Automotive cooling system testing

Conducting thorough testing for the cooling system of vehicles

Conducting thorough testing for the cooling system of vehicles

Technological innovations are posing new challenges to the testing of cooling systems of vehicles. The requirements for testing cooling systems and their components are changing rapidly, due to more efficient combustion engines, different fuel types and the introduction of hybrid and electric cars. With those innovative mobility solutions also the quality and compliance requirements increase. TÜV SÜD carries out a range of tests to determine whether cooling systems and components meet relevant standards as well as manufacturer specifications.

What is cooling system and component testing?

The evaluation of automotive cooling systems and components can encompass a number of different safety and performance issues. A thorough evaluation can include testing for system and component durability, pressure pulsating, ageing, corrosion and erosion, climatic temperature cycling, pressure-vibration-temperature and materials testing, as well as permeation measurement. During the cooling system and component validation all relevant components are tested for their endurance and safety.

Why is cooling system testing important?

Automotive cooling system and component testing offers various benefits for OEM’s and suppliers:

  • Maintain the optimal operating temperatures and optimises overall performance of an engine's cooling system.
  • Ensure compliance with industry standards and manufacturers’ specifications by thoroughly testing your cooling systems and components such as the water pump of a cooling system or its thermostat.
  • Verify the safety and quality of your products to increase market acceptance.
  • Save time and money by identifying automotive component compliance considerations and technical requirements at the earliest possible stages of the product development process.
  • Minimise risks by reducing the occurrence of supply chain problems that can result in product recalls and reputational harm.

TÜV SÜD is your reliable partner for cooling system testing

For more than 100 years, TÜV SÜD has been the preferred testing and certification partner for automobile and automotive component manufacturers worldwide. Our state-of-the-art testing facilities, combined with our global network of technical experts, can provide your company with a single source solution for achieving compliance with all applicable regulatory requirements, standards and voluntary industry schemes. These qualifications allow us to be a competent business partner for cooling system testing.

TÜV SÜD offers a wide range of cooling system and component testing that simulates the diverse range of operating and environmental stresses to which the critical cooling system parts are exposed. Cooling system and component testing by TÜV SÜD provides your customers with independent and impartial verification of safety and quality claims consistent with both OEM and industry standard requirements. And our global network of automotive testing capabilities and experts can support your testing efforts regardless of location.

Our automotive cooling systems and components testing services

TÜV SÜD tests all engine cooling parts as well as the entire cooling system.
Amongst others, we perform pressure tests of the cooling system and cooling system leak tests as well as conduct checks of the cooling system for exhaust gas.

Especially for alternative fuel vehicles like electric vehicles we support you with our various colling and component testing solutions in ensuring your automotive battery technologies of your electric and hybrid vehicles perform safely and reliable.
The operating temperature of li-ion batteries plays an important role to ensure its functionality, reliability, safety and durability. Keeping a constant temperature of EV batteries and providing sufficient cooling solutions if needed ensures a valid performance.

We offer the following tests for cooling systems and cooling system components:

 

  • Durability testing

    Durability testing of cooling systems calculates how long a component of a cooling system can safely and reliably perform its function. The component is exposed to a number of relevant external factors (such as internal pressure, temperature, and flow). The life cycle of a component can thus be represented via time lapse in the laboratory. Our durability testing methods use several fluids: coolant, oil, and air.

  • Ageing test

    The cooling system components built into vehicles go through an ageing process which is influenced by factors such as temperature, coolant, oil, static pressure and flow. Ageing tests calculate how much each factor influences the ageing of the cooling system components.

  • Static pressure and temperature test

    The static pressure and temperature tests for cooling systems calculate the ageing of components when influenced by temperature, pressure and fluids (e.g. coolant, oil, air etc.) and, as such, often forms part of the ageing test.

  • Pressure cycle test

    This test evaluates the long-term performance of a cooling system’s components. They are exposed to dynamic pressure changes as well as impacted by temperature and flow. Coolant, oil, and air are used as the fluids.

  • PVT test

    The acronym PVT stands for pressure, vibration and temperature. During this test, cooling system components are exposed to three factors at the same time: dynamic pressure changes, different temperatures, flow and vibration or motion. With this, the PVT test simulates the various components when exposed to several influencing factors and can predict reliable numbers about their durability. PVT tests can be performed using coolant, oil, air and other fluids. Some standard test procedures include the regulations SAE J2044, SAE J2045, DIN 73379 and numerous regulations from notable OEMs.

  • Temperature change test

    The temperature change test investigates the behaviour of a cooling system’s component under defined temperature conditions ranging from -70 °C to +180 °C. The component is constantly monitored as the temperature is switched between these two extremes to ascertain the component’s operational reliability. Temperature gradients up to 6 K/min and with temperature chambers with volumes ranging from 0.8 m³ to 3.5 m can be simulated. TÜV SÜD further has chambers according to the requirements of the European Explosion Protection Directive ATEX for testing.

  • Climatic test

    The climatic test for cooling system is similar to the temperature change test: components of the cooling system are exposed to specific temperatures between -40 °C and +180 °C. The relative humidity, ranging from 0 to 98 %, is an additional factor. In our modern climate chambers volumes of 0.8 m³ to 3.5 m³are possible. They offer temperature gradients of up to 4 K/min.

  • Ageing of hoses and pipes

    The impact of ageing on the cooling system’s hoses and pipes and their systems is measured by exposing them to long-term influences such as temperature and various fluids including coolant, oil, and air. Additional variables considered are static pressure and flow.

  • Material testing

    While testing the material of the cooling system’s components a comprehensive range of leak tests, burst pressure tests, compression and tensile tests, ball-drop tests, cold impact tests and fire tests in the laboratory are performed. These tests help calculate the reliability, safety, and quality of the materials and show whether the cooling system components meet the legal requirements and standards.

  • Flow testing

    Each test that involves flow of fluid through a component is considered a flow test. They tend to include the use of temperature, fluid (e.g., coolant, oil etc.), static pressure and flow. Typical flow tests include erosive flow testing as well as an internal corrosion test.

  • Pressure impulse testing

    Pressure impulse testing exposes cooling system components to high-frequency, dynamic changes in pressure. Additional factors include temperature – ambient and of the component itself – and flow rate. Possible fluids here include coolant, oil and others.

  • Temperature shock testing

    Temperature shock testing exposes the components of the cooling systems to fluids (like coolant, oil etc.) that are heated up to a pre-defined temperature. It is then alternated between high and low temperatures within short intervals. Due to the extreme speed and extreme change in temperature this is called temperature shock.

  • Erosion testing

    The erosion test is a form of flow test in which specific dirt particles are added to the fluid flowing through the cooling system’s component, thus allowing conclusions to be drawn about the component’s erosion behaviour.

  • Internal corrosion testing

    During this test the cooling system components are flushed with a mixture containing specific salts. The test provides reliable data about the corrosion behaviour of the components.

  • Tests for charge air components

    These tests are specially designed to investigate the endurance limit of a component when it is exposed to factors including temperature, pressure, and multi-axial motion. TÜV SÜD uses a specially designed robot to achieve the multi-axial motion for this test.

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