Application

Temperature Control System for Endurance Tests with Six Fluid Outlets for Drivetrains in Electric Vehicles (BEV/HEV)

For endurance tests according to LV124 (or VW8000/IEC 60068-2) for electric vehicle (BEV/HEV) drives, conditioning with 6 separately flow or pressure controllable fluid outlets each is required.

The temperature control is set to a common setpoint since all DUTs are intended to be subjected to identical setpoint profiles.

Conditioning System with Six Individually Flow-Controlled Fluid Outlets and a Common Set Temperature Ranging from -40 to +140 °C

During the test runs, the test specimens are subjected to load cycles. Special attention is given to the safe regulation of even small flow rates below 1 l/min and the precise control of the smallest heat inputs in addition to maximum power. Furthermore, the medium used, transmission oil, experiences extreme changes in viscosity between the operating temperature limits.

The 6-fold conditioning system with separately flow and pressure controllable fluid outlets, equipped with DUAL cooling, achieves maximum energy efficiency even in high-temperature and temperature cycling endurance tests.

Temperature control system for endurance tests with six fluid outlets for electric vehicle drive units.

High-performance oil conditioning for endurance tests according to LV124.

Benchmarks:

  • Medium DUT: Gear oil
  • Temperature range: -40 °C .. +140 °C
  • Accuracy temperature: < 1K stationary
  • Heating power: 26kW
  • Cooling power using buildings' cooling water system:
    60kW
  • Cooling power low temperatures:
    20 kW (against brine circuit -50 °C)
  • Volume flow range: 
    6 x 0..12l/min via servo-speed-technology
  • Volume flow sensor:
    6x integrated, screw spindle technology, 0.1 % class
  • Differential pressure: each max. 5bar @ 12l/min
  • Control modes: Temperature and 6x flow/pressure
  • Safety: limit monitoring and integrated safety module with external emergency stop connection
  • Interface: Profibus
  • Design: Mobile on casters, compact construction

Benefits

Full Flexibility with one Temperature Control System

Specifications Tailored to Your Test Object

Media temperature, flow range, system pressure level, cooling capacity, heating capacity, and more – all individually tailored to your requirements. If any parameter deviates from standard requirements, no problem, contact us. We have the solution for you.

DUAL-cooling

Energy efficiency is of the utmost priority. Pollux installs two heat exchangers for cooling against a building-side brine circuit at -50 °C or against a cooling water circuit at a temperature level of +20 °C. This enables efficient cooling depending on the inlet temperature against two different cooling temperatures.

Minimal Volume Flows at the Inlet Without Valve Technology

With the combination of a volumetric main flow pump with a servo motor and a screw spindle flow meter on the flow, even the smallest flow rates can be easily regulated. Especially in the low-temperature range at -40 °C and with the high viscosity of the gear oil, the test specimen can be supplied with typically encountered small volumes of oil flow without any problems. Flow rates significantly smaller than 1 l/min per strand can be precisely regulated.

Full Media Conditioning with 6 Inlet Branches for Endurance Tests According to LV124 / VW8000 / IEC 60068-2

The high-performance tempering system features six individual inlet branches that can be controlled in terms of flow rate and pressure at the inlet. The temperature control is implemented via a central tempering circuit in a temperature range between -40 and +140 °C. Each inlet branch is equipped with its own inlet pump, flow rate meter, and pressure sensor. The return is carried out through a central outlet. With the conditioning system, endurance tests according to LV124 (or VW8000, IEC 60068-2) with 6 test specimens can be simultaneously executed with just one media conditioning solution - all from a single source.

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