Test Planning & Preparation
- Develop detailed test plans to assess thermal management systems, driving range, and energy efficiency for electric vehicles under various real-world conditions (e.g., hot, cold, or humid environments).
- Work closely with design, powertrain, and thermal teams to establish performance targets and define testing parameters for range and efficiency validation.
- Select appropriate test environments such as climatic wind tunnels, on-road testing, or chassis dynamometers to simulate real-world driving scenarios, and ensure proper instrumentation for thermal and energy data collection.
- Coordinate the setup and calibration of sensors for temperature, energy flow, and efficiency measurements across different subsystems like the battery, motor, power electronics, and HVAC.
Test Execution
-Thermal System Testing:
- Conduct thermal performance testing on critical EV systems including the battery thermal management system (BTMS), electric motor cooling, power electronics, and HVAC system.
- Test and evaluate thermal stability and cooling performance during high-load driving conditions, fast charging cycles, and extreme ambient temperatures.
- Assess the impact of thermal management on energy efficiency and vehicle range, identifying potential improvements to maximize battery life and vehicle performance.
-Range & Efficiency Testing:
- Plan and execute range testing under various driving conditions (city, highway, mixed) and load scenarios, both in controlled environments and on-road testing.
- Monitor and analyze vehicle energy consumption, regenerative braking performance, and auxiliary power usage to optimize driving range.
- Evaluate and compare vehicle efficiency during different drive modes (e.g., eco, normal, sport) and develop strategies to enhance energy recovery and reduce consumption.
- Ensure that testing adheres to regulatory standards for electric vehicles, including WLTP (Worldwide Harmonized Light Vehicles Test Procedure), EPA, and NEDC.
Data Analysis & Reporting
- Analyze test data using tools like MATLAB, Python, or Excel to assess thermal behavior, energy efficiency, and range performance across various test conditions.
- Identify trends, performance deviations, and areas for improvement, providing detailed technical reports with insights for optimizing thermal management and energy efficiency.
- Generate comprehensive validation reports for internal stakeholders and regulatory compliance documentation.
- Provide actionable recommendations to the design and development teams to enhance system performance and resolve any issues identified during testing.
Problem Solving & Troubleshooting
- Strong diagnostic and troubleshooting skills for identifying and solving issues related to thermal performance, energy efficiency, or range degradation.
- Ability to analyze complex test data and develop actionable recommendations to improve system performance.
Collaboration & Communication
- Excellent communication skills to effectively present test results, analysis, and recommendations to both technical and non-technical stakeholders.
- Ability to work in cross-functional teams and communicate with external testing facilities, suppliers, and regulatory agencies.
