THE Applus+ SOLUTION
Environmental & Durability Testing
Our dedicated 2000m2 high voltage laboratory features more than 30 specialized test benches capable of running 85 test samples in parallel, providing comprehensive environmental and durability validation with HV operation features in all benches:
Environmental Testing:
- Temperature shock tests (K-05) from -40°C to +120°C
- Corrosion and salt spray testing (K-06)
- Thermal shock with splash water (K-12)
- Damp heat testing (K-09), (K-14) with humidity control & frost
- Complete water IP protection testing (K-10)
- Dust testing (M-03)
Thermal Durability:
- High/Low temperature aging (K-01)
- Incremental temperature testing (K-02)
- Thermal durability assessment (K-03)
- High-temperature endurance testing (L-02)
- Temperature cycle testing (L-03)
- 24/7/365 automated operation with fast failure reporting
Mechanical & Abuse Testing
Our specialized abuse testing facilities provide unique capabilities for safety validation under extreme conditions:
Mechanical Durability Testing:
- Free fall testing (M-01) with maximum mass of 1500 kg
- Stone impact testing (M-02) for mechanical robustness
- Vibration testing (M-04) under various environmental conditions
- Low temperature impact testing for cold climate performance
- Hosedown testing for water resistance validation
Advanced Abuse Testing:
- Specialized drop test facility for short circuit induction in HV components
- Super capacitor bank of 18.57 Farads with 46.9 mOhm internal resistance
- Power ratings up to 430 Volts - 8 kA discharge capability
- Energy capacity of 1.7 MJoule for realistic battery simulation
- Maximum impact velocity of 35 km/h with high-frequency optical tracking (10 kHz)
- High-speed cameras for detailed failure analysis
Electrical Performance & Safety Testing
We provide comprehensive electrical testing for automotive high voltage components up to 1000V and 2000A, ensuring compliance with worldwide safety standards:
High Voltage Electrical Testing:
- Dielectric strength testing (E-20)
- Insulation resistance testing (E-18)
- HV service life testing (EHV-13)
- On/Off durability testing (EHV-14)
- Over Temperature Protection testing for thermal safety systems
- Efficiency testing and performance characterization
Safety Standards Compliance:
- G.T.R. Nº 20, ECE R.100 for global automotive standards
- GB/T 18384 (China), FMVSS 305 (USA) for regional compliance
- ISO 6469-3, ISO 13063 for electric vehicle safety
- UNE-EN 60529 for IPXX protection rating validation
- EN17128 (PLEV), EN15194 (EPAC) for electric mobility applications
Component-Specific Testing
We specialize in testing various automotive high voltage components across the electric vehicle ecosystem.
Power Electronics Components:
- Integrated power boxes
- DC/DC converters performance and efficiency testing
- On-board chargers (OBCs) validation and certification
- Home chargers’ safety and performance testing
- Inverter characterization and durability assessment
HV Ancillary Components:
- PTC heaters thermal performance and safety testing
- Heat pumps efficiency and environmental testing
- HV cables & connectors
High Voltage Power Electronics Engineering Services
Beyond testing, IDIADA provides comprehensive engineering services that complement our testing capabilities, positioning us as a complete solution provider for automotive high voltage power electronics development.
Virtual Development & Simulation
Our multidisciplinary engineering teams utilize state-of-the-art simulation tools to optimize your automotive high voltage systems before physical testing:
Advanced Simulation Capabilities:
- 1D Electronic drive unit simulation for current pattern analysis and system-level integration (SIMULINK/SIMSCAPE, GT-SUITE)
- 1D & 3D Thermal simulation for cooling & heat distribution evaluation (STARCCM+, GT-SUITE)
- 3D Structural and Multi-Body simulation for vibration and NVH analysis (AVL EXCITE)
- 2D/3D Electromagnetic simulation for motor design and torque/efficiency analysis (ANSYS MOTORCAD/MAXWELL)
- EMC simulation including parasitic effects analysis for electromagnetic compatibility (ANSYS EMC/EMI)
Power Electronics Development Services:
- Hi-fidelity simulation of power electronics systems
- Model-in-Loop (MiL) to Power Hardware-in-Loop and to (PHiL) development
- Benchmark analysis of inverter calibration data
- Power electronics optimization for improved efficiency and performance
Benchmarking & Analysis Services
Our comprehensive benchmarking services combine advanced testing with detailed simulation analysis:
Full Detail Drive Unit Benchmark:
- Material characterization and CAD modeling
- Winding pattern analysis and electromagnetic mapping
- Back-EMF validation and torque response analysis
- Power electronics characterization including parasitic effects simulation
- Performance comparison and optimization recommendations
- Inverter strategy analysis and Inverter clone for physical testbench analysis of e-machines
Consultancy & Technical Support
Our experts provide specialized consultancy services throughout your development process:
High Voltage Safety Consultancy:
- Electrical safety expertise for high voltage systems design
- Design Validation Plan (DVP) development and execution
- Technology trend surveillance and market intelligence
- Regulatory compliance guidance for global markets
- Risk assessment and mitigation strategies
Design Validation Plan Generation:
- Complete DVP creation based on product specifications and market requirements
- Simulation, test, and homologation planning
- Prototype configuration and testing strategy
- DVP execution in our state-of-the-art facilities
High Voltage Testing Facilities Specifications
IDIADA's high voltage laboratory represents a significant investment in cutting-edge technology and infrastructure, providing unique capabilities that differentiate us from the competition.
HV Laboratory Infrastructure
Our purpose-built facility offers unparalleled testing capabilities:
Facility Specifications:
- 2000m2 dedicated HV testing facility designed specifically for high voltage component validation
- More than 30 specialized test benches with parallel testing capability for up to 85 samples
- High voltage testing capability up to 1000V and high current capacity up to 2000A
- Multi-standard compliance supporting LV 123, VW 80300, GS93025, and ISO 21498-2
- ISO 17025 certification ensuring the highest quality standards
Advanced Equipment & Technology
Power Supply & Conditioning:
- Battery simulators up to 400kW / 1000V / 1400A for realistic testing conditions
- Coolant conditioner of 25kW @ -20°C with independent flow and temperature control
- Power amplifier and HF transformer solutions for various testing requirements
- Tailor-made conditioning systems for specific client requirements
Climatic & Environmental Control:
- Climatic chambers operating from -40°C to +120°C
- Chamber dimensions: 1,400 × 1,400 × 1,000 mm with capacity up to 1,000 kg
- Humidity control capability in selected test benches
- Independent control for ambient and coolant temperatures
Monitoring & Analysis Systems:
- High precision sensors for mechanical, electrical, and thermal parameters
- State-of-the-art CAN communication and control equipment
- Damage pre-detection systems based on vibration analysis
- High-frequency optical tracking systems (10 kHz) for detailed analysis
- High-speed cameras for failure mode documentation
We deliver comprehensive testing solutions with advanced capabilities including parallel testing, specialized abuse testing, and real-world simulation technology. Our 24/7 automated operations ensure fast reporting and immediate failure detection, while our in-house expertise covers the complete development cycle from prototype to production.
With global standards compliance and end-to-end service delivery, we provide tailored solutions that meet your specific automotive high voltage power electronics requirements. Our responsive support and consulting expertise ensure your projects stay on track and ahead of industry trends.