The Challenge
Our client, a global OEM manufacturer specializing in the design and distribution of engines for nearly all vehicle types, needed to expand their R&D testing capabilities. This expansion was essential for new product lines, specifically for truck engines, and involved new technologies like batteries, inverters, and E-motor drive systems and components. Their existing facilities were not equipped for these advanced tests, creating a critical need for a dedicated new space and an experienced test cell enclosure manufacturer on their technical center campus. This specifically included the need for electric vehicle battery testing.
The Solution
ACS, a leading test cell enclosure manufacturer, delivered a comprehensive turnkey solution that established a complete new testing laboratory on the client’s campus, separate from their existing technical center. This innovative approach involved seven modular enclosure units specifically designed for electrification testing. To ensure high quality and minimize disruption at the client’s site, all seven modular enclosure units were constructed and assembled at ACS’ manufacturing facility, which also significantly reduced onsite installation time. Of the seven enclosures, two were dedicated to E-motor testing, two for battery testing (including capabilities for electric vehicle battery testing), and one for inverter tests, with the remaining two housing essential electrical and test cell support equipment. Key test equipment and skidded systems—including enclosure cooling and heating, safety systems, PLC controls, and battery suppression systems—were designed, built, and Factory Acceptance Tested (FAT) at ACS, then installed within the modular enclosures before shipment to the client’s site.
ACS effectively managed site preparations (such as concrete slabs and utility installations) in parallel with the off-site fabrication of the enclosures. This synchronized approach, leveraging ACS’ expertise as a test cell enclosure manufacturer, ensured the client’s ambitious schedule for an operational test lab was met efficiently.
The Outcome
ACS successfully delivered a robust and fully integrated testing complex that significantly enhanced the client’s engine development capabilities. The newly established modular test lab provides the necessary infrastructure for rigorous R&D testing of new product lines, including E-motor, battery, and inverter drive systems and components. This now includes advanced capabilities for electric vehicle battery testing, allowing the client to thoroughly validate their power systems. By managing the project from initial design and fabrication of the enclosures to site preparation and final commissioning, ACS ensured a seamless and rapid deployment of the new facility for advanced electric vehicle battery testing. This project empowers the client to advance their next-generation truck engine technologies, ensuring operational precision, safety, and efficiency in their expanded testing operations.
Key Features
- Test enclosures specifically designed and fabricated at ACS for E-motor, battery, and inverter R&D
- Integrated heating and cooling, safety, battery suppression, and control systems designed, built, and FAT at ACS, and pre-installed in the modular enclosure units
- New substation and comprehensive new electrical distribution for all seven enclosures at the customer site
ACS Services
- Turnkey design, engineering, integration, and fabrication of seven modular enclosures
- Managed site preparation, including concrete footings, pads, utilities, and support systems
- Fabricated and installed control panels, instrumentation, and devices at ACS manufacturing
- Designed, built, installed, and integrated systems for heating and cooling, safety, and battery hazard suppression
- Commissioned all ACS-provided equipment and controls within the enclosures prior to shipment and completed final commissioning after delivery to the client site
