The realization of innovative systems for industry and research purposes once again required the expertise of Stahl-Projektbau Wentz, the specialist company for individual steel construction, which provides planning, statics, construction and assembly from a single source. A world-famous car manufacturer planned to build a new simulation center for vehicle development, in which the cars of tomorrow would be developed, tested and brought to series production.
 

The heart of the simulation center was to be a climate roller dynamometer with a wind tunnel that simulates climatic conditions around the world as realistically as is technically possible today. The challenge, however, was also to push this feasibility limit further in order to be able to test vehicles even better under simulated real conditions.

This goal was achieved, so that our customer now has an ultra-flexible climate roller test bench on which tests and inspections of drive trains as well as thermal management analyses can be carried out in the temperature range from -7 to +50 °C. Vehicles of all common drive types can be pushed to their limits: newly developed fully electric vehicles (BEV) as well as hybrid vehicles (HEV) or vehicles with petrol and diesel engines.
 

Stahl-Projektbau Wentz was involved in the planning of the simulation center from an early stage. Specifically, we were entrusted with the task of designing and building a climate roller dynamometer for vehicle development that could withstand these extreme conditions. Because the relative humidity in the simulation room can be between 10 and 95% and the wind turbines can also exert strong mechanical forces on the structure, it was necessary to make it extremely robust. We achieved this on the one hand through the architecture of the climate roller test bench itself and on the other hand through the use of resistant steels, some with certain coatings. The design of the transitions and welds was also implemented in such a way that thermal and mechanical forces ensure constant simulation and test conditions even in the long term.

Neben der gesamten außen- und innenliegenden Stahltragkonstruktion, haben wir auch den Windkanal sowie die höhenverstellbare Decke nebst Antrieben gefertigt und montiert. Die Inbetriebnahme haben wir ebenfalls begleitet.

In addition to the entire external and internal steel support structure, we also manufactured and installed the wind tunnel and the height-adjustable ceiling including drives. We also supported the commissioning.

“I would like to expressly thank our team for their great effort. We have shown once again that even demanding tasks in other European countries are no problem for our team and that we can create real added value for our customers,” says Managing Director Felix Wentz.

For ambitious industrial companies in the automotive and aerospace sectors as well as for research institutions such as the German Aerospace Center and renowned universities, Stahl-Projektbau Wentz is THE partner for individual steel construction. As part of our mechanical and plant engineering, we create flow channels, wind tunnels, engine test benches or climate roller test benches. For example, we also planned and built a highly innovative and flexible climate roller test bench for the Lower Saxony Research Center for Vehicle Technology (NFF). Read the story here.

What project do you have in mind? Contact us. Together we will discuss how our services can contribute to the success of your project.

Note: For confidentiality reasons, some of the images in the article are symbol images generated using AI.