en-testing

environmental testing

Design qualification and design verification.

Safety tests

Extract of possible tests:

• High strain rate impact test

• Burst pressure tests (fluids & gases) & Batch burst pressure test

• Hydrostatic burst pressure test

• Fire Tests (e.g.: Of systems or components under pressure or voltage)

• Proof of safety relevant components and functions

• Pressure relief valves

• Thermo fuses

• Short-circuit tests of HV batterys

• Surface damage test

• Drop test

• Boss torque test

Abuse tests of HV Systems

Electrical (Overload, Shortcircuit, ...)
Mechanical (Nail penetration, Crush, Drop, ...)
Thermic (Heat, Cold, ...)

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high pressure testing

Gases

Liquids/Fluids

On more than 600m², we carry out complex test setups for your development systems or component and test them with different fluids and gases. Gases up to 1500 bar, liquids up to 4000 bar.

Whether measuring the characteristics of a compressor or testing proof pressure of a container, we ensure your development with practical tests. On request, we also carry out the test planning on the basis of the applicable standards and guidelines.

The technical documentation of the results will be sent to you as a follow-up to your specifications.

Extract of possible tests:

Over-pressure or Proof pressure test
Leak test at nominal working pressure (internally or externally)
Leak test at varying pressure differences (combination with varying temperature possible)
Hydrostatic test
Hydraulic residual pressure test
High temperature static pressure test
(Periodic) Pressure cycling test & Cycle test
Ambient cycling test & Extreme temperature pressure cycling test
Test for expected on-road performance according to UN GTR or SAE J2579
Residual burst test
Chemical exposure and ambient pressure cycling
Determination of flowrates
Response characteristics and functional tests of mechanical or electrical components
Fueling and Defueling of complex systems such as hydrogen tanks systems or NG tank systems
System or component tests for performance durability

High Pressure testings with Gases

On our gas-monitored test areas and test facilities, we test your development components or systems up to a pressure of 1500 bar.

Possible Gases:

Hydrogen (compressed (CH2) or liquid (LH2))
Natural Gas (CNG, LNG)
Forming gas
Inert gas (helium, argon, nitrogen)
Other gases upon request

Examples of components and systems for high pressure gas tests:

Type 4 hydrogen cylinder or cylinders for natural gas (CNG, LPG)
Hydrogen composite tank systems or natural gas systems for cars&trucks
Pneumatic components & systems
Valves, Fittings, Armatures

We will test according to your specifications, or according to the standards applicable to you or technical regulations.

Hydraulic testing with Liquids/fluids

With special hydraulic power units and tubes, we pressurize your desired test component or system up to a test pressure of 4000 bar.

Our liquids:

Water and their mixtures or blends (e.g. Water/Glycol)
Oils (thermal oils, lubricants)

Examples of components and systems for hydraulic tests:

Type 4 hydrogen cylinder or cylinders for natural gas (CNG, LPG)
Hydrogen composite tank systems or natural gas systems for cars&trucks
Water-bearing components & systems
Valves, Fittings, Armatures
Container

We will test according to your specifications, or according to the standards applicable to you or technical regulations

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HV Testing

"New energies" and "alternative drives", especially stationary electricity storage systems, as well as electromobility, enormously increase the demands placed on electrical systems. We accompany you during the development and market launch for example with the following exams:

Insulation resistance measurements
Dielectric strength test
Current / voltage measurements
Capacitance measurements
Ground impedance measurement
Charge / discharge test
Pulse-Power-Test
More tests from common codes & standards

EnviroNmental

testing

IP-Protection

Climate

chamber 1m³

Climate
chamber 14m³

Component and system security using environmental testing techniques are a must have for development processes.

We are pleased to provide you with our extensive know-how in this field.

We accompany you for example in design verification tests with the following performance portfolio:

Climatic tests:

- DIN EN 60068-2-1 Kälte
- DIN EN 60068-2-2 – Trockene Wärme
- DIN EN 60068-2-14 – Temperature change test / Temperature shock test
- Hard-Freeze
- Extreme temperature cycling test

Mechanical Shock / Vibration testing
Corrosion tests / Chemical Exposure
Drop test (e.g. handling drop)
High strain impact tests
Immersion tests (e.g. Salt water immersion test)
IP protection tests according to DIN EN 60529 or ISO 20653
HV battery tests (Durability, charging & discharging cycles, short circuit tests)
Electromagnetic compatibility (EMC tests)

Protection against ingress of water:

Temperature chamber 1m³

Performance Overview:

min. Temp.

max. Temp.

Heating rate

Cooling rate

According to

DIN Space

Usable Space

Inflow

Test load

-113°F*¹ (-45°C)

+203°F*¹ (+95°C)

adjustable up to 6K/min*¹

adjustable up to 2K/min*¹

DIN 60068

0,72m³

100 x 100 x 100 cm (LxWxH)

direct or indirect

150kg (more on request)

Temperierkammer 14m³

Performance Overview:

min. Temp.

max. Temp.

Heating rate

Cooling rate

According to

DIN Space

Usable Space

Inflow

Test load

-113°F*¹ (-45°C)

+203°F*¹ (+95°C)

adjustable up to 1K/min*¹

adjustable up to 0,5K/min*¹

DIN 60068

7,08 m³

310 x 210 x 210 cm (LxWxH)

indirect

1t (more on request)

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Special tests

Superposition

Leakage test

Commissioning

In practice, it is often the case that there are special test requirements which can not be tested by an "isolated" test method.

This requires the combination of several interlinked tests. For example, a climate test in combination with a pressure test.

In the field of special tests, we have built up many years of know-how - please do not hesitate to contact us.

Examples of special tests:

Execution of multi-part and complex test sequences (e.g., EOL, HALT)
Gas flow tests
Permeation and Emission tests
Commissioning (fuel cell test stands, high pressure storage systems, tank systems (CNG, LNG, H2))
Short circuit tests

Superposition

In a superposition test, more than one size acting on the component is superimposed with a different size.

As a result, weak points of the component can be detected caused by alternating loads.

For example, temperature cycles with superimposed pressure cycles can yield different results than tests which are carried out separately.

Examples:

Temperature cycles with superimposed pressure cycles
Temperature cycles with vibration tests
Temperature cycles with vibration tests and pressure cycles
Temperature cycles with discharging / charging processes of a HV battery

Leakage test / leak testing / Permeation testing

You want to know not only whether your component is tight, but also how high is the possible leakage rate?

It is possible to determine the minimum leakage rates, even in extreme temperature ranges of your component.

The leakage measurement is based on the principle of liquid displacement.

In case of a leakage, a pressure difference between the measuring chamber and ambient pressure is created and thus a volume change within the pipette. This can be monitored by the changing of the water column in the pipette.

As well as a leakage test a permeation test of your system or component is possible as well. Temperatures can be applied too.

Commissioning

Commissioning and performance tests for complete tank systems or test stands:

Cold start tests
Fueling and Defueling tests with varying state of charge (SOC)
On-Road performance tests
Performance Durability tests under real operating conditions

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Certifications

Natural gas (CNG & LNG)

ECE-R 67
ECE-R 110
ECE-R 115
ISO 15500
ANSI NGV 3.1/CSA 12.3

Environmental testing

DIN EN 60068 (IEC 60068)

In cooperation with the TÜV, we accompany you to the final certification;

Examples:

Hydrogen

EC 79/2009 & EU/406/2010 "Verordnung (EG) Nr. 79/2009 des europäischen Parlaments und des Rates vom 14.01.2009 über die Typgenehmigung von wasserstoffbetriebenen Kraftfahrzeugen und zur Änderung der Richtlinie 2007/46/EG"

GTR No.13 "global technical regulation (gtr) on hydrogen and fuel cell vehicles"

ECE-R 134 "Uniform provisions concerning the approval of motor vehicles and their components with regard to the safety-related performance of hydrogen-fuelled vehicles (HFCV)"

ANSI/CSA HGV 3.1 "Fuel system components for compressed hydrogen gas powered vehicles"

ISO 17268 "Fuel system components for compressed hydrogen gas powered vehicles"

SAE J2600 "Compressed Hydrogen Surface Vehicle Fueling Connection Devices"

ANSI HGV "Compressed hydrogen gas vehicle fuel containers"

ECE/TRANS/WP.29/2014/78