Ford Designs a Track to Improve Aerodynamics
Wind tunnels have been used for many years to create and experiment with aerodynamic and energy-efficient vehicles. Today, Ford has merged modern wind tunnel technology with a vehicle-sized treadmill to aid in producing its next-generation automobiles, such as the brand-new Mustang Dark Horse.
The Rolling Road Wind Tunnel (RRWT) can simulate wind and road surface speeds of up to 200 mph. This facility tests the efficiency and performance of various vehicles in the Ford lineup, including the next generation of electric, hybrid, and gas-powered models.
“The amount of air moved by our wind tunnel is enough to fill a K-Class blimp in just over 5 seconds.”
-John Toth, North America Wind Tunnels Engineering Supervisor
The RRWT has a significant advantage in providing precise wind drag and downforce data compared to previous wind tunnel designs. These factors are crucial for optimizing range and efficiency. Additionally, it enables more in-house testing that replicates real-life road conditions, reducing design expenses and speeding up the design process.
“The closer we can get to reality in the lab, the better and faster we can create more energy efficient vehicles with great on-road and track stability. Testing while the wheels and tires move is instrumental to improving aerodynamics for track-ready vehicles, like Mustang Dark Horse which has to balance both aerodynamic drags and downforce.”
-Toth
Ford has developed a new rolling road system that consists of five belts. This system can simulate real-world drag using an aerodynamic tunnel. This system is innovative and efficient by bringing the road to the vehicle instead of the vehicle to the road.
Five belts are used in the process to test for the best aerodynamic performance. The first four are dedicated to each wheel, while the fifth runs beneath the vehicle’s center. A crane is employed to switch between the two systems, similar to an industrial plug-and-play. The crane allows for testing high-speed performance vehicles at up to 200 mph with a single belt, opening up a new realm of possibilities.
“We spent approximately 250 hours in the wind tunnel developing the 2024 Ford Mustang which includes Dark Horse. The aerodynamics of Mustang Dark Horse along with several other factors have created the most track- and street-capable 5.0-liter Mustang to date.”
– Program Aerodynamicists for Mustang and Bronco, Jonathan Gesek
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