Test Bench Thermal Simulation via Segmented Heat Flow Control
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Solution Overview
Problem
Current test benches fail to accurately reproduce the thermal conditions of real test runs due to limitations in simulating heat transfer processes, leading to discrepancies in emission measurements and thermal behavior between virtual and real test runs.
Innovation Solution
A method and test bench that measure temperatures at specific points on the test object, subdivide components into segments, and use a thermal simulation model to calculate and adjust heat flows with actuators, simulating thermal interactions and heat transfer processes to approximate real-world conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If test benches simulate thermal conditions using conventional methods, then test runs can be conducted without real vehicles, but thermal interactions and heat transfer processes are not accurately reproduced
Solution Approach 1:
The test object components are subdivided into segments, with thermal simulation models calculating heat flows for each segment individually. This segmentation enables precise control of thermal interactions for different components, accurately reproducing real-world thermal conditions while maintaining test bench productivity
Solution Approach 2:
The system dynamically adjusts thermal parameters (heat flows, temperatures) based on measured values and simulation calculations. By continuously modifying these parameters to match real-world conditions, the test bench achieves accurate thermal reproduction without requiring actual vehicles, resolving the contradiction between test execution capability and thermal accuracy
2Reliability
If heat flows are adjusted based on measured temperatures, then thermal interactions are accurately simulated, but the system complexity increases
Solution Approach 1:
The system employs feedback loops where measured temperatures from the test object are continuously fed into thermal simulation models, which calculate required heat flow adjustments. These adjustments are then applied via actuators, creating a closed-loop control system that achieves accurate thermal simulation through systematic feedback rather than complex open-loop control
Solution Approach 2:
Thermal simulation models act as intermediaries between measured temperature data and actuator control signals. These models translate raw measurement data into meaningful heat flow calculations, simplifying the control architecture by introducing a computational mediator rather than requiring direct complex hardware control
3Measurement precision
If thermal conditions are precisely controlled segment by segment, then emission measurements become more accurate, but the measurement and control infrastructure becomes more complex
Solution Approach 1:
Components are divided into segments with individual thermal control, allowing precise reproduction of thermal conditions at each location where emissions are generated. This segmentation enables accurate emission measurements by ensuring each component operates at its authentic thermal state, with complexity managed through modular control of individual segments rather than monolithic system control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for realistic simulation of thermal environmental conditions, reducing discrepancies between virtual and real test runs by accurately replicating thermal interactions and heat transfer processes, thereby improving the accuracy of emission measurements and thermal behavior simulation.
Implementation Method 1
the thermal simulation model calculates the segment heat flow which acts on the at least one segment
Implementation Method 2
simulating thermal interactions and heat transfer processes to approximate real-world conditions
Data Source
AI summary
To subject a test object during a test run on a test bench to real environmental and/or surrounding conditions, particularly thermal conditions, it is provided that at least one temperature is measured at a measurement point as a measured variable during the test run on the test bench. At least one test object component of the test object is subdivided in a number of segments. The thermal interaction of at least one segment with the environment of the vehicle is simulated during the test run by a thermal simulation model of the simulation model. The thermal simulation model calculates the segment heat flow that is supplied to or dissipated from the at least one segment. This segment heat flow is adjusted as a function of the measured temperature at the test bench on at least one segment by means of a number of heat flow actuators.