Gaseous and liquid media have a significant impact on the UUT’s behavior. Conditioning systems bring these media into a selectable and predefined range. To perform tests with high precision and reproducibility, stable environmental conditions are crucial. These are conveniently and reliably provided by conditioned media. When the UUT development takes place in different locations, media conditioning ensures that testing conditions remain comparable. Conditioning systems are therefore an indispensable key part of testbed equipment in development, calibration and certification.
Accuracy
High control accuracy in steady-state and dynamic mode increases testbed efficiency.
Reproducibility
Good reproducibility allows a fast achievement of development goals.
Conditions
Emulate/ Simulate/ Replicate extreme temperature and pressure conditions on the testbed which is hard to achieve on the road.
Automation
Easy integration into the automation system enables a quick installation (plug & play).
To simulate extreme driving conditions on the testbed, conditioning systems must be able to create extreme media conditions. To enhance the efficiency of the testbed, it is essential to establish the initial conditions in a timely manner. Oil and coolant conditioning systems facilitate rapid cooling of the UUT at the conclusion of each test cycle, thereby enhancing the number of tests that can be conducted within a given time frame (e.g., cold start tests).
Our media conditioning systems are distinguished by their modular design, exceptional functional expandability, and compactness, which makes them highly mobile and versatile on the testbed. They are engineered to be exceptionally robust and optimized for maximum dynamics and control quality. An installed base of over 4,000 systems is proof of their quality and durability.
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AVL ConsysCool
The AVL ConsysCool is a highly versatile tool that can be used for a variety of applications, including development, certification, end-of-line testing, and dynamic race car engine applications. It precisely controls coolant temperatures within defined limits, featuring integrated electric heating for rapid preheating and enhanced control dynamics, thus ensuring optimal performance. The high level of control accuracy guarantees the reproducibility of test conditions in both steady-state and dynamic modes. Additional options are available to expand the unit's functionality and ensure optimal results. For less demanding applications such as endurance testing, we offer a compact and cost-effective basic coolant conditioning unit.
AVL ConsysBoost
The AVL ConsysBoost precisely conditions the UUT's boost air to a predefined value with a narrow tolerance, ensuring precise and reliable results. The system ensures constant boost air temperature, maintaining test condition reproducibility. The original vehicle intercooler is replaced by an industrial water/air intercooler. An adjustable flap is installed to simulate different boost air cooler pressure drops, making the system versatile for various UUTs. Alternative solutions, such as spray conditioning systems or water-jacketed intercoolers, are available for use with the original UUT intercoolers.
AVL ConsysLube
The AVL ConsysLube system provides precise control of oil temperature and pressure, with integrated electric heating for rapid preheating and enhanced dynamic operation accuracy. It offers a variety of connection types and options to suit your needs. Connect AVL ConsysLube to the oil sump to maintain optimal oil temperature during UUT shutdown, preventing any adverse effects on the circuit. Connect to the pressure oil circuit to regulate oil pressure and temperature during both steady-state and dynamic operations.
AVL ConsysAir
The AVL ConsysAir system is designed to adjust intake air temperature, humidity, and pressure to set points, regardless of actual ambient conditions. This is a crucial feature for ensuring optimal UUT performance. Its patented Dynamic Bypass ensures stable pressure at engine intake and exhaust in steady-state and dynamic operations. Key features include rapid stabilization after set point changes (less than three seconds for pressure). Paired with AVL Altitude Simulator, ConsysAir facilitates testing across diverse environments — from sea level to high-altitude mountain roads in various climates like winter, summer, tropics, deserts, or arctic regions on a standard testbed.
Battery packs, modules and cells, fuel cells, e-motor and e-axle solutions must operate safely and reliably in any environment. This can include extreme temperatures and humidity, which cannot be reproduced on the test track or in real test scenarios on the road. This is why we developed the modular AVL Climate Chamber.
The AVL Gas Sampling Unit is an outstanding safety device, which measures and analyses the gas composition while battery testing inside the test chamber.
AVL ThermalLab™ tests the entire VTMS, including all coolant circuits and the refrigerant cycle, under dynamic conditions using model-based testing. The UUT is the complete VTMS embedded in an emulated vehicle while the environment is fully simulated. The entire system can be tested in the lab under realistic driving and ambient conditions.
For battery (module/pack) testing, we offer complete test systems, stand-alone equipment, or even entire turnkey test labs.
For battery cell testing, we offer complete test systems, stand-alone equipment, or even entire turnkey test labs.
We offer complete test systems for the testing of modules/packs. Learn more about which hard- and software products are included in our test systems.
Your success is our goal. This is what we are aiming for and this is how we understand AVL Customer Services since decades. Our goal is not new, but the way how we do it, is constantly evolving.
The primary goal for our AVL Customer Support Teams is, to be a helpful and reliable partner for all kind of questions and issues you might have, when using AVL’s technology.
AVL RACETECH, the motorsport department of AVL, presents the prototype of an innovative H2 internal combustion engine. The power unit is a compact, hydrogen-powered 2-liter turbo engine, with intelligent water injection, which achieves a totally new performance level. The first racing engine that AVL RACETECH is developing and building in-house.
