Bringing the 2027 Chevrolet Bolt EV to dealerships after it was discontinued and revived required substantial ingenuity. General Motors’ reversal on the budget-friendly EV led to relocating an assembly line and stockpiling components to create prototypes for a swift restart in production. However, as Bolt’s lead engineer Jeremy Short shared with The Drive, there was another unexpected factor in meeting the tight timeline: virtual crash testing.
Virtual crash testing is just as it sounds. Instead of physically damaging metal, engineers execute simulations using complete 3D representations of a vehicle. These utilize commercially available software along with certain GM enhancements, aligned with real-world testing of specific elements like airbags and seats. These software tools have been utilized for some time, but for the 2027 Bolt EV, engineers were so assured of their effectiveness that they largely avoided crashing pre-production vehicles, only performing the essential final test required for regulatory approval in reality. As Short remarked, “we’ve significantly diminished the number of vehicles we crash into barriers.”
“It’s remarkably accurate,” noted Short. “It’s a fairly sophisticated 3D model of the automobile that encompasses every element of the vehicle, and it must also capture the mechanical properties of the plastics, the steel, and all materials involved.” Engineers can simulate crash tests and even repeat variations, such as altering a weld or modifying a single bracket’s dimensions, or testing at different speeds, all without the necessity of crashing an actual vehicle.
The 3D representations are dynamic, and they do depict a deformed car at the conclusion of a test, but they’re not photorealistic, Short clarified. GM chose not to share screenshots or videos from their actual Bolt tests, but this older YouTube video provides a general sense of how it appears. Observe how visually accurate the simulation is when compared to reality, and keep in mind that this video is more than 15 years old. It’s safe to say the technology has improved significantly since that time.
Virtual crash test of Taurus utilizing ATI FirePro V8800 and HyperWorks
Nevertheless, the visuals are secondary to the metrics being generated. These figures correspond to the force exerted on specific components of the vehicle or a crash-test dummy, which is how the assessments are graded. The presentation of a crash—whether virtual or otherwise—can also be deceiving.
“Sometimes the crash that looks the worst is better, and at times the one that appears insignificant is actually the one where we need to make adjustments,” Short stated.
The revived Bolt EV shares many similarities with the model that was phased out after the 2023 model year, but sufficient alterations were implemented that a comprehensive suite of crash tests was still necessary. New regulations were enacted following the last crash tests of the Bolt EV, and adjustments to the interior had to be evaluated to confirm they wouldn’t disrupt airbag deployment. Engineers made “dramatic” modifications to the front structure, but testing them in a virtual environment saved time and expenses, according to Short.
Virtual crash testing eliminated the need to dismantle around two dozen costly pre-production vehicles, and acquiring those vehicles would have been challenging since, during the development phase, GM was in the process of relocating the Bolt EV assembly line from Michigan to Kansas. Thus, obtaining bodies to create prototypes was difficult. However, the flexibility that virtual crash testing provided made it beneficial on its own, Short remarked.
“If you presented me with a traditional program, I would undoubtedly take a virtual approach because it’s simply superior.”
Have a tip? Send us a message: [email protected]
**GM’s Integration of Virtual Crash Testing to Accelerate the Chevy Bolt’s Comeback**
General Motors (GM) has positioned itself as a leader in automotive progress, especially in the field of electric vehicles (EVs). One of the most significant advancements in this sector is the Chevy Bolt, which encountered substantial hurdles due to battery-related safety issues. To resolve these challenges and hasten the vehicle’s return to the marketplace, GM has adopted cutting-edge virtual crash testing methodologies.
**The Issues with the Chevy Bolt**
The Chevy Bolt was initially recognized for its cost-effectiveness and range, making it a favored option among electric vehicle buyers. However, in 2020 and 2021, GM issued recalls for the Bolt due to battery fires associated with manufacturing flaws. These safety issues prompted the automaker to cease production and sales of the vehicle while they sought remedies to guarantee customer safety.
**Exploring Virtual Crash Testing**
Virtual crash testing, also known as computer-aided engineering (CAE), utilizes sophisticated simulation software to model vehicle behavior during collisions. This technology enables engineers to assess the structural soundness and safety performance of a vehicle without needing physical prototypes. By simulating various crash scenarios, GM can pinpoint potential vulnerabilities and efficiently implement necessary design alterations.
**Advantages of Virtual Crash Testing for the Chevy Bolt**
1. **Speed and Efficiency**: Conventional crash testing necessitates the creation of physical prototypes and conducting real-life assessments, which can be lengthy and expensive. Virtual crash testing allows GM to rapidly iterate designs and evaluate multiple scenarios within a fraction of the time.
2. **Cost Savings**: By minimizing the requirement for physical crash evaluations, GM can reduce expenditures on materials and labor related to constructing and testing prototypes. This economic efficiency is particularly vital when addressing safety recalls.
3. **Improved Safety Evaluation**: Virtual simulations generate comprehensive data on how a vehicle reacts to different crash scenarios. This information allows engineers to identify specific areas needing improvement and make focused enhancements to the vehicle’s design.
4. **Incorporation of Advanced Technologies**: Virtual crash testing can integrate sophisticated technologies like artificial intelligence and machine learning, enabling more complex modeling and predictive analysis of crash outcomes.
**Application in the Chevy Bolt’s Revival**
For the Chevy Bolt, GM employed virtual crash testing to evaluate and improve the safety of the vehicle’s battery. By modeling crash scenarios that could pose risks to battery integrity, engineers identified crucial design modifications required to reduce fire hazards. This included strengthening battery casings and enhancing thermal management systems.
Moreover, the virtual testing process enabled GM to swiftly validate these modifications, resulting in a more efficient approach to gaining regulatory approval and boosting consumer confidence. Consequently, GM was able to restart production of the Chevy Bolt with enhanced safety features, ultimately returning the vehicle to market faster than would have been feasible through traditional testing avenues.
**Conclusion**
GM’s embrace of virtual crash testing signifies a major leap in automotive safety and engineering. Through the utilization of this technology, the company has not only accelerated the return of the Chevy Bolt but has also established a benchmark for future vehicle development. As the automotive landscape continues to change, the integration of virtual testing strategies will likely play a pivotal role in ensuring the safety and dependability of electric vehicles, paving the way for a more sustainable future in transportation.