Ford Designs a New Racetrack Even Lightning McQueen Would Be Proud of

Wind tunnels have been used for years to create and test aerodynamic and energy-efficient vehicles. Ford has now combined modern wind tunnel technology with a vehicle-sized treadmill to help produce its next-generation automobiles, including the all-new Mustang Dark Horse.

At the Rolling Road Wind Tunnel (RRWT), the American automaker’s vehicles can be tested for efficiency and performance. This facility can simulate wind and road surface speeds of up to 200 mph, which helps stretch 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 stands out in its ability to offer accurate wind drag and downforce data, essential for enhancing efficiency and range. Furthermore, it allows for in-house testing that mimics real road situations, reducing design costs and faster design cycles than previous wind tunnel models.

“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 

The American automaker has created an innovative and efficient rolling road system with five belts. This system can simulate real-world drag using an aerodynamic tunnel. Rather than bringing the vehicle to the road, this system brings the road to the car, making it highly effective.

Five belts are utilized during testing to ensure optimal aerodynamic performance. The first four belts are allocated to each wheel, while the fifth belt runs under the vehicle’s center. A crane switches between the two systems, functioning similarly to an industrial plug-and-play. This setup allows testing high-speed performance vehicles at up to 200 mph using just one belt, providing exciting new 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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Photo Source/Credit: Ford Authority