Following a review of future customer trends and market requirements, Red Arch (RA) embarked on a two year development program to produce a driver switchable valve exhaust system.  From it’s inception in 2012, completion and first application of the exhaust system was planned and successfully delivered for quarter four 2014.

Scope & key features:

• Wireless, driver controlled system
• Protected for compliance with all current and future worldwide legislation
• Layout and interface to suit factory line, end of line or dealer installation
• Inputs and outputs protected for expansion
• CAN interface for intelligent switching
• Mobile phone app switching and “CAN telemetry” option

Key Inputs (from customers):

• Market requirements – potential markets and volumes plus future trends
• Legislative requirements – Noise & electromagnetic, current and future.

Key outputs (from RA):

• Prototype electronics and exhaust kit for customer demonstration
• Production intent, fully functional kit, homologated worldwide

Timing:

• 12 months electronics development program
• 12 months first exhaust application and electronics implementation

Project detail:

A parallel development was conducted for the exhaust system and electronics control system.

A prototype valve exhaust system was produced for the R56 MINI Cooper S with RA John Cooper Works kit.  Operated by a wireless control system, this was designed for maximum static sound level and quality differential for demonstration purposes using RA’s suite of in-house software.

Initially various wireless options were assessed, considering future proofing, worldwide compliance, power consumption and maintenance.  Following a review of all options, Bluetooth Low Energy (BLE or Bluetooth 4) was selected.  In 2013 this was relatively new technology, but had the major advantage of being the future choice of all mobile phone manufacturers and importantly having extremely low power consumption.  A functional switching prototype system was developed within 12 weeks with CAN input and data output functions taking a further 16 weeks.  In developing the software, a full DFMEA was conducted, defining the safety case and failsafe strategies.  Following further software iterations the functional test program was conducted.

The table below highlights some of the tests conducted.

On completion of the functional test, pre-testing and final homologation testing was conducted to the following standards.

 

Project outcome:

Sales of MINI F56 have exceeded all expectations, topping 3000 units in 2015. Widely praised amongst the motoring press and automotive industry, in April 2015 Autocar called it “a phenomenal exhaust” and “one of the naughtiest sounding cars on the road”.

A further six projects with three separate OEMs have followed with further applications currently in development at RA.