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

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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