Thermal Management Test Bench for the Development of Hybrid and Electric Vehicles

More Efficiency – Less Energy Consumption

In order to better test future thermal management developments in vehicle systems, IPETRONIK has teamed up with a leading European automotive manufacturer. Together, we have developed a test bench with extraordinary possibilities. Under realistic conditions, it collects precise data vital for the advancement of thermal management systems, especially regarding electric and hybrid vehicles. The target is to increase the vehicle efficiency and minimize the energy consumption for various operational scenarios.

The Challenge

Vehicle development requires precise data of thermodynamic processes under different climatic conditions. For realistic and repeatable test results, the test bench must be able to control predefined parameters, such as humidity, inflow, temperature, etc. Specific test components have to be cooled or heated to simulate various operating conditions. It is vital to simulate the complex loads that occur when driving as well as to collect and process large amounts of measurement data in real time. In addition to the technical requirements, the test bench has to fit into an existing building.

Requirements

Three air handling units with 100 – 540 kg/h up to 840 – 8.400 kg/h
Relative humidity control in the air handling units 10 % – 90 %
Temperature ranges of -20 °C – 60 °C up to -20 °C – 75 °C
Six simulation modules with up to 3.000 l/h as well as pressure-, temperature-, and power-control plus simulation of pressure drops
Power supply for customer-provided system components of 80, 500, 1.000 VDC in various power levels
An environmental chamber with independent temperature as well as optional humidity control
A corresponding chiller with appr. 200 kW power at -40 °C vaporization
Installation in an existing building with limited space

The Solution

A modular, highly developed facility fulfilling every requirement. In the three air handling units, the airflow of up to 8.400 kg/h can be precisely controlled, with adjustable temperature ranges of -20 °C up to 75 °C and an adjustable relative humidity between 10 % and 90 %. Six coolant modules simulate vehicle components in the water-glycol circuit by creating heating and cooling loads, with optional hydraulic decoupling from the customer circuit. Adjustable flow rates of 300 l/h up to 3.000 l/h as well as temperatures of -20 °C up to 120 °C guarantee highly realistic simulations. Precise pressure drops can be simulated with a differential pressure control from 0 to 2,5 bar and a system pressure control from 0 to 2,5 bar. The test bench also includes a rugged environmental chamber ready for the most challenging tasks as well as a central coolant supply of -30 °C at a refrigeration capacity of 200 kW and -40 °C vaporization.

The Advantages

With our highly developed test facility, the automotive manufacturer is now able to conduct realistic thermodynamic tests under controlled conditions. Thanks to the precisely adjustable ambient parameters and the possibility to simulate various operating conditions, the efficiency of new vehicle models can be considerably increased. The real-time data analysis helps to better understand thermodynamic processes and identify room for improvement. The test facility offers: