Test Benches for Components and Systems

On the IPEcomp validation test bench for automotive refrigerant compressors, both electrically (eKMV) and mechanically (mKMV) driven DUTs can be subjected to performance and endurance tests. By mounting the test item on a mechanically decoupled, seismic mass, NVH tests on the test item are also possible.

Our IPEload load units are compact systems for the thermodynamic load testing of automotive refrigerant compressors. The IPEload can be used to test both electric and mechanical compressors under various thermodynamic load conditions. Our load units are characterized by their low power consumption, since no evaporator power has to be applied to the refrigerant circuit.

Our range of services also includes system test benches and individual air conditioning modules. Complete vehicle air conditioning circuits with their components and various refrigerants can be tested under real environmental conditions on system test benches. Thanks to their modular design, the test benches can be flexibly adapted to different air conditioning systems, thus reducing set-up times. The use of so-called test carts plays a particularly important role here. This means that a new circuit can be set up on its trolley outside the test stand while tests are still being carried out on the test stand with another circuit. This not only makes more effective use of the setup time, but also reduces the downtime of the test stand. The necessary media supply modules for air conditioning and coolant circuits (IPEsim) can be individually assembled and operated according to customer requirements. Temperature, humidity and air mass flow are set with a very high control quality and accuracy to ensure reproducible test results.

For technical, regulatory, or logistical reasons, it is not always possible to integrate the actual vehicle components in the coolant circuit on the test bench for validation. This often concerns electrical components such as batteries or power electronics. The IPEsim coolant circuit simulation module has been developed for cases like these to simulate individual components in the coolant circuit of a modern hybrid or electric vehicle and thus replace them in the test bench application. After the connection to a recooling circuit, the IPEsim can simulate both heat sinks and heat sources. It automatically controls the process variables such as cooling and heating capacity, flow temperature, volume flow, system pressure, and pressure drop flow. The system is conveniently operated via a master computer, e.g. with our IPEmotion software, or via the integrated PLC touch panel. Depending on the application, different test circuit volumes are possible and recooling can be active (with integrated refrigeration system) or passive. For passive recooling, the minimum test item temperature depends on the flow temperature of the recooling medium.

The IPEflush high-performance flushing device has been developed to ensure the reliable measurement of the oil circulation ratio. IPEflush cleans the test circuits or individual components from any residual oil. The device uses a multi-stage flushing process to separate out – virtually residue-free – all the oil, dirt particles, and other contaminants retained throughout the various refrigeration circuits. A liquid refrigerant - R134a - is used as flushing medium since it binds most of the oils used in the automotive sector.

With the IPEcomp validation test bench for automotive refrigerant compressors, both electric and mechanical refrigerant compressors can be tested for performance and endurance. By mounting the compressor on a mechanically decoupled seismic mass, NVH tests are possible as well.

The IPEvalve component test bench has been developed for high-standard automated performance or endurance tests for various automotive refrigerant circuit valve types. The version for functional tests includes a device for measuring and controlling the oil circulation rate (OCR) at various points in the circuit (unlike the version for endurance tests). In addition to the superheat of the refrigerant in the suction line, the low pressure and the high pressure can also be controlled. The control of the valves is customized, e.g. via LIN bus or a PWM signal, and operated via the integrated PLC, in which all control parameters and software limit values are stored. The integrated safety system automatically switches off the test bench if the set limit values are exceeded or if a refrigerant leakage is detected. The test bench is operated via a central computer on which the IPEmotion test bench software with the corresponding test bench configuration is pre-installed. By connecting the test bench to a coolant system, it is recooled. Since the test bench performs pressure holding tests independently, the connection to a nitrogen cylinder is necessary. The integrated vacuum pump as well as the refrigerant extraction station facilitate the test bench setup.

Component development in "mini format"! The little brother to the IPEcomp is the IPEload auto. As already mentioned with the IPEcomp, this product can be used to determine the properties of the test specimen. Here the focus is more on durability and lifecycle performance. This is realized by means of Raffertests specified in the customer's specifications, or the determination of the test matrix is worked out individually with the expertise of IPEengineering. Due to the small installation space and the resulting low space requirement, this load box can be used for other development-relevant topics around the refrigerant compressor. In conjunction with a separate climatic test cabinet, the test specimen can be subjected to various temperatures, both in the positive and negative Celsius range.

In the modern development of vehicle air conditioning and in connection with thermal management, the technical design or the validation of the function of the refrigerant compressor is the focus of the holistic development process. Especially due to the changing requirements in the automotive sector, it is indispensable to reproduce a flawless function of the test item to be tested by means of reliable test bench equipment. Be it in the classic AC mode or in the now increasingly important heat pump mode. The interaction of sustainable hardware in the test bench and the coordinated control in the form of the in-house software IPEmotion make this test bench a unique product in the service sector of the automotive industry.

In the context of application and measurement tasks, it is sometimes necessary to design and manufacture special hardware solutions. In addition to experienced employees, a comprehensive range of machinery is available for this purpose.

In the early development phase of the electric refrigerant compressor, a variety of assurances for durability, efficiency and performance are necessary even before the actual design and process validation tests. For this purpose, there are test cases that require flexibility in their requirements and mapping while maintaining high quality standards. Here, IPEengineering's experience in handling such complex setups is unique in the service field. Through a strong team of engineers and technicians who have built up years of experience in the evolution of refrigerant compressors, the development accompanying tests from the start of development to the finished product provide a complete package in the service sector of the automotive industry.