Ford vehicles keep cool under pressure through innovative testing.

Dearborn June 30, 2006; Summer heat can weigh heavily on a vehicle. However, improvements in design and engineering led by programs such as Ford’s Heat Protection and Underhood Temperatures (HPUT) department have ushered in a new era of heat management in cars and trucks.

In the past, it was not uncommon to see cars overheated and drivers in distress on the highway, but advanced engineering has dramatically reduced the effect of heat under the hood.

Ford is among the leading manufacturers conducting vigorous temperature and environmental factor tests on all its vehicles by using proprietary computer modeling software. To maintain Ford’s “Tough Truck DNA,” the HPUT department uses unique heat management testing before vehicles enter production, such as the Ford Escape, Explorer, Ranger, F-Series and Super Duty models. Testing methods include simulating worst-case environmental conditions for Ford vehicles to determine the engineering necessary to best protect customers.

“We are able to simulate extreme heat conditions so that before our vehicles are put into production, we can design them to maximize performance and sustainability,” says Scott Slimak, manager of Heat Protection and Underhood Temperatures at Ford. “There is an important safety and performance benefit to Ford customers through our testing process, and we are constantly improving the process by applying new technologies.”

The analytical computer-aided engineering (CAE) used by Ford enables engineers to virtually determine which components need to be modified before real-world vehicle testing begins on actual prototype vehicles. This innovative approach saves time and money because CAE helps identify and resolve issues early in the development process, without the costly destruction of actual vehicles.

HPUT computer modeling also profiles the “worst-case customer,” one who drives a fully loaded vehicle with maximum tow. Then Ford performs a series of tests that emulate worst-case driving conditions. Such testing helps ensure systems and components will meet harsh temperature and environmental requirements among some of the highest road grades and hottest terrain in North America.

Ford’s HPUT team emulates desert conditions, idling, towing and highway speeds through the use of wind tunnels and other facilities. After extensive CAE analysis, HPUT ultimately confirms its virtual findings by putting real vehicles through the rigorous heat testing process.

“During real-vehicle testing in our heat management chamber, we ensure that key system temperatures of the test vehicle are constantly monitored so that our development and facility engineers are safe at all times,” says Slimak.

HPUT’s series of tests, coupled with testing from other departments, enables Ford to create more robust engine and under-hood designs, ultimately producing safer vehicles.

“We’re constantly looking for new ways to improve innovation during the virtual testing process,” says Slimak.

Currently, Ford is piloting a number of programs that will enable it to improve speed and thoroughness earlier in the HPUT development process.