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TEST BENCHES

You require assistance with a complicated problem or need to solve a certain research question?

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for e-powertrain components

Cooling Lab

Our Lab – Your Solution

 

Hot spots lead to decrease of lifetime, efficiency and reliability of e-powertrain components​

Maximizing efficiency involves operating components safely and reliably, pushing them close to their thermal limits without leaving safety margins.
VIRTUAL VEHICLE cooling lab achieves this through local operation-dependent temperature monitoring and the use of digital twin technology for precise temperature detection and prediction.
By incorporating these methods into component design and operation, it’s possible to extend their lifetime while ensuring fail-safe performance.​

Typical Problems with…

Power Electronics

 

  • Additional costs for the cooling system due to avoidable safety margins not to reach junction temperature limits​
  • Reduced lifetime because of high thermal stresses of power electronic components

Battery

 

  • Difficulty to achieve local well-being temperature for all operating conditions (even for fast charging) ​
  • Lifetime decrease due to the temperature gradients
  • Worst case thermal runaway

Tailored and advanced measurements

Multi-physics Simulation

• Combined multiscale multi-physics simulation platform

Simulations and Digital Twins

Thermal Digital Twins

• Realtime runnable
• Predictive operation

Inner temp. and gradient

• Heat flux + surface temp.
• Fiber Bragg

New local non-instrusive surface temp. measurement

• Optical temp. measurement

Research Activities

Tailored measurement and diagnostics for complex thermal and fluid systems

Thermal impedance spectroscopy

  • Heat conductivity and capacity measurements
  • Parameter changes over lifetime

Local non-intrusive surface temperature measurement

  • Spectroscopic temperature measurement

Inner cell temperature and gradient

  • Heat flux + surface temperature
  • Fiber Bragg
  • Inverse problem cell temperatures

Coolant and cell aging

  • Long term measurements with cooling system
  • Coolant aging

Research Activities

Multi-physics simulations and digital twins

SIMBAT – Simulation for Batteries

  • Combined Multiscale Multi-Physics Battery Simulation Platform
  • Prediction of failure mechanisms and development of mitigation strategies from cell level to full battery pack level
  • Accelerated simulations using Novel physics-based ML ROM approaches

 

Electrical and thermal high-fidelity simulation of power electronics

  • Electrical simulation with hardware testing
  • High fidelity thermal simulations for design and data generation

 

Thermal digital twins and PHM

  • Developing thermal digital twins (TDT) using new physics-based ML ROM approaches
  • Using TDT for predictive control, predictive operation and embedded into system simulation tools
  • Data driven PHM with ML-based fault detection and State-of-Health (SOH) estimation

 

Research Activities

Power Electronics Cooling

Investigations and development of novel cooling designs and their impact

  • Immersion cooling, dielectric coolant performance, impingement cooling, and two-phase cooling
  • Research on advanced heat spreading designs, e.g. pin-fin optimization
  • Power electronics cooling design and prototype cooler development

Research Activities

Battery Thermal Management System

Advanced cooling concepts for next-generation battery systems and their impact

  • Development and validation of battery thermal management system concepts
  • Immersion cooling, di-electric coolant efficiency, impingement cooling and two-phase cooling
  • Module-level battery cooling design and prototype development

Advanced Measurements​

Thermal impedance spectroscopy

Heat conductivity and capacity measurements ​

Parameter changes over lifetime ​

Local non-intrusive surface temperature measurement​

Spectroscopic temperature measurement

Inner Cell Temperature and Gradient

Heat flux + surface temperature​

Fiber Bragg​

Inverse problem cell temperatures

Coolant and Cell Aging​

Long term measurements with cooling system​

Coolant aging

Thermal Digital Twins and Fast CFD​

  • Developing TDT based on the high fidelity thermal CFD results using new ML based ROM approaches (e.g. POD methods)​
  • Using TDT for predictive control, predictive operation and embedded into system simulation tools​
  • Running research projects for  in the field​
    • Multi zone cabin comfort ​
    • Cabin and human comfort digital twin​
    • Power electronics and e-motor cooling ​
    • Battery thermal management​​