Blog

In the era of the rapid development of new energy vehicles, the discussion of their extreme testing is no longer a topic limited among technicians; instead, it is closely related to the vital interests of every consumer. As the market demand for new energy vehicles continues to grow, the performance of vehicles in extreme environments has become a key criterion for measuring their performance and reliability.   From the stringent tests of the vehicle's three highs testing, to the meticulous inspection of components, and then to the long - term challenge of the vehicle's durability testing, each link is a deep exploration of the technological limits of new energy vehicles. These tests not only showcase the forefront of technology but also provide a comprehensive guarantee for the vehicle's safety and durability. Therefore, understanding the details of these extreme tests is an important window for each of us to perceive the future development trends of automobiles.   Vehicle Three Highs Testing: The Ultimate Inspection in Extreme Environments   Vehicle three highs testing is one of the standard tests for new energy vehicles, and its importance cannot be overstated. This series of tests includes three major links: high - temperature, high - altitude, and high - cold, aiming to test the performance and reliability of the entire vehicle under the harshest natural conditions.     First is the high - temperature test, usually carried out in Turpan, Xinjiang, where the surface temperature in summer can reach up to 70°C. Under such extreme high - temperature conditions, the vehicle's thermal management system and the safety performance of the battery will face severe challenges. It tests whether the vehicle can maintain normal operation in an overheated environment and whether it has effective heat dissipation strategies and overheat protection mechanisms.   Test Conditions: High - temperature exposure > 6h Temperature higher than 35°C Total driving mileage should be no less than 10,000 km, with no less than 2,000 km on urban roads, no less than 3,000 km on rural roads, and no less than 5,000 km on highways. Subjective Evaluation Tests: Evaluation of power performance, drivability, NVH performance, electrical performance, etc. Evaluation of air - conditioning cooling and comfort Inspection of daily function operations Objective Evaluation Tests: Collection of key - point temperatures during the test under different working conditions Monitoring of temperature changes and working status Engine - related Tests: Engine Shutdown Protection (Test condition: Temperature 40°C - 60°C): To prevent the engine from being damaged due to overheating, which may affect its service life. Engine Matching Test (Test condition: Temperature 40°C - 60°C): To ensure the matching of the engine and its accessory systems (such as the cooling system, fuel system, and emission system) under high - temperature conditions. Other Tests: Light Aging Test (Test condition: Temperature 40°C - 60°C): To evaluate the performance and durability of automotive components, materials, and the entire vehicle under long - term exposure to sunlight. High - temperature Range Test (Test condition: Temperature higher than 35°C): The vehicle drives from SOC100 to 0%, and the vehicle's range and energy consumption rate are statistically analyzed. High - temperature Charging Test (Test condition: Temperature higher than 35°C): The power battery is discharged to SOC 0% and then charged to full. The charging efficiency = (electricity entering the power battery / electricity from the charging network) * 100%. Also includes forward function testing, reverse function testing, software function testing, scenario simulation testing, extreme function testing, user function experience testing, etc. And temperature testing of the ECU (Electronic Control Unit) and various sensors, electrical system performance testing, basic calibration (such as chassis system calibration), etc.   The high - cold test is completely the opposite. It is often carried out in places like Heihe and Hailar, where the ambient temperature is as low as - 30°C. In such a low - temperature environment, the chemical reaction rate of the battery will drop significantly, affecting the vehicle's range and power output. The focus of the test is the response speed and efficiency of the battery heating system, as well as the battery's discharge performance and low - temperature protection mechanism in severe cold conditions. Test Road Types: High - speed snow loop, snow dynamic square, ice dynamic square, ABS open - circuit, ice and snow roundabout, handling stability road, checkerboard road, snow - melting pool, split - slope ramp Test Conditions: Vehicle soaking > 12h Temperature lower than - 10°C Total driving mileage should be no less than 10,000 km, with no less than 2,000 km on urban roads, no less than 3,000 km on rural roads, and no less than 5,000 km on highways. Subjective Evaluation Tests: Evaluation of power performance, drivability, NVH performance, electrical performance, controllability, braking performance, suspension system performance, etc. Objective Evaluation Tests: Starting Performance Test (Test condition: Ambient temperature - 20°C to - 40°C): To evaluate the cold - start performance, power, efficiency, and reliability of the engine. Heating Performance Test (Test condition: Ambient temperature - 20°C to - 40°C): Collection of key - point temperatures during the test under different working conditions, and monitoring of the temperature changes and working status of the ECU (Electronic Control Unit) and various sensors. Defrosting Performance Test (Test condition: Ambient temperature - 20°C to - 40°C): With the blower at the maximum setting and full - warm defrosting, pay attention to the field of view of the front windshield area and the exterior rear - view mirror during the test. Other Tests: Snow - covered Area Passability Test (Test condition: Ambient temperature - 10°C to - 40°C): Tests include snow - covered road passability test and snow - covered slope passability test. Snow - blowing Test (Test condition: Ambient temperature - 20°C to - 40°C, with a snow - blower set on the high - speed snow loop): To detect whether there is snow accumulation and icing in the front cabin, fan, trunk, lamps, etc., and the operation of functions. Low - temperature Range Test (Test condition: Ambient temperature - 20°C to - 40°C): The vehicle drives from SOC100 to 0%, and the vehicle's range and energy consumption rate are statistically analyzed.   Low - temperature Charging Test (Test condition: Ambient temperature - 20°C to - 40°C): The power battery is discharged to SOC 0% and then charged to full. The charging efficiency = (electricity entering the power battery / electricity from the charging network) * 100%. Also includes forward function testing, reverse function testing, scenario simulation testing, software function testing, extreme function testing, user function experience testing, etc. And calibration of various system and performance parameters of the vehicle in a cold environment, such as engine performance calibration, air - conditioning system performance calibration, basic calibration, "three - electric" system calibration, thermal management system calibration, chassis system calibration.   Finally, the high - altitude test is mainly carried out in areas above 4,000 meters above sea level to detect the electrical safety of new energy vehicles in a low - oxygen environment and the stability of the motor and electronic control systems. In the high - altitude environment, the air is thin, and the insulation performance between electrical equipment will be tested, and arcs are likely to occur. Therefore, this test focuses on whether the vehicle's electrical system can maintain stable operation under oxygen - deficient conditions and the effectiveness of its safety protection measures.   Typical regions for three - high tests   Through vehicle three highs testing, not only can the adaptability of new energy vehicles in extreme environments be comprehensively evaluated, but also direct and effective data support can be provided for subsequent technological improvements, ensuring that new vehicle models have sufficient environmental adaptability and safety guarantees when they are launched on the market.  

Clarify the test requirements Determine the type of parts: There are many new energy vehicle parts, such as power batteries, drive motors, charging systems, thermal management systems, body and chassis systems, electronic control systems, etc. The test requirements of different parts vary greatly, and the corresponding test equipment needs to be determined according to the specific parts. Understand the test items: Clarify the test items to be carried out, such as power batteries need to be tested for electrical performance, safety performance, environmental adaptability, etc.; drive motors need to be tested for power performance, reliability, electromagnetic compatibility, etc., and select equipment with corresponding functions according to these items.   Pay attention to equipment performance indicators Accuracy: For measuring equipment, such as battery charging and discharging test equipment, motor performance tester, etc., accuracy is crucial. High-precision equipment can provide more accurate test results and help accurately evaluate component performance. Stability: The equipment should maintain stable performance during long-term operation and multiple tests to ensure the consistency and reliability of the test results and avoid inaccurate test data due to equipment fluctuations. Speed: On the production line or in large-scale testing, equipment with faster test speeds can improve test efficiency and shorten the test cycle, but it is also necessary to ensure that the speed does not affect the test accuracy and quality.   Consider compatibility and scalability Compatibility: The equipment should be able to adapt to the testing of new energy vehicle parts of different models and specifications, and have certain versatility and compatibility. For example, battery charging and discharging test equipment should be compatible with various types of power batteries. Scalability: With the development of new energy vehicle technology and the continuous improvement of testing requirements, the selected equipment should have certain scalability to facilitate subsequent upgrades or add new test functions to meet future testing needs.   Investigate equipment quality and reliability Brand and reputation: Choose equipment from well-known brands. Usually these brands have a certain reputation and credibility in the market, and the product quality and after-sales service are more guaranteed. You can understand the brand's reputation through online evaluation, industry recommendations, etc. Certification and qualifications: Check whether the equipment has passed the relevant standard certification and qualification review, such as ISO and other quality management system certification, metrology certification, etc. These certifications are a reflection of the quality of the equipment.   Evaluate after-sales service Maintenance service: Understand the maintenance service capabilities of the equipment supplier, including maintenance response time, maintenance cycle, maintenance costs, etc., to ensure that the equipment can be repaired in time when it fails and reduce downtime. Technical support: The supplier should be able to provide professional technical support, including equipment operation training, test method guidance, troubleshooting, etc., to help users better use and maintain the equipment.   Consider cost factors Purchase cost: According to the budget and actual test needs, choose reasonably priced equipment to avoid blindly pursuing high-end equipment and causing excessive costs, but also ensure that the equipment performance meets basic test requirements. Use cost: Including equipment energy consumption, consumables, maintenance costs, etc., choose equipment with low energy consumption, low frequency of consumables replacement, and simple maintenance, which can reduce long-term use costs.