- testbenches · hybrid & electrical vehicle development what. ipetronik what a device or an...
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November 2011
- Testbenches
IPETRONIK
IPETRONIK GmbH & Co. KG Founded 1989 > 140 employees Global presence Owned by INDUS Holding AG
Germany:Baden-Baden
DuesseldorfHamburg
Ingolstadt
Globally:France
UKItaly
AustriaUSA
SwedenBrazilIndia
ChinaSouth Korea
JapanAustralia
IPETRONIK
Experience
IPETRONIK
ca. 83 PeopleDAQ-Systems forPowertrain, Engine cooling, A/C, HVAC
ca. 40 PeopleDevelopment of A/C, climate test benches, Leakage testing, Climate NVH, RLDA testing,Fleet operation
ca. 11 PeopleDevelopment, Construction,Update,Service,of Testbenches for Thermal Management
ca. 10 PeopleSoftware for data acquistion, Test bench control, Data analysis, Thermaldynamics
IPETRONIK
Where
Location: Hamburg, Germany
IPETRONIK
Competences
‣ Climate module calorimeter test bench ‣ Climate system test bench‣ Test circuits für R134a / 1234yf / CO2
‣ Climate acoustic chambers‣ NVH- test bench for climate compressors‣ Compressor endurance test benches (Raffertest/VDA/FAT)‣ Media Supply Modules‣ Climate chambers for componentes testing and fully equipped vehicles‣ Rebuilding/replacement of existing equipment‣ Service/maintenance of
Climate-/cooling test benches/Climate chambers
IPETRONIK
Why “Many products in the market will only have a chance to
survive over long periods of time, if they are able to work under constant pressure and withstand external environmental stress.”
Required features: Durability Reliability Flawless functionality Performance Progress in product
development Competitive advantage
(TUV Germany)
IPETRONIK
Test benches by IPEtec focus on components and systems around thermal management Vehicle climate control Engine cooling
IPEtec test benches feature: Testing under real-life conditions Highly reproducible environments Highest control accuracy
Typical users / department: R&D Quality control Hybrid & Electrical Vehicle
Development
What
IPETRONIK
What A device or an appliance to test an objects technical
characteristics in repeatable manner Test benches include
Preparation and maintaining of test conditions such as temperature, humidity, mass flow
Mechanical device to integrate the test object Machinery, sensors and control system
to provide and maintain above mentioned conditions as well as to log measured valuesand create test reports
IPETRONIK
Goal The goal is to optimize the overall thermal management of
the vehicle Lower fuel consumption Lower emission Ensure sufficient engine and component cooling Optimization of passenger compartment air conditioning
Performance Comfort Energetic efficiency
IPETRONIK
How Test benches need to provide a wide range of changes
in temperature and humidity, e.g. from -40°C to +100°C in 2hrs stress test in time-lapse effect
Constant monitoring of functionality + performance of components / system
All kinds of media like cooling water, refrigerant fluid, engine oil, transmission oil, exhaust, .. are provided by test bench
Requires robustness of test bench itself and long expertise of test bench design
Process intelligence transferred into bench by customized PLC programs and operating software IPEtec test benches
IPETRONIK
How
IPETRONIK
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Project Customer specify basic testing conditions Joint development of test specification, procedure and bench
layout Mechanical and electrical components for testing are defined
and selected during engineering phase Manufacturing of the test bench including
Components Control system Software User interface Reporting
IPETRONIK
Benefits1. Customized solutions 2. Proven system technology3. Flexible design4. User orientated MMI5. Comprehensive expertise from single source:
Mechanical, Electrical, Fluid technology, Controls, DAQ, Software6. Modularity for future extensions7. Excellent team
1. Decades of global experience2. Lean project management structures 3. Strong in consultancy4. Efficient workflow
IPETRONIK
Thermal management
Engine cooling Vehicle air condition
Vehicle radiator
Cooling circuit
HVAC components HVAC system
Compressor Heater
Condenser EvaporatorCharge air cooler Oil cooler Water pump
Coolant radiator
Battery cooler
Control valves
Applications
IPETRONIK
Engine cooling: Radiator wind-tunnel
Performance measurement of radiators balancing Closed loop air circuit +20 ° to +60°C Option for frontend module testing Up to 25,000 m³/h 300 kW radiator performance Depending on requirements,
different media modules canbe integrated for: Coolant Charge air Oil cooling
IPETRONIK
Engine media-supply units
Oil conditioning Oil temperature +80 °C to +160 °C Up to 150 kW performanceUp to 250 l/min
Coolant SimulationGlycol/water mixture: –20°C to + 140°CPerformance: up to 300 kWFlow rate: 25 m³/h
Charge air simulationUp to 300 °C3 bar system pressuremax. 1,000 kg/h
IPETRONIK
Thermal management
Engine cooling Vehicle air condition
Vehicle radiator
Cooling circuit
HVAC components HVAC system
Compressor Heater
Condenser EvaporatorCharge air cooler Oil cooler Water pump
Coolant radiator
Battery cooler
Control valves
Applications
IPETRONIK
HVAC-module calorimeter HVAC system test bench Refrigerant circuits: R134a / 1234yf / CO2 Acoustic chambers for A/C testing Noise and vibration test bench for HVAC-compressors Compressor endurance
Vehicle air-conditioning
IPETRONIK
Thermal management
Engine cooling Vehicle air condition
Vehicle radiator
Cooling circuit
HVAC components HVAC system
Compressor Heater
Condenser EvaporatorCharge air cooler Oil cooler Water pump
Coolant radiator
Battery cooler
Control valves
Applications
IPETRONIK
Calorimeter test bench for complete AC systemsOriginal refrigerant circuit componentsSeparate air loops for evap. + condenserAir loop
Evap / Heater: -20°C to +50°C, 1,000 kg/h
Condenser: -5°C to +50°C, 8,000 kg/h
HVAC system testCalorimeter test bench for AC modulesExternal refrigerant circuit module Water-cooled condenserAir loop from -20°C to +50°CHumidity controlAir mass-flow range up to 1,000 kg/h
IPETRONIK
HVAC system test
IPETRONIK
Test setup with original components Double test room arrangement Simulation of air intake with conditions for
evaporator / heater and condenser
Passenger compartment
Engine compartment
HVAC system test
IPETRONIK
Thermal management
Engine cooling Vehicle air condition
Vehicle radiator
Cooling circuit
HVAC components HVAC system
Compressor Heater
Condenser EvaporatorCharge air cooler Oil cooler Water pump
Coolant radiator
Battery cooler
Control valves
Applications
IPETRONIK
HVAC components
Evaporator
Condenser
IPETRONIK
Compressor test benchRefrigerant circuit moduleWater-cooled condenserWater heated evaporatorTemperature controlled compressor chamberTorque measurement
Condenser test benchRefrigerant circuit moduleAir supply circuit +5°C to +50°CAir mass-flow up to 8,000 kg/h
Evaporator test benchRefrigerant circuit moduleAir supply circuit +5°C to +50°CAir mass-flow up to 1,000 kg/hAir humidity control
Heater test benchCoolant supply moduleAir supply circuit -20°C to +30°CAir mass-flow up to 1,000 kg/h
HVAC components
IPETRONIK
Refrigerant Supply Module For the evaluation of thermodynamic
properties of A/C-system componentsIPEtec offers a “refrigerant supply module” Mobile unit Verified operation Electrical super-heater Refrigerant compressor with belt drive Refrigerant filling system Expansion valve for super-heat control Evaporator performance up to 15 kW Condenser performance up to 30 kW Applicable refrigerants: R134a, HFO 1234yf, R744
IPETRONIK
Battery cooling for EV / Hybrids
New electrical vehicles and hybrids require special attention to battery cooling
Tmax of Li-ion battery: ~40°C
Cooling module
Coolant connectionsHigh voltage connectionVoltage control
Battery managementBattery cells
IPETRONIK
Total System Responsibility
single source responsibility
Features: Test bench machinery
& supply units Vehicle Bus Simulation Data Acquisition Evaluation software &
test reports service & maintenance
IPETRONIK
IPEtec climatic acoustic test Features:
Temperature range of -30 °C to +50 °C Relative humidity 20 % to 70 % IR-Solar Simulation up to 1200 W/m² Engine in operation Fresh air and exhaust system
IPETRONIK
IPEtec test benches
IPETRONIK
References (09/2010 – 09/2011)
‣ IPETRONIK, test bench for entire climate- and cooling circulation, application E-car, Frontendluftmodul, Verdampferluftmodul, accumulator simulation module (colling liquid conditioning, simulation Wärmeeintrag accumulator), E- engine simulation module (cooling liquid conditioning, simulation Wärmeeintrag E-engine)‣ AUDI AG, climate chamber -40°C/+60°C Vehicle test chamber for several tests of the entire vehicle climate and cooling,
specific channel and nozzle dimensioning via numeric stream simulation, AirVolume 100.000 m³/h
‣ Valeo Compressor Europe, climate system test bench for compressor testing -20°C / +60°C air processing for condensator and evaporator, electrical compressor
drive , automated endurance testing and thermal dynamic analysis about IPEmotion‣ Sanden of Europe, 5 compressor test benches automated Raffer- and VDA- endurance testing for electrical compressors
IPETRONIK
‣ WEBASTO StockdorfProcessing upgrade/rebuild of climate test bench‣ BMW AG 3 Verdampferluftversorgungen 2 cooling liquid modules‣ IPETRONIK Thermal management test bench E-cars Verdampfer- und Frontendluftversorgung 3 simulation module for cooling liquid
Overall solution > HiL (Hardware in the Loop)- test bench‣ Maintenance/service several maintenance-/service and rebuilding orders for test
benches and climate chambers i.a. for AUDI AG, Webasto, Volkswagen AG
References (09/2010 – 09/2011)
November 2011
- Testbenches