It’s important to understand all connected loads and most importantly the diversity of your testing operation. ACS can assist you with evaluating your connected load and applying a diversity factor to determine your overall power needs. Once the overall power requirements are known, an evaluation of your current switch gear and utility feeds can be completed to determine if any upgrades are necessary.
Always start with a solid plan to ensure that the layout of equipment within your test space is well thought out and that all support utilities are available. We recommend hiring an experienced systems integrator and contractors who understand the complexities of a test facility.
Absolutely. We start by understanding and documenting your specific goals and EV testing requirements. From there, we can work with your team to create the design criteria that will guide performance specifications and ultimately, your equipment selection.
ACS works with a wide variety of test equipment suppliers which allows us to choose the best solution for each client and project. Our own internal staff designs and builds custom equipment to fit your specific needs. We can help you evaluate all the options so you can make an informed decision about your equipment for electrification testing.
A battery cycler and a climatic chamber are two key EV components needed for testing battery packs. After that, it really depends on the specific type of development you are planning. Additional testing components may include shaker tables, drop test stations, dust chambers, inverter emulators, etc. We have helped many clients determine exactly what they need, now and for the future.
You will need a power source, an inverter, and a dynamometer to load the e-motor. These functions can be accomplished either via live systems or simulators. Additional components could include a climatic chamber, fluid conditioning for the e-motor and of course, all the necessary safety equipment.
When testing e-motors directly, faster is better. Manufacturers continue to push the limits and increase the output speed of traction motors in vehicle applications. Many new dynamometer systems are in the 20,000 to 25,000 RPM range.
It is difficult to do since manufacturers are developing both higher voltage and higher current packs for today’s and tomorrow’s vehicles. There are modular battery simulator/cycler solutions that provide some modularity, allowing you to increase voltage and current levels.
ACS can work with your team to identify the specific upgrades and safety concerns/considerations required for the transformation to EV testing and put together a plan outlining the various options and associated costs.
ACS has delivered electrified test cells in both traditional brick and mortar as well as modular buildings. The right answer depends on your specific needs and situation. Modular solutions allow more work to be completed off-site and result in less construction/installation on-site. Modular solutions can also be installed as a stand-alone structure, creating separation from existing buildings, which is a safety advantage.
Not necessarily. It is nice to have the extra space to locate some of the support equipment but mounting this equipment on the main level is always an option.
Check with your landlord to be sure you understand any restrictions on your lease. A modular solution may be a good option for you to minimize the construction work to the building.
When deciding open space for your new test stand vs. a dedicated room, it is critical to consider all potential hazards and ensure the new test stand has adequate safety systems in place. This ensures a safe working environment both for the operator and anyone in the surrounding area.
There are two considerations you want to keep in mind. First is whether you plan to conduct any acoustical tests in this cell and second, you will want to make sure the modular cell is acoustically isolated from other sensitive work or outdoor space nearby.
Start first by understanding your connected loads and the diversity of your testing setup. Based on your testing diversity, ACS can assist you in identifying your true power needs and then designing a power distribution system specific for you and your building. If necessary, ACS can work with your utility provider to upgrade your service.
There are several options for providing cooling to your test cells and test articles. The true heat rejection of the test process needs to be understood and then an appropriate HVAC system can be designed.
Yes, we can. It is critically important to have all safety systems fully integrated with any building fire protection or alarm systems. We can also integrate building automation systems such as HVAC and lighting.
A test automation solution will allow data from different sources to be integrated into a single repository at a test cell level. At the lab level, ACS can specify and provide a lab management system that allows all test stands in a lab to be managed on a centralized basis.
A PLC with a SIL (Safety Integrity Level) rating will help reduce the overall risk level of your test process. ACS can help you evaluate the correct SIL and ensure that all safety monitoring devices are properly specified and installed.
The type of testing you are performing will play a large part in determining what you should install for fire prevention and protection. There are several great technologies that can be implemented to best reduce the potential risk of fire. Early involvement of your risk management team as well as the local fire marshal are key to finding the best solution.
The materials and types of testing you are performing need to be evaluated to determine the potential hazards and off-gassing. Any gas detection installed can be tied into the SIL-rated PLC system.
Containing a battery fire is critical to ensuring a safe testing environment. Whether or not a burn box is a viable or optimal solution for your case depends on a host of factors including the size of the pack, the specific tests to be executed (cycling vs. destructive), and its relative location within the facility. Alternative mitigation measures include water bath/deluge, high airflow, inert gas purge, and others. As with other test facility design aspects, ACS can help evaluate and/or validate your options.