Innovation Days Efficient Dynamics. Energy and Environmental Test Centre.
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1 Innovation Days Efficient Dynamics. Energy and Environmental Test Centre.
2 Workshop: Environmental Wind Tunnel.
3 Environmental Wind Tunnel.
4 Environmental Wind Tunnel.
5 Environmental Wind Tunnel.
6 Environmental Wind Tunnel: specifications. Plenum: 14 m x 10 m Temperature range: -20 to +55 C Relative humidity controllable in the range 5-90%, from +5 C Four-wheel dynamometer with max. power 750 kw Max. wind speed: 250 km/h Nozzle: W x H 3.5 m x 2.4 m = 8 sq.m. Fan diameter: 4750 mm Max. rpm: 518 rpm max. power: 2060 kw Solarium: 400 to 1200 W/m2 Moving belt: L x W 2.7 m x 0.55 m Rain simulation at speeds up to 250 km/h Snow simulation at up to 160 km/h
7 Range of tests performed in Environmental Wind Tunnel. Thermal reliability Components/ structure Cooling performance Powertrain Brake cooling ECU functionality Operational and functional performance testing under a variety of environmental conditions Altitude simulation Water management Battery charging performance Snow simulation Emissions performance at altitude Engine calibration Low-temperature performance Off-cycle emissions Cold-start testing Crankcase icing Heating/climate control development Function-testing of heating and climate control systems Comfort enhancement of heating and climate control systems Power management/thermal management Power management strategies Thermal management strategies Powertrain electrification Fluid management
8 Environmental Wind Tunnel. Objective: Move testing into the ETC, while at the same time continuing to ensure reliability and safety under all weather conditions Focus Environmental wind tunnel: Simulation of extreme environmental conditions heat, cold, sun, rain, snow
9 Complex environmental simulation. Free body analysis of interaction between vehicles and a wide range of climatic conditions Transfer of partial realities to test bed
10 Slope gradient [%] Energy and Environmental Test Centre (ETC). Climate testing in the laboratory around the world in eight hours C - 5 C +3 C +15 C +25 C +35 C 14 V [km/h]; Humidity [%] AC off AC 25 C AC max VOKO Zeit [min] engine engine engine engine engine engine off on off on off on vehicle speed [km/h] humidity [%] slope gradient [%]
11 Range of tests in the Environmental Wind Tunnel. Solar simulation Calibration of air conditioning system Rain simulation A-pillar water management / keep mirrors and side windows free of water / windshield wiper design / wet response of brakes / headlights fogging Snow simulation Snow deposition on sensors, air inlets, headlights Motorcycle belt Cooling performance testing, weatherproofing
12 Environmental Wind Tunnel rain simulation. Water exposure testing (full vehicle) using rain rig.
13 Environmental Wind Tunnel rain simulation. Water exposure testing (full vehicle) for optimised wiper design.
14 Improvement of A-pillar water management. Optimisation of braking system wet response.
15 Environmental Wind Tunnel snow simulation. Snow making (full vehicle) using snow gun.
16 Environmental Wind Tunnel snow simulation. Snow deposition on vehicle front and rear, headlights and sensors.
17 Ensuring snow simulation quality in the ETC.
18 Environmental Wind Tunnel motorcycle flatbelt. Simulation of extreme weather conditions: heat and rain Testing portfolio on flat belt: cooling system performance, weatherproofing Distinctive feature of flatbelt: front wheel is moving, rolling road under the motorcycle ensure realistic simulation of airflow at the engine cooling system ensure realistic simulation of water spray
19 Energie- und umwelttechnisches Versuchszentrum (EVZ). Intelligent energy management at ETC. Recycling of electrical energy from the dynamometer and the fan Optimal synchronicity between test cells Maximum isolation of test cells Refrigeration equipment design/optimisation based on the cascade principle Free cooling with outside air
20 Thank you for your attention.
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