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fan — Climatic Aerodynamic Wind Tunnel

A one of a kind testing experience.

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Climatic Aerodynamic Wind Tunnel

The ACE Climatic Aerodynamic Wind Tunnel (CAWT) is one of the most sophisticated of its kind in the world. It is designed to provide a multitude of industries with world-class and independent testing capabilities to validate prototype products under a wide range of climatic conditions. Climatic simulation systems include solar capabilities, rain, freezing rain, light snow and blizzards - all with wind speeds capable of 300 km/h at temperatures ranging from -40˚C to +60˚C. The ACE CAWT is unique due to its seven to 14.5 m² variable nozzle, which enables testing of subjects ranging from very small to extremely large, in a wide variety of wind and climatic combinations.

Examples of tests conducted in the Climatic Aerodynamic Wind Tunnel include:

aerodynamic testing
heating, ventilation, and air conditioning (HVAC) testing in vehicles
physiological/cognitive tests (human trials)
product quality control
snow mitigation (architectural)
thermodynamic testing
wind turbines

Key features

Adjustable nozzle (7to 13m2) and long test section to accommodate a wide range of vehicle sizes and types, from small cars to Class 8 trucks and buses, with wind speeds in excess of 240 kph.
Temperature from -40˚C to +60˚C and relative humidity (RH) from five per cent to 95 per cent.
Low background noise level (64 dBA at 50 kph) for the detection of vehicle drive-away anomalies such as misfires, transmission hesitation, etc.
Unique independently powered rolls chassis dynamometer in a turntable to enable crosswind testing.
Solar simulation system up to 1,100 W/m2 intensity with sunrise-sunset simulation capabilities.
Complete suite of ancillary systems for customer vehicle operation, including hydrogen and electric vehicle compatibility.

350 kW DC Fast Charger and Hot Road Soak Testing

ACE recently introduced the 350-kilowatt, 500-amp modular DC Fast Charger, which permits faster charging with the capability to operate in a temperature-controlled environment in three of its five chambers, the Climatic Aerodynamic Wind Tunnel, Large Climatic Chamber, and Small Climatic Chamber. As the future of the automotive industry progresses, ACE provides OEMs access to a world-class research facility that will actively assist in guiding this sector towards the development of electric vehicles.

Garage bays

Featured with the Climatic Aerodynamic Wind Tunnel is three high-secure garage bays that are available for use throughout testing. Garage bays come equipped with a hoist and tools and requires badged access for the highest level of secuirty and privacy.

Specifications of the Climatic Aerodynamic Wind Tunnel

Test section dimensions
Wind speed and thermal performance
Background noise level
Chassis dynamometer specifications
Solar simulation system specifications
Rain & snow simulation systems
Ancillary equipment

Test section dimensions:

Overall dimensions	Length: 20.1 metres Width: 13.5 metres Height: 7.5 metres
Useable length	14.3 metres for cars and trucks 19.1 metres for trucks and buses
Vehicle entry clearance	Width: 3.93 metres Height: 4.49 metres (Corner No.1 turning vane set open)
Adjustable nozzle	7 to 13.0 m2: Height: 2.9 metres Width: 2.4 to 4.5 metres 14.5 m2: Height: 2.9 metres x 5 metres (slightly diverging)
Canopy for buses	22 m2: Height: 4.4 meters Width: 5 metres (used with 13 or 14.5 m2 nozzle)
Turntable diameter	11.7 metres
Boundary layer removal	Width: 5.25 metres main suction system Provision for secondary suction
Vehicle exhaust extraction system	Dual or single exhaust pipes. Open or closed mode with back pressure regulation. Maximum flow rate: 0.62kg/second (8.5 litre, 400 horse-power engine). Maximum inlet exhaust temperature: 650^oC.
In-chamber fuelling	Station for regular, Reid vapour pressure (RVP) and diesel. Plumbed in for hydrogen.
In-chamber power	Outlets for plug-in vehicles.

Wind speed and thermal performance:

Full thermal control wind speed: 7 to 9.3 m2 nozzle settings.

Full Thermal Control Wind Speed

Increased maximum wind speed: ambient conditions

Nozzle (m2)	Wind speed (kph)	Temperature (oC)
7.0	280	25
9.3	250	25
13.0	225	25

Humidity – temperature performance

Humidity Temperature Control

Cooling system

R507 primary loop with Dynalene HC-50 secondary loop.
Total heat capacity: 500 kW at -40^oC , 2100 kW at ambient.

Thermal performance

Parameter	Set point change	Rate	Test condition
Temperature	<12°C	0.8°C/minute	70 to 105 kph; 32°C to 50°C
<6°C	0.6°C/minute	<115 kph
	>6°C	0.08°C/min	<115 kph
Humidity	20% RH	1% RH/minute	38°C dry bulb

Flow quality

Parameter	Uniformity (σ)	Stability
Wind speed	1% of set point	±0.5 kph
Flow angularity	0.5°
Temperature	0.3°C	±0.2°C at velocity > 48 kph
Humidity	0.5°C (dew point)	±0.5°C (dew point)

Boundary layer displacement thickness

δ* less than 5 mm at 0.9 m ahead of the front chassis dynamometer roll set at 90 kph, 25^oC air temperature

Background noise level: 9.3 m2 nozzle

Wind speed (kph)	Out-of-flow sound pressure level (SPL) (dBA)
50	64
100	81
140	90
250	107

Chassis dynamometer specifications:

Manufacturer and model	Burke E. Porter (custom design)
Vehicle types	Passenger car, light and medium duty trucks, buses
Axle configurations	front-wheel drive rear-wheel drive four-wheel drive all-wheel drive (four independent rolls)
Roll width	812 mm (four identical)
Roll diameter	1219 mm (four identical)
Roll surface	Tungsten carbide, aggressive finish (0.8µ)
Clear space between rolls	1,067 mm (identical front and rear)
Wheelbase range	1,600 to 5,842 mm
Location of front fixed axle from nozzle exit plane (0o yaw)	3,000 mm
Location of rear fixed axle from nozzle exit plane (180o yaw)	9,200 mm
Normal maximum yaw angle range	±30o
Floor features	Automatic floor track and side roll cover system. Moveable central inspection port with infrared camera.
Total inertial simulation range	907 to 9,072 kg
Maximum axle load	5,000 kg
Maximum vehicle weight	9,072 kg
Maximum speed	250 kph
Motor type	AC (vector drive duty)
Nominal maximum power	187 kW per roll, motoring and absorbing; 92 to 250 kph
Base speed	92 kph
Continuous tractive force rating	7,301 N per roll ; 0 to 92 kph
Tractive force overload	150 per cent for 60 seconds; 0 to 92 kph
Features	robot driver customer specified drive cycles
Configuration	Elevator and air bearings permit removal from test section.

Solar simulation system specifications:

Full diurnal function with azimuth and altitude.
Full-spectrum capability with vertical and bi-axial movement.

Manufacturer	KHS Steuernagel
Target size	Length: 6.5 metres Width: 2.5 metres 1.5 metres above test section floor
Intensity range	600 to 1,200 W/m2
Intensity incidence	0 to 52.5o
Spectrum	ASTM Std E-892
Intensity quality	Uniformity ±10 per cent Stability ±2 per cent
Lamps	Metal halide 21 total

Rain & snow simulation systems:

Rain simulation system

Frontal rain simulation system located at the nozzle exit.

Up to 12 nozzles of various sizes as needed to provide adequate coverage of a given vehicle.
Designed for 150 kph at 20°C but will operate as low as -5°C to perform freezing rain tests.

Snow simulation systems

There are two possible snow simulation configurations: frontal (blizzard) and overhead. In both cases, snow guns are used to create the snow.

Ancillary equipment:

Vehicle starting power	200 amp 12 vDC and 24 vDC
Pressure radiator fill	System capable of charging from a pressurized vessel.
Gas tank and differential cooling	Cooling water system to provide cooling during high-load tests.
Refrigerant charging system	Two charging systems: one for R134A or equivalent; the other for alternative refrigerants. Capability to pull a vacuum once refrigerant has been reclaimed.