Catesby Tunnel: A Game-Changing Innovation in Automotive Aerodynamics
The winner of Autocar’s prestigious Innovation Award for 2024 goes to Catesby Tunnel, a 1.7-mile tunnel in Northamptonshire that has been transformed into a groundbreaking aerodynamic testing facility. This unique facility has caught the attention of the automotive industry due to its impressive features and capabilities.
The brainchild behind Catesby Tunnel is Rob Lewis, a renowned aerodynamicist who previously worked with BAR and Honda Formula 1 teams. Lewis recognized the need for a full-scale moving-ground automotive tunnel in the UK, as the existing wind tunnels were not ideal for testing designs. After stumbling upon Catesby Tunnel, Lewis saw its potential and began exploring the idea further.
What sets Catesby Tunnel apart from other tunnels used for testing is its length and width. With its arrow-straight design and ample length, Catesby Tunnel allows for extensive testing at high speeds without losing valuable test time. Additionally, its wide cross-sectional area minimizes an aerodynamic effect called ‘blockage’, where a smaller area causes air to move more quickly around the vehicle, often resulting in noisy results. Catesby Tunnel’s size effectively mitigates this issue, providing more accurate and reliable data.
Furthermore, Catesby Tunnel’s constant 1-in-172 gradient proves advantageous for certified testing, such as WLTP. This slight slope allows for testing in two directions, resulting in an offset that helps cancel out certain variables in the data. This feature is particularly useful when determining the rotational inertia of various vehicle parts.
Bringing Catesby Tunnel to life was no easy task. Securing funding and support proved challenging, as aerodynamics often receives less investment compared to other areas of automotive technology. However, Semlep’s local growth fund provided £4.2 million, enabling the project to move forward. Subaru also contributed by purchasing shares and time in the tunnel. Despite several hurdles along the way, Catesby Tunnel is now fully operational, with plans for a £4 million innovation center near the tunnel entrance.
The potential benefits of Catesby Tunnel are immense. In a typical road car, half the fuel is consumed to overcome aerodynamic drag. By optimizing aerodynamics, vehicles can achieve greater fuel efficiency and range, making them more environmentally friendly and cost-effective. Electric vehicles, in particular, stand to benefit from improved aerodynamics, as reducing drag can extend their range and reduce battery size and weight.
While it may take time for automotive manufacturers to fully embrace the advantages of Catesby Tunnel, the innovation and potential it represents cannot be overlooked. The recognition of Catesby Tunnel as Autocar’s 2024 Innovation Award winner solidifies its position as a game-changer in the field of automotive aerodynamics. As the industry continues to evolve, Catesby Tunnel is poised to play a significant role in shaping the future of vehicle design and efficiency.