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VW's virtual revolution

New 3D technology is revolutionising vehicle development at Volkswagen and setting standards in the automotive industry: using real-time “Ray Tracing”, 3D objects are displayed, moved and modified instantly and interactively. Thanks to powerful computer technology, large and complex volumes of data can now be processed. Even realistic shadows, refractions of light and reflections can be generated. Real-time “Ray Tracing” was chiefly developed by Professor Dr.-Ing. Philipp Slusallek of Saarbrücken University and is making its world industrial debut at Volkswagen.

A 3D Golf on display at VW's visualisation centre

Two unique visualisation centres have been built within Technical Development at a cost of around €20 million . Here, developers, designers and engineers from all departments will work together, thereby making the vehicle development process more efficient and reducing cost and time expenditure considerably. Engineers can get a realistic and detailed impression of a planned vehicle in the early stages of development on large projection screens.

A special projection screen, the so-called “Powerwall” (5.10 m x 2.10 m), enables designers or test engineers to display life-sized vehicles. Preliminary virtual designs are produced at short notice and cost-effectively to be viewed and discussed: reflections, curves or paint jobs can be assessed on these virtual models just the same as on a real vehicle. The highlight of the technology: in the direct comparison between “actual” and “target”, cameras pick up images from a real development vehicle (“actual state”) which are then compared with the virtual images (“target state”) on the “Powerwall”. Any differences are then measured and immediately incorporated into the modification process before components are produced.

The so-called "Cave" in which images are projected onto each of its screens from outside

Another key element of the project visualisation centre is the “Cave”, a cube with a side length of 2.35 metres. An image is projected onto each of its screens from outside – as in a 3D cinema. Inside, the developer is transported into the virtual world by means of special glasses and the virtual models stand out three-dimensionally. The user checks the ergonomics, visibility and design of the interior and equipment. At a later stage it will be possible to go for a virtual drive through the city and the countryside.

Also in the second centre, the complete vehicle mock-up centre, the latest computer technology is used to power a projection onto two levels. Interactive, virtual applications such as the routing of wiring are checked in a similar way to the checks carried out in the “Cave”. This means that new wiring can be created or the ways of existing wiring can be modified.

Hardware, visualisation space and offices cover a total area of around 4,500 square metres in the complete vehicle mock-up centre and the new project visualisation centre. Intense work has been going on since April to complete both centres. The new buildings provide space for a total of 150 employees, creating 45 new jobs.

The so-called “Powerwall” (5.10 m x 2.10 m), enables designers or test engineers to display life-sized vehicles.

Volkswagen anticipates a reduction of up to 30 per cent in cost and time through the use of the innovate 3D technology and the subsequent optimisation of the product development process. Modifications during the planning and production stage had previously been associated with high levels of financial and time investment. Today, initial experiences of the virtual product can be analysed through computer simulations before models or tools are created for the actual production .