AeroDyn Wind Tunnel — Direction B: Report TN-1856

Facility ReportAWT–1856 · Rev. 15

Full-Scale Closed-Jet Contoured-Wall Facility
with Moving-Ground Simulation

Gary EakerDesigner and Founder B.S.M.E., General Motors Institute — Senior Project Engineer, Advanced Aero Group, GM Aerodynamics Laboratory — Aerodynamicist, Hendrick Motorsports

Gary RombergConsultant Flight Test Engineer, Boeing — Aerodynamic Engineer, NASA Saturn V Program — Head of Racecar Aerodynamics, DaimlerChrysler — Chief Engineer, DaimlerChrysler Aero-Acoustic Wind Tunnel

Abstract

As an independent wind tunnel, we serve all brands of cars. Our first and only priority is to provide you with an accurate, repeatable, and productive facility. Our focus is strictly limited to testing. By avoiding any vehicle-related consultation, our customers will be assured complete confidentiality.

Reserve a shift — (704) 799-1856 Read the facility report

135 Godspeed Lane · Mooresville, NC 28115 Race City USA Open Monday–Friday

1.0 Facility

The AeroDyn Wind Tunnel is a full-scale, closed-jet, contoured-wall facility employing a revolutionary moving-ground simulation. The test section measures approximately 185 ft² and operates at speeds to 130 MPH.

1.1 Fan Array

Unlike other tunnels, the facility features 22 individual 100HP fans. This allows for rapid start up and shut down. Active fan braking slows the array after a run, allowing a fast turn around.

Table I — Facility envelope
Parameter	Value
Test section area	185 ft²
Maximum test speed	130 MPH
Fan array	22 × 100 HP
Wheelbase accepted	104.5″ – 123″
Track accepted	55″ – 65″
Front axle weight	4,000 lbs
Rear axle weight	2,000 lbs

Exterior view of the AeroDyn Wind Tunnel — **Fig. 1** — Exterior view, AeroDyn Wind Tunnel, Mooresville, North Carolina.

2.0 Moving-Ground Simulation

2.1 Rotating Wheels

To complete our simulation of a moving ground plane, we are able to rotate the wheels to match the wind speed. This, coupled with our boundary layer control, allows us to simulate what the car experiences while on the track.

2.2 Automated Yaw

Unlike most wind tunnels, AeroDyn yaws the vehicle about the front axle, similar to what is seen on track. Our tunnel is able to yaw the vehicle from +3° to −5°. This automation allows for quick aero-mapping with precise, repeatable results.

2.3 Ride Height Control System

Our in-house designed Ride Height Control System (RHCS) revolutionized the way we do testing. This is the 3rd generation of our RHCS, allowing precise movements to 0.001″. Complex ride height maps are loaded via a simple Excel spreadsheet, with manual fine tuning available to the customer in the tunnel.

Rotating wheel matched to wind speed — **Fig. 2** — Wheel rotation matched to freestream velocity.

3.0 Instrumentation

Because of our unique boundary layer control solution, we are able to provide customers with unprecedented instrumentation of the underbody. Beneath the car, integrated into our floor, we have a grid of 264 static pressures. In addition, we can interface with up to 62 customer supplied vehicle pressure taps.

Underbody static pressure map — **Fig. 4** — Underbody static pressure distribution, 264-tap floor grid.

4.0 Add-On Systems

AeroDyn offers a number of add-on systems that customers can use as part of their testing. These systems are provided at no added cost to the customer.

Table II — Customer systems, provided at no added cost
Designation	System	Capacity
HDPS	High Density Pressure System	124 sensors
ICADS	In Car Analog Data System	20 channels
HARPS	High Amperage Remote Power Supply	iPad control
—	Duct anemometers	(6) 3″ · (6) 3.5″ · (2) 4″
—	Radiator anemometers	3 configurations
—	Continuous motion / real-time acquisition	—
—	Customer DAQ trigger (Pi / Motec)	—
—	Smoke wand, macro flow visualization	—

References & Downloads

1. AeroDyn Wind Tunnel Policy (PDF)
2. Wind Tunnel Prep Procedure, Rev. 8 (PDF)
3. Vehicle Spec Template, Rev. 15 (XLSX)
4. ICADS press release (PDF)
5. HARPS press release (PDF)
6. Real-time data acquisition announcement (PDF)