SIMULATION SOLUTIONS TEST SYSTEM SOLUTIONS Electrification TESTING Battery EQUIPMENT E-Motor Dynamometers and Actuators Power Electronics Test Vehicle Systems Testbeds Component Test Cell Mechanics Test and Control SystemsRooms MBD Media on Conditioning the virtual testbed Consumption Engine Measurement End Injection of Line Testing Combustion Real Measurement Life Driveline Emission Analysis and Measurement Fuel and Lube Test In Vehicle Systems Measurement Emission and Certification Vehicle Racing TESTING EQUIPMENT SIMULATION TOOLS TESTING TOOLS AVL Media Conditioning Systems APPROACH The performance of combustion engines strongly depends on media conditions. For better reproducibility under almost real conditions, highly dynamic control of the media conditioning units is necessary. For 30 years, AVL has intensively developed different compact conditioning systems and technologies used in high-end engine test cells. Where standard systems are not sufficient, AVL designs customerspecific units. BENEFITS AT A GLANCE The Modular design ensures applicability in a wide range of testing. Various modules are available for different applications High control accuracy in steady state and dynamic mode ensures exact data from the test procedure and increases the testbed efficiency Extreme temperature and pressure ranges for simulating conditions at the test bench, which are hard to achieve on the road Easy integration with the automation system enables quick initialisation (Plug & Play using AVL ActiveLink ) Good repeatability allows rapid achievement of the development goal Minimized downtime with robust and reliable design Short commissioning time Flexible use due to mobile design Less maintenance work required TASK The thermodynamic and mechanical behavior of a combustion engine is influenced by the combustion of air and the engine fluids. The relationship between temperature and pressure in fluids and gases offers great potential for the development of different applications. Test consistency and reproducible conditions are in high demand, particularly for exhaust emissions. Compared to application on the road, there are normally constant ambient conditions in a test cell. To prepare the engines for these real situations (see RDE), it is necessary to simulate different conditions such as altitude or climatic conditions in the test cell. High reliability and reproducibility of control and measurement results over a wider range of applications is needed to achieve high testing efficiency. CUSTOMER SERVICES / 122
MORE THAN 1,500 SYSTEMS ALL OVER THE WORLD IN DIFFERENT S UNDERLINE THE PERFORMANCE AND RELIABILITY OF THE AVL MEDIA CONDITIONING DEVICES. REFERENCES ConsysAir applications The combustion air conditioning system has been delivered 600 times around the world. There has also been a large number of customized systems for extreme conditions. Pressure ranges from 400 to +200 mbar and temperatures from 40 to +90 C. ConsysBoost applications The boost air conditioning system is designed as a secondary cooled heat exchanger or as a spray version for pressures up to 5 bar and temperatures of 200 C or more. Units with a cooling power of up to 250 kw have already been delivered. ConsysCool applications AVL coolant conditioning systems are installed at 1,000 test cells worldwide. The application is used in end-ofline, research and high dynamic racing test cells. ConsysLube applications The oil conditioning system is installed in engine test cells, single cylinder research engines and gearbox test cells. / 123
SIMULATION SOLUTIONS TEST SYSTEM SOLUTIONS Electrification TESTING Battery EQUIPMENT E-Motor Dynamometers and Actuators Power Electronics Test Vehicle Systems Testbeds Component Test Cell Mechanics Test and Control SystemsRooms MBD Media on Conditioning the virtual testbed Consumption Engine Measurement End Injection of Line Testing Combustion Real Measurement Life Driveline Emission Analysis and Measurement Fuel and Lube Test In Vehicle Systems Measurement Emission and Certification Vehicle Racing TESTING EQUIPMENT SIMULATION TOOLS INTAKE AIR CONDITIONING AVL ConsysAir The intake air conditioning AVL ConsysAir is a conditioning system to control the main parameter of the combustion air. Independent of the engine speed and torque, temperature and humidity are kept within small tolerances. To control the pressure under dynamic conditions, AVL offers the Dynamic Package with a very short delay time (< 3 sec.). CONTROL PRINCIPLE The intake air temperature is adjusted by cooling and heating and the humidity by cooling and moistening. The desired pressure is increased by the blower or decreased with throttle valves. An internal air re-circulation system also provides high control response at low air flow rates. There is broad range of applications covered by the five standard units. For special applications, tailored systems can be delivered. The customer can choose between THP stationary (ACS-Mode closed air inlet to the engine) or TH dynamic (TCS-Mode open air inlet to the engine). Climate chambers and altitude simulations of several thousand meters enable simulation of extreme conditions on the testbed. BENEFITS AT A GLANCE The dynamic package allows high dynamic test runs with a near-zero delay time Optimized investment costs through parallel operation of two-or-three testbeds with one ConsysAir The high repeatability of the measuring values increases the efficiency of the test cell Wheels allow a flexible usage on different testbeds A tested interface to the AVL PUMA Open system ensures short commissioning time Installation example of an AVL ConsysAir together with an Air Mass Flow Meter (AVL FLOWSONIX ) and with the Dynamic Option. A short connection line improves the performance of the whole system. A maximum length of 12 m should not be exceeded. TESTING TOOLS CUSTOMER SERVICES / 124
COOLANT CONDITIONING AVL ConsysCool The coolant conditioning system AVL ConsysCool with combined primary and secondary circuit control is used to bring the coolant of the Unit Under Test (UUT) to a freely definable temperature and keep it within tight limits. Integrated electrical heating supports the pre-heating and improves the control stability. CONTROL Integrated control loops and algorithms are optimized for various requirements on steady-state and dynamic/transient testbed tasks. Besides temperature control, the unit further enables exact simulation of coolant pressure and flow behavior (e.g. radiator, cooling pump). The wide range of configurations of the AVL ConsysCool meets the requirements of nearly all automotive testbed applications. In endof-line tests, friction tests, high-dynamic racing engines and all kind of cooling loops in electrification components, the AVL ConsysCool supports the engineers to solve their development and certification tasks efficiently. BENEFITS AT A GLANCE One system for a wide application range due to its modular design and several options Easy integration into the automation system (AVL PUMA Open ) with a comfortable device user interface (ActiveLink ) Integrated controllers ensure flexibility in operation High reproducibility due to great control accuracy for steady-state and dynamic operation, ensures short development time Robust design in stainless steel piping for a long lifetime and, therefore, lower operating costs Compact build and easy installation in the test cell or false floor due to its very compact design The main components are installed in the bottom part of the system CC-200/450. This allows the separation from the upper part (electric panel, expansion tank) and the placement in the intermediate floor. More space in the test cell is the benefit. / 125
SIMULATION SOLUTIONS TEST SYSTEM SOLUTIONS Electrification TESTING Battery EQUIPMENT E-Motor Dynamometers and Actuators Power Electronics Test Vehicle Systems Testbeds Component Test Cell Mechanics Test and Control SystemsRooms MBD Media on Conditioning the virtual testbed Consumption Engine Measurement End Injection of Line Testing Combustion Real Measurement Life Driveline Emission Analysis and Measurement Fuel and Lube Test In Vehicle Systems Measurement Emission and Certification Vehicle Racing TESTING EQUIPMENT SIMULATION TOOLS TESTING TOOLS OIL CONDITIONING AVL ConsysLube The oil conditioning system AVL ConsysLube conditions the engine or transmission lube oil temperature and oil supply pressure to a pre-definable set value and keeps it within a certain tolerance at steady state and dynamic operation of the unit under test (UUT). The effective temperature value can be taken at the device or preferably at the UUT. The effective pressure value must be taken at the UUT. Electrical heating is incorporated for preheating the lube oil and better control dynamics in transient operation. CONTROL PRINCIPLE The PID control is carried out by an external system (e.g. AVL PUMA Open ). The temperature control is performed by a mixing valve (heat exchanger/electrical heating). The supply pressure control is handled by a control valve in the bypass between the supply and return lines to and from the unit. The main applications for ConsysLube are engines up to 400 kw, with customized solutions for larger engines. Several connection modes and unit options allow different applications like oil pan conditioning, oil pressure control and pre-heating. For oil conditioning on gear boxes, the AVL ConsysLube can also be used. All components are installed in a compact frame with wheels and covers. This allows a flexible use in different test cells. The arrangement of the components at the bottom of the unit ensures that the oil level in the oil pan is always higher than in the conditioning unit. Oil backflow to the oil pan is therefore prevented. BENEFITS AT GLANCE Stainless steel tubing avoids dissociation of rust particles and guarantees long service life High control accuracy and dynamics increase the testbed efficiency Faster control response thanks to primary controlled oil circuit The compact design enables installation close to the unit under test (engine or transmission) and, therefore, keeps the external oil volume small Flexible in applications due to several connection modes, such as connection to the oil sump or to the oil pressure circuit CUSTOMER SERVICES / 126
BOOST AIR CONDITIONING AVL ConsysBoost The boost air conditioning system AVL ConsysBoost conditions the boost air temperature to a pre-definable value and keeps it within a tight tolerance range mainly for steady state applications, or at least those with constant demand values. The boost air from the turbo charger is indirectly conditioned by controlling the cooling water flow on the secondary side of the heat exchanger. CONTROL PRINCIPLE The boost air temperature control is performed indirectly by controlling the cooling water flow through the heat exchanger. A circulation pump ensures an adequate flow of cooling water in the heat exchanger even for low-power applications. In addition, this pump improves control behavior by returning the heated cooling water to the heat exchanger inlet. BENEFITS AT GLANCE The precise adherence to a pre-defined boost air temperature significantly improves the reproducibility of measurements on turbo-charged combustion engines and, therefore, increases the testbed efficiency The ability to simulate different pressure losses for different vehicle intercoolers allows use on a wide range of engines The compact and mobile unit can be moved to different testbeds, saving investment costs by eliminating the need for extra units Space-saving installation close to the engine by separating the conditioning part from the heat exchanger For simulating the pressure drop of different engine intercoolers, a valve is installed between the AVL ConsysBoost and the engine intake duct. The standard ConsysBoost 1200 or 3000 units are basically designed for stable temperature control during a steady state or dynamic engine operation. Alternative solutions, such as spray variants or intermediate circuits, are available for simulating dynamic temperature profiles. The AVL ConsysBoost is installed in the test room, close to the engine for a fast response time and good control stability. To save space around the engine, the intercooler and stand can easily be removed from the conditioning unit and located separately, close to the engine. / 127