Climatic Chamber Portfolio

Ensuring E-Mobility Reliability Through Extreme Environmental Testing.

Climatic chambers are the solution for simulating extreme environmental conditions for batteries, fuel cells, e-motors and e-axles in the testing environment.

rendering climatic chambe

Battery packs, modules, cells, fuel cells, e-motors, and e-axles must perform safely and reliably across a wide range of environmental conditions. Extreme temperatures and humidity levels pose significant challenges that are difficult to replicate on test tracks or in real-world scenarios. To overcome these challenges, we have developed the AVL Climate Chambers.

Our climate chambers are engineered to simulate controlled environmental conditions, making it possible to thoroughly test each component of the electric powertrain under extreme conditions. This ensures that your powertrain components are evaluated for durability and performance, regardless of environmental extremes.

By utilizing climate chambers, you can confidently validate the performance and safety of your electric powertrain components. Our modular design provides the flexibility to test various components in a controlled environment, ensuring that they meet the highest standards of reliability and durability.

Vehicle components must endure a wide range of environmental conditions to ensure reliable performance. Our state-of-the-art climate chambers offer precise regulation of both temperature and humidity, making it possible to simulate harsh conditions from arctic cold to tropical heat.

Our climate chambers are designed to replicate extreme environmental conditions, ensuring that every product undergoes rigorous testing. This capability allows us to validate that your components can withstand the full spectrum of real-world scenarios, providing confidence in their performance under any circumstance.

By using AVL's climate chambers, you can achieve comprehensive environmental testing that guarantees your components meet the highest standards of durability and performance. This thorough validation process ensures that your products will perform reliably and efficiently, regardless of the conditions they face.

Climatic Chamber
Integration of Different Parts of the Testbed

AVL provides the complete test solution.

Battery Destruction During the Test

The AVL safety system is developed according to the customer's needs.

No Standard Solution for Test Area Requirements

Customized adaptations of standard products are possible.

Battery Testing Is a New and Growing Application

AVL is an experienced and reliable partner for test systems.

The climate chambers operate within a specified temperature range, with temperature gradients for heating and cooling in accordance with IEC 60068-3-5 standards. The average temperature is measured in the supply air, without any thermal load, and thermal compensation values are adjusted based on the type of power used.

For walk-in chambers, the dimensions are optimized to accommodate different types of test equipment, ensuring the chamber size is suitable for a variety of testing needs. Similarly, the size of cell test chambers is carefully calibrated to provide optimal solutions for cell testbeds.

The chamber's insulation material can be selected based on the required safety level, with options including polyurethane or mineral wool. To reduce energy consumption, a domestic water connection can be used to lessen the cooling power required by the chiller, thereby decreasing overall energy usage.

When testing battery prototypes, critical thermal issues can arise. To mitigate potential damage, the chambers can be equipped with a flooding option that protects the surrounding building. Additionally, AVL offers a comprehensive safety system designed to meet Hazard Level 4 or 6 standards for testbeds.

For outdoor installations, a complete thermal testbed can be housed within a container, providing a versatile and efficient solution for thermal testing needs.

Technical Data

 

Temperature range

40 °C up to +90 °C

Standard rate of
temperature change

2 K/min or 4.5 K/min
(higher rates possible)

Battery pack test cell volume

16 m³ or 22 m³
(individual sizes possible)

Battery cell test chamber size

720 – 1.500 liter

Insulation material

Polyurethane or mineral wool

Cooling water flow

12 °C up to 30 °C

Safety version up to Hazard Level 6
Installation

Climatic Chambers for battery pack and fuel cell system

Climatic Chamber for Battery Cell Testing

Our battery cell testing climatic chambers are designed to hold up to 12 or 16 cells, making them ideal for rigorous testing. They offer a wide temperature range from -40°C to 90°C and use environmentally friendly CO2 as a refrigerant. The chambers are equipped with a water-cooled system to maintain optimal conditions and ensure even airflow, minimizing temperature fluctuations. With the ability to quickly heat or cool, these chambers are perfect for testing in various scenarios. They are energy efficient, supporting heavy racks with loads up to 500 kg, with an option for 750 kg. Integrated in the AVL Battery Cell TS™, they deliver accurate and reliable test results.

Climatic Chambers for Battery Pack Testing

Our climatic chambers for battery pack testing provide precise control over internal operating temperatures, with a temperature range of -40°C to +90°C. These chambers are available in volumes of 16 m³ or 22 m³, with customizable sizes also possible. They ensure reliable testing results and adhere to IEC 60068-3-5 standards. The temperature gradient for heating and cooling is carefully managed, with average values measured in the supply air, even without a thermal load. For battery prototypes, our chambers can be flooded as a safety measure to prevent critical thermal issues, ensuring protection for both the batteries and the surrounding building.

Climatic Chamber Battery Cell Testing
Climatic Chamber Battery Module Testing
Safety Systems

Our climate chamber can be designed for EUCAR Hazard Level 4 or Hazard Level 6. They also offer superior safety with flooding options for maximum protection of the testbed and facility. Moreover, we provide customized battery testing safety systems with our automotive testing experience.

Individual Solutions

Our climatic chambers offer a seamless integration into existing testbeds with their unique and application-based design, facilitated by pre-defined interfaces. With their high functional flexibility, these chambers allow for easy and fast upgrades. Each climatic chamber can be tailored to meet the specific requirements of every customer.

Individual Design and
Premium Material

The climate chamber is constructed of high-alloy, corrosion-resistant steel. They are suitable for testing batteries, fuel cells or electric drives. Porthole packages, mounting options and electrical feedthroughs are specifically designed for each test area.

Battery Module Testing Tech Center Module E-Motor and E-Axle Testing AVL ConsysActive Monoblock AVL Gas Sampling Unit
Climatic Chamber Battery Module Testing
Battery Module Testing

The climatic chambers for battery module testing offer a spacious solution with capacities up to approximately 6 m³ and a temperature range from -40°C to 90°C. Fully integrated into the AVL Battery Module TS™, these chambers allow comprehensive testing of larger battery modules, ensuring accurate simulation of real-world conditions. The integration allows for efficient and precise control, which is critical for evaluating battery performance and safety. With the option of a double side door with window, the chamber can be rotated 90° and has an additional door for even greater flexibility and accessibility during testing.

Tech Center Modules
Tech Center Module - AVL Battery Pack TS™

The AVL Tech Center Modules are versatile container solutions designed for rapid and flexible expansion of testing capabilities. These modular units offer a robust and mobile platform for technical equipment and measurement systems, facilitating the swift setup and adaptation of test infrastructures. The tech center module for battery testing serves as a cost-effective and quickly available solution for climatic testing of battery packs and modules. This module achieves a short delivery time by optimizing a standard solution with proven components, ensuring both efficiency and reliability. 

→ More on Tech Center Module for Battery Pack Testing 

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E-Motor and E-Axle Testing

Our climatic chamber for e-motor and e-axle testing provides an economic and energy-efficient solution. By minimizing chamber space, energy consumption is significantly reduced, lowering operational costs and aligning with sustainability goals. The system's flexibility is enhanced by a separate air conditioning unit, allowing for precise, independent control of temperature and airflow. This setup ensures optimal testing conditions for a wide range of e-motor and e-axle evaluations, making it versatile for various scenarios. The compact design also means easier installation and maintenance, contributing to its cost-effectiveness.

AVL ConsysActive - Monoblock Solution
AVL ConsysActive Monoblock

Walk-in climatic chambers are the state-of-the-art solution for battery, fuel cell, and other components testing. However, their large size and volume present certain complexities in project logistics, onsite installation, and commissioning. The ConsysActive Monoblock solution is supplied as a single unit, making it easy to integrate into locally sourced enclosure solutions or retrofit existing ones. The complete cooling, heating, and humidification system is designed for seamless and efficient integration. The climate system is thoroughly tested in advance to ensure optimal integration and performance.

→ More on ConsysActive Monoblock

gas sampling unit
AVL Gas Sampling Unit

Testing a battery cell, module, or pack can damage the unit under test, resulting in various EUCAR hazard levels. When Hazard Level 4 or higher is reached, a large amount of characteristic gases are released. Quick detection of these gases can help prevent damage to the climate chamber or the entire testbed by allowing immediate fire suppression measures. The AVL Gas Sampling Unit analyzes the gas composition in the test chamber in less than ten seconds and takes action to address safety issues. Additionally, it can be integrated with existing safety systems to enhance overall testbed security.

→ More on Gas Sampling Unit

peter kerschenbauer

AVL has an outstanding and long-term experience in designing testbeds for customer’s needs. Therefore, the AVL Climatic Chambers reach the highest standards in performance, safety, and customer satisfaction.

Peter Kerschenbauer, Global Product Manager, AVL List GmbH

AVL E-Mobility Testing Solutions – Brochure

Tested and Trusted.

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AVL Thermal Testing Solutions – Brochure

Keep Cool, Drive Further.

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AVL Climatic Chamber Portfolio – Brochure

Ensuring E-Mobility Reliability Through Extreme Environmental Testing.

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AVL ConsysActive Monoblock – Solution Sheet

Streamlined Climate Control - One Unit for All Testing Needs.

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Tech Center Module – AVL Battery Pack TS™ – Solution Sheet

The fast track to battery testing excellence.

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AVL Gas Sampling Unit – Solution Sheet

Application-driven solution for best-in-class thermal development.

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Tech Center Modules
AVL Tech Center Modules

Customer requirements show the need for additional test capacity for ambitious product development plans. AVL Tech Center Modules significantly shorten this process. The flexible, location-independent and easily relocatable modular test system is particularly helpful.

AVL Conditioning Systems
Conditioning Systems

Thermal conditions and environment of Units Under Test have strong impacts on real results in driving. For this reason, the thermal simulation must be as exact as possible – which can be achieved via deployment of high performing media conditioning systems.

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AVL ThermalLab™

AVL ThermalLab™ tests the entire VTMS, including all coolant circuits and the refrigerant cycle, under dynamic conditions using model-based testing. The UUT is the complete VTMS embedded in an emulated vehicle while the environment is fully simulated. The entire system can be tested in the lab under realistic driving and ambient conditions.

battery testbed
Battery Testing Solutions

For battery (module/pack) testing, we offer complete test systems, stand-alone equipment, or even entire turnkey test labs.

Test Systems for battery cells
AVL Battery Cell TS™

For battery cell testing, we offer complete test systems, stand-alone equipment, or even entire turnkey test labs.

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AVL Battery Module/Pack TS™

We offer complete test systems for the testing of modules/packs. Learn more about which hard- and software products are included in our test systems. 

e-motor performance
E-Motor Testing Solutions

AVL has a wide portfolio consisting of dedicated e-motor test systems, software, tools, and processes to test and validate these modern e-drive systems in shortest time and with highest quality standards.

Electric Driveline Development
E-Axle System

In addition to the individual components, we develop integrated e-axles including transmission. One example of our innovative ability is our high-performance highspeed e-axle, which currently has one of the highest power densities among e-drive systems on the market.

AVL Customer Services
Customer Services

Your success is our goal. This is what we are aiming for and this is how we understand AVL Customer Services since decades. Our goal is not new, but the way how we do it, is constantly evolving.

AVL customer support
Customer Support

The primary goal for our AVL Customer Support Teams is, to be a helpful and reliable partner for all kind of questions and issues you might have, when using AVL’s technology.

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AVL at the 44th Vienna Motor Symposium
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Honorary Citizenship Helmut List
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AVL Brain
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Matthias Dank
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