Application
Endurance Test Bench for Water Pumps and Valves with Separated Fluid and Ambient Conditioning
A high-performance test bench with environmental simulation and precise cooling water conditioning is required for testing automotive coolant pumps and valves. The goal is to simulate the conditions that can occur in the vehicle as accurately as possible.
Robust Test Stand for Endurance Testing of up to 12000 Hours for the Validation of Cooling Circuit Components
Continuously increasing customer requirements and increasingly complex test scenarios demand high-performance testing environments. Additionally, there are high demands for availability to conduct time-critical endurance tests without major interruptions. At the same time, there is a desire for high flexibility in testing capabilities to be able to test products in a customer-specific manner.
The system must quickly and accurately capture both hydraulic and electrical parameters of the test specimens in both manual and automatic test procedures.
The compact endurance test bench consists of a custom-made stainless steel temperature chamber, media conditioning, and two control cabinets for power supplies, measurement technology, and automation with a user interface.
The test bench has four hydraulic test circuits. Each test circuit includes an inlet and two outlets. Each outlet, in turn, has a throttle valve for setting the operating point and a flow meter. This allows for testing up to eight test specimens simultaneously.
Compact special test bench for testing components of the automotive cooling circuit. Media conditioning including a refrigeration unit on the left side. Temperature chamber and test specimen glycol circuit in the middle. Patch panel and measurement technology on the right side.
Control and measurement technology in the control cabinet and 19-inch rack, including operator's computer.
Custom stainless steel temperature chamber with large viewing windows and lighting for up to eight test specimens.
Measurement data from a step temperature test (-> dark blue: medium temperature setpoint, -> orange: chamber temperature setpoint, -> light blue: medium temperature actual value, -> red: chamber temperature actual value). The temperature behavior in the water-glycol circuit and in the temperature chamber is plotted. Every hour the temperature changes by 5°C. The control deviation in the stationary state is significantly below the required +-1K.
Benchmarks:
Temperature Chamber
Minimum temperature of chamber: -40°C
Maximum temperature of chamber: +150°C
Accuracy temperature: < 1K stationary
Temperature change rate for cooling: 3K/min
Temperature change rate for heating: 3K/min
High-Performance Conditioning System for Fluid
Medium: Water/glycol
Minimum temperature: -40°C
Maximum temperature: +150°C
Accuracy temperature: < 1K stationary
Temperature change rate for cooling: 3K/min
Temperature change rate for heating: 3K/min
Automation and Measurement Technology
Integration into the customer's higher-level control system
Real-time system for controlling the temperature units and data acquisition
LIN- & PWM-interface for specimen control
Measurement Parameters
Voltage
Current
Temperature
Flow
Differential pressure measurement via the test specimen
System pressure
Temperature chamber (left) with patch panel (right) for easy installation of test specimens.
Measurement data from a temperature change test (-> dark blue: medium temperature setpoint, -> orange: chamber temperature setpoint, -> light blue: medium temperature actual value, -> red: chamber temperature actual value). The temperature behavior in the water-glycol circuit and in the temperature chamber is plotted. The ramps in the left area are 1K/min, in the middle 2K/min and in the right area 3K/min.
Benefits
High-Performance Test Stand, Perfectly Tailored to Your Application
Custom Temperature Chamber
The temperature chamber is tailored to your needs and requirements. The dimensions have been chosen to allow ergonomic handling of up to eight test specimens.
Separately Adjustable Ambient and Fluid Temperatures
The two independently acting conditioning systems for air and medium allow the simulation of entanglement states with a difference of up to 130°C.
DUAL-cooling
Energy efficiency is of the utmost priority. Pollux incorporates an additional heat exchanger for direct cooling against the costumers' cooling water system when the temperature level allows it. The integrated refrigeration compressor only engages when necessary. Direct cooling using the cooling water system always offers energy advantages, reducing costs and the operating hours of the refrigeration compressor.
Cooling Water and Power in Your Test Environment Are Sufficient
With this conditioning system, you have combined all functions: Our powerful temperature control system and the temperature chamber are equipped with an integrated deep cooling machine. A building cooling water circuit, cooled via a cooling tower, and a high-voltage connection are sufficient.
