Conditioning Systems

To simulate extreme driving conditions on the testbed, conditioning systems must be able to create extreme media conditions. In order to improve the efficiency of the testbed, the initial conditions must be established quickly. Oil and coolant conditioning systems cool the UUT very fast at the end of each test cycle, which helps to increase the number of tests per time unit (e.g. cold start tests).

AVL media conditioning systems are characterized by their modular design, their excellent functional expandability and their compactness, making them mobile and versatile on the testbed. They are designed to be truly robust and optimized for maximum dynamics and control quality. An installed base of more than 4.000 systems demonstrate their quality and durability.

You can apply the AVL ConsysCool in development, certification, End of Line (EOL) testing, as well as in highly dynamic applications for race car engines. The system controls the coolant to a freely definable temperature and keeps it within tight limits. An inte grated electric heating system ensures quick pre-heating and improves control dynamics.

The high control accuracy achieved in steady-state and dynamic modes delivers high-class test condition reproducibility. You can extend the basic unit’s functionality with additional options in order to reach the best results for your application. For less demanding applications like endurance testing, we additionally offer an elementary coolant conditioning unit which is both compact and cost-efficient.

AVL ConsysBoost conditions the UUT’s boost air to a predefined value within a very narrow tolerance range. It is chiefly used to keep the boost air temperature at a constant level, regardless of the UUT operation state. By maintaining the exact boost air temperature, the reproducibility of the test condition is guaranteed. The original vehicle intercooler is replaced by an industrial water/air intercooler.

To simulate the pressure drop of different boost air coolers, an adjustable flap is installed. This makes the device suitable for a wide range of UUTs. In case you require the use of an original UUT intercooler, we offer alternative solutions such as spray conditioning systems or intercoolers inside water jackets.

With AVL ConsysLube you will be able to precisely keep the oil temperature and oil pressure to definable values. The integrated electric heating system allows a fast preheating of the oil. Furthermore, it optimizes the control accuracy in dynamic operation. Several connection types and device options permit a variety of applications. For instance, you can:

• Connect AVL ConsysLube to the oil sump to avoid any negative impact on the UUT’s oil circuit and to control temperature even when the UUT is being stopped.
   
• Connect it to the pressure oil circuit to control the pressure and temperature of the UUT’s oil supply – both in steady-state and dynamic operation.

AVL ConsysLube is suitable for internal combustion engines, gearboxes or oil cooled e-drive components.

The performance of the UUT depends strongly on the intake air temperature, humidity and pressure. With AVL ConsysAir, these key factors can be adjusted to any set point, irrespective of the actual ambient conditions at the testbed. The patented Dynamic Bypass enables an unrivalled pressure stability at engine intake and exhaust in steadystate and even in highly dynamic engine operation.

Another crucial feature of this device is the short stabilization time after a set point change (for pressure even less than three seconds). Combined with AVL Altitude Simulator, AVL ConsysAir enables testing from sea level to high mountain road in winter or summer, in the tropics, deserts or arctic regions on a normal testbed.