The project was implemented by colleagues at the SPIE AUTOMATION branch in Haßfurt. The development process was as follows: At the beginning, the performance specifications were analyzed in detail to fully capture all functional and technical requirements for mechanics, electronics, and software. The focus was particularly on the required limit values, interfaces, and the intended operating conditions within the climate chamber. Based on this, the mechanical design of the test bench was developed and finalized in close coordination with the customer. After approval, it was handed over to production. In parallel, all electrical components were selected. Only components that meet the high requirements for precision, reliability, temperature resistance, and scalability were used. The complete system concept—consisting of mechanics, electronics, and software architecture—was presented to the customer, jointly coordinated, and approved. After completion of the mechanical production, the electrical design was implemented, and the control cabinet was built and installed. Software development ran parallel to the assembly of the system. Functions were implemented to support manual and automated test sequences, dynamically configurable test parameters, and an intuitive user interface. This allows for the flexible configuration of individual test cycles and driving profiles. After the electrical installation, the initial commissioning of the hardware took place. Subsequently, the PC program was integrated, and the entire system was fully put into operation. All functions were tested and validated. For quality assurance, multi-day endurance tests were carried out under real ambient temperatures. The measurement data collected was documented and provided to the customer for evaluation. After completion of all technical and functional work, the full technical documentation was created. This included, among other things, circuit diagrams in Eplan, parts lists, software descriptions, operating instructions, and safety assessments. Within the framework of the CE declaration of conformity, all relevant directives and standards were checked and complied with, and the system was labeled and handed over accordingly.

Several technical challenges had to be overcome during implementation. One of the greatest was designing the testing and measurement technology to permanently withstand the extreme climatic conditions within the walk-in climate chamber. To avoid moisture ingress and strong temperature fluctuations, automated climate control was developed for the testing area. This allows for active heating as needed, as well as targeted cooling with ambient air from outside the climate chamber. The PC tower with all the measurement technology was deliberately positioned outside the climate chamber and connected to the test frame via pluggable connections. This reduces climatic stress and facilitates maintenance and replacement. Another central challenge lay in software development. The simulation of real load curves required high-resolution and time-synchronous processing, as the specification curves contain new setpoints every 0.1°. Additionally, a mechanical stop in the vehicle had to be simulated by the servo drive. A torque of 40 Nm had to be generated within 120 to 150 ms without significant overshoot. These requirements were reliably met through optimized control and powerful hardware.