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Drive-in climate solar chamber at Škoda Auto a.s. for testing electric cars.

Škoda Auto a.s. tests the resistance of its cars to various negative environmental influences that have a direct impact on the final quality and service life of individual models rolling off the production line. A very common testing requirement is the need to test the car's resistance to climatic influences such as different temperatures, humidity, and solar radiation. For such tests, Škoda Auto a.s. uses equipment in its laboratories and testing facilities in Mladá Boleslav and at other locations, not only in the Czech Republic.

Request from Škoda Auto a.s.

Škoda Auto a.s. tests the resistance of its vehicles to various negative environmental influences that have a direct impact on the final quality and service life of individual models rolling off the production line. A very common testing requirement is the need to test the car's resistance to climatic influences such as different temperatures, humidity, and solar radiation. For such tests, Škoda Auto a.s. uses equipment in its laboratories and testing facilities in Mladá Boleslav and at other locations, not only in the Czech Republic.

Our long-standing partner, Škoda Auto a.s., has decided to expand its testing facility in Mladá Boleslav with a special large-volume climatic solar chamber that can accommodate entire vehicles. In such a chamber, it is possible to test entire vehicles as well as individual parts or components against the effects of extreme climatic conditions and solar radiation.

At first glance, our partner's request for a drive-in climate chamber for aging testing according to DIN 75220 was relatively simple and straightforward, as the technical specifications were based on this well-known standard. Unlike previous generations of climate chambers, when we delivered the first chamber of this type in Czechia to the quality department at Škoda Auto a.s. in 2008, this new device must meet the requirements for testing electric passenger cars and their derivatives. In practice, this means that there is a strong emphasis on the safety of using the entire testing system.

The minimum requirements for the test area were strictly defined so that the climate chamber could accommodate vehicles with a maximum length of 5500 mm, width of 2500 mm, and height of up to 2000 mm. Considering that 28 powerful metal halide lamps for simulating sunlight also need to be placed in such a space, entering such a test chamber will, with a slight exaggeration, resemble entering a small sanctuary.

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View of the solar climate chamber solution.

For implementation, we decided to come up with a technical solution from proven suppliers of equipment in the field of climate and solar testing. The solution is mainly a combination of equipment and components from WeissTechnik / VötschTechnik for climate testing and Atlas for solar testing.

  • The overall dimensions of the proposed climatic chamber are approximately 7200 mm wide, 10200 mm deep, and 7200 mm high. The usable test space volume is approximately 450 m³. This allows the chamber to accommodate even large vehicle models or a larger number of vehicle parts.
  • The temperature range of the climate chamber is from -20 °C to +50 °C with a temperature time deviation of up to ±1.0 K/min, which is an impressive performance for such a large volume, and the chambers thus provide excellent homogeneity of the test space.
  • The speed gradient is approximately 1 K/min during the heating phase and 0.5 K/min during cooling. These values are related to a load such as a passenger car weighing up to 2500 kg without the radiators switched on and are measured under the rear axle of the car to achieve reduced circulation conditions.
  • The humidity range with the radiators switched on is 25% to 70% RH at temperatures between +10 °C and +50 °C. Solar radiation is simulated by a set of 28 metal halide radiators with a total output of approximately 80 kW. These radiators are designed so that the spectral curve of the emitted light is as close as possible to the real spectral curve of solar radiation. These radiators are adjustable, and the angle of incidence plays an important role in creating an energy-temperature map on the tested vehicle.
  • The thermal compensation of the chamber is also worth mentioning. If we consider kW, such a chamber with the above-mentioned parameters must be able to cope with (compensate for) up to 180 kW of heat. That's a pretty powerful "sports car," and the engine room with all the necessary "ballast" and accessories, such as external air cooling units/condensers, oil cooler, steam generator, exchangers, and many other components that ensure that the law of conservation of energy is respected in practice, is also impressive.
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Preparation for installation and long-term operation.

Such technology cannot be hidden away in a few square meters, as is the case with classic smaller laboratory climate chambers. Therefore, great emphasis is placed on so-called infrastructure preparation, where coordination between the technology supplier, construction contractor, safety authorities, and end user is absolutely crucial. To give you an idea, it took 24 months from the project assignment to the first start-up of the chamber in test mode!

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From the above description, it is clear that this is not a technically simple solution. However, everything was successfully completed within 24 months and the equipment is now operational in Mladá Boleslav. In addition to the aforementioned requirement for testing in accordance with DIN 75220, the chamber also allows for other tests in accordance with derived standards. This will enable the quality of entire vehicles to be verified, both those with electric drives and those with conventional powertrains. Thanks to this, Škoda Auto a.s. will be able to further improve the quality of its products for us, the end users, in the future.

If you are interested in similar climate chamber solutions or other testing equipment, our experts are available HERE.

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