Hot gas testing in component test benches

Excellent services for thermal testing combined with innovative technology and state-of-the-art equipment — this is ATESTEO division Calsim. In seven fully-automated hot gas test benches, thermal testing of, for example, complete exhaust systems and components such as catalytic converters, exhaust gas heat exchangers, gaskets, mufflers, suspensions, and pipe elements are conducted.

Hot gas tests in component test benches:

  • Thermo cycle test
  • Thermal shock test
  • Increased thermal shock test
  • Production control
  • Overtemperature loading
  • Time-lapse function (accelerated testing)
  • Boiling test
  • Tension measurement using strain gauges
  • Thermography
  • Efficiency measurement
  • Pressure pulsation test (positive and negative)
  • Testing of waste heat recovery [WHR] components

Calsim hot gas test center

For thermal testing of components or complete exhaust systems, ATESTEO division Calsim offers seven fully automated hot gas test benches. The modular design of these component test benches is suitable for conducting endurance tests and for high complex test requirements. For testing exhaust gas recirculation (EGR) coolers, controlled cooling circuits are installed. In addition, a Clausius-Rankine-cycle for testing waste heat recovery (WHR) components may be added. The working fluids may be demineralised water, ethanol, or special fluids; for example, cyclopentane or acetone. All test benches are designed such that the performance range of a passenger car to that of a commercial (utility) vehicle is covered; that is, up to 800 kW heating capacity, 1,300°C hot gas temperature, 4,000 kg/h hot gas mass flow, and 5 bar(rel) hot gas pressure.

Processing of orders

After receipt of the specimens, the hot gas test bench is set up ready for operation in close cooperation with the contractor. Subsequent to the successful start-up, an exemplary cycle is measured, the customer releases the start and the test run is started. Supervision of tests is guaranteed 24 hours a day by ATESTEO. During the entire duration of the test, the relevant data are transmitted in the form of updates on weekdays.

Technical data of the hot gas test benches:

Burner power 20 to 800 kW
Hot gas mass flow 40 to 4,000 kg/h
Hot gas temperature 250 to 1,300°C
Hot gas pressure up to 5 bar(rel)
Coolant mass flow up to 15 kg/s
Fuel natural gas, propane, diesel/heating oil EL
Operation 24/7

Turn-key hot gas test benches

The PLC-controlled hot gas generator F1 produces hot gas for technical test purposes. In particular, the thermal testing of components in the vehicle exhaust system can be conducted in a time- and energy-saving way. The modular set-up enables conducting not only endurance and durability tests, but also turbocharger tests.

How the hot gas generator works

Hot gas is generated by burning a fuel-air mixture. Natural gas, propane, diesel, or heating oil EL may be used as the fuel. The desired hot gas temperature is controlled by adjusting the burner power and mixing in cold air.

Technical data burner:

 Standard Option
Height of hot gas outlet 911 mm By arrangement
Burner power 10 to 500 kW By arrangement
Temperature up to 1,300°C up to 1,300°C
Temperature gradient > 200 K/s > 200 K/s
Mass flow 50 to 1,500 kg/h up to 4,000 kg/h
Hot gas pressure up to 8 bar(rel) up to 8 bar(rel)
Fuel consumption approx. 1 m3 (STP) natural gas/10 kWh approx. 0.4 m3 (STP) propane/10 kWh
approx. 1 l heating oil EL/10 kWh
Dimensions (LxWxH) approx. 2,031 mm x 808 mm x 1,274 mm Special setups possible

Options:

  • Computer-aided test bench automation system and data acquisition
  • Gas mass flow measurement and control
  • Thermal shock operation
  • Interface to connect to superior automation systems via CAN, Profibus, and Modbus TCP. Further interfaces on request.
  • Installation of an air compressor in cooperation with renowned partners is possible
  • Installation of a natural gas compressor in cooperation with renowned partners is possible
Download Hot Gas Tests Broschure