Containerized test cell

 

DynoEquip containerized test cell represents a cutting-edge solution tailored for the development and testing of hybrid and fully electric drivetrains and engines. As the automotive industry increasingly shifts towards electrification, the demand for robust testing environments has surged. These containerized test cells provide a flexible and efficient platform that accommodates the specific requirements of e-mobility projects, enabling engineers to conduct thorough performance evaluations in a controlled setting.

With various laboratory configurations and layouts available, these containerized test cells can be customized to meet the diverse needs of customers, allowing for tailored testing parameters and methodologies essential for evaluating electric and hybrid powertrains.

The containerized nature of these test cells offers significant logistical advantages, as they can be easily transported and deployed in different locations, making them ideal for organizations without dedicated testing facilities. Each test cell integrates versatile electrified bench configurations, enabling the testing of various components such as batteries, motors, and control systems. Equipped with advanced monitoring and data acquisition systems, these test cells allow for real-time analysis of performance metrics during testing, enhancing the efficiency of the development process.

Containerized test cells provide versatile platform for the development and testing of hybrid and electric drivetrains.

Modular containerized test cell solutions integrate with electrified bench configurations, offering comprehensive platform for advanced testing.

What is the containerized test cell for automotive?

A containerized test cell for automotive is a portable and self-contained facility housed within a shipping container. It provides a controlled environment for testing automotive components or systems, offering mobility and flexibility in conducting tests at different locations. The facility can be easily transported and deployed, making it ideal for on-site testing or remote facilities. It offers a controlled environment for accurate and repeatable testing by regulating factors such as temperature, humidity, and ventilation. Additionally, the containerized design provides noise isolation and ensures safety during testing procedures.

 

Containerized test cell and automated test station integration solutions

 

  1. Wide range of applicability

    The containerized test cell can be applied to product testing in many areas, including motors, controllers, electric axle powertrain, engines, etc.

     

  2. Comprehensive test scope

    The test covers all aspects of product performance, durability, NVH characteristics and other indicators, enabling a comprehensive assessment of product performance.

     

  3. Automated testing

    Adoption of mobile containerized test cell enables automated replacement of tested parts and cyclic testing, which improves the efficiency and productivity of testing.

     

  4. Integrated design

    The containerized test cell integrates a variety of test systems, realizing automated integrated testing.

     

  5. Convenient deployment

    The containerized design can be directly placed outdoors, avoiding restrictions on the test site and solving the problem of insufficient test sites.

     

This containerized test cell with automated test station integration solution provides a complete set of bench test AC dynamometer and automated measurement and control system.

 

Containerized test cells enable automated testing of motors, powertrains, and engines, optimizing product performance and efficiency.

 

New energy vehicle powertrain containerized test cell has the following advantages:

 

  • Save time

    The test cell is completely built and laid out before delivery, the customer only needs to provide the media connections (electricity, water, etc.). The customer’s site can be a large open space or outdoors, which saves time and money on design and interior wall construction, as well as time and money needed to consider installation and noise insulation.

     

  • Minimal space requirements

    Conditioning systems and distribution cabinets can be mounted on the outside walls of the container, making full use of the interior space and providing enough room for operation and engine replacement modifications or build-outs. The external conditioning system can also be easily maintained.

     

  • Modularity

    The containerized test cell solution helps to track the economic growth of the company. New containerized equipment can easily be added at a later date, depending on demand, without major changes to the existing building.

     

  • Safe investment

    Containerized test cell are transportable. When it is necessary to move from one location to another building or to a different location, there is no need to replan, build and install, and almost all of the equipment can be used again.

     

The containerized test cell system is mainly composed of the following parts: box, acoustic door, acoustic window, floor, fence, ladder and so on. The front and back of the box are divided into test and control rooms, and the top is the equipment level. Designed for engine as well as powertrain testing, the optimized structure and space of the container bench is well suited to the environmental requirements of modern engine testing.

The container body is a three-dimensional steel structure, which allows the entire containerized test cell to be lifted by crane and transported in one piece with all equipment installed. The walls of the container are noise protected and the operator is located in front of the container. For the outdoor containerized bench, the container includes a test room and a separated control room. In order to effectively control the noise leakage in the test room and to ensure the working environment of the testers, sound-absorbing and sound-insulating treatments are carried out inside the test room and the control room.

 

Containerized test cells provide versatile, pre-configured solution for new energy vehicle powertrain testing, minimizing site preparation.

 

 

Engine containerized test cell

 

Further demands for test grounds include flexibility in addition to modularity. This holds true for both the quantity and size of test cells in a test field. Building upon years of experience in configuring and managing rigs, DynoEquip has created a containerized test cell that is both modular and versatile. From passenger cars to heavy-duty engine (unit under test, UUT as below) testing, size can be flexibly adjusted to meet customer needs. As a result, there may be less disruption to the current facilities and shorter installation durations on site.

Modules are used to build containerized test cell. Originally, these were mostly just regular shipping containers that had been specially altered to meet structural and environmental requirements. Since then, this idea has been expanded to provide specially designed modules that get around some of the drawbacks of shipping containers. Increased structural integrity, expanded breadth, height, and insulated walls are some of these enhancements. One module is frequently sufficient for a small test cell to hold all the necessary parts and be easily accessible and user-friendly for the personnel. Multiple modules can be joined to create appropriate floor space for larger applications, including multi-axis testing or entire vehicle testing.

The containerized test cell can be positioned both indoors and outdoors, allowing for the development of a completely new facility without requiring significant construction work, or they can be used to replace existing test capacity indoors.

 

Containerized test cell offers flexibility to accommodate various engine testing requirements, from passenger cars to heavy-duty.

 

Containerized test cell system function overview

 

The containerized test cell for performance test is mainly composed of a test and control system. After the UUT is docked to the load machine, the performance test is carried out. The UUT test can be set in manual test, automatic run-in and automatic test modes. The test data can be stored in the database as needed.

 

Containerized test cell system includes control setup that supports manual, automatic run-in, and automatic testing modes.

 

The test cell for EOL (end-of-line) test mainly consists of a conveying system, a test and control system. The UUT is conveyed to the exchange slide table of the rig through the traveling car and the motorized track outside. Then it is conveyed to the bench and docked to the load machine through the lifting roller conveyor, positioning rail, pallet pick-up and compression devices. The load machine carries out the factory test. The UUT test can be set up in manual test, automatic run-in and automatic test modes.

Test data can be stored in the database as required. After the test, the UUT is automatically transferred to the exchange slide, and then transported to the track outside the seat table, which can be transported away by the trolley. The quick-connect tray and the roller track outside the stand are strong and reliable, and can adapt to the shock load when the UUT is dropped and put down.

 

Containerized test cell for EOL testing incorporates comprehensive system including conveying and control functionalities to automate.

 

Containerized test cell system configuration

 

  • Test control system

    The measurement and control system is mainly divided into rig electrical control system and diesel engine test control system. The system consists of electrical control cabinet, test measurement and control system, IPC, various controllers and actuators, as well as a variety of sensors required for the test.

     

  • Container

    The containerized test cell is divided into 2 areas, the test room and the control room. Both areas are soundproofed. The control room is equipped with air-conditioning and office supplies such as an industrial console and chairs. In the control room, the operator can observe the situation inside the test room through the glass window with a wide view.

    The container is integrated with the base damping system for the UUT test, which has a good damping effect. The container is equipped with sound-absorbing wall and soundproof door, and the soundproof door adopts electric soundproof door, which is firm and reliable with good soundproof effect.

    The container test system is fully equipped with accessories, mainly including: air inlet and exhaust system of the test room, UUT exhaust system, ground grating, load machine pressure stabilizing system (including pressure stabilizing water tank), diesel fuel supply system and oil seal oil supply system. The bench piping system in the test room is divided into oil, water, gas piping and electrical piping.

     

Robust containerized test cell construction, with features like soundproofing, and reinforced elements, ensures controlled test setup.

 

  • Load machine

    The system can utilize alternative current, eddy current, or hydraulic.

     

  • Fuel consumption meter

    The fuel consumption meter is a continuous measurement system, which can measure the instantaneous value of fuel consumption and also the average fuel consumption over a period of time. The average fuel consumption time and fuel consumption weight can be set arbitrarily, and there is a power-down protection function. The fuel consumption meter is sealed reliably, so that the fuel will not overflow under any special circumstances, ensuring the safety of use.

     

  • Fuel thermostatic device

    The fuel thermostatic device automatically controls the fuel feed temperature according to the set temperature. The fuel is cooled by a heat exchanger, and the flow rate of the cooling water is automatically adjusted according to the fuel temperature, so that the fuel temperature is maintained at the constant temperature setting value.

     

  • Air leakage gauge

    The accuracy of air leakage measuring instrument is not less than ±5%FS.

     

  • Smoke meter

    Equipped with a smoke meter capable of measuring smoke in Rb units, it meets the requirements for automatic measurement of free acceleration smoke.

     

  • Coolant closed circulation system

    During the UUT test, this system serves as the external cooling circuit of the UUT. Adopting the closed loop structure, the system consists of inlet and outlet pipes connected to the inlet and outlet of the UUT through the inlet and outlet ports of the self-closing quick-connect tray on the platform.

     

  • Intercooler temperature control system

    In the exhaust gas turbocharged UUT, the high temperature air after turbocharging needs to pass through the intercooler for heat exchange, and the excess heat in the high temperature air after supercharging will be moved into the external cooling water. The intercooler temperature control system can automatically control the intake air temperature of the UUT after intercooling by setting the temperature sensor in the intake pipeline after intercooling. The intake air temperature is controlled within the pre-set range.

     

  • Emergency stop device

    The emergency stop adopts cutting off the air intake mode, the emergency stop valve adopts pneumatic diaphragm type, and the running out of control protection speed can be arbitrarily set in the UUT measurement and control system.

     

  • Throttle actuator

    The throttle actuator shall be equipped with both mechanical and electronic throttle controls. The throttle comes with a setting device for manually setting the throttle position, which allows the zero point and fullness of the throttle to be calibrated at any time when the UUT is not started.

     

  • Starter power supply and voltage stabilized power supply

    The containerized test cell is equipped with a starter power supply for starting the UUT. In addition, there is a 24V regulated power supply, which is used to supply power to the ECU of the test stand.

     

  • Large screen display

    The test room is equipped with a large screen display. The large screen display system is a large wall-mounted display that is used to show the main parameters such as power, torque, speed, fuel consumption rate, etc. at the UUT test site. It enables the operator to understand the important test conditions at a glance.

     

  • The bench quick-loading system (For EOL test)

    The bench quick-loading system consists of exchange slide table, lifting and lowering motorized roller conveyor, middle base of test vehicle, fine positioning guide rail and pressing mechanism, pallet pick-up and drop-off device, quick-connecting pipeline, flexure drive shaft and docking mechanism, quick-loading pallet, hydraulic system, control system and so on.

    The main function is to convey the UUT to the exchange slide table through the roller conveyor outside the traveling car and seat table, and after docking, the UUT is automatically conveyed, automatically docked to the loading machine and pressed. Manually connecting the intake and exhaust pipe after the test, after the test is over, the UUT is automatically detached from the loading machine and conveyed to the exchange slide waiting to be transported out.

 

 

Advantages of containerized test cell

 

  • Containerized test cells are portable and may be relocated using common haulage and shipping equipment. The cell can be flattened in the plant and lifted onto a truck by a crane in order to be transported. At that point, the system is unloaded and recommissioned at the site. Relocating a small-scale test cell takes one to two weeks on average.

 

  • Design and building requirements are low for containerized solutions since they need not much in the way of building work. In addition to a flat concrete platform, the test cells usually need access to water and power.

 

  • The equipment may be deployed concurrently with any ongoing construction projects because the test cells are built in containerized form. The entire project completion time might be significantly shorter than that of a concrete-constructed test cell as the requirements for construction on location are also decreased.

 

  • A comprehensive factory acceptance test of a test cell may be performed before shipment since the test cell can be constructed completely elsewhere. Since it might be hard to verify environmental control capabilities in the cell prior to the equipment being transported to the location, this can be especially helpful when these characteristics exist. Due to the ability to resolve issues before shipment, a factory acceptance test can also significantly shorten the commissioning period.

 

  • It is possible to design the test cells to be nearly fully independent. This covers the potential for local firefighting equipment, transformer, regeneration, and local water chilling for the electrical supply. This implies that more test cells can be added to an existing facility or to a facility without any test plant equipment currently in place without requiring any structural changes to the structure.

 

Containerized test cell incorporates a quick-loading system with automated mechanisms for conveyance, docking, transfer for testing.

 

  • Locating the cells at a safe distance from adjacent buildings might be helpful for applications where safety is a top priority, including testing engine using hydrogen.

 

  • A modular approach allows for the addition of test cells when necessary, and the expense is distributed equally throughout all test cells in the event that more are required in the future. On-demand addition of new containerized test cell is possible because they are independent of one another.

 

Containerized test cell offers advantages in portability, rapid deployment, and independent operation, enabling flexible testing setups.

 

Constraints with the concrete-constructed design

 

  • The preparation of test cells for usage in a newly constructed facility may need many years. Construction foundations, followed by the building structure, walls, and roof, must be constructed in the correct order of construction. Test cell installation and commissioning must come first, followed by piping and electrical work. The planning approval process for this kind of project might take many months in advance.

 

  • The procurement procedure is even more complicated and calls for a full-time project supervisor for a large-scale concrete-constructed building. The project supervisor will be responsible for overseeing safety and health concerns, construction of structures, test cell construction, and facilities, as well as making certain that the different project phases may be transferred between partners at the appropriate periods. To handle every facet of the project, this full-time position could need a number of individuals.

 

  • The fact that a concrete-constructed cell is a permanent construction once it is finished is one of its more evident disadvantages. This implies that it is unable to be transported, hence building new concrete-constructed cells would be necessary if the facility were to be transferred.

 

Containerized test cell avoids lengthy construction timelines and complex coordination for concrete-built facilities, enabling faster deployment.

 

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