Tongzhou Weipu MCe Integrated Circulating Chiller for EV Battery Pack Fatigue Testing

Overview

The Tongzhou Weipu MCe Integrated Circulating Chiller is a purpose-engineered thermal management system designed specifically for high-reliability, long-duration fatigue testing of electric vehicle (EV) battery packs under dynamic thermal load conditions. Unlike conventional vapor-compression chillers, the MCe operates via direct heat exchange with facility-supplied chilled water or glycol-water coolant—eliminating onboard refrigeration compressors, condensers, and refrigerant circuits. This design delivers inherent energy efficiency, ultra-low acoustic emissions (<58 dBA at 1 m), and zero direct greenhouse gas emissions during operation. The system maintains precise temperature setpoints across its full operational range (+10 °C to 95 °C) while sustaining stable flow delivery to multiple test stations or large-volume DUTs (devices under test), including battery modules, traction inverters, and motor controllers subjected to ISO 16750-4, SAE J2380, and GB/T 31467.3 thermal cycling protocols.

Key Features

• Direct chilled-water heat exchange architecture—no internal refrigerant loop, compressor, or oil management required
• Five selectable pump flow configurations (2–20 L/min up to 10–150 L/min) to match thermal mass and pressure-drop requirements of diverse test fixtures
• Industrial-grade stainless-steel circulation loop with EPDM and FKM elastomer seals rated for continuous operation at 95 °C
• Dual-stage PID temperature control with real-time adaptive tuning, achieving ±1 °C stability over 24-hour continuous duty cycles
• Modular electrical interface supporting 380 VAC / 50 Hz three-phase input; optional 480 VAC / 60 Hz configuration available for North American and EU installations
• Integrated safety monitoring: flow rate validation, high-temperature cutoff, low-flow alarm, and dry-run protection with relay outputs for PLC integration

Sample Compatibility & Compliance

The MCe chiller is engineered to interface with standardized battery test chambers, HIL (hardware-in-the-loop) racks, and powertrain thermal test benches. Its wide temperature range and scalable flow capacity support both single-cell thermal characterization and full-pack (up to 100 kWh) endurance cycling per IEC 62660-2 and UN GTR 20. All wetted materials comply with RoHS Directive 2011/65/EU and are compatible with common battery coolant formulations (e.g., 30/70 ethylene glycol/water, Kryo 55). The unit meets CE marking requirements for machinery (2006/42/EC) and electromagnetic compatibility (2014/30/EU). Optional documentation packages include Factory Acceptance Test (FAT) reports and material traceability certificates aligned with AS9100 Rev D quality systems.

Software & Data Management

The MCe features an embedded industrial controller with Modbus RTU and Ethernet/IP communication protocols, enabling seamless integration into LabVIEW, MATLAB, or custom SCADA environments. Temperature setpoint, flow rate, and status alarms are logged at user-configurable intervals (1 s to 10 min) with timestamped CSV export capability. Audit trail functionality complies with GLP and GMP data integrity principles (ALCOA+), including operator ID tagging, change history, and electronic signature support when paired with validated third-party supervisory software. No proprietary cloud services or vendor lock-in—the system operates fully offline and supports local historian storage on removable SD card (up to 32 GB).

Applications

• Accelerated calendar and cycle life testing of lithium-ion, LFP, and NMC battery packs under controlled thermal stress
• Thermal validation of battery thermal management systems (BTMS) during charge/discharge pulses and regenerative braking simulation
• Steady-state and transient thermal profiling of power electronics (inverters, DC-DC converters) in automotive-grade environmental chambers
• Supporting ISO 12405-2 cold-start, hot-soak, and thermal shock sequences for EV component qualification
• Integration into automated test systems performing UL 2580, GB 38031, and ECE R100-02 compliance verification

FAQ

Does the MCe require refrigerant charging or annual servicing of a compressor?
No—the MCe has no refrigeration circuit. Maintenance is limited to periodic inspection of pump seals, filter cleaning, and coolant quality verification.
Can it operate continuously at 95 °C with full flow capacity?
Yes. The system is rated for continuous operation at maximum temperature and maximum specified flow rate within its configured pump module.
Is remote monitoring supported over standard industrial networks?
Yes. Modbus TCP and EtherNet/IP interfaces allow integration with existing plant SCADA or MES platforms without middleware.
What is the typical lead time for custom flow/pressure configurations?
Standard models ship within 6–8 weeks; engineered variants with non-standard pump curves or extended temperature sensors require 10–12 weeks from PO confirmation.
Are calibration certificates provided with shipment?
Each unit ships with a factory calibration report traceable to CNAS-accredited standards (GB/T 28043), covering temperature sensor accuracy (±0.3 °C) and flow meter linearity (±1.5% FS).