Dellner Bubenzer Relocates, Upgrades Pioneering R&D Facility

Dellner Bubenzer has moved its state-of-the-art research and development (R&D) centre to the company’s production facility in Kirchen, Germany.

17/09/2026

Relocating the first-of-its-kind operation from a dedicated R&D site in Betzdorf-Dauersberg (10 km away), brings research, development, testing and manufacturing together in one place, allowing each department to collaborate more closely and accelerate advancement of new products.

The new 700-square-metre testing space, complemented by additional office accommodation, brings nine staff into closer proximity with all R&D functions as part of the wider 24-person technical department. Integral to the infrastructure repurposing project was the installation of an 8t capacity overhead crane, climate chambers and a large flywheel test bench, which required a 50-square-metre reinforced foundation. These works had to be completed before the relocation could take place.

The new test bench uses a rotating flywheel to store and release kinetic energy, allowing engineers to simulate demanding operating conditions and test the performance and braking capacity of components such as industrial brakes. The flywheel dynamometers are used to measure things such as braking torque, rotational speed, energy and braking power.

The centre is equipped with a range of complementary test facilities, providing Dellner Bubenzer with the flexibility to evaluate braking systems across different applications and performance levels. At its heart is the large-capacity flywheel dynamometer capable of delivering a wide range of braking torque at friction speeds of up to 130 m/s and 25 MJ of energy, with a maximum braking power of 3.5 MW. A second, smaller-capacity flywheel dynamometer extends the testing range, handling a smaller range of braking torque and 316 kJ of energy. Completing the suite is a sword test bench, a dedicated system for measuring braking force and performance, with hydraulic pressure and cooling capabilities and a maximum braking force of 880 kN. Together, the three systems provide a comprehensive platform for testing and developing braking solutions under a wide range of operating conditions.

Full-scale testing

Rene Hamann, engineering director at Dellner Bubenzer, said: “This is a much more integrated solution than before, allowing us to test industrial braking systems, thrusters and other solutions. Our test centre is something quite special. It was the first facility of its kind in our industry, and even today, very few companies have the capability to carry out full-scale testing of industrial braking systems under real operating conditions. That capability is a genuine competitive advantage for us and an important part of what sets us apart.”

The test bench is central to the Kirchen site, but it is the combination of dynamic testing, environmental simulation and wider R&D capabilities that makes the facility genuinely pioneering. The flywheel test bench gives the R&D centre the ability to move beyond static testing and replicate the dynamic conditions that braking systems encounter in operation. By introducing controlled levels of kinetic energy into the brake, engineers can assess performance across different speeds, braking forces and energy combinations, as well as investigate repeated duty cycles and other operating scenarios. The facility can also be used alongside a climate chamber capable of temperatures from -50°C to +180°C, enabling products to be evaluated under a wide range of environmental conditions.

Hamann added: “Every new prototype undergoes extensive testing, with some designs completing as a minimum of two million operating cycles or more before they reach the market. This rigorous approach helps us ensure the highest standards of safety, reliability and performance. The Kirchen site is essentially where we develop and test our full range of products, including the BUEL® thruster line.”

The R&D centre is not intended to be a static facility. Dellner Bubenzer expects its capabilities to evolve continuously, moving beyond traditional mechanical testing to incorporate more electronics, monitoring and data-driven analysis. Testing capacity will also increase, enabling multiple products of the same type to be assessed simultaneously. Alongside development work, the centre will play an increasingly important role in quality assurance, from testing brake linings and evaluating new suppliers to verifying that each new batch meets the company’s exacting standards.