TEXA PROJECT

TCEM-40+125 Climatic Chamber for Electric Motor Testing

For a leading automotive development center, Il Disgelo designed and manufactured a dedicated climatic chamber for thermal and climatic validation of high-performance electric motors integrated with an external dynamometer test bench.

The objective of the project was to ensure controlled environmental conditions during static and endurance testing of e-motors, maintaining climatic stability even in the presence of active loads and thermal dissipation.

Customer Technical Requirements

The customer required:
 

• Extended temperature range from −40 °C to +125 °C

• Climatic mode with humidity control from 10 to 95 % RH

• High thermal stability (±1 K in temperature mode)

• Climatic temperature deviation of approximately ±0.5 K

• Operating dew point up to +89 °C

• Direct integration with external dynamometer

• Dedicated mechanical shaft interface

• Multiple technical feedthroughs for cables and cooling lines

• Remote supervision and industrial network integration

Technical Solution Implemented

The system was configured with a modular architecture consisting of:

Climatic Chamber Box

Approximately 1.5 m³ usable volume, featuring:
 

• Internal construction in AISI 304 stainless steel

• 120 mm mineral wool insulation

• Fixed technical wall interfaced with the test bench

• Movable section on wheels for installation and maintenance flexibility

The technical wall includes:
 

• 2 air connections Ø 200 mm

• 5 cable feedthroughs DN125

• 6 refrigerant/coolant line passages

• Dedicated shaft passage for motor–dynamometer coupling

External Conditioning Unit

The separate conditioning unit integrates:
 

• DORIN two-stage compressors

• Direct expansion cooling system

• Refrigerant R452A

• Air treatment unit with 3000 Nm³/h recirculation flow

• Electric heating system with dual independent safety thermostats

Connection between the box and the conditioning unit is ensured through flexible ducts up to 5 meters in length.

Operational Performance

Temperature Mode
 

• −40 °C to +125 °C

• Temperature deviation over time ±1 K

Climatic Mode
 

• +10 °C to +95 °C

• 10 to 95 % RH

• Temperature deviation approx. ±0.5 K

• Humidity deviation approx. ±3 to ±5 % RH

• Operating dew point from +7 °C to +89 °C

Control is managed by the DOT industrial PLC platform, featuring:
 

• Up to 50 programs × 20 steps

• Programmable macro sequences

• Ethernet remote supervision

• Modbus TCP/IP integration

• Continuous data logging

Project Outcome

The TCEM solution enabled the customer to:
 

• Perform validation testing on electric motors under controlled environmental conditions

• Simulate repeatable thermal cycles

• Integrate the chamber seamlessly into the existing dynamometer bench

• Maintain climatic stability during active thermal dissipation

This project represents an advanced integration between climatic control systems and high-performance dynamometer testing environments, developed according to real application-specific requirements.