Altitude climate roller Berlin

With the altitude climate roller (HKR), it is possible to simulate drives in the high mountains up to 5,300 meters with appropriate air pressure and temperature conditions – cost-effectively, efficiently and reproducibly. By means of the intelligent coupling of test bench automation and simulation, the vehicle can be integrated “closed loop” into the simulation.

In the high-altitude climate roller, extreme weather conditions can be reliably and reproducibly replicated for vehicle tests. Temperatures of minus 30 to plus 40 degrees Celsius up to a minimum ambient pressure of 500 millibar can be set in the facility, which went on stream in 2017. Therefore, the most extreme conditions of the high mountains can be reproduced up to 5,300 meters realistically.

In contrast to conventional roller test benches, the height simulation not only allows predefined speed time profiles to be simulated, but also simulation of cornering, such as on real mountain passes or trailer operation.

The customer has the option of carrying out the vehicle test through road routing via monitor, but can also control the drive from an external cockpit in an operator’s room. If required, a robot driver system takes over, which above all can trace repetitive cycles precisely, thus increasing the efficiency of the application.

A special feature of the HKR is the synchronized real-time coupling of roller control, robot driver system and simulation environment, through which the vehicle can be integrated into the simulation in a closed-loop way. In the test chamber, up to 230 kW of power per axle can be driven. The humidity as a control parameter can be set up to a height of 1,800 meters. The altitude climate roller is large enough to examine vehicles from a Mini (for example, Smart) to the maxi format (for example, transporter).

  • IAV Test Center Berlin
    • Project management
    • Test planning/preparation
    • Vehicle preparation/measurement setup
    • Commissioning
    • Complete test execution (using all common tools)
    • Test evaluation and presentation of results
    • Customer support
  • Roller dynamometer
    • 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 control: up to 1.800 m altitude
    • Humidity control possible between 10°C and 30°C
    • Airflow speed: 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 cooling tower capacity: 1885 kW
    • Air flow rate: 187,400 m³/h
  • Emission measuring systems & conditioning boxes

    Emission Measurement Systems

    • 3 x raw gas measuring lines: NOx
      THC & CH4
    • Volume flow: SickFlow
    • Particulate Matter: Pegasor Micro 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
    • Dimensions entrance conditioning box (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 room
    • Integrated automation concept from VETS ONE, STARS for Vehicle and CARMAKER