DOT TCEM Climatic Systems for E-Motor and Powertrain Testing for TEXA

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Il Disgelo developed for TEXA two different DOT TCEM climatic systems dedicated to testing electric motors and electric-drive systems: a 1.5 m³ chamber for testing a single E-Motor integrated with a dynamometer, and a 6.0 m³ solution with a separate ACU system, developed for E-Motor, e-Axle, powertrain and larger electric-drive applications.

Both systems were designed to reproduce controlled temperature and humidity conditions around the DUT while maintaining integration with dynamometers, support structures, shafts, cooling circuits and external data-acquisition systems.

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Developed Solution

The project integrates two DOT TCEM configurations developed for different test architectures.

The 1.5 m³ solution uses a modular chamber with a movable section and a fixed wall dedicated to interfacing with the test bench. The air-treatment unit and refrigeration unit are installed externally and connected to the chamber through flexible air ducts, allowing the system layout to be adapted to the laboratory configuration.

The 6.0 m³ solution is a larger modular climatic system with a separate ACU, designed to support testing on E-Motors, e-Axles, powertrain systems and other electric-drive components requiring greater usable volume and higher thermal-load management.

The systems were designed to provide:

• controlled climatic testing on E-Motors and electric-drive systems;
• integration with dynamometers and test benches;
• temperature and relative humidity control;
• temperature change rates up to 4 K/min;
• compensation of thermal loads generated by the DUT;
• dedicated feedthroughs for shafts, wiring and cooling circuits;
• modular structures designed to facilitate DUT access;
• connection to external data-acquisition and supervision systems;
• test-cycle management through the CliMaLogic® control system.

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Main Technical Data

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DOT TCEM-40+125 1.5 m³ E-Motor

• usable volume: approximately 1500 L;
• internal dimensions: 1200 × 1100 × 1150 mm;
• temperature range: −40 °C to +125 °C;
• climatic range: +10 °C to +95 °C;
• relative humidity: 10% to 95% RH;
• dew point: +7 °C to +89 °C;
• heating rate: approximately 4 K/min;
• cooling rate: approximately 4 K/min;
• permitted heat load at +20 °C: 6 kW;
• DUT: E-Motor + dynamometer;
• DUT + support weight: approximately 100 kg;
• recirculating air volume: 3000 Nm³/h;
• ACU installed power: 52 kW;
• maximum flexible duct length: 5 m.

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DOT TCEM-40+125 6.0 m³ ACU System

• reference usable volume: approximately 6.0 m³;
• reference internal dimensions: approximately 2800 × 1800 × 1200 mm;
• temperature range: −40 °C to +125 °C;
• climatic range: +10 °C to +95 °C;
• relative humidity: 10% to 95% RH;
• heating rate: up to approximately 4 K/min;
• cooling rate: up to approximately 4 K/min;
• permitted heat load at +20 °C: up to 24 kW;
• configuration: modular climatic chamber with separate ACU system;
• applications: E-Motor, e-Axle, powertrain and electric-drive systems;
• integration: dynamometers, load systems, shafts, cooling circuits and data-acquisition equipment;
• control: DOT PLC with CliMaLogic® software.

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Result

The project enabled TEXA to implement a platform dedicated to climatic testing of electric motors and electric-drive systems, with solutions sized for different DUT dimensions, thermal loads and test-bench configurations.

The DOT TCEM systems combine climatic conditioning, mechanical integration with the test bench, thermal-load management and DUT accessibility within custom solutions developed around the specific requirements of the testing application.