1. R&D department
Test rig in
Hydac SA

2. Time schedule Power heat dissipation test rig Pulsation test rig
Paolo 2
Test rig in Hydac
Time schedule
Power heat dissipation test rig
Pulsation test rig
VG 320 test rig
Situation 2001

3. Power heat dissipation
Paolo 3
Test rig in Hydac
Power heat dissipation
Why this test rig
To measure :
POWER HEAT DISSIPATION
PRESSURE DROP
on liquid/air coolers.
Analyse our and the competitors’
coolers to acquire know-how
and win on the market !

4. Power heat dissipation
Paolo 4
Test rig in Hydac
Power heat dissipation
Technical data
Liquid : mineral oil VG68
Flow max : 350 l/min
Power max : 120 kW
Inlet air temperature : ambient temperature
Inlet liquid temperature max : 70 °C
Available motors :
Electrical AC until 6 kW ( Hz)
Electrical DC until 32 V & 30 A
Hydraulic until 80 l/min & 180 bar

5. Power heat dissipation
Paolo 5
Test rig in Hydac
Power heat dissipation
Tests following DIN/EN 1048
TÜV SÜDDEUTSCHLAND certify that Hydac SA
makes the tests following the norm EN/ISO 1048 !
This mean that the accuracy of instruments and the complete system is guaranteed. The variations of values, during a test, are :
± 0.2 °C for temperatures
± 0.02 bar for pressures
± 1 % for liquid flow rate
to stay in the declared tolerances !
The tests are made at :
inlet temperature drop = 40 °C
oil viscosity = 30 mm2/s
to declare what we measure !

6. Power heat dissipation
Paolo 6
Test rig in Hydac
Power heat dissipation
Costs and improvements
A test takes in average 1 day to be done.
An operator dedicated at 60 %, the power to heat
the oil and the electricity to run fan, pumps and
other elements are not the only cost that we have
to assume. The certification from TÜV, to calibrate the probes and maintenance have to be summarised to the construction and the new improvemtns.
We are looking at an investment to run completely automated tests, to make tests during the night too !

7. Pulsation NEW Why this test rig Test rig in Hydac
Paolo 7
Test rig in Hydac
Pulsation
Why this test rig
To evaluate the matrix of liquid/air coolers in dynamic pressure.
We start this year to test with this rig.
In the past this test was made with external resources. This was a problem because we lost know-how and to have the results we wanted was not always possible.
NEW

8. Pulsation Technical data Test rig in Hydac Liquid : mineral oil VG22
Paolo 8
Test rig in Hydac
Pulsation
Technical data
Liquid : mineral oil VG22
Upper pressure range : bar
Frequency range : 0,1..3 Hz
Ambient temperature max : 110 °C
We can test 1 big element (EL11) or 3 small (EL3).

9. Pulsation Tests following ISO/DIS 10771-1 Test rig in Hydac
Paolo 9
Test rig in Hydac
Pulsation
Tests following ISO/DIS
In the liquid/air coolers market, the matrix is characterised by tests which follow the norm ISO/DIS p t pu pl
= 5% pu TR
T1  30% T TF
90% T1  T2  110% T1
T = 1 / f (f  3 Hz)
40% T  (TR + T1)  60% T
p(T2)  pl
p(T1)  pu
Test code : ISO /0.8 bar-107-2Hz/190ms
Means that the test had :
pu = 16 bar
Pl = 0.8 bar
N° cycles = 107
Frequency = 2 Hz
T1 (time for p > pu) = 190 ms

10. Test result Why follow a norm Test rig in Hydac
Paolo 10
Test rig in Hydac
Test result
Why follow a norm
It is important that the data that is declared follows a norm, because otherwise it is impossible to compare values !
How can you win against competitors ?
Imagine a test like this. They can easily declare a test with :
f = 2 Hz
pu = 16 bar
and get results like 109 cycles! p t pu pl
= 5% pu TR
T1  30% T TF
90% T1  T2  110% T1
T = 1 / f (f  3 Hz)
40% T  (TR + T1)  60% T
p(T2)  pl
p(T1)  pu
This is also valid for the power heat dissipation tests.

11. VG320 NEW Why this test rig Test rig in Hydac
Paolo 11
Test rig in Hydac
VG320
Why this test rig
During the integrated bypass project we saw that the viscosity was not sufficient to create the necessary pressure drop in the matrix. Now we are able to see the correct functionality of this particular element.
We had other requests from the lubrication systems and wind turbine gear box market: to test with a synthetic and high viscosity oil.
NEW

12. VG320 Technical data Test rig in Hydac
Paolo 12
Test rig in Hydac
VG320
Technical data
Liquid : mobilgear oil VG320 (sinthetic)
Pressure max : 20 bar
Flow rate max : 170 l/min
Heat power : 4 kW
Cooling power : 30 kW