Battery, Inverter, Electric Vehicle (EV) Test Enclosures
ACS engineers, integrates and builds modular battery, inverter and electric vehicle test enclosures, optimized to meet customer requirements. Construction features and options include:
- Size and finishes
- Structural base and skeleton
- Floor, walls and doors
- Electrical systems
- Controls
- Safety and fire protection
- Ventilation
- Process systems
Frequently Asked Questions About Planning for and Integrating Electric Vehicle (EV) Test Cell Projects
Safety
What should I install in terms of fire detection and prevention?
The type of testing you are performing will play a large part in determining what you should install for fire prevention and protection. There are several great technologies that can be implemented to best reduce the potential risk of fire. Early involvement of your risk management team as well as the local fire marshal are key to finding the best solution.
I’ve heard of using burn boxes to contain battery fires. Is that an option?
Containing a battery fire is critical to ensuring a safe testing environment. Whether or not a burn box is a viable or optimal solution for your case depends on a host of factors including the size of the pack, the specific tests to be executed (cycling vs. destructive), and its relative location within the facility. Alternative mitigation measures include water bath/deluge, high airflow, inert gas purge, and others. As with other test facility design aspects, ACS can help evaluate and/or validate your options.
Do I need hazardous gas detection in my test cell?
The materials and types of testing you are performing need to be evaluated to determine the potential hazards and off-gassing. Any gas detection installed can be tied into the SIL-rated PLC system.
Test Equipment Considerations
How do I protect for ever-changing voltage and current outputs of battery packs?
It is difficult to do since manufacturers are developing both higher voltage and higher current packs for today’s and tomorrow’s vehicles. There are modular battery simulator/cycler solutions that provide some modularity, allowing you to increase voltage and current levels.
What are the major components I need to test battery packs?
A battery cycler and a climatic chamber are two key components needed for testing battery packs. After that, it really depends on the specific type of development you are planning. Additional testing components may include shaker tables, drop test stations, dust chambers, inverter emulators, etc. We have helped many clients determine exactly what they need, now and for the future.
What are the major components I need to test e-motors?
You will need a power source, an inverter, and a dynamometer to load the e-motor. These functions can be accomplished either via live systems or simulators. Additional components could include a climatic chamber, fluid conditioning for the e-motor and of course, all the necessary safety equipment.
Test Cell Considerations
I have an existing fueled test cell that I want to repurpose for EV testing. What should I consider?
ACS can work with your team to identify the specific upgrades and safety considerations required for the transformation to EV testing and put together a plan outlining the various options and associated costs.
I’ve heard of modular/containerized rooms being used for EV testing. What are the advantages?
ACS has delivered electrified test cells in both traditional brick and mortar as well as modular buildings. The right answer depends on your specific needs and situation. Modular solutions allow more work to be completed off-site and result in less construction/installation on-site. Modular solutions can also be installed as a stand-alone structure, creating separation from existing buildings, which is a safety advantage.
Do I need to have a mezzanine above my test cell?
Not necessarily. It is nice to have the extra space to locate some of the support equipment but mounting this equipment on the main level is always an option.
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