Testing

Testing

In addition to the classic durability tests, in which the test items are tested for their durability according to customer requirements, we also offer the option of testing with environmental simulation. Temperature and humidity can be varied in order to test the test items under all potential environmental conditions. Various test systems are available for this purpose: dyno test benches, back-to-back test benches, inverter test benches as well as battery module cycler test benches. In addition, we have the option of carrying out all necessary high-voltage tests in our test laboratory.

Durability and reliability tests

  • Testing of:
    • Electric Motors
    • Inverter
    • E-axles
    • Battery modules
    • DUT conditioning for cooling water and/or oil according to customer requirements from -40°C to 130°C
    • Temperature conditioning of the environment from -72 °C to 185 °C
    • DC source-sink with up to 500kW at up to 1000V and up to 2000A
    • fully automated, flexible test bench control
    • continuous supervision during endurance tests
Standart-Test-Portfolio:
  • IEC 60068-2-1
  • IEC 60068-2-14
  • IEC 60068-2-2
  • IEC 60068-2-30
  • IEC 60068-2-38 
  • IEC 60068-2-67
  • IEC 60068-2-78 
  • ISO 16750-4, Damp heat steady 
  • ISO 16750-4, High temperature 
  • ISO 16750-4, Hum heat cyclic 
  • ISO 16750-4, Low temperature 
  • ISO 16750-4, Temp.cycling 
  • ISO 16750-4, Temp.steps 
  • VW 80000
  • LV123
  • LV124

Services

  • Creation of customer-specific durability tests
  • Component assessment and analysis
  • Measuring point application
  • Measurement data evaluation
  • Reporting

Examples of test setups

Example of two battery module cycling endurance runs

This setup shows two battery module cycler test benches. The modules are each located outside in 1500l climate chambers, which are housed in containers. The cycling is carried out using one of our VES 4.1c systems with up to 1000V, 1000A and 300kW. The test runs are fully automated with PATools from Kratzer (NI / Emerson) and of course run 24/7.

Example of an invertr PTCE endurance run

This setup shows a continuous temperature change for 5 inverters in parallel. These are cooled by 5 separately adjustable cooling circuits in the range of -25°C to 65°C and are all located together in a 1000l climate chamber. The inverters are supplied on the DC side via one of our VES 4.1c systems with up to 1000V, 1000A and 300kW. On the AC side, they are loaded via passive loads with up to 700A. The DC/DC converters integrated in the inverters are also loaded by regenerative loads.

Example of a OBC HTOE endurance run

This setup shows an on-board charger high-temperature endurance test, in which the test object is in a climate chamber for environmental simulation during the test. The temperature and humidity to which the OBC are treated by a Lauda XT1850 conditioning unit regulated. The OBC is powered by a wallbox. This current is discharged via a sink (power supply unit). These currents can be measured and monitored using a Dewetron power analyzer. The control can be carried out either with PAtools or with imc-Studio.

Example of a back-to-back test setup

In back-to-back tests, electric machines are tested in coupled operation. These can be controlled by the customer's own inverters or those provided by us. In the setup shown, the ambient conditions are regulated in a climate chamber. It is possible to test the inverters in the same test environment or in a specially provided climate chamber. The cooling media of the test objects can also be tempered between -30°C and 130°C using conditioning units.

Example of a thermoshock test

The new ShockEvent D 210 thermoshock chamber from Weisstechnik is suitable for vibration-sensitive measuring technology and sensors thanks to its static test chamber, as well as for test objects that are to be temperature shocked without any other influences. The three chambers can be used to run 3-zone tests. The heat chamber ( 50°C to 225°C), the test chamber (-65°C to 200°C) and the cold chamber (-80°C to 0°C) allow test objects to be shocked within a very short time by the abrupt temperature change in the motionless test chamber.

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