Automotive radiator wind tunnel test bench

This test system is primarily designed for the research and development of thermal management systems and product testing for passenger vehicles, commercial vehicles, special-purpose vehicles, and construction machinery, and it meets requirements not exceeding— 200KW Testing and evaluation of thermal management systems for internal combustion engines and new-energy vehicles.

Based on the development trends and requirements of cooling systems for various motor vehicles, by applying rational design principles, selecting advanced testing instruments and equipment, and adopting test methods that better reflect real-world conditions, we can further enhance the testing capabilities of thermal management systems. This will enable these systems to meet the performance testing needs of diverse heat exchangers—such as water radiators and intercoolers—and to conduct validation tests that accurately simulate the actual operating performance of integrated cooling systems. The ultimate goal is to provide practical evidence for improving the efficiency of vehicle cooling systems and refining the design of both systems and their components.

I. Test Project:

1 Standard heat dissipation

2 ． Heat dissipation on the wind side

3 Heat dissipation on the water (oil, gas) side

4 Air resistance

5 Water (oil) resistance;

Gas pressure drop (internal resistance)

6 Heat dissipation coefficient

7.  Cooling module simulation test bench

II. Composition of the Computer-Based Measurement and Control System for Radiator Fan Duct Testing:

1 The test chamber for wind tunnel experiments

2 Fan frequency conversion speed control system

3. Water Circulation and Temperature Control System

4. Hydraulic Oil Circulation and Temperature Control System for Construction Machinery

5. Hydraulic torque converter oil circulation and temperature control system

6. Boosted Air Circulation and Temperature Control System

7. Computer-based measurement and control system:

On-site testing instruments and meters

Lower-level process control system

Host computer control system

8. Electrical and Power Distribution

III. Key Performance Indicators (for discussion reference):

(1) Air-side, test specimen parameters, and environment

1 Fan wind speed: 4.0–15.0 Rice / Seconds (variable-frequency speed control, PID Control)

With standard radiator: 800X800mm For measurement reference

Airflow: 3000 ~ 37000m³/h

2 Maximum front-side dimension of the test radiator: 800×800mm ；

3 Minimum front surface dimension of the test radiator: 300×300mm

4 The thickness of the radiator 40–300mm Between. Most commonly used 60–160 mm

5 Ambient temperature: 5 ~35℃

6 Environmental temperature of the computer-based measurement and control system: 15 ~30℃

(2) Performance Testing of Water (Coolant) Radiators

1. Circulating water (coolant) flow rate: 40–400 L/min (frequency conversion adjustment, PID control)

2. Circulating water (coolant) temperature: Normal temperature ~ 100 ℃ ±0.5℃ (PID control)

3. Thermal equilibrium error (average): ≤ ±3.0%

4. Repeatability (mean): ≤3.0%

5. Maximum heat dissipation of the water radiator ≤ 200 kW

6. The design pressure of the water circulation system is ≤300 kPa.

7. Water resistance: Max. 100 kPa

8. Warm-up time: 40 min

(3) Performance Testing of Hydraulic Oil Coolers

1 · Circulating oil flow rate: 40–400 L/min Frequency conversion adjustment, PID Control)

2 Circulating oil temperature: 120℃ ±0.5℃

3 Circulating oil resistance: <200kPa

4 Maximum temperature difference between import and export 10℃

5 · Warm-up time: 40min

(4) Performance Testing of Hydraulic Torque Converter Oil Cooler

1 · Circulating oil flow rate: 20–200 L/min Frequency conversion adjustment, PID Control)

2 Circulating oil temperature: 120℃ ±0.5℃

3 Circulating oil resistance: <200kPa

4 Maximum temperature difference between import and export 10℃

5 · Warm-up time: 40min

(5) Intercooler Performance Testing

1 — Circulating air flow: 5000 ~ 30,000 L/min ±1.5% (Roots blower frequency conversion speed regulation, PID Control)

2 — Circulating air temperature: 100~230 °C ( PID Control)

3 Circulating air pressure: 50~220 kPa

4 · Maximum heat dissipation of the intercooler ≤ 120KW

5 · Pressure drop across the intercooler’s internal resistance: ≤ 100KPa

6 · Warm-up time: 40min