NEV Thermal Management Component Testing

New Energy Vehicle Thermal Management System Key Components Testing Solutions

In traditional fuel vehicles, thermal management mainly serves the engine and air conditioning system. In new energy vehicles, however, the scope of thermal management has been greatly expanded. Every core component — battery, motor, electronic control system and air conditioning system — has stringent temperature requirements.

The core components of the thermal management system fall into two categories: first, various pipelines for medium transmission, including coolant pipelines, refrigerant pipelines and air-conditioning pipelines; second, cooling plates responsible for direct heat exchange, such as water-cooled plates, liquid-cooled plates and direct-cooled plates. The reliability of these components directly determines the efficiency of the thermal management system, and further affects the safety and service life of the entire vehicle. With years of experience in R&D of testing equipment, Getes now provides an in-depth analysis of the pain points and targeted testing solutions for key components of new energy vehicle thermal management systems.

Diversified Test Media and High Compatibility Requirements

Thermal management test media for traditional vehicles are relatively single, mainly coolant. By contrast, new energy vehicle thermal management systems involve a wider variety of media, including glycol coolant, refrigerant (R134a), battery coolant and more.

These media differ greatly in chemical properties, corrosiveness and viscosity. Some are corrosive, which may affect the pipelines, pumps, valves and seals of the test bench during long-term cyclic testing. In addition, cleaning and replacement are time-consuming when switching between different media.

To address this pain point, Getes has developed a complete set of test equipment to meet testing requirements including pressure cycling, pressure burst resistance, high and low temperature cycling, and air tightness.

In terms of media compatibility, Getes pulse test benches support water, glycol, antifreeze and other media. For pulse testing of water-cooled and liquid-cooled plates, a mixture of 70% glycol and 30% aqueous solution can be used as the test medium. For refrigerant pipeline testing, our equipment supports R134a refrigerant or hydraulic oil as the working medium, satisfying the testing demands of air conditioning pipelines and direct-cooled plates.

Wide Temperature Control Range and Thermal Shock Resistance Test

The operating temperature range of NEV thermal management systems is far wider than that of traditional vehicles. The inlet temperature of battery coolant may fluctuate between -30℃ and 60℃, and air conditioning pipelines undergo drastic temperature changes under cooling and heating modes.

More importantly, thermal management components must withstand not only steady-state temperature but also thermal cycling shock — rapid temperature swings from extremely low to extremely high levels in a short time, which may cause material fatigue and seal failure.

The medium temperature range of Getes servo pulse test benches covers 10℃~130℃, with the ambient temperature ranging equally from 10℃ to 130℃, fully meeting the testing demands of NEV thermal management components under normal operating temperatures.

Taking water-cooled plate testing as an example, the system can realize cyclic temperature changes: medium temperature rises from 20℃ to 80℃, drops back to 20℃, and further decreases to -40℃, with a temperature change rate of 2.5~10℃/min.

Complex Pulsating Working Conditions and Diverse Waveform Requirements

The pressure pulsation characteristics of NEV thermal management systems differ significantly from those of traditional hydraulic systems. Frequent pressure fluctuations are generated by the start-stop of water pumps and the opening/closing of valves in battery cooling loops.

In air conditioning pipelines, the start-stop of compressors and regulation of expansion valves also produce complex pressure pulses, featured by diverse waveforms accompanied by temperature variations.

Getes pulse test benches support adjustable multiple pulse waveforms, including triangular wave, sine wave, trapezoidal wave and quasi-square wave.

For pulse testing of water-cooled and liquid-cooled plates, the equipment can complete 10,000 pressure cycles at medium temperature of -20℃±3℃ and ambient temperature of -40℃±3℃, followed by 90,000 pressure cycles at medium temperature of 80℃±3℃ and ambient temperature of 80℃±3℃, with a temperature change rate of 1.3~3℃/min.

High Leakage Detection Standard and Critical Sealing Performance Verification

In NEV thermal management systems, coolant leakage may lead to battery short circuit, while refrigerant leakage will degrade air conditioning performance. Especially for scenarios with strict air tightness requirements, micro-leakage detection is highly challenging, and the traditional bubble leak detection method is limited in accuracy and efficiency.

Getes provides integrated air tightness and water immersion test benches with full computer automatic control. The test pressure ranges from 3~600 bar (0.3~60 MPa), with a pressure display accuracy of 0.1 bar.

Leakage judgment adopts a combined method of bubble recognition (wet testing) and automatic pressure drop measurement per unit time. The pressurization time for a single workpiece is about 10 minutes, and the pressure holding time can be arbitrarily set within 1~9999 seconds.

The rapid development of new energy vehicles has posed new challenges for key components of thermal management systems. From media compatibility and wide temperature range coverage, to complex pulse waveforms and high-precision leakage detection, every pain point places comprehensive demands on the capability of test equipment.

With in-depth expertise in the field of testing equipment, Getes has launched dedicated testing solutions tailored to the special requirements of NEV thermal management key components. Our product portfolio covers full-dimensional verification capabilities including pulse test benches, burst test benches, thermal cycling test benches, and air tightness test benches.

If you have testing demands for NEV thermal management components or plan to upgrade your laboratory testing capabilities, please feel free to contact us.

New Energy Vehicle Thermal Management System Key Components Testing Solutions

Diversified Test Media and High Compatibility Requirements

Wide Temperature Control Range and Thermal Shock Resistance Test

Complex Pulsating Working Conditions and Diverse Waveform Requirements

High Leakage Detection Standard and Critical Sealing Performance Verification

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