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.

Summary of technical specifications:

 

Hot-gas burner:

Output: 2-200 kW

 

Temperature range: 100-1200 °C

 

Mass flow: 30-1000 kg/h

Vehicle electrical system

Four loads: Rated power: 400 W at <60 Volt

 

Four loads: max. current: 52 A

 

One load: Rated power: 1500 W

 

One load: Voltage: 0-80 V

 

One load: Current: 0-200 A

 

One load: resistance: 0-100 Ω

Cooling system:

Max. cooling capacity: 50 kW

 

Max. heating capacity: 6 kW

 

Max. pump capacity: 27 l/min (max. 4.5 bar)

 

Temperature range: 10-110 °C

 

System pressure 1-6 bar

Component test bench

Max. temperature: 1000 °C

 

Max. thermal output: 5000 W

 

Underpressure housing: max. -950 mbar

 

Max. contact pressure: 125 kN

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