Testing

In addition to the classic endurance tests, in which the products are tested for their endurance and durability according to customer specifications, we also offer these test scenarios with environmental simulations, such as temperature and humidity, in order to test the products under all possible conditions. We have a wide variety of test systems at our disposal: Dyno test benches, Back-to-back test benches, charging stations and OBC-Charger test benches. Furthermore, we carry out all necessary high-voltage tests in our test laboratory.

Endurance and Reliability Testing

  • Test conditioning using cooling water and/or oil according to customer requirements from -30°C to 130°C
  • Temperature conditioning from -72°C to 185°C
  • DC source up to 1000V and up to 1000A
  • Fully automated, flexible test bench control
  • Continuous supervision of endurance tests
Endurance Tests:
  • PTCE - Powered Thermal Cycling Endurance
  • HTOE - High Temperature Operating Endurance
  • HTHE - High Temperature High Humidity Endurance
  • TS - Thermal Shock Requirements
  • THC - Thermal Humidity Cycle
  • SSTE - Shipping/Storage Temperature Exposure

Services

  • Creation of customer-specific endurance tests
  • Component inspection and analysis
  • Measuring point application
  • Measurement data evaluation
  • Report compilation

Example of an OBC test setup

This on-board charger test setup shows the climate chamber in which the test object is located and the connected conditioning unit, which regulates the temperature and humidity to which the test object is exposed. In addition, the climate chamber is connected to a wallbox and a Dewetron power analyzer, which also contains the source-drain power supply unit. It can be controlled either with PA-Tools or with imc Studio.

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 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.

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.

Preparation of a two-axis test rig for a durability test of an electric machine

This test bench is being prepared to subject a high-performance e-machine to an endurance run and performance test. For this purpose, the power is distributed to two wheel-output machines.

Operation of a gearbox test bench

Here, on a three-e-machine test bench, a continuously variable transmission is tested for functionality, efficiency, and durability

Example of a Back-to-Back test setup

In the back-to-back test, the electric machines are tested in coupled operation. These can be controlled by the customer's own inverters or those provided by us. The environmental conditions are regulated here. We also have the option of testing the inverters in the same test environment or in a seperately connected climate chamber. The DUTs can also be temperature-controlled between -30°C and 130°C with conditioning units.