DOT TCEM Back-to-Back Climatic System 2 × 1.2 m³ for TEXA

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Il Disgelo developed for TEXA a DOT TCEM Back-to-Back climatic system consisting of two independent 1.2 m³ chambers, designed for simultaneous climatic testing of two electric motors connected in a Back-to-Back configuration.

The two chambers are connected to a separate ACU unit, which integrates two independent air-treatment systems, one for each test compartment. This architecture allows autonomous and precise control of the climatic conditions around the two E-Motors during functional testing, durability cycles and validation activities.

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Developed Solution

The configuration was specifically designed for E-Motor Back-to-Back applications, in which two electric motors are tested simultaneously inside two separate climatic environments.

Each chamber has its own supply and return air circuit, connected to the central ACU through flexible insulated ducts. The modular configuration allows the chamber layout to be adapted to the test-bench arrangement and facilitates installation, access and maintenance of the DUTs.

The system was designed to provide:

• simultaneous climatic testing on two E-Motors;
• dedicated Back-to-Back configuration;
• independent climatic control for each chamber;
• integration with dynamometers and test benches;
• temperature and relative humidity control;
• temperature change rates up to approximately 4 K/min;
• compensation of thermal loads generated by the motors;
• dedicated feedthroughs for shafts, wiring and cooling circuits;
• modular chambers with removable sections for easier DUT access;
• connection of the chambers to the ACU through flexible ducts up to 5 m;
• test-cycle management through the CliMaLogic® control system;
• data acquisition and export, with connection to external systems.

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Main Technical Data

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DOT ACU TCEM-40+125 – Double 1.2 m³ Back-to-Back

• number of chambers: 2 independent;
• usable volume per chamber: approximately 1.2 m³;
• internal dimensions per chamber: 1000 × 1000 × 1200 mm;
• external dimensions per chamber: approximately 1200 × 1200 × 1400 mm;
• temperature range: −40 °C to +125 °C;
• temperature deviation: ±1 K;
• climatic range: +10 °C to +95 °C;
• relative humidity: 10% to 95% RH;
• humidity deviation: approximately ±3% to ±5% RH;
• dew point: +7 °C to +89 °C;
• recirculating air volume: 3000 Nm³/h per chamber;
• heating rate: approximately 4 K/min;
• cooling rate: approximately 4 K/min;
• permitted heat load at +20 °C: 6 kW per chamber;
• DUT: E-Motor + dynamometer;
• DUT + support weight: approximately 100 kg per chamber;
• cable feedthroughs: 5 × DN125;
• cooling circuit feedthroughs: 4 × DN32;
• shaft feedthrough: approximately 500 mm;
• maximum air-duct length: 5 m.

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ACU – Air Conditioning Unit

• configuration: separate ACU with two independent air-treatment systems;
• external dimensions: approximately 2500 × 2200 × 2400 mm;
• weight: approximately 1500 kg;
• installed power: 58 kW, up to 92 kW in the specified configuration;
• refrigeration system: Dorin two-stage compressor;
• refrigerant: R452A or equivalent;
• condenser cooling: water-cooled;
• cooling dissipation: up to 107 kW;
• power supply: 400 V ±10%, 50 Hz, three-phase + neutral + earth;
• control: DOT PLC with CliMaLogic® software.

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Result

The project enabled TEXA to implement a system dedicated to Back-to-Back climatic testing of electric motors, allowing two E-Motors to be tested simultaneously under controlled environmental conditions inside two independent chambers.

The combination of two 1.2 m³ climatic compartments, a separate ACU with dual air treatment, modular architecture and integration with the dynamometer test bench provides a flexible solution for functional testing, durability cycles and validation activities on electric-drive systems.