Modine Brazil Technical Center Laboratory...

Modine Brazil Technical Center

Laboratory Capabilities

1 14 de setembro de 2018

The Modine Brazil Technical Center conducts performance and durability tests for heat transfer components, modules or systems. The Modine Brazil Tech Center is certified to ISO 9001:2015 and is audited for compliance with the laboratory requirement sections of ISO/IATF 16949:2016 as a remote location, providing test services for our manufactured products. The total Modine Brazil Laboratory areas is 950m2, divided in two major types of test capabilities which have been established for the purpose of ensuring design adequacy for the intended use.

• Thermal Test Lab:

The primary activity of this laboratory is heat exchanger calorimetry. The laboratory provides a variety of stable fluid inputs with flow rate, temperature, and pressure control to establish the fundamental thermodynamic characteristics of heat exchangers and systems (e.g. engine cooling radiators, air to air coolers, air cooled oil cooler and liquid cooled oil coolers).

• Structural Test Lab:

These laboratories are used to assess durability and reliability of components and assemblies under a variety of loading scenarios. Tests include pressure cycle, thermal cycle, single-axis vibration, hydrostatic burst test, cold aging, field data acquisition and others.


FACILITY MAP

SALT SPRAY ROOM

ENGINEERING ROOM

THERMAL TEST

STRUCTURAL LAB 1

STRUCTURAL LAB 2

SAMPLE SHOP

SAMPLES STORAGE

VEHICLE

INSTRUMENTATION

AREA

FACILITIES


THERMAL TEST LAB The Modine Brazil thermal laboratory deals with single phase heat transfer using a calorimeter to support product development, quality control and validation activities. It provides water, cold and hot air and oil as stable fluids inputs with flow, temperature, and pressure control to establish the fundamental thermodynamic characteristics of heat exchangers and systems (e.g. engine cooling radiators, air and liquid cooled oil coolers, charge air coolers, shell and tube heat exchangers, etc.). Information regarding operational ranges and control capability can be found below:

SINGLE PHASE LIQUID TO AMBIENT AIR HEAT TRANSFER

Name Hot Water-to - Cold Air Hot Oil-to- Cold Air

Location SAO PAULO -GUARULHOS SAO PAULO -GUARULHOS

Test Rig nº 10 10

Cold Fluid Ambient air Ambient air

Mass flow min kg/h 1000 kg/h 1000 kg/h

max kg/h 12000kg/h 12000kg/h

System pressure max kPa ambient - not controlled ambient - not controlled

Differential pressure min Pa ± 20 Pa ± 20 Pa

max Pa ± 3000 Pa ± 3000 Pa

Temperature min °C not controlled (≈ 10) not controlled (≈ 10)

max °C not controlled (≈ 35) not controlled (≈ 35)

Hot Fluid Water Oil Mobil Delvac Super 1400 15W-

40

Mass flow min kg/h 2000 kg/h 800 kg/h

max kg/h 15000 kg/h 5400 kg/h

System pressure max kPa 300 kPa abs not controlled 1000 kPa-g not controlled

Differential pressure min kPa 0.4 kPa 0.4 kPa

max kPa 133 kPa 500 kPa

Temperature min °C 60 °C 60 °C

max °C 90 °C 100 °C

Dimension test specimen HxW m 0.90 m x 0.90 m 0.90 m x 0.90 m


SINGLE PHASE CHARGE AIR TO AMBIENT AIR HEAT TRANSFER

Name Charge Air

Location SÃO PAULO -GUARULHOS

Test Rig nº 10

Cold Fluid Ambient air

Mass flow min kg/h 1000 kg/h

max kg/h 12000kg/h

System pressure max kPa ambient - not controlled

Differential pressure min Pa ± 20 Pa

max Pa ± 3000 Pa

Temperature min °C not controlled (≈ 10)

max °C not controlled (≈ 35)

Hot Fluid Charged Air

Mass flow min kg/h 360 kg/h

max kg/h 3600 kg/h

System pressure min kPa 150 kPa abs

max kPa 350 kPa abs

Differential pressure min kPa 0.4 kPa

max kPa 80 kPa

Temperature min °C 90 °C

max °C 200 °C

Dimension test specimen HxW m 0.90 m x 0.90 m

Structural Test Lab Equipment in these laboratories is used to assess durability and reliability of components and assemblies under a variety of loading scenarios. Tests include vibration single axis, hydrostatic burst test, pressure cycle, thermal cycle, temperature chamber test, erosion, corrosion, field data acquisition and others.


VIBRATION The single axis is used to simulate a field-operating environment or a defined vibration profile requirement. The test procedure is generally used to evaluate durability of systems and components under the mixed loading encountered in the field. The Structural lab has two hydraulic single axles tables, able to run time-domain and frequency-domain signals. Those tables have the following features:

SINGLE AXIS HYDRAULIC VIBRATION TABLES

TEST RIG Nº

TABLE DIMENSIONS

[meters]

Manufacturer / Model

Heating Skid

Main Features

15 0,8 x 0,8 SCHENCK /

10GPM N/A

Dynamic Displacement Range

±50mm

Force 28 kN

Max. Gross Weight 250kg

Degrees of Freedom 1

Frequency Range 10 a 200Hz

Vibration Direction Vertical

Actuator

Piston Area = 25.81cm2)

16 0,8 x 0,8 MTS / 10

GPM -248.05

Air Heating up to 260ºC


±25.4mm

Force 48.9 kN

Max. Gross Weight 500kg ( @ 10G /

100Hz)

Degrees of Freedom 1

Frequency Range 10 a 200Hz

Vibration Direction Vertical

Actuator (Piston Area =

28.5cm2


High Frequency Vibration: is used to simulate a field-operating environment or a defined vibration profile requirement. The test procedure is generally used to evaluate durability of systems and components under the mixed loading encountered in the field. The Structural lab has one High Frequency Vibration table, able to dwell, random-on-random, sine-on-random, and sine-on-random capabilities. Real Data Acquisition and Playback (RDAP). Those tables have the following features:

SINGLE AXIS HYDRAULIC VIBRATION TABLES

TYPE OF TEST

TEST RIG Nº

TABLE DIMENSIONS

[meters]

Manufacturer / Model

Heating /Cooling System

Características Principais

18 1,0 x 1,0 THERMOTRON

DS 642 919S 24HV

Environmental Chamber ( # 19)


±25.4mm

Nominal Force Sinusoidal (peak) Shock ( ½ wave ) Random ( RMS )

6000 lbf (26,7 kN) 3000 lbf (13,35 kN)

5400 lbf (24 kN)

Max. Gross Weight 250kg

Degrees of Freedom

1

Frequency Range 5 to 2000Hz

Vibration Direction Vertical /

Horizontal

24" armature; Effective Nominal Mass Resonance axial Net Weight

145 lb ( 65,8 kg) 2050 hz

+/5 % 1000 lb (453,7 kg)


ENVIRONMENTAL CHAMBER Environmental Chamber to test resistance to thermal cycling. The programmable chamber temperature controller handle cycling, ramp rates and soak times.

ENVIRONMENTAL CHAMBER

Test Rig nº

Dimensions Inside the Chamber HxWxD [meters]

Temp. Range

Manufacture/ Model

Relative Humidity Range (limited by the Dew Point at + 4°C)

Dry Bulb Temperature range

Heating / Cooling Speed

Temperature Control Tolerance (Stabilized Chamber)

19 1,42 x 1,83

x 1,37 -73º to 177ºC

Thermotron F126CHMV

20 to 95% +4 to +85ºC

2ºC / min AVG

between +80º e 40ºC

±2º C

MECHANICAL SHOCK Drop Test ( Test rig nº14) a) DOF: Single Axis b) Drops/Second: approximately 1 sec/drop c) Weight Capability: 100kg d) Drop Height: 40mm


PRESSURE CYCLE Low Pressure Cycle –Glycol

Low Pressure – Liquid Pressure Cycle test rigs are used to simulate in accelerated tests, the operational pressure cycling in Radiators and surge tanks, evaluating welding, brazing, clamping, tanks pressure resistance and others. The structural lab have five test rigs for low pressure liquid pressure cycle as described below:

PRESSURE CYCLE RIGS – FLUID IS GLYCOL

TESTS Test Rig nº

DIMENSIONS (for the UUT) High x width x depth [meters]

TEMPERATURE AND PRESSURE RANGE

FREQUECY RANGE

WAVE FORM

COOLANT HEATING

Low Pressure

Liquid Pressure

Cycle (Radiator, EGR and

DAT)

1 1,2 x 1,6 x 1,0

Amb. up to 120ºC / 0 up to 250kPa 0,25 to 1 Hz S+T+C Glycol Electric

2 3,4 x 2,7 x 1,0

Amb up tp100ºC / 0 up to 250kPa 0,25 to 1 Hz S+T Water Electric

3 1,3 x 1,98 x 0,8

Amb. up to 120ºC / 0 up to 250kPa 0,25 to 1 Hz S+T+C Glycol Electric

4 1,3 x 1,98 x 0,8

Amb up to 120ºC / 0 up to 250kPa 0,25 to 1 Hz S+T+C Glycol Electric

5 1,6 x 1,85 x 0,96

Amb up to 120ºC / 0 up to 250kPa 0,25 to 1 Hz S+T+C Gycol Electric

C= Constant Pressure T = saw tooth S = Sine


Air Pressure Cycle Test Rig

Air Pressure Cycle test rig is used to simulate in accelerated tests, the operational pressure cycling in Charge Air Coolers, evaluating welding, brazing, clamping, tanks pressure resistance and others. The test rig has 4 test cells, pressure independent.

PRESSURE CYCLE RIG –FLUID = AIR

TESTS Test Rig nº



FREQUECY RANGE

WAVE FORM

INTERNAL FLUID

HEATING

Air Pressure

Cycle (CAC) 8

1,7 x 1,87x 1,48

Amb up to 270ºC / up 0 to 500kPa 0,25 to 1 Hz S Air Gas

C = Constant Pressure T = saw tooth S = Sine


High Pressure - Liquid Pressure Cycle Test Rig & Burst Test

High Pressure- Liquid Pressure Cycle test rig is used to simulate in accelerated tests, the operational pressure cycling in Oil Coolers, evaluating welding, brazing, clamping, tanks pressure resistance and others. The test rig has 6 test cells.

PRESSURE CYCLE RIGS – FLUID =OIL

TESTS Test Rig nº



FREQUECY RANGE

WAVE FORM

COOLANT HEATING

High Pressure

Cycle (Oilcoolers)

6 0,9 x 1,2 x 0,9

Ambient up to 90ºC / 0 up to 400kPa 0,25 to 1 Hz T

Oil SAE15W40 Electric

17 1,0 x 1,6x 0,9

Ambient up to 90ºC / 0 up to 400kPa 0,2 to 10 Hz S

Oil MOBIL ATF 200R Electric

C = Constant Pressure

T = saw tooth S = Sine

Test Rig 17 in Burst Test Mode Ramp Pressure Control Pressure up to 1600kPa 1 Test Cell Fluid is Oil Mobil ATF 200R Ambient Temperature


Test Rig 6 - High Pressure Cycle - Oilcoolers Filled with oil SAE 15W40 Sample Capacity : 4 samples can be tested at same time (same pressure) Pressure 1 to 40 bar Freq.: 0.1 to 3.0 Hz. Depends on the unit volume. Maximum temperature : 120 ºC


THERMAL CYCLE Test Rig 11 - Water/Glycol Hot/Cold Thermal Cycle (Radiators Typical) Temperature: -20ºC to 107ºC Flow rate: (300 l/min) Samples capacity : 3 samples at same time Cycle Rate: (10ºC – 107ºC) ~ 45 seconds to 1.0 minute of hot flow, then 45 seconds to 1.0

minute of cold flow.


Test Rig 9 Air Thermal Cycle (CAC Typical) Capacity: 2 cells with 4x4 foot (1.2mx1.2m) windows. Chamber fan can draw ambient air across the core Gas Fired Heated/Chilled Water Cool Cooled air through the core. Temperature range: 110°F to 600°F (43 – 316ºC) Frequency: .0083 to .015 Hz, (1 min/Cycle - 20 min/cycle) Ramp from 120 to 500 F (49 - 260 C) in less than 120 sec. at Charge Air Cooler INLET. Charge air Mass flow: 25 to 35 lbs./min (11 - 16 kg/min) during Hot cycle the flow can varies

during the heating up phase, total flow during the Cold Cycle. Leak Test by pressure decay measurement at set intervals. - Stop at specific pressure.

Monitor for Pressure loss below specific pressure. Data Storage: Frequency and storage time are configurable.


FIELD TESTS & DATA ACQUISITION

Instrumentation and Field Test Data Acquisition (strain, pressure, temperature, flow, vibration),

using the software Catman® and DAQ system MGC-PLUS and/or Quantum, by HBM.


CORROSION

External Corrosion Test Rig (SWAAT)

a) SWAAT test according to:

ASTM – B-117, B-287, B-368,

D-1735; D-2247

ABNT-NBR – 8094, 8823, 8824,

8095

DIN – 50021

ISO - 9227

JIS – Z- 2371

BSI – 7479

AFNOR – A05 – 101

Inner size cabinet:

W 1500x H 860 x D 860 mm ( Net volume 710 liters)

Manufacturer/Model: BASS / CCT-MP-GS-02/2004

External Corrosion Test Rig (SALT SPRAY)

a) Salt Spray Test according to:

ASTM B-77, G-85

DIN 50021

ISO 99227, 12944-5

Inner size cabinet:

W 1160 x H 820 x D 820 mm

Manufacturer/Model: Equilam SSE 800M

Date post:	02-Oct-2020
Category:	Documents
Upload:	others
View:	6 times
Download:	0 times

Modine Brazil Technical Center Laboratory...

Documents