Ford’s Weather Factory allows engineers to simulate a range of extreme conditions under one roof. This means vehicles can be tested in conditions similar to those found in the Sahara Desert, in Siberia, or atop the tallest Alpine peaks.
However, even the most experienced human test drivers may become tired or unwell.
This has prompted the US car maker to recruit two robot test drivers, nicknamed Shelby and Miles, to help take the strain, especially on altitude tests where a key requirement can be that the test is replicated perfectly multiple times.
For human drivers, wind tunnel testing – in particular at high altitude – requires numerous safety protocols, such as having oxygen bottles, medical equipment and a paramedic on-site, while driver health has to be monitored constantly.
However, each robot test driver is able to operate at temperatures ranging from –40 °C to 80 °C, as well as at extreme altitudes, and can be set up and programmed for different driving styles, without any of these protocols in place.
The robot test driver’s legs extend to the accelerator, brake and clutch pedals, with one arm positioned to change gears and the other to start and stop the engine.
Despite the addition of the new team, Ford says it continues to conduct real-world testing in European locations and across the world, including the Grossglockner mountain, in Austria, and the snowy Arjeplog region, in Sweden.
“These two new drivers are fantastic additions to the team, as they can take on the challenging endurance tests at high altitudes and in hot temperatures,” says Ford Europe wind tunnel testing supervisor Frank Seelig.
“Once the robot is in the driver’s seat, we can run tests through the night without ever having to worry that the driver will need a sandwich or a bathroom break.”
Carroll Shelby and Ken Miles were the key figures behind the development of the Ford GT40 that won the 24 Hours of Le Mans race in 1966.
Shelby was also well-known for his involvement with Ford Mustang and the modified vehicles that bear his name.