Electric & Hybrid Vehicle Technology - July 2021
E-mobility test systems (Poppe + Potthoff)
2021-07-21 03:43:11
High-performance technologies designed for the development of thermal management and cooling systems
►► For measuring the strength and durability of components in automotive engineering, it requires precise and high-performance specialist machines. Poppe + Potthoff Maschinenbau (PPM) designs and manufactures test stands for this requirement with its high-pressure and test technology used in research, development, and production.
The portfolio includes test stands for measuring bursting pressure and tightness, impulse testing, autofrettage, as well as automated testing. In addition, comprehensive component tests are also offered as a service.
To prove the quality of media-carrying components, drive units (e-motors), valves, cooling and heating systems, hose lines, pipes, pressure vessels and other components are pressurized. Poppe + Potthoff Maschinenbau offers testing solutions individually tailored to any specific requirements. This includes dynamic pressure cycling tests, static pressure holding tests, flow measurements or classic burst pressure tests. In addition to pressure and service life tests, PPM’s test benches offer the ability to perform a function test on live components. The focus of this feature is to highlight efficient energy management and performance under changing temperature conditions.
In a typical test, the component is inserted into the test chamber of the pressure cycling test bench. This can be an auxiliary heater for an electric car or valves, hoses and other hollow bodies that need to withstand more than 100,000 load changes over the lifetime of the vehicle (up to 15 years). The test medium is a water-glycol mixture or pure glycol (for example Glysantin G40, G44, G48). The cooling circuit is tested at -40°C to +20°C (-40°F to +68°F) while a heating circuit is tested in temperatures from +20°C to +140°C (68°F to 284°F). A specially developed closed test media circuit uses pressure to prevent the formation of alcoholic vapors (which create a risk of explosion). A system can also be analyzed in a climate chamber.
In addition, Poppe + Potthoff Maschinenbau offers a function test bench for electrical appliances such as cooling and heating units, control valves and pumps.
Power consumption and performance are typically tested at alternating temperatures – optionally with a low- or high-voltage power supply to simulate operation via onboard battery and generator or the traction accumulator.
In many EVs, the heating and cooling systems drain the battery and negatively affect the vehicle’s range. Comparison of test results before and after a load test on the pressure cycling test bench can show how power consumption and performance change over the vehicle’s service life. The test object is connected to the power supply (low voltage 0-20VDC/5A) or high voltage (0-600VDC/150A) and the test media circuit. The test medium is circulated at a temperature of between -31°F to +212°F (-40°C to +100°C) and a flow rate of 1-50 l/ min. The test can also be carried out in a climatic chamber at -40°F to +284°F (-40°C to +140°C) simulating changing ambient temperatures.
FREE READER INQUIRY SERVICE To learn more about Poppe + Potthoff, visit: www.magupdate.co.uk/PEHV
©MAB - Aviation & Auto. View All Articles.