Content

Information security and TISAX
Focus on climate goals: simulation of hydrogen systems
A hydrogen technology center near Braunschweig?
Everything automated with MoBA Automation
New control technology in our test rigs
Development support to series production
Calculation of multiphase flow in innovative cooling systems
Education in the home office: online training courses


Information security and TISAX

To protect the information and data entrusted to us, we are using an information security management system. The TISAX results are now available for this system.
Further information on ISO 9001 and TISAX.


Focus on climate goals: simulation of hydrogen systems

In our TIL add-on library Hydrogen Energy Systems, further fluid data, component and system models are created, which enable the design and evaluation of future hydrogen energy systems.

We at TLK can rely on many years of experience from various consulting and research projects in the field of modeling and simulation of hydrogen systems. With our multifunctional software tools, we offer suitable solutions for the diverse challenges in this field.

Together with our customers, we applied this knowledge and the respective tools for the model-based analysis of various hydrogen filling station concepts. Figure 1 shows a simplified illustration of these concepts. Based on the implemtation of models for

  • liquid (LH2) and gaseous (CGH2) filling station-side hydrogen storage
  • cascading buffer storage
  • direct compression as an operating strategy

and different on-board pressurized gas tank systems (Type III/ Type IV), we simulated and analyzed a variety of concepts already.

Simplified P&I flowchart of a hydrogen refueling station concept in DaVE.
Figure 1: Simplified P&I flowchart of a hydrogen refueling station concept in DaVE.

Many of our software tools are put to good use in the simulation of hydrogen systems. For the model-based design of these systems, the exact calculation of fluid data is essential. For example, when considering hydrogen in a cryogenic state, it must be taken into account that it occurs with two different nuclear spin configurations - as ortho-hydrogen and as para-hydrogen. The differences can be seen, for example, in the specific isobaric heat capacity (see Figure 2 a). The necessary exact fluid data calculation is accomblished with our fluid property data library TILMedia 3.9.1, which is included in TIL Suite 3.9.1. Not only for hydrogen but also for a huge variety of pure fluids and fluid mixtures, TILMedia provides the efficient and robust calculation of the required thermophysical properties.

Figure 2 a) Temperature dependent specific isobaric heat capacity of para-, ortho- and normal hydrogen. b) Temperature dependent composition of equilibrium para- and ortho-hydrogen.
Figure 2 a) Temperature dependent specific isobaric heat capacity of para-, ortho- and normal hydrogen. b) Temperature dependent composition of equilibrium para- and ortho-hydrogen.

The TIL Suite and its add-ons are continuously improved and expanded. We determine the need for new functionalities and specifications with regard to industrial applicability in the course of daily use in our research and service projects. This concerns also customer-specific developments of model libraries for the design and optimization of PEMFC and SOFC systems.

Our software DaVE is used for the comfortable evaluation and visualization of stationary and dynamic effects in complex systems. MoBA Automation allows the flexible creation and processing of extensive simulation studies and workflows. In combination with the Optimization Suite, an efficient system and component design is achieved.

Based on our expertise, we support you in the modeling and design of your hydrogen systems. Do you have specific requirements and wishes - e.g. for the development of a component and system model library, or a workflow we can realize in MoBA Automation? We will be happy to support you in this matter as well.

For further information please contact Ingo Frohböse (i.frohboese@tlk-thermo.com) or visit our product pages.


A hydrogen technology center near Braunschweig?

Together with the Technical University of Braunschweig we are engaged in the Technology- and Innovation Center Hydrogen Technology in Braunschweig-Salzgitter.
Further information can be found in the press release (german) from Allianz für die Region.


Everything automated with MoBA Automation

MoBA Automation 2.1 simplifies the parameterization of complex workflows, results are accessible more quickly. The new version offers additional use cases for test bench automation, measurement data evaluation and model regression testing.

Software for automated workflows

Our software MoBA Automation enables the automation of individual workflows for model or measurement data based development, analysis and optimization of technical systems. For example, users can automatically evaluate complex simulations or measurements, create individual automated reports and documentation (PowerPoint, PDF, etc.), or run simulations in a network. Further examples can be found on our homepage. More about MoBA Automation.

Release of version 2.1

MoBA Automation version 2.1 is available for download since December 2020. The most important new features are summarized below.
We continue to work with great passion and enthusiasm on new features to improve the ergonomics of our MoBA Automation. If you have any feature requests, please contact us: E-mail to Philipp Ebeling (p.ebeling@tlk-thermo.com).

Simplified handling of complex workflows with new interface tasks

In complex workflows, many tasks typically use the same input values (for instance parameter file paths or target directories). The adjustment of parameters due to workflow changes in all individual tasks, which was necessary in the previous version, proved to be inconvenient. In addition, the output values of the workflow were only accessible via the respective tasks, which made it difficult to quickly access important results.

ew Input and Output Interface Tasks
New Input and Output Interface Tasks (far left and far right) in our Dymola Simulation and Check Steady State Results workflow. Connections to and from the tasks are hidden.

Via new interface tasks, input and output values can be defined globally and linked to individual tasks via connections. The connections are marked by a colored accent but remain hidden. Thus, the clarity of the graphic representations is ensured. Furthermore, the values of the interface tasks provide a filter for the inputs and outputs of the workflow. If the workflow is instantiated as part of an entire work process in a comprehensive workflow, the parameters or connectors of the interface tasks are displayed primarily.

The Dymola Simulation and Check Steady State Results workflow as part of a control-oriented system analysis process.
The Dymola Simulation and Check Steady State Results workflow as part of a control-oriented system analysis process. When parameterizing the workflow, only the input interface inputs are now displayed, which significantly simplifies the handling of extensive workflows.
Further new features
  • A new command prompt allows for instance the installation of new Python modules for a Python environment registered in MoBA Automation (see "Edit" in the toolbar)
  • Access to the output files via the context menu in the Status monitor
  • Faster reading of large Mat files in the data processing tasks
  • MDF files (MF4) can now be read by all data processing tasks in the Standard Task Library
  • Many new features for easier and more intuitive workflow development in the Configurator View

Usage of MoBA Automation in test benches

In recent months, MoBA Automation has found new applications in many fields of work, not only at TLK. Especially in tests on our test benches, it increasingly takes over the complete evaluation, analysis and PDF documentation of the measurement data of a single day and relates it to the entire measurement campaign.

In a workflow with recognition of stationary states, MoBA Automation offers the possibility to validate measurement points during operation and to trigger the initiation of the next measurement point. This can save valuable test bench time.

Automated measurement campaigns.

Model regression tests for quality control

For quality control of model libraries, regression tests are available in MoBA Automation in the form of predefined workflows in a task add-on. The repeated execution of model simulations and corresponding evaluations means that errors in modifications can be quickly detected and corrected. The regression tests provide evaluations regarding the following aspects:

  • Simulation success
  • Comparison of time series or simulation end values to a reference
  • Comparison or validation of validity ranges of the models
  • Structural analysis of Modelica models (system of equations, translation log, etc.)
  • For further information please contact Philipp Ebeling (p.ebeling@tlk-thermo.com).


New control technology in our test benches

Using innovative concepts we are able to perform highly dynamic control in our refrigerant compressor test benches. They are used, for example, for time-lapse tests in long-term operation.

Due to our many years of experience with refrigerant compressors, we are able to use our test benches in continuous operation for highly dynamic time-lapse tests or thermal cycling investigations. Degradation effects are evaluated online on the test bench and compared in real time with empirical values or as a software-in-the-loop model. This allows aging effects as well as damage to be detected at an early stage.
For further information please contact Christian Seck (c.seck@tlk-thermo.com).

Development support until series production

Many do not know: Our services also include experimental support for the development of overall thermal management systems - in the area of heating and cooling of passenger compartment and battery.

We adapt our measurement concept to your task. The measurement of the individual components of the overall system represents the basis of our cooperation. The subsequent measurement and evaluation within an overall concept as well as the support up to series production builds on this. Especially actuators and sensors that communicate in the bus system can also be evaluated by us in the overall system. Only the LIN or CAN bus configuration of the target system provided by you is necessary for an integration of the components.
For further information please contact Norbert Stulgies (n.stulgies@tlk-thermo.com).

Pressure reducer on a nitrogen gas cylinder at a test bench

In addition, we offer the following measurement options on our 820 m² test bench area. In the field of components, we perform tests on the following components, among others:

  • Refrigerant compressors for R-744, R-134a, R-1234yf, R-290 and other refrigerants (performance measurement, detailed analysis, development support etc.)
  • Heat exchangers refrigerant-air, refrigerant-miscellaneous fluids (performance, icing detection, de-icing strategies, de-heating etc.)
  • Expansion valves
  • Pumps
  • Fans and blowers
  • Refrigerant collectors (charging curves)
  • Leakage measurements
  • Humidifiers for fuel cells
  • Materials (explosive decompression of elastomers, etc. under R-744)
  • Heat pipes for heat transfer
  • Thermal properties of battery modules
  • Temperature control of battery modules / battery packs
  • Investigation of refrigerant-oil mixtures
  • Support for measurement system testing

In the field of testing complete systems, we have experience and testing capabilities for, among others:

  • Test bench for the investigation of switchable heat pumps for mobile applications (also R-744, incl. battery conditioning)
  • High temperature refrigeration cycle for butane and R-1234ze(Z)
  • Acoustic investigation of flow noise in refrigeration cycle
  • Climatic chamber for long-term tests of components or e.g. for the investigation of stationary heat pumps
  • Support for test bench design (control strategies, etc.)
  • Water extraction from ambient air (research project)

If required, we supplement the measurements carried out with detailed and thermodynamically based post processing of the measurement data using our in-house software tools.

It is our objective to implement the requests of our customers quickly and flexibly. According to your requirements, we realize new test benches in our test laboratory, with which we investigate your problems and collect the measurement data you require.

For further information about our test facilities please contact Norbert Stulgies (n.stulgies@tlk-thermo.com) or Nicholas Lemke (n.lemke@tlk-thermo.com).


Calculation of multiphase flow in innovative cooling systems

As part of the e-Tractiv research project, TLK is expanding its CFD expertise in the area of multiphase flows. STAR-CCM+ is used to model innovative cooling systems.

In the area of field calculations, we recently started to use STAR-CCM+ in-house, to model complex multiphase flows. A special focus is set on disperse multiphase flows, as they occur in heat exchangers. By modeling the fluid flow in detail, we can improve geometries and the refrigerant distribution.

Flow paths of liquid particles.
Flow paths of liquid particles when distributed on flat tubes of a heat exchanger.

Interoperability

Interoperability is a very important aspect of our 3D models. Using TISC or the FMI standard, we can solve complex thermal problems by coupling 3D component simulations with 0D/1D system models. For example, we are currently working on innovative cooling concepts as part of the publicly funded project e-Tractive with our partners Siemens, Infineon and the University of Bayreuth. Together, we are researching efficient coolers for power electronics used in the operation of regional trains and are linking detailed 3D-CFD simulations with 0D/1D system models.

Optimization

In the automotive sector, we recently successfully completed the SiCModul project, expanding our range of expertise in modeling and simulation of active cooling concepts for power electronics. Our central research topic of the project was the fully automated optimization of a pin-fin-geometry considering heat transfer and pressure loss of the cooling element. In this context, the TLK Optimization Suite was used to find an optimal size based on the results of a conjugate heat transfer simulation of the cooling device.

For further information please contact Björn Flieger (b.flieger@tlk-thermo.com).


Education in the home office: online training courses

We are organizing an online training course on Modelica and TIL from March 15 - 19, 2021.
Further information on training.