Case Study Title: Heat Exchanger Performance Characterization
Client Type: International Automotive Parts manufacturer & supplier
Scope and Capabilities:
This project delivered a custom-engineered test stand for evaluating the performance characteristics of automotive heat exchangers. The system was designed with two independent fluid circuits—one for oil and one for coolant—each featuring dedicated pumps, heating and cooling systems, flow and pressure measurement, and safety controls. The stand could execute Transmission Oil Warmer and Engine Oil Cooler tests, as well as custom procedures, under tightly controlled temperature, flow, and pressure conditions. An enclosed, safety-interlocked test bay housed a universal mounting fixture, while a fully integrated control and data acquisition system enabled automated and manual test operation. ATA’s Engine Component Test Software (ECTS) provided configurable test sequencing, PID control, high-speed data logging, and customized reporting.
Key Features:
Dual independent oil and coolant circuits with dedicated pumps and reservoirs
Flow rate control accuracy to ±0.25 L/min, with optional Coriolis mass flow meters for ±0.10 L/min precision
Temperature control: oil up to +165°C, coolant up to +130°C, ±0.2°C stability
High-accuracy inlet, outlet, and differential pressure measurement for both circuits
Automated supply pressure control option (oil up to 15 Bar, coolant up to 5 Bar)
Inline filtration to 10 microns and air bleed valves for system purging
Variable frequency drive motor control for pump speed adjustment
Safety features including emergency stop, interlock switches, alarm monitoring, and automated shutdown
Enclosed anodized aluminum and polycarbonate frame with integrated spill containment
Engine Component Test Software (ECTS) with Plan Editor, real-time monitoring, alarm handling, and automated reporting
Capability to log data at rates from 1 Hz to 1 kHz (up to 100 kHz with optional high-speed DAQ)
Manual and automated test operation modes with four user access levels
Deliverables:
Complete design, build, and delivery of a heat exchanger performance test stand meeting defined specifications
Integrated oil and coolant circuits with heating, cooling, flow, and pressure control systems
Engine Component Test Software (ECTS) installation with preconfigured test plans and reporting templates
Factory Acceptance Testing with witness participation and measurement system verification
On-site installation, commissioning, and operator training
Full safety certification to applicable machinery and electrical standards
Comprehensive documentation including user manuals, schematics, calibration certificates, and maintenance guidelines
