Electronic Vehicle Components: Pressure Testing

Cooling and heating systems are essential for electronic vehicles: they protect against overheating of essential components for the operability of the vehicle and ensure comfort. In order to validate them for use, components are put to the test under changing pressure and temperature conditions. The performance and power consumption of the systems must also be checked in realistic service life tests so that the air conditioning unit and other electronic components do not limit the range of the vehicle. The BMW M-07 is an example of a test standard for a pressure cycle test under changing temperature conditions, as well as an overpressure and underpressure test.

The flow rate of the test medium can vary from 1-50 l/min at a pressure of 0.2-12 bar or higher. The load changes are freely programmable with a sinusoidal or trapezoidal rise at a 0.2-2 Hz test frequency or faster. The test stand can be used for complete systems, assemblies, and components made of various plastics, metals, and sealants. Weak points in the material combination – for example around a weld seam – can be sounded out and optimized early in the development process as well as during production.

A long-term test usually takes 20-30 days, depending on the frequency of the load changes. The temperature and volume flow of the test medium as well as the ambient temperature (if the test takes place in the climatic chamber) vary according to the test specification. The temperature at the inlet and outlet of the test object is measured continuously, as well as the flow rate, pressure, and pressure drop, and current and voltage (both in the high and low range). The focus is on the thermal and electrical performance of the heating and cooling unit under varying environmental conditions. Thermal sensors can be mounted on the product to indicate during the test when energy is lost (thermal bridges) or when the component becomes very hot (and thus presents a fire hazard).

Safe and easy to use

Poppe + Potthoff Maschinenbau test systems are easy to operate and extremely safe. The test chamber consists of welded stainless steel and a high-strength polycarbonate safety window. Any test sequences created on the PC can simply be called up manually via coded recipe management or by a handheld scanner. The integrated LabView software from National Instruments enables efficient data acquisition and visualization. Test procedures and data are automatically stored on the system and can be exported to the network for evaluation. The open software structure makes it possible to integrate additional sensors and data during testing. Poppe + Potthoff Group can provide numerous testing services, remote maintenance, and on-site technicians, if necessary.