Current Temperature Testing Solutions
Get ready, because this post is going to get hot…and cold. Testing components at super low/high temperatures have become a standard request now from OEMs. Whether it is a static test (i.e. performance tests at specific temperature operating points) or a dynamic test (durability tests that entail operating the component continuously across a range of temperatures), you will need to source a piece of equipment that will help you achieve these requirements. Today, we are going to discuss different solutions, how they might integrate with each other, and some of the pros/cons of each.
Chillers
Chillers are very common and it is likely you have one somewhere in your facility. The technology is well-known, as it closely resembles a typical refrigeration cycle. Simplicity lies in both the integration and operation of the unit. These modules typically have an inlet and an outlet port for the cooling fluid (typically a water/glycol mixture), which would flow through a heat exchanger with your process. Things get a bit more complicated when it comes to utilizing this equipment with multiple applications. Chiller units are typically specifically sized for a single application, meaning that heat rejection conditions beyond the envelope considered for the application may be incompatible. Chillers are designed to reach a desired temperature set point and stay there. This is sufficient for static tests, but not particularly useful for dynamic tests (unless you engineer a temperature control system as part of the test bench). For test applications, in particular, integrating a chiller may not be as simple as hooking up a few hoses and running tests. It is up to you to determine what size heat exchanger you will need based on the desired temperature ramp rates, expected energy loss, and heat rejection required.
Liquid cooling can be up to 25x more efficient than air cooling
Thermal Chambers
Thermal chambers use a similar methodology as refrigerators and are used for many applications. Thermal chambers are typically used for dynamic testing because unlike chillers, they have the ability to jump between different temperature extremes (hot and cold). Thermal chambers have coils that distribute hot or cold temperatures along its aluminum walls, which then heat/cool the air around the component sitting within the chamber.
In the electronics industry, the traditional approach has been the use of thermal chambers to create the desired ambient conditions for temperature and humidity. To a large extent, the automotive industry has adopted the use of this equipment and tried to leverage its performance capabilities in the standard form. Unfortunately, it has proven to be fairly inefficient in conditioning fluid components. In comparison to air, liquid cooling can be up to 25 times more effective in transporting heat away from a source to a secondary cooling surface. With that being said, companies promote their systems with high rates of change but fail to mention that they are referring only to the air surrounding the component. This is a problem because of how inefficient the process is (coils condition the aluminum panels > then the air in the chamber > then the component > and then finally the test fluid).
The struggle of keeping the component at the desired temperature is combined with the heat generated by a running pump. On top of that, there is no way of natively mounting/operating the component to properly validate during performance and durability tests. Some test labs resort to drilling, insulating, and then creating a physical interface but this takes more time and money to implement.
ATA’s Fluidify™ (Horizontal Model)
Fluidify™
Fluidify™ is optimized for rapid fluid temperature control. Ideal for performance or durability testing. This module contains a single robust refrigeration circuit, engineered for prolonged use between extremes. The convenient roll-around architecture allows for easy plug-and-play testing of components (i.e. batteries, heat exchangers, pumps, and valves) or entire thermal management subsystems.
Fluidify™ is one product that combines fluid temperature conditioning, refrigeration, and flow delivery. It reduces risk by being a single off-the-shelf solution to deliver conditioned fluid to a test apparatus, freeing up internal resources, budget, and floor space. Compared to traditional refrigeration solutions, Fluidify™ combined with Horai™ technology is able to achieve greater cooling power at lower temperatures, while maintaining a small footprint.
Unlike chillers, Fluidify™ has an integrated heat exchange and flow delivery system that is tailored to your application. A benefit to sourcing a Fluidify™ unit is that ATA will handle the heat exchange calculations for you and source the right components from our Section ID™ platform that is appropriate for your application. This is often the most difficult part of sizing and implementing an effective fluid conditioning system for a broad array of test applications.
How we can help
Test systems to benchmark performance, durability, and end-of-line production validation
Robust fluid conditioning subsystems, engineered for prolonged use between extremes.
Accurately measure key parameters for on/off and proportional multi-port control valves.
On the control side, simulate various test conditions (i.e. hot/cold fluid and air temperature) according to industry standards
Fluidify™ is a plug-and-play rapid fluid temperature control module, Ideal for performance or durability testing of oil and coolant components
We also utilize our systems, standards, and technologies to support clients with test services
Responsive support services that range from 24/7 engineering assistance to full system calibration (meets ISO 17025 standard).