Vehicle Endurance Testing

With its NVH system test bench, IPETRONIK offers the possibility of recording and analyzing the noise development at the HVAC (air conditioning unit) using in-house acoustic measurement technology. For this purpose, microphones are placed in the near field of local sound sources and, if necessary, the so-called acoustic camera (GFAI, see figure on the right) is used for sound localization. Sensors for vibration and pulsation of the refrigerant can also be placed in the system.

The acoustic development of automotive components benefits significantly from the interaction of testing and simulation. While general experience and analyses of measurements form the basis for new developments, simulation allows the evaluation of components and concepts in advance, independently of time- consuming and cost-intensive hardware. Thus, it is possible to select from several designs, weak points can be identified and avoided at an early stage. Thus, the parallel management of simulation and testing allows a constant mutual optimization - the quality of each hardware construction stage benefits from the previous simulation; likewise, the accuracy of the simulation models can be optimized by comparison with the subsequently available measurement data.

Starting with consulting and system procurement, we take over the entire project management. We install the measurement technology, including cabling and the complete application of sensors and actuators. Configuration and data evaluation are just as much part of the scope of services as calibration, functional testing and subsequent dismantling of the test vehicles. A modern technology center and an experienced team of application engineers and mechanics are available specifically for this purpose. In the course of the steadily growing importance of hybrid systems and electric vehicles, we have developed our own high-voltage hardware solutions for current, voltage and temperature. These allow all relevant measured variables to be recorded via IPEmotion or our CAN bus data logger. They can also be integrated into existing CAN bus systems. In the context of the development of hybrid systems and electric vehicles, these are becoming increasingly important. Thanks to TÜV certification of our HV measurement technology as well as continuous further education and regular training in the high-voltage field, we guarantee the highest level of quality and safety. A separate area is available for the safe upgrade of electric and hybrid vehicles.

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.

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.

IPETRONIK offers its customers innovative options for the pre-development of refrigeration and coolant circuits, combining the advantageous features of a test bench setup with the flexibility of vehicle measurements: We build customer-specific vehicle subsystems in a vehicle body with extensive measurement technology. This allows system characteristics of new bodies to be experienced directly in the passenger compartment during measurement operation, which otherwise (as usual) only have to be interpreted on the basis of test bench measurement data. In addition, development carrier vehicles of this type can also undergo measurements in the climatic wind tunnel, on test tracks or in stationary operation. Our prototype workshop enables concepts to be realized at an early stage of development, when only a few components are available.

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.

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.

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.

In our strain gauge laboratory we apply any kind of components. By means of strain gauges, we record a wide variety of parameters. With the information gained from this, we can make targeted changes to prevent material fatigue, for example. We also advise on the optimum positioning and calibrate the strain gauges and the complete measurement chain. Special torque applications including telemetry are also part of our services.