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There has been significant progress in developing test facilities for automotive wind noise and automotive components since the early 1990s. The test technology is critical to the development of modern vehicles, and essentially every major automotive manufacturer owns and operates their own aeroacoustic wind tunnel, or has rental access to one and conducts a significant amount of wind noise testing. The current status for climatic wind tunnels is that many new CWTs are being defined with acoustic test requirements. These test capabilities in AAWTs and CWTs will continue to enable the development of vehicles with better wind noise attributes, fewer problems with sunroof ‘booming’, and lower noise levels for HVAC and auxiliary systems. In the future, it is expected that the test demand for AAWTs and CWTs with low acoustic background noise will continue to increase as customers expect better automotive products, especially across more of the product line.

Low frequency pressure oscillations in open jet wind tunnels are produced by vortices shed from the nozzle exit coupled with several feedback mechanisms in the circuit. These undesired pressure fluctuations can cause structural vibrations, reduction of flow quality, and delays in delivery of newly-built wind tunnels. One effective method to mitigate this problem is incorporation of Helmholtz resonators in the wind tunnel circuit. In this paper important factors in the design of Helmholtz resonators for open jet wind tunnels are described and a specific design procedure is outlined. Finally, successful design and installation of Helmholtz resonators in several modern open jet wind tunnels is reported.

The new BMW Aerodynamisches Versuchszentrum (AVZ) wind tunnel center includes a full-scale wind tunnel, "The BMW Windkanal" and an aerodynamic laboratory "The BMW AEROLAB." The AVZ facility incorporates numerous new technology features that provide design engineers with new tools for aerodynamic optimization of vehicles. The AVZ features a single-belt rolling road in the AEROLAB and a five-belt rolling road in the Windkanal for underbody aerodynamic simulation. Each of these rolling road types has distinct advantages, and BMW will leverage the advantages of each system. The AEROLAB features two overhead traverses that can be configured to study vehicle drafting, and both static and dynamic passing maneuvers. To accurately simulate "on-road" aerodynamic forces, a novel collector/flow stabilizer was developed that produces a very flat axial static pressure distribution. The flat static pressure distribution represents a significant improvement relative to other open jet wind tunnels.

Recently, computational fluid dynamics (CFD) was applied to investigate blockage (or velocity) corrections using the nozzle method for a climatic wind tunnel (CWT) test environment (SAE 2003-01-0936). The study included two blockage corrections to the nozzle method reference velocity: vehicle frontal velocity and vehicle upper surface pressure trace. These methods resulted in well correlated predictions between the open road and CWT flow conditions. These CFD predicted blockage corrections are experimentally verified in a climatic wind tunnel in this study. A non-intrusive method applying particle image velocimetry is applied to acquire the velocity field in front of the test vehicle. The experimental data verifies the blockage correction predictions derived from the previous CFD work.

The unsteady near wake of a ground vehicle body was investigated using hot wire anemometry and an unsteady pressure measurement system. A three dimensional bluff body model was used to simulate the time dependent, three dimensional near wake flow field generated by trucks, buses, and automobiles. Coherence and coherence phase were effective methods to analyze the unsteady pressure field and to relate different pressure signals. Spectral analysis of the velocity and pressure signals was used to identify periodic wake flow structures. The time averaged near wake contains a ring vortex enclosed by shear layers which start where the model boundary layer separates from the body. At the start of the shear layer, vortex shedding was measured at a dimensionless frequency, StH(shed) = 1.157. As these vortices convected along the shear layer, vortex pairing was observed which approximately halves the characteristic frequency.

The Lockheed Martin Aeronautical Systems Company Low Speed Wind Tunnel has been used for aircraft testing and full scale automotive testing since 1967 In 1993, an improvement program was initiated to reduce background noise, improve test section flow quality, and reduce the aerodynamically induced vibrations affecting the main drive The initial aerodynamic work discussed here included optimizing the setting angles of the turning vanes in the first and second comers and modifying the orientation of the test section breather slots Optimizing the turning vane setting angles was required to minimize flow irregularities in the circuit A CFD panel method program was used to study the effects of various turning vane setting angles While the computational study had limitations, it was used to identify large pressure gradients at the outer corners and qualitatively related the effects of flow constriction at the vane trailing edges to the rotation angle of the vanes Final decisions on vane setting angles were based on measured velocity profiles in the second diffuser and upstream of the fan The improved turning vane configurations minimized the separated flow in the second diffuser, increased the uniformity of the flow into the fan, and reduced the flow swirl angle in the test section by approximately 50% Modification of the breather slots and sealing leaks in the circuit reduced the pressure difference acting across the walls of the closed test section by 85% These actions reduced the test section longitudinal static pressure gradient by 33% and reduced the velocity of air leaking into the test section The reduced air leakage lowered the test section background noise 2 dB at frequencies above 2 kHz