Mercedes SLS AMG Development

Mercedes SLS AMG Development.

For the first time in its more than 40-year history, Mercedes-AMGGmbH has carried full responsibility for the design and development of a completely new car. This is not only solidly based on more than four decades of motor racing experience, but also on enormous know-how in the production of luxurious, high-performance cars plus networked development with selected Mercedes-Benz departments at the Mercedes Technology Center (MTC) in Sindelfingen.

Exhilarating driving dynamics and the day-to-day suitability typical of a Mercedes were central attributes in the specifications for the Mercedes-Benz SLS AMG. When realising and implementing their ambitious aims, the specialists at Mercedes-AMG in Affalterbach relied on the latest simulation programmes and sophisticated practical trials on every continent. The design and development of the new super sports car were concluded and approved at the end of 2006.

Before the first physical prototype could be built, the virtual prototypes had to be put through their paces. Accordingly the new Gullwing model was first brought to life on the computer screen as a digital prototype (DPT). Extensive research on this basis helped to establish how the objectives for the new super sports car could be achieved. Whether weight distribution, the installed position of the engine, centre of gravity, axle configuration, driving dynamics, aerodynamics, ergonomics, crash behaviour or the production process – the very latest simulation programmes allowed a realistic reflection of the vehicle and all its characteristics. The digital prototype was therefore a complete, virtual automobile.

The digital prototype was also a help in planning and building the first driveable technology carriers, i.e. cars equipped with the primary technical components such as the engine, brakes and axles - so-called "mulettos". Thanks to the virtual preparation work, these test vehicles in use since spring 2007 already had a very high level of maturity from the start. Ultra-modern measuring technology in these vehicles supplied valuable findings on e.g. the temperatures of the engine oil, coolant and brake discs - with an additional focus on lap times around the North Loop of the Nürburgring, for example, as well as measurable, precisely defined handling manoeuvres as a basis for comparing different axle kinematics or spring/damper variations.

The first disguised, physical prototypes of the SLS AMGhave been undergoing worldwide trials since summer 2008. Whether for the air conditioning, tyres, suspension, engine cooling, dynamic control systems or brakes, this standardised, highly sophisticated development and testing programme on test tracks and racing circuits, Alpine passes and specifically chosen public roads is aimed at achieving continuous further development and the identification of problem areas - and therefore the highest possible quality. More than 40 vehicles are in continuous operation for these tests.

In addition to these tests, individual components such as the engine, powertrain, transmission, axles and brakes, as well as the complete body structure, are tested to their limits on test rigs.

When development is concluded in January 2010, around 40 test cars will have absolved a distance of approx. 1.25 million test kilometres. The final aim is
"overall vehicle acceptance" – the long-awaited "Job No. 1", i.e. production of the first Mercedes-Benz SLS AMG cars for delivery to customers, can commence.