Gaseous and liquid media significantly influence the behavior of the UUT. To ensure high precision and reproducibility in testing, conditioning systems are essential as they bring these media into a selectable and predefined range.
Stable environmental conditions are crucial for achieving accurate test results. Conditioning systems provide these stable conditions conveniently and reliably by using conditioned media. This stability is essential for maintaining test precision and reproducibility.
When UUT development occurs in multiple locations, media conditioning systems ensure that testing conditions remain comparable. This consistency is vital for reliable development, calibration, and certification processes.
Accuracy
High control accuracy in steady-state and dynamic mode increases testbed efficiency.
Reproducibility
Good reproducibility allows a fast achievement of development goals.
Conditions
Emulate/ Simulate/ Replicate extreme temperature and pressure conditions on the testbed which is hard to achieve on the road.
Automation
Easy integration into the automation system enables a quick installation (plug & play).
To accurately simulate extreme driving conditions on the testbed, media conditioning systems must create extreme media conditions. This capability is essential for conducting precise and effective tests.
Efficiency on the testbed is significantly enhanced by the timely establishment of initial conditions. Oil and coolant conditioning systems facilitate rapid cooling of the UUT at the conclusion of each test cycle. This rapid cooling process allows for an increased number of tests, such as cold start tests, to be conducted within a given time frame.
Key Features of our media conditioning systems:
- Modular Design: Our systems are designed to be modular, offering exceptional functional expandability to meet diverse testing needs.
- Compact and Mobile: The compactness of our systems ensures high mobility and versatility on the testbed, making them easy to integrate and use.
- Robustness and Durability: Engineered for maximum dynamics and control quality, our systems are exceptionally robust and built to last. With an installed base of over 4,000 systems, their quality and durability are well-proven.
AVL thermal conditioning systems are optimized for dynamic performance and control quality. They enable precise simulations and enhance the overall efficiency of the testbed by allowing more tests to be conducted in less time.
ICE | Transmission | Battery | E-Motor | Power | Fuel Cell | |
| Coolant | ✓ | – | ✓ | ✓ | ✓ | ✓ |
| Boost Air | ✓ | – | – | – | – | ✓ |
| Oil | ✓ | ✓ | ✓ | ✓ | ✓ | – |
| Intake Air | ✓ | – | – | – | – | ✓ |
| Exhaust Back Pressure | ✓ | – | – | – | – | ✓ |
| Altitude Simulation | ✓ | – | – | – | – | ✓ |
AVL ConsysCool Dynamic
The ConsysCool Dynamic revolutionizes the control of e-drive cooling fluids, ensuring precise adherence to temperature and pressure levels with unmatched accuracy and responsiveness of 6 K/s. It has a capacity of 20 kW to 60 kW and handles temperatures from -25°C to +120°C, providing flexibility for different test conditions. It integrates real-time simulation with hardware-in-the-loop (HIL), effectively simulating refrigerant circuits, e-motors, batteries, etc. This accelerates development by enabling testing of individual components and complete cooling systems, evaluating thermal comfort for parts and passengers under real-world driving conditions on a testbed before moving to more costly wind tunnel or road testing. Therefore, the ConsysCool Dynamic is a key feature of the AVL ThermalLab™.
AVL ConsysActive
Refrigeration units are critical to climatic testing, providing precise cooling for optimal test gradients while maintaining energy efficiency. The AVL ConsysActive products feature efficient compressor control, ensuring that testing conditions are met without excessive energy consumption. Our ConsysActive conditioning units are available with refrigerants with a Global Warming Potential (GWP) of less than 2500, and also in a CO2 version for environmentally friendly options. Air handling modules regulate the air within a walk-in climatic chamber or remote climatic box, ensuring consistent environmental conditions throughout the testing process. These features make ConsysActive an ideal choice for efficient, sustainable and accurate climatic testing solutions.
If standard media conditioning systems do not fully meet your requirements, we offer customized solutions tailored to your specific testing environment. Whether it involves a special design, the use of unique materials, or compliance with custom safety standards, we adapt our systems to fit your needs precisely.
Our customization options cover everything from individual thermoregulators and temperature control units to complete product series. For end-of-line testbeds, we provide customized fill and drain solutions. Additionally, we can integrate customer-specific components from various suppliers, streamlining spare parts management and maintaining optimal productivity.
Adaptation
Adaptations to special building interfaces.
Customization
Customization of temperature, pressure, flow or power range.
Requirements
Tailored to requirements regarding control dynamics and control accuracy.
AVL ConsysCool
The AVL ConsysCool is a versatile solution for diverse testing needs, excelling in precise coolant temperature control for development, certification, end-of-line testing, and dynamic race car engine applications. It maintains strict temperature limits for optimal performance and reproducibility. Its integrated electric heating system enables rapid preheating and enhances control dynamics, offering high accuracy in both steady-state and dynamic modes. ConsysCool also provides additional options to meet specific requirements, with a cost-effective coolant conditioning unit available for less demanding tasks like endurance testing.
AVL ConsysBoost
AVL ConsysBoost ensures precise conditioning of the UUT’s boost air to a predefined temperature with exceptional accuracy, maintaining a constant boost air temperature regardless of the UUT’s operational state. The system replaces the original vehicle intercooler with an industrial water/air intercooler and features an adjustable flap to simulate pressure drops across various boost air coolers, ensuring compatibility with a wide range of UUTs. For cases where the original intercooler must be retained, AVL offers alternatives like spray conditioning systems and intercoolers integrated into water jackets, providing flexibility for specific testing needs.
AVL ConsysLube
The AVL ConsysLube is designed for precise control of oil temperature and pressure across various applications. Its integrated electric heating system provides quick, safe preheating and enhances control accuracy under dynamic conditions. Suitable for internal combustion engines, gearboxes, and oil-cooled electric drive components, it offers customizable connection options. Connected to the UUT shutdown system, it maintains optimal oil temperature during shutdowns, preventing adverse effects on the oil circuit. It also regulates oil pressure and temperature during steady-state and dynamic operations through the pressure oil circuit.
AVL ConsysAir
The AVL ConsysAir system precisely controls intake air temperature, humidity, and pressure, ensuring optimal UUT performance regardless of external conditions. Its compact design and patented Dynamic Bypass maintain stable pressure at the engine intake and exhaust during both steady-state and dynamic operations, stabilizing pressure in under three seconds after setpoint changes. Combined with the AVL Altitude Simulator, ConsysAir enables comprehensive testing across various environments – from sea level to high-altitude roads and diverse climates – all on a standard testbed.
AVL Altitude Simulator™
The AVL Altitude Simulator provides a cost-effective, highly accurate solution for simulating altitude, closely mimicking real road conditions for combustion engines, fuel cells, and other components on any system or chassis dynamometer testbed. Its exceptional repeatability is vital for efficient Real Driving Emissions (RDE) development and calibration. With a compact design, it integrates seamlessly into new and existing testbeds, and its mobility allows for easy relocation between setups. The innovative control strategy supports a broad range of altitude profiles, including transitions from negative to positive pressure within a single test run.
AVL elevates thermal testing with the AVL ConsysCool Dynamic and AVL Model.Connect. This combination enables hardware-in-the-loop testing of thermal systems, accelerating development from road testing to a controlled laboratory environment."
– Andreas Baumgartner, Global Product Manager Conditioning Systems, AVL List GmbH
AVL E-Mobility Testing Solutions – Brochure
Tested and Trusted.
AVL Thermal Testing Solutions – Brochure
Keep Cool, Drive Further.
AVL Conditioning Systems – Brochure
Simulate real and extreme conditions with best reproducibility.
AVL ConsysActive Portfolio – Solution Sheet
Precision Climate Control for Versatile and Sustainable Testing.
AVL ConsysCool Dynamic – Solution Sheet
Patented High Dynamic and Precision for HiL Thermal Testing.
AVL ConsysCool – Solution Sheet
Versatile Cooling Solutions for Optimal Performance.
AVL ThermalLab™ tests the entire VTMS, including all coolant circuits and the refrigerant cycle, under dynamic conditions using model-based testing. The UUT is the complete VTMS embedded in an emulated vehicle while the environment is fully simulated. The entire system can be tested in the lab under realistic driving and ambient conditions.
For battery (module/pack) testing, we offer complete test systems, stand-alone equipment, or even entire turnkey test labs.
AVL has a wide portfolio consisting of dedicated e-motor test systems, software, tools, and processes to test and validate these modern e-drive systems in shortest time and with highest quality standards.
At AVL, we develop e-axle solutions that can be easily installed without impacting the productivity of your engineering facility.
In the search for green and sustainable mobility, AVL has addressed the challenges of developing and validating automotive fuel cell systems – from a single cell up to complete systems for various applications.
Your success is our goal. This is what we are aiming for and this is how we understand AVL Customer Services since decades. Our goal is not new, but the way how we do it, is constantly evolving.
The primary goal for our AVL Customer Support Teams is, to be a helpful and reliable partner for all kind of questions and issues you might have, when using AVL’s technology.
AVL RACETECH, the motorsport department of AVL, presents the prototype of an innovative H2 internal combustion engine. The power unit is a compact, hydrogen-powered 2-liter turbo engine, with intelligent water injection, which achieves a totally new performance level. The first racing engine that AVL RACETECH is developing and building in-house.
