Yuelian YL-YG-8000D Walk-in Combined Salt Spray, Dry Heat & Humid Cycling Chamber for Battery Pack Environmental Stress Testing

Overview

The Yuelian YL-YG-8000D is a walk-in environmental stress test chamber engineered for comprehensive, standards-compliant validation of electric vehicle (EV) battery packs and energy storage systems under combined corrosive, thermal, and hygroscopic conditions. It integrates three critical environmental stress profiles—neutral salt spray (NSS), acidic salt spray (ASS), and cyclic humidity-temperature conditioning—within a single, fully programmable platform. The system operates on the principle of controlled electrochemical corrosion acceleration combined with thermomechanical cycling, enabling accelerated life assessment per IEC 62660-2, GB/T 31467.3, UN ECE R100.02, and ISO 16750-4. Its large 8000 L internal volume accommodates full-scale battery modules (up to 2000 kg payload), while its split-type architecture permits flexible site installation and integration into existing battery validation laboratories. Unlike benchtop salt fog cabinets, the YL-YG-8000D maintains strict spatial uniformity and temporal reproducibility across all test zones—critical for regulatory audit readiness and inter-laboratory comparability.

Key Features

• Triple-mode environmental simulation: programmable salt spray (neutral or acidic), high-humidity soak (up to 95 %RH), and dry heat cycling—all within one integrated chamber
• High-fidelity climate control: dual PID-regulated temperature and humidity systems with real-time feedback loops; ±0.5 °C temperature fluctuation and ±2 %RH humidity fluctuation (at >75 %RH)
• Corrosion-grade chamber construction: interior lined with 2.0 mm thick SUS#304 stainless steel; exterior housing fabricated from reinforced cold-rolled steel with epoxy-polyester coating for long-term chemical resistance
• Optimized salt delivery system: precision-machined nozzles, calibrated pressure tank (0–63 °C range, ≤45 min ramp), and standardized collection funnel array compliant with ASTM B117 and GB/T 2423.18 requirements
• Human-centric interface: 10.4-inch color TFT-LCD touchscreen with intuitive multi-segment cycle programming, data logging, and alarm history (including over-temperature, low-level brine, door open, compressor fault)
• Modular refrigeration: dual-stage or parallel industrial compressors (GEA Bitzer or Tecumseh OEM units) delivering stable cooling performance across full load conditions (100–2000 kg)

Sample Compatibility & Compliance

The YL-YG-8000D is validated for testing EV traction battery enclosures, module assemblies, and complete pack-level systems conforming to dimensional envelopes up to 200 × 200 × 200 cm. Its design supports both stationary and dynamic mounting configurations via optional vibration-isolated sample carts and configurable support rails. All operational parameters align with mandatory test sequences defined in GB/T 2423.18 (Salt Mist Test, Severity Level 5), GB/T 31467.3 (Electric Vehicle Battery Safety Requirements), and ISO 16750-4 (Road Vehicles – Environmental Conditions and Testing for Electrical and Electronic Equipment – Climatic Loads). The chamber’s temperature and humidity uniformity profiles are verified per IEC 60068-3-5 and meet GLP audit criteria for traceable calibration records, sensor placement documentation, and uncertainty budgets. Optional validation kits (e.g., NIST-traceable PT100 probes, gravimetric salt deposition collectors) support IQ/OQ/PQ protocol execution.

Software & Data Management

Embedded firmware enables full-cycle definition—including salt spray duration (2 h), wet storage (20–22 h at 40 ±2 °C / 93 ±3 %RH), ambient recovery (23 ±2 °C / 45–55 %RH for 72 h), and repetition logic (4 total cycles). Data is logged at user-selectable intervals (1 s to 60 min) and stored internally (≥30 days) with timestamped CSV export via USB or Ethernet. Optional PC-based software (Yuelian TestSuite v3.2) provides remote monitoring, multi-chamber synchronization, automated report generation (PDF/Excel), and 21 CFR Part 11-compliant user access control (role-based permissions, electronic signatures, audit trail). All measurement channels—including chamber air temperature, relative humidity, salt solution pH, nozzle pressure, and compressor discharge temperature—are assigned unique calibration IDs linked to external metrology certificates.

Applications

• Accelerated corrosion validation of aluminum housings, busbar coatings, and gasket materials used in high-voltage battery systems
• Functional integrity testing of BMS sensors, HV connectors, and venting membranes under combined thermal-hygric-saline stress
• Pre-certification screening for UN 38.3 Section 38.3.4 (altitude, temperature, vibration, shock, and external short circuit) and IEC 62619 compliance
• Root cause analysis of field failures related to electrolyte leakage, terminal oxidation, or seal degradation in coastal or de-icing salt environments
• Material qualification for battery thermal management system (BTMS) components exposed to condensate and road-salt aerosols

FAQ

Does the YL-YG-8000D comply with ASTM B117 for neutral salt spray testing?
Yes—the chamber meets all apparatus requirements in ASTM B117, including fog collection rate (1.0–2.0 mL/80 cm²/h), pH control (6.5–7.2), and temperature stability (35 ±2 °C during spray phase).

Can the system perform acidic salt spray (ASS) testing per ISO 9227?
Yes—pH adjustment capability (3.1–3.3) and corrosion-resistant internal plumbing support ASS protocols without modification.

Is the chamber suitable for testing battery packs with active thermal management systems?
Yes—integrated power feedthroughs (optional) allow continuous DC/AC power supply and coolant line routing through sealed bulkheads.

What calibration documentation is provided with shipment?
A factory calibration certificate (traceable to CNAS-accredited labs) covering temperature, humidity, and salt deposition uniformity is included. On-site IQ/OQ support is available upon request.

How is safety ensured during extended unattended operation?
The system features dual independent over-temperature cutouts, brine level sensors with auto-shutdown, door interlock switches, and refrigerant leak detection—meeting IEC 61000-6-2 EMC and IEC 61000-6-4 emission standards.