How To Design And Build EV Test Cells

February 28, 2024 - Author: Randy Rozema - Director, Acoustics & Vibration

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Electrification in automotive industry


Electrification in Automotive Industry and Systems Integration Management

In the realm of evolving electrification in automotive industry, there’s a rising demand for advanced EV integrated building systems. These intricate systems require seamless integration of components tailored to diverse testing needs. Electrification test facilities, for instance, need specialized elements like battery simulators, chassis/powertrain dynamometers, and high voltage charging systems. Similarly, traditional internal combustion engines have unique requirements, including exhaust systems and emissions analysis equipment.

Regardless of the test cell type, smooth collaboration among components is vital for accurate testing. This is where systems integration management comes into play. Without their expertise, constructing an automotive test cell would be challenging, risking costly errors and delays. Systems integrators possess the technical know-how to plan, design, and construct a functional system that meets testing goals.

They also ensure safety, compliance, and optimize performance. In essence, their involvement ensures not only the successful integration and operation of the facility but also contributes significantly to the success and reliability of the testing processes.

In the article published in Assembly Magazine, Randy Rozema, Principal and Director of Applications Engineering, and Ed Marriott, former Equipment Project Manager, address the mistakes to avoid and prerequisites for a systems integrator in the design and construction of EV test cells. Check out the full article to learn about:

Mistakes to Avoid:

  1. Misaligned stakeholder objectives – Failing to adopt a unified approach that considers the broader context may result in facility limitations, impacting test cell capabilities and workflow efficiency. This can lead to lagging behind industry competitors and missed opportunities for market share.
  2. Overlooking new opportunities – Despite possessing extensive knowledge of existing test cells, test engineers may miss out on alternative marketplace options and innovative industry approaches that enhance efficiency, increase throughput, or give superior data.
  3. Absence of a project champion – Assigning test cell integration tasks to an engineer or facility manager, alongside their primary responsibilities, can be overwhelming. Engaging with a dedicated systems integrator often proves to be a more effective alternative.

Prerequisites for a Systems Integrator:

  1. Clearly defined project integration role – An organization that outlines its testing goals can effectively align with a qualified systems integrator possessing relevant expertise and hands-on industry experience.
  2. Emphasis on comprehensive planning and design – To avoid common pitfalls during test cell construction, thorough planning in the early stages is crucial. A systems integrator, with comprehensive project knowledge, efficiently plans and designs within budget, scope, and schedule to meet industry standards and testing goals.
  3. Inclusive communication for stakeholder alignment – Successful system integrators actively engage and seek insights from all involved parties, spanning from the C-suite to engineers and suppliers to the construction team, ensuring seamless alignment.
  4. Dedication to knowledge transfer – Systems integration management extends beyond completion, requiring effective knowledge transfer for seamless system operation and maintenance once the manufacturer concludes involvement.

Conducting comprehensive research and evaluation is crucial when choosing a systems integrator for an automotive test cell project. This ensures selecting the right professional, guaranteeing timely completion, staying within budget, and meeting the highest standards of quality and safety.

Read the full article here.