Measuring and testing in the high-voltage range
Whether it's range, charging time, operating costs or safety - with the advent of electric mobility, the battery is taking on a decisive role in the value chain of the e-vehicle. This results in new requirements for measuring and testing. Be prepared for the future and rely on our expertise! With our reliable and safe measurement systems, we offer solutions for every application in the HV sector. Hardware and software are perfectly matched and enable efficient testing, analysis and validation in the entire e-mobility environment.
E-mobility solutions from a single source
The new drive technology for electric and hybrid vehicles places technological as well as safety-relevant demands on manufacturers and suppliers. Electric energy storage units and drive units with voltages of up to 1000 VDC are used. This requires the highest level of quality and safety.
With IPETRONIK high-voltage measurement technology and our specialists, we carry out a wide range of measurements on high-voltage components. We provide meaningful data on the functionality, efficiency and driving behaviour of electric and hybrid vehicles and safely upgrade and disassemble your vehicles and fleets.
In addition to bench testing of the individual components, system testing during a road endurance run is essential. User behaviour, driving operation and ambient temperatures have a great influence on the overall performance of an electric vehicle. With our system of services, data loggers and high- voltage measurement technology, we are able to test the vehicle under real conditions.
Our service portfolio
- Testing of electric and hybrid vehicles
- Fleet tests and endurance tests
- Investigation and development of thermal management
- Acoustic measurement during charging current processes
- Measurement of charging current and energy inflow
Electric and hybrid vehicle testing
With our high-voltage solutions for current, voltage and temperature, you can record all relevant measured variables. We optimally cover all applications in terms of functionality, efficiency and operational stability and, with the combination of IPEmotion software and IPETRONIK hardware, offer a perfectly coordinated overall system for every application. Our specially trained team takes care of the installation, commissioning - if necessary testing - and data evaluation of test items, as well as the calibration and subsequent dismantling of the test vehicles.
Fleet endurance testing
We carry out your complete fleet projects with electric and hybrid vehicles. Typical use cases of endurance tests are, for example, investigations of driving situations, driving behaviour, discharge procedures and consumption measurement according to e-vehicle- specific driving cycles. The recorded data can be transferred directly to our IPEcloud or to your servers via remote data transmission. The system also provides you with daily status reports and error analyses. Vehicle inspections, conversions or adjustments are carried out at any time in our Technical Centre or by our technicians on site.
Thermal management and investigation
When considering efficiency, air conditioning/thermal management has the highest energy consumption in the vehicle - after the drive. With our focus on vehicle air conditioning, thermal management and eKMV validation, we provide you with appropriate solutions. Our system test bench facilities, component tests, climate chambers and simulation modules enable us to realistically simulate real-life conditions and thus ensure efficient thermal management.
As a specialist in the acoustics of air conditioning components, we offer solutions for acoustic and vibration engineering tasks. In our air-conditioning acoustics chamber, we carry out noise investigations of the drive technologies of electric and hybrid vehicles or the electric refrigerant compressors (eKMV). Disturbing noise components/vibrations are analysed in the exterior (front fan, eKMW, ...), interior (cabin fan, eKMW, ...) and transfer path (airborne noise, structure-borne noise, ...).
Charging current and energy measurement
Measurements of charging current and absorbed energy at the chargepoint are of particular importance to improve efficiency, usability and battery durability. Our HV charging station achieves a charging power of up to 350 kW and enables DC fast charging in addition to AC charging. This allows parameters of the charging process, e.g. energy loss rate, time factor or battery life, to be optimally analysed. The column is integrated into our climate- acoustics chamber - this also enables typical acoustic test scenarios that occur during a charging process to be carried out (such as the analysis of disturbing noises, vibrations and oscillations in the 'vehicle & charging column' system network).
Find the right solution!
HV Charging Column Acoustic Chamber
The acoustic chamber with HV charging column offers a wide range of possibilities for acoustic testing of vehicles, vehicle subsystems and general technical superstructures. Designed as a semi-open-air room with large hinged doors on two sides, the acoustic chamber has a vehicle lifting platform that allows very flexible control and modification of test setups already being tested. The combination of HV charging station and acoustic environment supports tests and development steps, as recently demanded in automotive engineering with purely electric vehicles and fast charging technology.
Function Test Bench Refrigerant Compressor
In the modern development of vehicle air conditioning and in connection with thermal management, the technical design or the validation of the function of the refrigerant compressor is the focus of the holistic development process. Especially due to the changing requirements in the automotive sector, it is indispensable to reproduce a flawless function of the test item to be tested by means of reliable test bench equipment. Be it in the classic AC mode or in the now increasingly important heat pump mode. The interaction of sustainable hardware in the test bench and the coordinated control in the form of the in-house software IPEmotion make this test bench a unique product in the service sector of the automotive industry.
Development-accompanying investigations of electric refrigerant compressors
In the early development phase of the electric refrigerant compressor, a variety of assurances for durability, efficiency and performance are necessary even before the actual design and process validation tests. For this purpose, there are test cases that require flexibility in their requirements and mapping while maintaining high quality standards. Here, IPEengineering's experience in handling such complex setups is unique in the service field. Through a strong team of engineers and technicians who have built up years of experience in the evolution of refrigerant compressors, the development accompanying tests from the start of development to the finished product provide a complete package in the service sector of the automotive industry.
Thermal Management Service on Test Benches
Thermal management is a key topic in vehicle development that is taken into account in the development process right from the start. Valuable development steps can be taken at an early stage on a TC5:E5hermomanagement system test bench. By integrating calculation models and simulators/emulators, qualitative statements on systems, components and control strategies for cooling, heating and refrigeration circuits could be made at an early stage of development (without a vehicle). In addition, early testing of operating strategies is possible. In further phases of development (including series production support), problems can be reproduced and causes investigated in a reproducible environment.
System Test Benches and Air Conditioning Modules
Our range of services also includes system test benches and individual air conditioning modules. Complete vehicle air conditioning circuits with their components and various refrigerants can be tested under real environmental conditions on system test benches. Thanks to their modular design, the test benches can be flexibly adapted to different air conditioning systems, thus reducing set-up times. The use of so-called test carts plays a particularly important role here. This means that a new circuit can be set up on its trolley outside the test stand while tests are still being carried out on the test stand with another circuit. This not only makes more effective use of the setup time, but also reduces the downtime of the test stand. The necessary media supply modules for air conditioning and coolant circuits (IPEsim) can be individually assembled and operated according to customer requirements. Temperature, humidity and air mass flow are set with a very high control quality and accuracy to ensure reproducible test results.
Thermal Management System Test Bench
Thermal management is a key topic in vehicle development that is taken into account in the development process right from the start. Valuable development steps can be taken at an early stage on a thermal management system test bench. By integrating calculation models and simulators/emulators, qualitative statements on systems, components and control strategies for cooling, heating and refrigeration circuits could be made at an early stage of development (without the vehicle). In addition, early testing of operating strategies is possible. In further phases of development (including series production support), problems can be reproduced and causes investigated in a reproducible environment.
System Test Bench
In the age of e-mobility, the refrigerant circuit serves not only to provide comfort air conditioning for the passenger cabin, but also to cool the electric drive train and the battery. It thus becomes one of the central subsystems of the vehicle and must be taken into account from the very beginning of development. Since neither vehicles nor subsystems are usually available at this early stage, the ducts, evaporators and other heat exchangers are built geodesically. The powertrain and battery are represented by emulators, and conditioned air is applied to the indoor evaporators. The air path for the condenser simulates temperature and driving speed. This allows caloric (performance) evaluation of the system, testing of different interconnections, comparison of different components, and development of operating strategies.
Component Test Bench
The measurement of thermodynamic properties of refrigerant circuit components is of great importance in the development of automotive components (and systems). Our measurement results are often used as a basis for decision-making for series production as well as for the analysis of optimization potentials or unique selling propositions. As a manufacturer- independent test center with many years of cross- industry experience in the field of thermodynamics, IPETRONIK offers component measurements including well-founded evaluations. OEMs and Tier 1 suppliers as well as development partners benefit from our services.