Industrial cooling is a critical support system for manufacturing and testing sites, where precision is paramount and chilled water systems are used to maintain the exact temperatures required for smooth operations. Without them, companies risk increased downtime, spoiled products or even safety hazards. This dependency on chilled water systems is especially evident in automotive dynamometer testing.
As the automotive industry pivots toward electrification, chilled water systems are being pushed to their limits in the development and manufacturing process of electric vehicle (EV) components. EV components go through rigorous testing to ensure they meet performance standards, which require different thermal loads and higher demands. As testing evolves, so too must chilled water systems, which must provide precise cooling to maintain optimal operating conditions. Chilled water system upgrades focus on expanding capacity and smarter operations.
An automotive manufacturer recently embarked on a project to address these challenges. The project involved upgrading the controls for its chilled water system to meet the increased demands of EV testing, specifically transitioning from internal combustion engine (ICE) testing to rigorous evaluation of electric drive motors (EDM).
Traditionally, the term “aftermarket” has been linked with replacing worn-out components. This project, however, highlights an expansive view, where aftermarket includes upgrades that extend system capabilities and make the existing infrastructure more intelligent, efficient and effective. The updated chilled water system showcases how legacy systems can adapt to modern challenges without requiring complete overhauls. The updated system is expected to deliver the following:
- Enhanced cooling capacity: The system will handle increased thermal loads, ensuring it can keep up with the demands of new EV testing parameters.
- Improved system oversight: Real-time monitoring and data analytics will provide operators with the tools to proactively manage the system, reducing the risk of downtime and enhancing overall reliability.
- Energy savings: Dynamic pump control will eliminate the inefficiencies of constant-speed operation. By running pumps only as needed, the system will optimize energy use, reducing costs and unnecessary carbon emissions.
Intelligence & Connectivity
Seamless integration with the existing building management system (BMS) was a priority for this project. To achieve this, the control system and associated input/output were chosen for their modular architecture and ability to communicate effortlessly with the manufacturer’s BMS. This integration also ensured the control system would have flexibility and scalability to adapt to future infrastructure needs.
A key design element of the project was the split system design, which consists of a main control panel and three remote panels. This was chosen to accommodate the distribution of equipment across the facility. One challenge identified in the planning of this project was the distances between the control panels, which at times exceeded the standard 100-meter range of traditional Ethernet cabling. To overcome this, fiber optic cables were used as the communication medium, extending the range to up to 2,000 meters.
Beyond meeting current connectivity needs, using fiber optic cables provides additional scalability to support future expansion or system modifications without major infrastructure changes. This approach ensures the communication backbone of operations remains reliable and delivers high-speed, interference-free performance as the facility expands or adopts new technologies.
Field instrumentation plays a vital role in achieving precise control over the chilled water network. Advanced sensors and monitoring tools, such as pressure sensors, flow meters, temperature monitors, pumps, control valves and heat exchangers, ensure every aspect of the system operates efficiently and reliably.
The integration of a human-machine interface (HMI) further enhances the system’s usability. By consolidating data from the remote panels and field instrumentation, the HMI provides operators with a view of all critical metrics, including pressure, flow rates, temperature and equipment status. Centralized monitoring of subsystems is essential for making informed decisions, quickly addressing system irregularities and using predictive maintenance to prevent potential issues before they arise.
Predictive Maintenance Strategies
The success of predictive maintenance hinges on the ability of the control system and BMS to process and analyze data effectively. The upgraded chilled water network in this project incorporates advanced technologies designed to support predictive maintenance at every level.
- Real-time data collection: Upgrades to field instrumentation, including pressure sensors and flow meters, create a robust network of data points. These components act as the eyes and ears of the system, continuously streaming information to the centralized control platform.
- Centralized monitoring and analytics: The modular control platform integrates seamlessly with the BMS, enabling operators to analyze real-time metrics through a single dashboard. Advanced algorithms identify trends and patterns, flagging deviations.
- Alarm and notification systems: Integrated alarms and alerts notify the maintenance team the moment an issue arises. This minimizes operational disruptions.
- Historical data analysis: The BMS stores historical performance data, allowing operators to track long-term trends and predict future maintenance needs with greater accuracy. For example, recurring instances of minor flow restrictions might signal progressive valve blockages.
Advanced Technologies for Energy Efficiency
Another cornerstone of the project was the introduction of variable frequency drives (VFDs) for the chilled water pumps. VFDs dynamically adjust pump speeds to match real-time cooling demand. This eliminates unnecessary energy use during periods of lower demand while ensuring sufficient cooling capacity during peak loads. VFDs function by varying both the voltage and frequency supplied to the electric motor, which allows for precise speed and torque control. The control logic, often integrated with sensors and automation systems, uses real-time data to determine the optimal pump speed at any moment. In terms of sustainability, VFDs are instrumental in supporting facility energy goals. Because they ensure pumps operate only at the speeds needed, they avoid wasteful 24/7 full-speed operation. Over time, this can translate to substantial reductions in both utility bills and the facility’s carbon footprint, making VFDs a critical tool for organizations seeking to comply with energy efficiency standards and environmental regulations.
Lessons for the Industry
This case study offers valuable insights for other industrial facilities considering aftermarket solutions.
- Start with a comprehensive evaluation: Early planning is crucial. For example, recognizing the limitations of Ethernet cables and planning for fiber optics avoided costly delays. Foresight is key to successful aftermarket upgrades.
- Maximize existing infrastructure: Investing in control system upgrades, rather than wholesale equipment replacements, proves that gains can be achieved at a fraction of the cost.
- Leverage advanced technologies: Integrating technologies like VFDs and modular control platforms demonstrates how existing systems can embrace innovation, maintain core functionality and achieve energy cost savings.
With careful planning and execution, aftermarket solutions provide the tools needed to thrive in a fast-changing market without discarding investments in legacy infrastructure.
