Researchers in the US have developed a facility that acts like a giant treadmill for trucks, where full-size vehicles can be pushed to their limits without ever leaving the building.

Backed by the US Department of Energy (DOE) and built by engineers at Argonne National Laboratory (ANL), the so-called Heavy-Duty Dynamometer Test Facility aims to accelerate progress in advanced freight technologies while cutting both time and cost.

The first-of-its-kind site uses a dynamometer, a precision device that measures force, torque, or power, to simulate real-world driving conditions in a controlled setting by applying load to a vehicle’s wheels.

It functions as a “road in a lab,” allowing engineers to test Class 8 trucks (heavy-duty vehicles with a Gross Vehicle Weight Rating (GVWR) exceeding 33,000 lbs) under controlled, repeatable conditions while accelerating validation of engines, fuels, and drivetrains.

Testing trucks under load

Building new medium- and heavy-duty vehicle tech is becoming more complex, expensive, and time-consuming. Companies have to evaluate new engines, fuels, automation, and connectivity under real-world conditions.

They also have to deal with regulations, high costs, and tight deadlines to remain competitive. “Medium- and heavy-duty trucks move our economy,” Claus Daniel, PhD, an associate laboratory director for ANL’s Advanced Energy Technologies (AET) directorate, pointed out.

To address the challenge, the scientists created a system that combines physical testing with advanced simulation, as well as corridor-level analysis within a single research environment. It features comprehensive energy instrumentation with an automated “Anything-in-the-Loop” workflow.

This is a method that bridges simulation and validation to iterate on technology improvements. It lets researchers test performance, efficiency, automation, and system interactions under controlled conditions that mirror real-world freight conditions.

“With this facility, Argonne delivers the rigorous, repeatable research and testing industry and government needs to bring new technologies to the market that reduce transportation costs,” Daniel noted in a press release.

Inside the truck lab

Funded by DOE’s Transportation Technologies Office, the site is expected to help the freight industry move faster by cutting development time and reducing both technical and financial risks. Gains of up to three percent can deliver hundreds of millions in savings over a decade, with even bigger returns at scale.

The site combines a state-of-the-art heavy-duty chassis dynamometer with virtual traffic environments, connectivity tools, and real-time simulation platforms. It also draws on advanced controls and modeling expertise.

The facility features a Burke Porter Model 4701 system equipped with four rollers and two centrally positioned electric machines for repeatable results. It reportedly supports Class 3-8 vehicles, and can handle test weights ranging from 10,001 to 82,000 lbs.

The setup also accommodates RWD, FWD, and AWD layouts, with an adjustable wheelbase spanning 100 to 280 inches. It is located within ANL’s Transportation Complex, and benefits from existing infrastructure, security, and close proximity to complementary labs.

Its electrical, mechanical, and data systems are fully scalable. This allows it to support future propulsion technologies and increasing levels of automation.