Hot gas test bench

Hot gas test stand

The institute has a hot gas test bench for experimental tests on systems for secondary energy utilisation. This test rig enables the overall system influence of self-developed heat recovery systems to be analysed.

In applications for converting heat from vehicle exhaust gases into electrical energy, all mutual interactions on the vehicle can be analysed.

A modular test bench enables the simulation of all relevant system components.

The hot gas test bench is used to test and measure heat exchangers, in particular as part of exhaust gas energy recovery systems. The influences on the relevant vehicle components, such as the vehicle electrical system and the vehicle cooling system, can be simulated and analysed on this test bench, while the control and data acquisition are fully automated. This enables complex driving cycles to be modelled and prototype structures for energy recovery, such as thermoelectric generators, to be measured.

The component test stand is used to determine the thermal properties of individual components of the heat recovery systems. For example, thermal contact resistances can be determined at various contact forces and temperatures. If necessary, the test specimens can be operated in a vacuum or under an inert gas atmosphere.

A shaker for simulating vibrations and oscillations and a long-term test rig are available for analysing the service life of the prototypes.

Technical specifications:

 

Hot-gas burner:

Output: 2-200 kW

 

Temperature range: 100-1200 °C

 

Mass flow: 30-1000 kg/h

 

High dynamics due to bypass

Modular measurement technology:

90x thermocouples type N

 

50x thermocouples type K

 

4x current measurements

 

20x voltage measurements

 

5x absolute pressure measurements

 

4x differential pressure measurements

 

10x force measurements DMS

On-board electrical system:

Rated power 4x 400W; 1x 1500W

 

Max. current: 4x 52 A; 1x 200 A

 

Max. voltage: 4x 60 V; 1x 80 V

 

Resistance: 0-100 Ω

Cooling system:

Max. cooling capacity: 160 kW

 

Max. heating capacity: 20 kW

 

Max. pump capacity: 200 l/min (max. 8.7 bar)

 

Temperature range: 10-110 °C

Component test bench:

Max. temperature: 1000 °C

 

Max. thermal output: 2x 5000 W

 

Underpressure housing: max. -950 mbar

 

Max. contact force: 125 kN

Further testing facilities:

Shaker

 

Long-term test bench

Contact

Dr.-Ing. Frank Rinderknecht

Head of Research Area
German Aerospace Center (DLR)
Institute of Vehicle Concepts
Alternative Energy Conversion
Pfaffenwaldring 38-40, 70569 Stuttgart