$124 million investment celebrated for multi-function capabilities, preparing for electrified future
One of the world’s most advanced wind tunnel automotive testing facilities is now located in the East Liberty area, following Honda’s grand opening Monday of its new $124 million Honda Automotive Laboratories of Ohio (HALO) facility at the independent Transportation Research Center.
The 110,000 square foot HALO building contains a 1/8-mile wind tunnel circuit, capable of reaching a max wind speed of 192.63 mph and powered by a 5-megawatt, 6,700 horsepower electric motor main fan measuring 8 meters in diameter, with 12 carbon fiber fixed-pitch blades.
Mike Unger, Automotive Development Center wind tunnel lead, said the site is revolutionary in its field for its ability to provide three separate, state-of-the art testing functions — aerodynamics, aeroacoustics and racing — all in one location. Previously, the company would send vehicles all over the U.S. and the world to test for these separate functions for Honda and Acura products, as well as the company’s race vehicles.
“As an aerodynamics engineer, you don’t see bigger or cooler toys like this in your lifetime; it’s a big deal,” said North Lewisburg resident Unger, who has worked for Honda since 1992. “We learned from the last five wind tunnel facilities built and spent time in each of those locations.”
“This facility was built by the best of the best. We tapped into Honda’s global expertise,” said Chris Combs, Automotive Development Center wind tunnel business strategy lead, regarding the facility that first broke ground in 2017. “It was a multi-year, collaborative effort.”
The close proximity to Honda R&D engineers is another critical piece of the puzzle, along with the convenience of testing vehicles from the nearby Honda of America East Liberty and Marysville Auto Plants.
“Our R&D engineers will be coming here to perform advanced research, and our factory teams will be coming here as well. We could sample cars directly from the line,” Unger said.
As Honda progresses toward its electrified future, the HALO facility’s aeroacoustics testing capabilities will be an important part of that development. With electric vehicles, absent engine and exhaust sounds make noise reduction an even more important element in vehicle design.
“As we move toward electric vehicles, motorists will notice wind noise and road noise. We deal with the wind noise here,” Unger said. “That’s why this facility is a big deal for the future.
“We’re looking to improve consumer experiences — not necessarily looking for zero noise, but for a balanced sound for consumers.”
Using the acoustic test system at HALO, Honda engineers will be able to identify the precise locations of both interior and exterior noise issues more quickly than ever before.
The aeroacoustic testing mode utilizes a powerful system of acoustic arrays, made up of microphones and cameras, able to collect real-time data and precision measurement. A total of 502 external directional microphones and cameras are part of the system — placed above, at the front and sides of the vehicle — along with 54 internal microphones inside the cabin for sound source detection.
In addition, the wind tunnel features a unique interchangeable modular ground plane system that can switch between two modules. The first is a five-belt rolling road module for production vehicle development, and the second is a wide-belt module, which will be utilized most often for high-performance sports cars and purpose-built race vehicles.
It takes about four hours to change between the two modules, with a crane utilized for the switchover of the 40-ton module belts.
HALO’s turntable for the vehicle undergoing testing is 12-meters in diameter and offers a complete 180-degree rotation. Most other wind tunnels only rotate plus or minus 15 degrees, officials noted.
Currently, Combs said the highly specialized engineers, technicians and other HALO employees are walking through the “operation readiness” mode for the facility, putting in practice the advanced training they have received. The automotive test site is expected to be fully online in the fall.
“We’re going through all of the processes for each module, and the very detailed line items,” Combs explained. “It’s a complex and sensitive system, and it’s important that we’re able to obtain the precise measurements required and that the equipment is properly calibrated, so that data points can be accurately compared.”
The HALO business strategy lead also showcased the four customer bays that could accommodate third-party companies outside of Honda in the future, with secure spaces complete with video conferencing capabilities.
The multifunctional and technologically advanced facility reinforces Honda’s commitment to developing fuel-efficient and fun-to-drive vehicles.
“Honda’s product development capabilities will advance to new heights thanks to this investment in our Ohio research operations,” said Jim Keller, executive vice president of Honda Development & Manufacturing of America, LLC (HDMA), and leader of the company’s North American Auto Development Center.
“With this new facility, Honda is not simply investing in an advanced technology facility, but in the future of the Honda engineers and other researchers who will work here.”