Testing

In the testing group, various investigations are carried out involving the different fields of research. The measurement results obtained are used to validate simulation models and develop suggestions to improve the design. Cutting-edge testing facilities are available, and are described below in more detail.

Engine test stand

Complete measurements of multi-cylinder engines (smaller passenger car size) and single-cylinder test engines can be performed on the engine test stand. The test stand is situated in a cutting-edge test bay with intake air conditioning and compressed air supply, enabling the operation of externally charged single-cylinder test engines with a boost pressure of up to 5 bar.

Hybrid test stand

On the hybrid test bench the entire electrical system within the drive train is investigated. The drive train comprises a DC-to-DC converter, an inverter and an electrical machine. Using the DC-to-DC converter the battery charge vs. state-of-charge (SOC) curve can be mapped. For the inverter, different control methods are available to achieve optimal energy conversion efficiency when controlling the electrical machine.

SCR test stand

One system that is often used to reduce nitrogen oxides in the exhaust fumes of combustion engines is selective catalytic reduction (SCR). During this process a urea solution is injected into the exhaust gas under high pressure, reacting to form the reducing agent ammonium. The reduction of the nitrogen oxides formed during the combustion process in the engine is then accelerated in the SCR catalyst.

Hot gas test stand

The hot gas test stand is used to investigate waste heat recovery systems, thermoelectric generators, turbo generators, exhaust-gas turbochargers and exhaust systems. The high reproducibility of the operating conditions is the perfect basis for producing reliable measurements and consequently providing thorough and reliable information on the setup or system investigated.

Mobile hot air test stand

The test stand is designed for the experimental analysis of expanders and steam boilers for ORC-based WHR systems. The focus is on the reproducible and time-optimized measurement of the components and the modification of special measurement technology. Besides a self-sufficient hot air supply the test stand has an optimized design that enables its adaptation to the exhaust tract of combustion engines.

Mini block heat and power plant test stand

A testing facility to investigate different mini CHP concepts offers the possibility to visualize the heat requirements of a single-family home. The flexible integration of the components means that different heat sources and storage concepts can be combined, and their interactions can be investigated.

Heat storage test stand

The main component of the test stand is the adsorber vessel, which allows the examination of a defined bulk material made of zeolite granulate. Here the amount of bulk material is considerably higher than in the usual laboratory scale, enabling realistic conditions for tests on thermochemical storage configurations. The test stand setup enables the measurement of complete storage cycles (adsorption and desorption), paving the way towards application.

Testing methodology

In the field of testing methodology, customer-representative and time-optimized testing procedures are developed on the basis of real driving data, taking all known influencing factors into account. The resulting testing methods can then be cost-efficiently implemented in the testing facilities of the Project Group for New Drive Systems.