PRODUCTS & SERVICES
Testing climate components
Repeatable and precise tests enable the development of cooling and heating systems
that can withstand extreme load changes and provide excellent performance and efficiency
Media-carrying components must
withstand maximum loads at extreme
low and high temperatures
www.electrichybridvehicletechnology.com // July 2019 // 207
Pressure cycling
tests for
components are
performed in a
climate chamber
Instead of testing cooling and
heating systems in proprietary
test setups or in real operation,
manufacturers can now analyze
their products in pressure cycling
and function test benches.
Repeatable and precise tests
enable products to be optimized
flexibly and economically from an
early stage of development to series
production. In a typical test, the
component is inserted into the test
chamber of the pressure cycling
test bench. This can be an auxiliary
heater for an electric car or valves,
hoses and other hollow bodies that
need to withstand several hundred
thousand load changes over a
period of 15 years.
The test medium is a
water-glycol mixture or pure
glycol such as Glysantin G40,
G44, G48. The cooling circuit
is tested at -40 to 20C (-40
to 68F), the heating
circuit at 20 to 140C
(284F). A specially
developed closed test
media circuit uses
pressure to prevent the
formation of alcoholic
vapors and risk of explosion.
Optionally, an environmental
simulation can be generated in
a climate chamber.
The flow rate of the test medium
can vary from 1 to 10gal/min (1 to 50
l/min) at a pressure of 0.2 to 12 bar
or higher. The load changes are
freely programmable with sinusoidal
or trapezoidal rise at a test
frequency of 0.2 to 2Hz or faster.
The test stand can be used for
complete systems, assemblies and
components made of various
plastics, metals and sealants.
Products made of new materials
can thus be reliably validated.
With the aid of realistic
simulation, the weak points in the
material combination, for example
around a weld seam, are precisely
sounded out to enable optimization.
In addition, Poppe + Pottho
Maschinenbau o ers a function test
bench for electrical appliances such
as cooling and heating units, control
valves, pumps, etc.
At alternating temperatures,
power consumption and
performance are tested – optionally
with low or high voltage power
supply – to simulate operation via
on-board battery and generator or
the traction accumulator. Realistic
tests on the test bench help to
precisely measure and improve the
energy e iciency of the units that
may otherwise cost valuable driving
range since the required electricity
drains the battery.
The test object
is connected to the desired power
supply, either low voltage (0 to
20VDC / 5A) or high voltage (0 to
600VDC / 150A), and the test media
circuit. The test medium circulates
at a freely adjustable temperature
of -35 to 100C (-31 to 212F) and a
flow rate of 1 to 10gal/min. Optional
testing in a climatic chamber at -40
to 140C (284F) simulates
changing ambient temperatures like
those on the vehicle test tracks in
the arctic cold or desert heat.
A comprehensive long-term test
usually takes 20 to 30 days –
depending on the selected
frequency of the load changes. The
temperature and volume flow of the
test medium, as well as the ambient
temperature if the climatic chamber
is used, vary according to the
programmed test cycles. The
temperature at the inlet and outlet
of the test object is measured, as
well as the flow rate, pressure and
pressure drop, current and volt-age
in the high and low voltage range.
The integrated LabView software
from National Instruments enables
e icient data acquisition and
visualization. All test procedures and
data are automatically stored on the
system and can be exported to the
network for evaluation. The open
software structure makes it possible
to integrate additional sensors and
data during testing. Also, as part of
the package, Poppe + Pottho
Group can provide numerous testing
services, remote maintenance and
on-site technicians, if necessary.
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To learn more about Poppe + Potthoff,
visit: www.magupdate.co.uk/PEHV
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