driver sits in front of a screen that provides a viewing angle of more than 180 degrees. Ten multiprocessor computers control the system with a total 60GB of RAM producing around 5GB of data per day. It features a 3500W Dolby Surround 7.1 sound system.

Speaking about the project, van den Dijssel says: "We are delighted with the success of this dynamic driving simulator for Ferrari. Engineering hardware and human-in-the-loop (H2IL) testing solutions in a driving simulator is an area in which we have over 20 years' experience, since Moog pioneered advanced cueing technology. Using Ferrari's software model, we can achieve enhanced fidelity through advanced platform kinematics and optimised motion cues."