Ford Robots Take Heat, Cold That Human Test Drivers Can't

Ford’s German weather testing center for vehicles is using robot drivers immune from extreme temperatures.

Its Weather Factory near Cologne simulates a range of extreme conditions under one roof. It has allowed engineers to test vehicles through the pandemic, which has greatly restricted real-world testing in extreme climate conditions.

However, conditions can be so realistic that even the most experienced human test drivers may suffer and become sick, for example, during altitude testing. Now two robot test drivers, nicknamed by the engineers as Carroll Shelby and Ken Miles after Ford’s Le Mans GT40 legends, bear the burden, especially on altitude tests where a key requirement is that the test be perfectly replicated multiple times.

The Weather Factory replicates climate conditions found in the Sahara Desert, in Siberia and atop the tallest Alpine peaks. For human drivers, wind tunnel testing – particularly at high altitude – requires numerous safety protocols, such as having oxygen bottles, medical equipment and a paramedic on-site, while driver health is constantly monitored.

Yet, “Shelby” and “Miles” are able to operate at temperatures ranging from -40°F (-40°C) to 176°F (+80°C), as well as at extreme altitudes, and can be programmed for different driving styles. The robots’ legs extend to the accelerator, brake and clutch pedals, with one arm positioned to change gears and the other used to start and stop the engine.

As travel restrictions ease, Ford says it continues to conduct real-world testing in European locations and across the world, including the Grossglockner, Austria’s highest mountain, and Sweden’s snowy Arjeplog region.

Says Frank Seelig, supervisor-wind tunnel testing for Ford of Europe: “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. 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.”