Application

Development test bench for high-voltage heaters with temperature chamber and powerful conditioning system

For development-related tests and validation of high-voltage heaters, a powerful test bench with environmental simulation and high-precision cooling water conditioning of the heater is required.

The system must be able to map both parameter tests and endurance runs.

Modular test bench for development-related testing and validation of vehicle components

Exactly reproducible conditions are of utmost importance for development-related tests and validation of vehicle components. The modular development test bench consists of a temperature chamber, powerful water-glycol conditioning and a rack control cabinet for high-voltage power supplies, measurement technology and automation with a user interface.

As standard, the tests can be carried out with up to three test specimens in the climate chamber. This significantly reduces the time required and allows you to carry out your tests in a time-optimized and efficient manner. You save valuable time when setting up and carrying out parameter tests, especially due to the synergy effects during temperature control.

Special test stand for development-related testing and validation of high-voltage heaters with environmental simulation and high-precision cooling water conditioning

Patch panel on the 19" rack control cabinet for connecting the test object, connecting the test bench modules, connecting various measurement sensors and flexible specification of additional setpoints.

Benchmarks:

Climate chamber

  • Dimensions of the test room (HxWxD in mm): 950 x 800 x 800
  • Minimum chamber temperature: -70°C
  • Maximum chamber temperature: +180°C
  • Temperature change rate cooling, no load: 6 K/min
  • Temperature change rate heating, no load: 6 K/min
  • Heat compensation max./at -20 °C: 5 kW

High performance conditioning system

  • Medium: Water/glycol
  • Temperature range: -40°C to +120°C
  • Accuracy temperature: < 0.2 K stationary
  • Heating power: 12 kW
  • Cooling power: 20kW (using costumers' cooling circuit)
  • Cooling power low temperatures:
    kW at -38 °C via integrated deep freezer
  • Refrigeration generator: semi-hermetic refrigeration compressor, two-stage
  • Volume flow range: 
    0-30 l/min using servo speed technology
  • Volume flow sensor:
    fully integrated, MID-technology, 0,2 % class, DakkS-calibrated
  • Differential pressure: 3 bar at 30 l/min
  • Control: temperature, flow, system pressure
  • Special features: Blow-out function for emptying the test specimens
  • Filling and venting routines for fully automated venting

Automation and Measurement Technology

  • Real-time capable LabVIEW automation with graphical user interface directly on the test bench
  • LIN interface for test object control with low-voltage power supply
  • Current and voltage measurement via measuring shunt
  • 8x temperature measurement
  • Differential pressure measurement via the test specimen

High-voltage power supplies

  • Two power supplies with 15 kW each: max. 500 VDC output voltage, max. 30 A output current
  • Output voltage up to 1000 VDC
  • Output current up to 60A
  • Switching unit with HV power contactors for software switching between parallel/serial connection of the HV power supplies
  • DC insulation monitor to switch off the power supply in the event of a fault

Mobile HV rack with automation

Benefits

Modular test bench, perfectly tailored to your application

Individual visualization and preparation of your measurement data

The user interface is tailored to your needs and requirements. The measurement data is prepared and displayed according to your ideas. It is stored in .tdms/.csv format and the measurement data can be evaluated and visualized using Excel, Diadem or other tools.

Efficient, time-optimized process thanks to Pollux sequencer

With the Pollux sequencer you can run through processes and validations fully automated. The control and measurement data recording is carried out using LabVIEW and a DCS real-time system. The high level of automation enables your tests and validations to run in a time-optimized manner.

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.

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