Fresh off the back of Domin’s visit to the Automotive Testing Expo Europe, we’re seeing a clear shift in focus across the industry. The automotive testing landscape is in a state of dynamic change, driven by growth and adoption of electric vehicles (EVs).
The global movement towards a reduced carbon footprint has accelerated the EV revolution, ensuring the demand for precise and reliable EV testing will set to rise. This transformation brings evolving demands driven by the unique characteristics of EVs, particularly when it comes to managing significant battery weight, integrating entirely novel components, and harnessing immense power densities. This significant shift brings new complexity to test environments, requiring a dramatic increase in precision, force, and speed without sacrificing efficiency or space.
The Evolution of EV Testing: Emerging Challenges on the Horizon
The unique characteristics of EVs present a distinct set of challenges for testing. We’re seeing a clear need for innovation in several key areas:
- Heavier Loads and Change of Structure: The weight of EV battery packs fundamentally changes how the car’s body and frame react to stresses from driving and, critically, from collisions. This demands entirely new structural and crash testing scenarios. Consequently, test systems must be capable of accurately simulating and validating the integrity of vehicle structures under significantly increased loads.
- Thermal Management Systems in Focus: Unlike traditional petrol cars where a cooling system primarily handles the engine, EVs have multiple heat-generating components and therefore rely heavily on sophisticated thermal management systems to maintain optimal battery and powertrain temperatures. This necessitates accurate simulation of cooling performance across a wide range of operating conditions, demanding precise control and rapid response from test equipment.
- Reimagining NVH Testing: NVH is a broad term encompassing anything a driver or passenger can hear (noise), feel (vibration), or perceive as unpleasant (harshness). While the sources of NVH change in an EV, the challenges of managing a quiet and smooth ride remain. Without the masking noise of the engine, unnoticed sounds and vibrations from electric motors, power electronics, and other sources become more noticeable. To ensure a premium, comfortable experience for passengers and to prevent premature wear on sensitive EV components, specialised testing methods and highly precise test equipment are absolutely essential to accurately identify, measure, and mitigate these new NVH issues.
- Increased Test System Complexity: EV development demands more sophisticated testing because of its complexity. There are more components, interconnected systems, and higher levels of integration in EVs. This translates into increased test system complexity, meaning tests manage more data, more control loops, and a greater need for seamless communication between various test elements. Thus, test systems must be capable of simulating and controlling multiple simultaneous, real-time parameters and their interactions, not just single functions.
- Higher Durability Requirements: Electric motors in EVs put components under immense stress due to their instant power and constant activity. It is crucial to guarantee these parts last, i.e. testing needs to be much tougher and run for much longer. This rigorous testing requires hydraulic actuation that can deliver sustained, precise force and movement over extended periods, ensuring component durability and reliability.
Domin’s Smart Solution: Unrivalled Reliability and Dynamic Performance for EV Testing
EV development downtime is costly and can impact the vehicle program roadmap. Test benches often run 24/7, simulating millions of cycles, to assess the long-term durability of components like electric motors and battery mounts. At Domin, we understand these evolving demands and have designed the products that will enable the next generation of automotive testing. Our advanced servo valves, especially the S10 Pro and S12 Pro, are engineered from the ground up to meet and exceed these new performance benchmarks.
- Robust Onboard Electronics: Domin Valves integrates modern, robust electronics directly into the valve. These advanced electronics facilitate precise control, enable remote diagnostics, and are engineered to withstand the demanding conditions of test environments, further contributing to consistent, reliable performance throughout the valve’s lifespan.
- Exceptional Bandwidth and Response Time: Domin Valves, combined with high-speed brushless DC motors, allow for incredibly rapid and precise spool movement. This enables the test system to achieve fast step responses and maintain control across a wide range of frequencies.
- High Power Density: This critical differentiator enables powerful actuation in incredibly compact spaces. In an industry where space is at a premium, our valves deliver maximum impact with minimal footprint.
- Compact, Efficient Architecture: Compared to traditional multi-stage designs, our products boast a compact and efficient architecture, significantly reducing space requirements and simplifying system integration.
Together, these capabilities empower OEMs and test engineers to meet the growing pressures of EV testing head-on. Our products deliver higher force, greater control, and improved repeatability, allowing for more accurate, efficient, and reliable testing.
Powering the Future of Mobility
The shift to electric vehicles is not just a technological evolution; it’s a revolution in how we design, build, and test the vehicles of tomorrow. At Domin, we’re not just keeping pace with these changes; we’re actively shaping the future of hydraulic solutions for automotive testing. The challenges of EV testing are big, bold, and demand equally ambitious solutions, which is exactly what we thrive on at Domin.
