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High-altitude climate roller Berlin

The Himalayas are in Berlin

With the high-altitude climate roller (HKR), driving in high mountains up to 5,300 meters can be simulated under appropriate air pressure and temperature conditions - cost-effectively, efficiently and reproducibly. Thanks to the intelligent coupling of test bench automation and simulation, the vehicle can be integrated into the simulation in a closed loop.  

Sophisticated equipment for precise measurements

In the altitude climate roller, the most extreme weather conditions can be reliably and reproducibly simulated for vehicle tests. The facility, which went into operation in 2017, can be used to set temperatures from minus 30 to plus 40 degrees Celsius up to a minimum ambient pressure of 500 millibars. This allows the most extreme conditions in the high mountains up to 5,300 meters to be simulated realistically.

In contrast to conventional chassis dynamometers, the altitude simulation allows not only predefined speed-time profiles to be simulated, but also cornering on real mountain passes or trailer operation.

The customer has the option of carrying out the vehicle test themselves via route guidance on a monitor, but can also control the drive from an external cockpit in an operator room. If required, a driving robot can take over, which can precisely reproduce repetitive cycles in particular, thus increasing the efficiency of the application.

A special feature of the HKR is the synchronized real-time coupling of roller control, driving robot and simulation environment, which allows the vehicle to be integrated seamlessly into the simulation. Up to 230 kW of power per axle can be driven in the test chamber. The humidity as a control parameter can be set up to an altitude of 1,800 meters. The altitude climate roller is large enough to test vehicles from mini (e.g. Smart) to maxi (e.g. vans).

Key data

IAV Test Center Berlin

  • Project management
  • Test planning/preparation
  • Vehicle preparation/measurement technology setup
  • Commissioning
  • Complete test execution (using all common tools)
  • Test evaluation and presentation of results

Roller test bench

  • Manufacturer: HORIBA
  • Type: All-wheel roller dynamometer
  • Roller diameter: 48" (1.219 m)
  • Wheelbase: 1,800 to 4,500 mm
  • max. axle load: 2,500 kg
  • max. braking power / braking force (per axle): 230 kW
  • max. drive power / drive force (per axle): 230 kW
  • max. test speed: 250 km/h
  • max. acceleration: 6 m/s²
  • Mass simulation: 450 to 4,770 kg
  • Gradient: ±100%
  • Vehicle fixation: wheel hub fixation, hook fixation

Altitude climate simulation

  • Max. Vehicle height: 2.95m
  • Max. Vehicle length: 6.00 m
  • Temperature range: -30°C to +40°C
  • Climate operation: up to 1,800 m altitude
  • Humidity control between 10°C and 30°C possible
  • Air blower: 200 km/h
  • Discharge cross-section (H x W): 0.65 x 1.2 m
  • Altitude simulation: Up to 500 hPa (5300 m)
  • Controlled ascent/descent: 200 m/min
  • Cooling tower capacity: 2000 kW
  • Total chiller capacity: 1885 kW
  • Air volume flow: 187,400 m³/h

Emission measuring systems Conditioning boxes 

Emission measurement systems

  • 3 x raw gas measuring lines: NOx, NO, CO, CO2, O2, THC & CH4)
  • Volume flow: SickFlow
  • Particle mass: PegasorMicro Soot Sensor
  • Particle count: Pegasor
  • Max. Emission extraction: 7300 kg/h

Conditioning boxes

  • Conditioning box dimensions (LxWxH): 8.0 x 3.0 x 3.2 m
  • Conditioning box entrance dimensions (WxH): 2.98 x 3.05 m
  • Number of conditioning boxes: 2
  • Temperature range: - 30 to + 40°C

Additional information

  • Dry zone for vehicle transfer
  • 2 climate boxes from -30°C to +40°C
  • Parking system for 9 cars (23°C)
  • Lifting platform/prototype room
  • Operating room with Carmaker driving simulation
  • Measurement technology room
  • Integrated automation concept comprising VETS ONE, STARS for Vehicle and CARMAKER

"We simulate journeys in the high mountains up to 5,300 meters efficiently and cost-effectively."

Thorsten Stappenbeck