AUBURN HILLS, MI—Stellantis recently unveiled a $30 million wind tunnel at its research and technical center here. The facility will be used to improve the aerodynamics of electric vehicles.
Using Moving Ground Plane (MGP) technology, the wind tunnel will be able to measure and reduce airflow resistance from wheels and tires, which can account for up to 10 percent of total real-world aerodynamic drag.
“Range is a core consideration for customers who are transitioning to cleaner mobility through battery power,” says Mark Champine, senior vice president and head of North America engineering technical centers at Stellantis. “That’s what makes this investment so critical. By reducing drag, we improve electric vehicle range and, ultimately, the overall customer driving experience.”
According to Champine, optimizing aerodynamic efficiency is crucial in the effort to extend the driving range of electrified vehicles on a single charge. “This enhancement directly contributes to improved efficiency, benefiting customers with longer EV ranges and potentially reducing battery sizes, which in turn could lead to cost and weight savings,” he points out.
The aero-acoustic wind tunnel simulates real-world travel while allowing test vehicles to remain static. Belts suspended by cushions of air enable wheel movement at all four corners, while a fifth belt runs longitudinally beneath the vehicle, mimicking on-road travel conditions. This realistic simulation allows for more precise testing and aerodynamic improvements.
“For EVs, a range increase enabled by improved aerodynamics can lead to potential battery-size reductions,” explains Champine. “This has positive implications from more efficient packaging to weight savings that, in the end, will enhance the customer experience.
“This apparatus is a great addition to virtual tools, which may not account for factors such as tire deformation that can compromise aerodynamics,” adds Champine. “With this technology, we can replicate such conditions and capture real-time data….”
The new facility also adds vital automation capability. For instance, changes to wheelbase and track testing, which can take as much as two hours in conventional wind tunnels, can now be done in minutes.
The measuring platform and turntable that comprise the heart of the MGP equipment weighs 137 tons, rests on a concrete foundation and are supported by a specially designed steel frame.
