MASERATI PROJECT

Installation of 3 DOT TCEM Climatic Chambers – Maserati Modena

Three DOT TCEM 2.7 m³ climatic chambers were installed at the Maserati facility in Modena for the thermal and climatic validation of electric traction systems under controlled environmental conditions.
 

The chambers were engineered for testing complete electric motors with transmission assemblies, integrated directly with external dynamometer benches and capable of managing active dissipation up to 10 kW at −40 °C.

Application Requirements

The project required:
 

• Temperature range from −40 °C to +120 °C

• Thermal gradients up to 4 °C/min according to IEC-EN-60068-3-5

• Permissible dissipation of 10 kW at −40 °C

• Humidity control from 20 % to 95 % RH

• Climatic operating field between +10 °C and +90 °C

• High thermal stability (±0.5 °C over time)

• Mechanical integration with dynamometer test benches

• Advanced safety systems for electric powertrain testing

Mechanical Architecture

The TCEM chambers are built with a dual stainless-steel half-shell structure consisting of:
 

• A fixed section interfaced with the test bench

• A movable section to simplify motor installation and maintenance

Total insulation thickness of 150 mm (polyurethane + mineral wool) ensures thermal stability and energy efficiency.

Sealing between the shells is guaranteed by double silicone gaskets with reinforced mechanical locking systems.

The chambers include:
 

• Configurable cable feedthroughs

• Fluid connections

• Air interface ducts

• Provision for inertization systems

Refrigeration and Air Treatment System

Each chamber is equipped with:
 

• DORIN two-stage compressor

• Water-cooled condenser

• Direct expansion refrigeration system

• Electric heating elements with SIL-rated protection

• PT1000 temperature sensors and capacitive humidity probes

The system can integrate continuous nitrogen inertization and internal/external oxygen monitoring.

Control and Supervision

The chambers operate via the DOT PLC platform with CliMaLogic® software:
 

• Up to 500 programmable cycles × 20 steps

• Programmable macro sequences

• Ethernet remote supervision

• Modbus TCP/IP integration

• Continuous data logging with CSV export

Operational Performance

• Temperature range: −40 °C to +120 °C

• Thermal gradient: 4 °C/min

• Permissible dissipation: 10 kW at −40 °C

• Relative humidity: 20–95 % RH

• Climatic field: +10 °C to +90 °C

• Sound pressure level at 5 m: 73 dB(A)

Project Outcome

The installation of the three TCEM chambers enabled Maserati to:
 

• Validate electric powertrain systems under extreme climatic conditions

• Perform repeatable thermal cycles compliant with international standards

• Integrate climatic control directly into existing dynamometer benches

• Operate safely thanks to SIL-rated protections and inertization systems

The TCEM solution represents a modular, high-reliability platform for advanced electric powertrain testing in high-performance automotive environments.

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