Testing at the Arjeplog facility focused on traction, power distribution and vehicle control on snow and ice, allowing engineers to evaluate system limits and refine control strategies under extreme conditions.

A key area of development is the new AMG Race Engineer system, which integrates hardware and software to enable detailed adjustment of vehicle dynamics. Three rotary controls allow drivers to tune response, agility and traction.

The Response Control adjusts electric motor response to accelerator inputs; Agility Control modifies cornering behavior by varying torque distribution, enabling transitions from understeer to controlled oversteer. A nine-stage Traction Control system regulates slip, building on technology used in previous AMG models. These functions are fully available with ESP disabled, targeting track use.

The model also introduces AMG Performance 4MATIC+ all-wheel drive in an all-electric configuration, using three axial flux motors. The system enables fully variable torque distribution between front and rear axles, as well as torque vectoring across the rear wheels. Sensors monitor wheel slip and adjust torque delivery in real time to maintain traction and stability.

The braking system combines carbon-ceramic discs at the front with steel discs at the rear in a hydraulic composite setup. Mercedes-AMG says this delivers consistent pedal feel across regenerative and friction braking scenarios.

Suspension development has focused on the AMG Active Ride Control system, which uses interconnected hydraulic elements in place of conventional anti-roll bars. Combined with three-chamber air springs and adaptive dampers, the system enables a wide range between comfort and dynamic performance while reducing body roll and improving cornering precision.

The vehicle’s drive system features three innovative axial flux motors and directly cooled battery cells, and was also tested under Arctic conditions. The battery uses directly cooled cells grouped into laser-welded modules, with a non-conductive coolant circulating around each cell. This allows rapid heating to optimal operating temperature and efficient cooling under load, supporting repeated high-performance use.

Mercedes-AMG’s winter test program forms part of a broader validation process. The entire test program for validating a new model comprises over 500 individual tests, supplemented by the specific tuning of driving dynamics and the ESP system.

In related news, Mercedes-AMG leverages Track Sport Concept for next-gen GT3 and Black Series

As electrification continues to transform the automotive sector, developers are under increasing pressure to validate systems that must operate reliably across a broad spectrum of conditions. The rapid expansion of electric mobility is driven by technological advances, global CO₂ reduction goals and supportive regulatory frameworks. Charging infrastructures are scaling, vehicle architectures are evolving, and OEMs are compressing development timelines. With this acceleration come engineering challenges that differ fundamentally from those of combustion engine platforms, ranging from high-voltage safety to the integration of complex power electronics.

At the center of these challenges lies thermal management. Batteries, power electronics and electric motors are highly sensitive to temperature fluctuations. Their efficiency, durability and safety depend on precisely regulated heat flows. Cabin climate control also becomes a strategic efficiency factor because electric vehicles do not generate waste heat from an internal combustion engine. Alternative heating concepts must therefore maintain comfort while preserving driving range. As a result, testing technology for thermal management components has become a pivotal enabler for innovation across the EV sector.

Poppe + Potthoff Maschinenbau, a Germany-based company, develops modular test benches designed to reproduce thermal and hydraulic conditions encountered in electric vehicle applications. The systems are built to support comprehensive testing methodologies that address efficiency, reliability and safety requirements. Integrated measurement and control technologies allow detailed analysis during development and validation processes.

The growing demand for robust thermal management testing

The shift toward electric vehicles has elevated thermal management to a defining performance factor. Batteries must remain within a narrow thermal window to ensure longevity and safety. Inverters and power electronics require cooling to maintain efficiency. High-performance traction motors generate significant heat during dynamic loads. At the same time, growing variability increases the overall validation workload. Each cooling circuit comes with its own media requirements and operating patterns that must be reproduced with high fidelity. Test systems therefore need not only faster reconfiguration but also precise calibration to the functional profile of each module. This reinforces the importance of modular test architectures capable of covering multiple cooling variants within a single infrastructure, thereby shortening development timelines and improving overall test efficiency.

Testing these systems under controlled conditions is crucial to validate long-term functionality. Components such as hose assemblies, valves, cooling plates, heat exchangers, electric pumps, pressure vessels and entire cooling loops must tolerate thousands of load cycles, temperature shifts and flow variations over the typical 10- to 15-year service life of an electric vehicle.

Poppe + Potthoff Maschinenbau’s portfolio addresses this need with dedicated solutions for dynamic pressure cycling, static pressure holding, flow measurement, burst pressure testing and functional testing of live components. These test benches replicate the thermal, mechanical and electrical stresses that occur during daily operation, enabling engineers to detect weak points early and optimize materials, joining processes and overall system architecture.

Dynamic pressure cycling: simulating lifetime stress in accelerated time

A central application is the simulation of pressure fluctuations in cooling and heating circuits. Components are placed inside the test chamber and exposed to load profiles that mirror real driving conditions. Depending on the system, the test medium is circulated at temperatures between -40°C and +140°C. Water-glycol mixtures such as Glysantin G40, G44 or G48 are commonly used.

Cooling circuits are tested between -40°C and +20°C, while heating circuits undergo thermal cycling from +20°C up to +140°C. Many components must withstand more than 100,000 load changes during their lifetime, and these conditions can be reproduced in the laboratory within only a few weeks. The system’s programmable pressure waveforms, either sinusoidal or trapezoidal, run at frequencies between 0.2Hz and 2Hz or higher. Flow rates range from 1 to 50 liters per minute at pressures between 0.2 and 12 bar or more. This level of control makes it possible to test plastics, metals, composites and sealing materials under consistent and reproducible conditions.

Test standards evolve continuously. Poppe + Potthoff test benches can be configured to meet specifications such as MBN 10306, VW 8000, GS 95024 3 1 and GMW 14193. Climate chamber integration enables combined environmental and functional stress testing, including tests with overpressure and underpressure, if required.

Identifying weak points and optimizing system design

Material transitions such as weld seams, press fits and adhesive bonds often represent sources of fatigue. By exposing components to realistic pressure and temperature cycles, engineers can identify early-stage cracking, swelling, deformation and leakage. These insights help refine design choices, improve production quality and stabilize system performance long before large-scale manufacturing begins. Throughout the test, inlet and outlet temperatures, flow rates, pressure drops, current and voltage for active components and ambient conditions are measured continuously. Thermal sensors placed on the test object highlight areas of energy loss or potential overheating, contributing valuable information for further optimization.

Accelerated durability testing for long-term reliability

Long-term tests generally run for 20 to 30 days, depending on the chosen load frequency. Ambient and media temperatures vary according to the test specification, and all key parameters are logged continuously. This accelerated method simulates several years of operation within a matter of weeks. It reveals aging behavior, degradation patterns and the effects of repeated thermal and mechanical stress on component performance. The data supports predictive maintenance approaches, extended warranty assessments and material qualification.

Functional testing under realistic electrical loads

Efficiency is a decisive performance factor in electric vehicles, since every watt drawn by thermal management components affects vehicle range. Poppe + Potthoff Maschinenbau therefore offers functional test benches that evaluate performance and energy consumption under low- and high-voltage conditions.

Cooling and heating units, control valves and pumps can be operated at voltages between 0 and 24V DC or up to 1,500V DC and 150A to simulate onboard battery or traction battery operation. Tests are carried out across a thermal spectrum from -40°C to +100°C, with optional climate chamber integration extending the ambient range to +140°C. Comparing measurements before and after a durability test shows how components degrade over time. These insights are essential for planning service intervals, improving efficiency and safeguarding long-term system stability.

Safety, usability and digital integration

Safety is an integral part of every system. Test chambers are built from welded stainless steel and equipped with high-strength laminated safety glass. A closed medium circuit prevents the formation of hazardous vapors. Operation is streamlined through recipe management, which enables predefined test sequences to be selected via PC or handheld scanner. National Instruments’ LabView platform provides comprehensive data visualization and acquisition. All test data is stored automatically and can be exported for further analysis. The open software architecture makes it possible to integrate additional sensors and custom data channels whenever needed.

Enabling the next generation of electric mobility

As electrification advances, precise and adaptable testing solutions are essential for validating new concepts and ensuring safe, efficient and durable electric vehicles. By reproducing the interaction of temperature, pressure, flow and electrical load, the test setups provide engineers with data that can support the design and assessment of components across the full service life of an electric vehicle. This contributes to a more detailed understanding of thermal management behavior within modern electric mobility.

Based on the popular CLE series, the vehicle is being put through its paces under extreme conditions. This phase is crucial to validate the performance and reliability of all components, even at the lowest temperatures.

Although it bears a clear resemblance to the popular CLE, the extreme model takes the concept several steps further, with Mercedes‑Benz promising an even more uncompromising appearance and positioning the vehicle as a genuine statement on the road – backed by a correspondingly powerful drivetrain and performance to match.

The upcoming model will be the second in the exclusive Mercedes‑Benz Mythos series, following the radical, open two-seater Mercedes‑AMG PureSpeed.

In related news, Mercedes-AMG Petronas F1 to use Microsoft cloud and enterprise AI technologies to enhance racing performance

Temperature at the facility can be adjusted from -40°C to +40°C, and snow cannons can produce a variety of snow types. Combined with the wind tunnel’s high-powered fan, this enables the replication of blizzards at speeds of up to 200km/h. 

In each tunnel, a rolling road simulates the road surface. Powerful electric motors drive four rollers each, enabling the OEM’s 4Matic models to be scrutinized under realistic conditions. Both rigs are designed for a total output of up to 780kW, enabling top speeds of up to 265km/h.

Vehicles can also be refueled and charged within the tunnels. In addition to the two test benches, there’s also a control room where technicians can regulate temperature, humidity wind speed and other parameters. Each test can be closely observed through large, fully insulated windows.

The resource also houses a heat chamber, where temperatures from -10°C to +60°C can be generated. A solar simulation system with 32 lamps produces a radiation spectrum equivalent to natural sunlight. Across an 8m × 2.5m area, radiation intensity can be adjusted between 200W/m² and 1,200W/m². The highest level is said to match extremely intense sunlight found only in remote desert locations, such as Death Valley in the USA.

Another development tool in the heat tunnel is the ‘Hot Road’ – a simulated road surface whose temperature can be continuously adjusted between +50°C and +70°C, accurately replicating the thermal conditions of pavement on a scorching summer day.

Engineers are using the climatic wind tunnels to test a range of vehicle components and functions. For example, they are assessing the performance of the windshield wipers to ensure they operate flawlessly in all weather conditions. In the cold tunnel, the engineers are also examining whether swirling snow can block the air intakes – a real-world risk caused by spray from passing trucks.

At frosty temperatures between -15°C and -20°C, the heating system must be able to defrost an icy windshield quickly. During evaluation, a camera records the entire de-icing process – the GLB is said to have performed impressively in these evaluations.

Mercedes‑Benz says that data captured in these facilities is helping to close the gap between simulation and physical testing.

In related news, Mercedes-Benz recently opened its new Light Testing Tunnel in Immendingen

Tyrone Johnson, managing director at Hyundai Motor Europe Technical Center, said, “The investment at Square Campus is a clear sign of our commitment to the region and reflects the importance of Europe in our long-term growth strategy. The extensive new capabilities at HMETC give us more independence and flexibility, while creating exciting new opportunities for collaboration between our brands. Fundamentally, Square Campus will also support us as we continue to grow our market share in Europe, developing new vehicles and technologies designed around the needs of our customers.”

New capabilities

The 25,000m² site is equipped with the largest semi-anechoic chamber within the Hyundai group, enabling unrestricted noise, vibration and harshness (NVH) and drive-by noise testing with complete independence from weather conditions.

Highly advanced dyno facilities at Square Campus play a key role in development, enabling the comprehensive testing of vehicles and individual components, compatible with all-electric, hybrid and internal combustion engine (ICE) powertrain applications. The facility is also equipped with an EV charging laboratory, a state-of-the-art driving simulator and new facilities for extended electronics system development – including over-the-air-updates (OTA), cybersecurity, and advanced driver assistance systems.

In related news, Site visit: Inside Mercedes-Benz’s light testing tunnel

The Future of Automotive Testing Conference

This day of high-level content will explore various topics and provide an engaging opportunity to learn from and connect with industry peers. Situated among the exhibits, it will have a relaxing atmosphere, and visitors will be able to dip in and out at their leisure. A highlight will be ATTI’s on-stage interview with Jon Quigley, who worked for Volvo for many years and now runs his own company, Value Transformation. With his broad experience and portfolio of contacts, he’s a very good person to know. He loves sharing his thoughts, too, hence his new gig as ATTI’s regular columnist.

Read Quigley’s latest column on p36 of the September issue.

Also during the conference, Venkat Adusumalli, software engineering manager at Stellantis, will reveal how Stellantis is using AI to accelerate E/E system testing and validation workflows. Click here for a pre-show interview with him.

Innovation Showcase

The free-to-attend Innovation Showcase also provides an interactive platform for learning about new technologies. Speakers will welcome questions and discussion after their presentations, making it a great way to explore ideas together. Like the conference, it will take place within the main hall, so it will be very easy to listen in while wandering through the exhibits, or to come and go throughout the day.

Technology debuts

The industry is moving quickly and it can be a challenge to keep up. Every year there is an abundance of new technologies on display. Some are incremental improvements to existing products, others are entirely new. It’s always surprising how companies find ways around bottlenecks. Often, these developments emerge from ongoing conversations between supplier and customer, ultimately benefiting multiple companies.

Read ATTI‘s comprehensive expo preview in the September issue.

Face-to-face discussions  

It sounds obvious, but the most fruitful conversations are usually the ones that happen in person – it’s how journalists find the best stories. Year after year, exhibitors and visitors report having forged unexpected collaborations at the show, in the form of technology tie-ups or service partnerships.

Detroit’s revival 

A lot of money has been plowed into Detroit in recent years, as evidenced by the stunning renovation of Michigan Central Station, which is well worth a visit. Much of the investment has been in the tech sector. Eleven years ago – when the station was still derelict – ATTI took a tour of some of the labs at GM and what was then the FCA headquarters (see The right wave length, November 2014, Seasonal highlights, September 2015, and Powerbase, March 2015). The facilities were impressive then and are even more so now, thanks to several years of investment in innovation leading to Detroit’s resurgence as an automotive powerhouse.

Visit the Automotive Testing Expo North America website to secure your FREE pass, which will give you access to the expo, the Future of Automotive Testing Conference and the Innovation Showcase

“BIAS’s technical depth and commitment to innovation make them an ideal partner to represent and support eMpulse systems in Türkiye. We are excited to work together to deliver advanced servoelectric testing solutions to customers who require higher precision, efficiency and sustainability in their testing operations,” said Richard Thompson, director of eMpulse Test Systems.

In a separate partnership, eMpulse has joined forces with XTemp Vibration, a South African company that develops corrosion test chambers, motion simulators, data acquisition systems, sensors and interfaces.

“We are excited to join forces with XTemp Vibration, a company that shares our passion for innovation, quality, and customer service. Together with XTemp Vibration, we look forward to delivering world-class testing solutions while jointly expanding the vibration testing capabilities available in the region,” commented Doug Boals, CTO of eMpulse Test Systems.

In related news, eMpulse recently debuted a new single-axis test machine. Read the full story here

The first episode of Behind the Badge shines a spotlight on the world of vehicle body testing. McLaren engineers working in vehicle body engineering and validation run more than 450 individual tests across the vehicle body, including atmospheric chamber tests that stress the vehicle body through huge temperature and humidity variations, encompassing a swing in ambient temperature from -40°C to +50°C in 90 minutes.

In related news, McLaren has concluded the cold-weather testing program for the prototype McLaren W1, completing a validation cycle in the Arctic Circle focused on verifying critical vehicle systems under subzero conditions. Click here to read the full story. 

TEES supports Texas A&M University by conducting engineering and technology-oriented research and educational collaborations. The new test cell will be used in cooperation with the Texas Department of Transportation.

The large dynamometer was installed below ground and is contained in two rooms. The rolls section is in a climate-controlled room to simulate Interstate driving in different road conditions and temperatures. The inertia wheel, load-simulating power absorption unit (PAU) and AC electric motor are in a separate room where the temperature created by the load will not affect the test.

“This project was unique in that there was an existing dynamometer at the university from which Mustang was able to reuse some existing parts and elements, which was a cost-reducing factor in the project,” said Michael Caldwell, senior account manager at Mustang. “MAE is more than capable of producing test stands at any scale. Our rugged design philosophy, along with state-of-the-art control technology, provides our customers with unparalleled performance in these challenging applications.”

The system can handle 80,000-pound gross vehicle weight rating (GVWR) trucks, as per state maximum limits.

In related news, Applus Idiada recently announced an investment in an Integrated Vehicle Dynamics & Ride Comfort Simulation Platform that will upgrade its existing VI-grade DiM250 driving simulator at its Santa Oliva facility in Spain, extending its capabilities into high-frequency vibration comfort and NVH development. Click here to read the full story. 

The program targeted the calibration and optimization of the W1’s chassis, traction control, torque vectoring and the electronic stability program on ultra-low grip surfaces. These systems were optimized to ensure performance in extreme conditions.

With these tests, McLaren has ensured that the 1,275ps and 1,340Nm power and torque produced by the new V8 hybrid powertrain at the heart of W1 can “truly deliver performance everywhere”, the auto maker said, adding that the stress testing of the HV battery, gearbox and new MHP-V8 engine in extreme cold pushed “durability and performance to the extremes”.

McLaren has shared elements of this development activity, offering rare insight into the engineering process behind its next-generation hypercar.

In related news, Nexen Tire recently announced the establishment of a dedicated winter tire testing center at the UTAC proving ground in Ivalo, Finland. Click here to read the full story.