Thermal Management

Thermal management is a key topic in vehicle development that is taken into account in the development process right from the start. Valuable development steps can be taken at an early stage on a TC5:E5hermomanagement system test bench. By integrating calculation models and simulators/emulators, qualitative statements on systems, components and control strategies for cooling, heating and refrigeration circuits could be made at an early stage of development (without a vehicle). In addition, early testing of operating strategies is possible. In further phases of development (including series production support), problems can be reproduced and causes investigated in a reproducible environment.

Thermal management is a key topic in vehicle development that is taken into account in the development process right from the start. Valuable development steps can be taken at an early stage on a thermal management system test bench. By integrating calculation models and simulators/emulators, qualitative statements on systems, components and control strategies for cooling, heating and refrigeration circuits could be made at an early stage of development (without the vehicle). In addition, early testing of operating strategies is possible. In further phases of development (including series production support), problems can be reproduced and causes investigated in a reproducible environment.

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.

As a reliable partner with many years of experience, we offer all-round service in the field of vehicle testing. Our core competencies lie in the successful organization of vehicle and endurance tests. This includes planning, execution and analysis. In addition to testing under extreme conditions, we also carry out tests on individual components. In doing so, we always act according to our core values of efficiency, quality, adherence to schedules, flexibility and customer orientation. This enables us to meet even the most demanding requirements.

With the Quiet Air Test Bench, IPETRONIK offers the possibility of testing air-flow systems and components. The Quiet Air Test Bench has established itself as a multifunctional tool for testing vehicle ventilation. The focus here is on aeroacoustic and flow-physical issues. The compactness and mobility of the test bench allow the realization of various test architectures from standardized to specific setups. The in-house developed test rig is used solo, but also in combination with other test equipment. Acoustic chambers and climatic-acoustic chambers are available for aeroacoustic tests.

In the age of e-mobility, the refrigerant circuit serves not only to provide comfort air conditioning for the passenger cabin, but also to cool the electric drive train and the battery. It thus becomes one of the central subsystems of the vehicle and must be taken into account from the very beginning of development. Since neither vehicles nor subsystems are usually available at this early stage, the ducts, evaporators and other heat exchangers are built geodesically. The powertrain and battery are represented by emulators, and conditioned air is applied to the indoor evaporators. The air path for the condenser simulates temperature and driving speed. This allows caloric (performance) evaluation of the system, testing of different interconnections, comparison of different components, and development of operating strategies.

The measurement of thermodynamic properties of refrigerant circuit components is of great importance in the development of automotive components (and systems). Our measurement results are often used as a basis for decision-making for series production as well as for the analysis of optimization potentials or unique selling propositions. As a manufacturer- independent test center with many years of cross- industry experience in the field of thermodynamics, IPETRONIK offers component measurements including well-founded evaluations. OEMs and Tier 1 suppliers as well as development partners benefit from our services.

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.

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.

One of the state of the art topics in the development of electric refrigerant compressors is the analysis of the conductivity, or the influence, of the compressor oil on the stator windings and the associated insulation resistance. With the equipment shown in the picture, a sample can be analyzed automatically and evaluated with the help of the associated software.

In addition to the analysis of the compressor oil, the measurement of the insulation resistance is not only one of the technologically important topics, but also one of the safety and, conversely, product liability of a refrigerant compressor. Here, too, IPETRONIK positions itself centrally in the overall development of the main compressor component. In test methods or test procedures developed with customers, either the entire test item or only its stator is tested for insulation resistance.

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.