Novel dynamic conditioning unit for the reproduction of real driving conditions on a test bed
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ORIGINAL PAPER
Novel dynamic conditioning unit for the reproduction of real driving conditions on a test bed Stefan Geneder1 · Günter Hohenberg1 Received: 4 June 2020 / Accepted: 25 August 2020 / Published online: 28 October 2020 © Springer Nature Switzerland AG 2020
Abstract The importance of thermal management has increased with the advent of electrification and fuel cell. The dynamic response required from the thermal circuit has also increased and cannot be reproduced by today’s conditioning systems. This contribution describes a novel, considerably more powerful conditioning concept with three main characteristics: – The positioning of the control actuator on the side of the unit under test without causing changes in the hydraulic circuit. The exchange of heat in this configuration occurs through mixing. – Model-based control including improved temperature measurement as the basis for the robust variation of fluid temperature.
– A small and compact design through the consequent optimization of component location. This has the effect of further improving the dynamic response and offers great flexibility in practical use.
The new conditioning concept is validated via simulation as well as by an application on a powertrain test bed. The system proved to be extremely robust in its function due to the consideration of all influencing parameters and, in addition, it is easy to use: no time-consuming configuration work is required prior to installation, nor when changing the test bed or the unit under test. The foundation for this is the model-based control that is based on a direct relationship between the temperature of the medium and the setpoint value. For the first time, temperature traces previously measured under real operation conditions can be reproduced and even temperature gradients of up to 60 K/s can be followed. The dynamic conditioning unit described here will be extended by a transient, real-time capable simulation model to a thermal emulator. This will enable future thermal management functions to be developed and optimized in ThermoLabs. Keywords Media conditioning · RDE · Test bed · Radiator emulation · Model-based control
1 Introduction Although, nowadays, the transfer of mechanical loads from the road to high dynamic test beds is feasible, thermal loading of the powertrain has not been sufficiently considered. The importance of thermal management has increased due to higher demands on power efficiency and the advent of electrified powertrains. The usage of electrical actuators such as electrical valves and pumps in a cooling circuit leads to high
* Stefan Geneder stefan.geneder@ivd‑hohenberg.at 1
IVD Prof. Hohenberg GmbH, Graz, Austria
dynamics with temperature gradients up to 60 K/s as well as operating point-dependent cooling temperatures, cf. Beidl et al. [1]. The current practice of constant media conditioning to emulate is now insufficient. For a realistic thermal behaviour of the unit under test at a test bed, a dynamic media conditioning is required. This paper presents a novel d
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