Thermal Testing is widely established today. The tests are comprised of multiple phases. Testing on environmental stress, performance verification, turn-on demonstrations, thermal hardware verification and numerous of tests from cell over stack to pack are part of this testing method.
In today’s electrified powertrain solutions thermal testing method focusses on:
- Battery long-term reliability testing focusing on dis/charging cycles (slow, fast), self-discharge
- Dyno Testing focusing on power, efficiency, reverse load feedback
- Environmental testing in climate chambers (temperature, humidity, pressure, … combined shaker) running on specific use-case oriented test profile
- Misuse and impact testing (overload, short-circuit, overheating, mechanical stress, defect)
- In-vehicle testing, summer/hot, winter/cold testing with transients
Thermal testing methods increase confidence in the design, ensure successful operation and thus its thermal management in all conditions and demonstrate robustness and thermal durability. They verify performances within specifications, measures critical parameters and are used for confirming thermal modelling assumptions.
Although thermal testing is an established testing method, it must deal with upcoming challenges and new requirements, but also to workflow – electrical safety, flexible daily extensions, new sensor and signal types and higher dynamics.