Why do new energy components have to use environmental testing equipment?

New energy accessories must use environmental testing equipment. The core reason is that the usage scenarios of new energy vehicles cover * * natural environments, and the core accessory environment is sensitive. Once it fails due to insufficient environmental adaptability, it will directly cause safety accidents, performance failures, or significantly shorten its lifespan. Environmental testing equipment simulates real working conditions through accelerated testing to verify the reliability of accessories in advance, avoiding serious problems such as recalls and safety accidents after mass loading.

Specifically, it can be broken down from the following four dimensions:

1、 The "environmentally sensitive attributes" of new energy core components determine that they must be verified

The core components of new energy vehicles have a strong correlation between their key performance and the environment, and even minor environmental changes may lead to failure

Battery system: Temperature: -40 ℃ Extreme cold can cause a capacity drop of more than 50%, and high temperature of 85 ℃ may cause overheating and loss of control; Excessive humidity can cause short circuits in battery cells; Salt spray corrosion can damage the sealing of the battery pack casing.

Vibration: Vibration during vehicle operation may cause module solder joints to detach, wire harness to break, resulting in power outages or short circuits.

Motor/Electronic Control System:

High temperature can lead to a decrease in efficiency of IGBT modules and demagnetization of permanent magnets; Low temperature will increase the viscosity of lubricating oil, leading to difficulty in starting.

The humid and hot environment will accelerate the aging of winding insulation and cause high-voltage leakage; Salt spray can corrode the motor casing and damage the seal.

High voltage system:

Temperature cycling can cause thermal expansion and contraction of connector contacts, increase contact resistance, and lead to heating and fire; Salt spray can corrode terminals and cause open circuits.

Dust/rain can damage the sealing of the charging interface, posing a risk of short circuit or electric shock.

Intelligent driving sensors:

High temperature can cause drift of CMOS sensors in cameras and distortion of radar signals; Low temperature can affect the transmission power of LiDAR, leading to perception failure.

2、 The usage scenarios of new energy vehicles far exceed traditional fuel vehicles, and the environmental challenges are more complex

The application scenarios of new energy vehicles cover different climate zones, and the environmental tests are more stringent than those of fuel vehicles:

Regional span: from extreme cold in Northeast China to high temperature and humidity in Hainan, from coastal salt spray areas to northwest sandstorm areas;

Differences in operating conditions: During fast charging, the temperature rise of the battery can reach over 40 ℃. When driving on mountain roads, the motor continues to generate high load heat, and the winter range degradation directly affects the user experience;

Higher safety requirements: Fuel vehicles often experience power outages, while high-voltage component failures in new energy vehicles may cause electric shock, fire, and explosion. Failure of intelligent sensors may lead to autonomous driving accidents.

These scenarios cannot be fully covered by "road tests" and must be quickly verified for long-term reliability through accelerated simulation testing of environmental testing equipment.

3、 Mandatory requirements of regulations and industry standards

The relevant regulations for new energy vehicles clearly require that core components must pass environmental reliability testing, and products that do not meet the standards are prohibited from being launched:

The battery pack needs to pass tests such as high and low temperature cycling, humidity, salt spray, vibration, and impact to meet the IP67 protection level;

The motor needs to undergo temperature cycling testing between -40 ℃ and 125 ℃ to verify insulation durability;

The high-voltage connector needs to undergo 1000 cycles of plugging and temperature cycling testing to ensure contact reliability.

If car companies fail these tests, they not only cannot obtain market access, but may also face recalls due to product failure.

4、 Reduce R&D and mass production costs to avoid post production risks

R&D stage: Quickly screen non-conforming designs through environmental testing equipment to avoid design rework caused by problems discovered before mass production, and shorten the R&D cycle by more than 30%;

Mass production stage: Conduct environmental sampling testing on incoming parts, intercept defective products, and avoid large-scale failures after batch loading;

After sales stage: Reproduce the fault scenario through environmental testing, locate the root cause and optimize, reduce after-sales maintenance costs and brand reputation losses.

summary

The four characteristics of "environmental sensitivity+complex scenarios+high safety pressure+mandatory regulations" of new energy accessories determine that environmental testing equipment is not an "optional" but a "mandatory" option - it is the core tool for verifying the reliability of accessories, ensuring the safety of the entire vehicle, and meeting regulatory requirements. It is also a key link for car companies to control costs and enhance product competitiveness.