Patent Publication Number: US-2021164866-A1

Title: Arrangement for testing vehicle components and a method for setting up an arrangement for testing

Description:
FIELD 
     The embodiments described relate to a testing arrangement for testing vehicle components, such as car batteries or electric motors. The described embodiments also relate to method of setting up an arrangement for testing vehicle components. 
     BACKGROUND 
     Manufacturers of vehicle components such as engine or battery manufacturers and car manufacturers require testing facilities for testing the vehicle components. The testing may involve testing operation and capabilities of the components under various scenarios, e.g. under different environmental conditions. The testing may involve measuring electric or other properties of the components. For that purpose, the component to be tested is disposed into a test chamber for testing. 
     Conventionally, testing of vehicle components such as batteries and electric motors is carried out in a special-purpose testing facilities within a manufacturing facility, for example. The testing facilities is built as an integral part of other facilities such as the manufacturing facilities. This results in costly investments, long construction times, and lack of flexibility in providing the testing capabilities and the currently known arrangements are causing larger and more costly damages in the event of fire or explosions caused by the components to be tested. 
     BRIEF DESCRIPTION OF THE INVENTION 
     An object of the present invention is to provide a testing arrangement and a method so as to solve or alleviate above mentioned problems. The objects of the invention are achieved by a test arrangement and a method which is characterized by what is stated in the independent claims. The preferred embodiments are disclosed in the dependent claims. 
     The invention is based on the idea of new layout introducing combination of infra structure module (s) and test modules. 
     An advantage of the new test arrangement and method is flexibility and scalability. Also, in case of extreme situation such as fire or explosion, the modular layout makes it possible to limit the damages caused to the test arrangement. Damages can be overcome by replacing the container-module with a new one. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the following the invention will be described in greater detail by means of preferred embodiments with reference to the attached drawings, in to which: 
         FIG. 1  is a top view layout of the test arrangement, 
         FIG. 2  shows the infra structure module, 
         FIG. 3  shows the test module structures inside the container, 
         FIG. 4  shows connecting elements between the infra structure module and the test module, 
         FIG. 5  shows the second embodiment of the test arrangement, having a monitoring room at the infra structure module, 
         FIG. 6  shows a top view of the test arrangement of  FIG. 5 , 
         FIG. 7  shows a top view of the arrangement having concrete foundation that is supporting the modules. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     There is provided an arrangement  10  for testing vehicle components C. In an embodiment, the component C to be tested may be a vehicle battery (a whole battery unit or a battery sub-component such as one cell of a battery). The vehicle, whereto to component relates to, can be a car, a fork lift or other loading vehicle, for example. In an embodiment, the electric car components to be tested in the container(s) comprise electric components of an electric car or a hybrid car, the hybrid car comprising both an electric engine and a combustion engine. The hybrid car may be considered as a conventional hybrid car that cannot be recharged or a plug-in hybrid electric car that can be recharged. The electric car components may include car components of a power supply system such as a battery and/or a power generation system such as an electric motor.  
     The arrangement comprises a test system TS and at least one test chamber  111 - 116  for components C to be tested. The shown embodiment comprises six test chambers  111 - 116 . The arrangement comprises at least one, such as six, test modules  121 - 126  comprising a transportable container  131 - 136  comprising said test chamber  111 - 116  for the vehicle components C to be tested. For example, test module  121  comprises transportable container  131  comprising test chamber  111 . 
     The arrangement comprises one or more, such as three, infra structure modules  221 - 223  comprising transportable containers  231 - 233  for accommodating test system equipment of the test system TS. In an embodiment, test system equipment may comprise frequency converter FC and the related rectifiers. 
     In an embodiment, the transportable containers  231 - 233  of the infra structure modules  221 - 223 , are standard-size freight containers. 
     At least one test module, such as test module  121 , is arranged next to the infra structure module such as infra structure module  221 . In the shown embodiment, six test modules  121 - 126  are next to the infra structure module, in such way that test three modules  121 - 123  are next to the infra structure module  221  and other three test modules  124 - 126  are next to the infra structure module  223 . 
     In an embodiment, referring to the layout, arrangement comprises two or more such as three test modules  121 - 123 ,  124 - 126 , wherein the test modules  121 - 123  are on different sides of the infra structure module so that the infra structure module is between the test modules. Referring to  FIG. 1 , each one of the three infra structure modules  221 - 223  are between the test modules so that to infra structure modules  221 - 223  are between test modules  121 - 123  and  124 - 126 . 
     The arrangement comprises at least two such as three infra structure modules  221 - 223 , wherein the infra structure modules  221 - 223  are next to each other and between the test modules  121 - 123 ,  124 - 126 . 
     Test modules  121 - 123  are on the left compared to the infra structure modules  221 - 223 , and the test modules  124 - 126  are on the right compared to the. The right hand ends of the test modules  121 - 123  are next to the left hand side of the infra structure module  221 , and in a corresponding way the left hand ends of the test modules  124 - 126  are next to the right hand side of the infra structure module  223 . Infra structure module  222  is between the infra structure modules  221 ,  223 .  
     In an embodiment, the test modules such as test modules  121 - 123  are in at least one test module group G 1  wherein the test modules of the group are next to each other on the same side of the infra structure module like  221 . 
     In an embodiment, test modules are in at least two test module groups G 1 , G 2 , wherein test modules  121 - 123  belong to group G 1  and test modules  124 - 126  belong to group G 2 . The test modules  121 - 123  of the first test module group G 1  are next to each other and on the one side (left) of the infra structure module  221 , and wherein the test modules  124 - 126  of the second test module group G 2  are next to each other and on a different side (right) of either the same infrastructure module or another infra structure module. If there would be only one infra structure module, the second group G 2  of test modules would be on the different side of the same infra structure module. But in an embodiment, since the in the layout the test arrangement comprises more than one infra structure modules, for example three infra structure modules  221 - 223 , then the test modules  124 - 126  of the second group G 2  are on the different side (of another infra structure module which is the infra structure module  223 . From the layout of  FIG. 1 , it can be seen that the principle is that one or more infra structure modules  221 - 223  are between the first and second group G 1 , G 2  of test modules. 
     Referring especially to  FIG. 4 , the test arrangement further comprises test system connection element CE 1  for operatively connecting the test system equipment TS at the infra structure module  221  to the test module  121 . 
     In addition to test system equipment TS, the infra structure module, such as module  222 , can include additional structures and functions. In an embodiment, test the arrangement further comprises a climate control system and then the transportable container of the infra structure module  221  further accommodates at least part (such as water filtering device  250 ) of the climate control system, and wherein the arrangement further comprises a climate control system connection element CE 2  for operatively connecting said at least part of the climate control system at the infra structure module  221  to the test module  121 . Corresponding connecting elements are used also between the infra structure  module  221  and test modules  122 ,  123  and also between the infra structure module  223  and the related test modules  124 ,  125 ,  126 . 
     The climate control system that is at least partly accommodated at the infra structure module(s)  221 - 223  is for controlling climate conditions in the test chambers  111 - 116  at the transportable containers  131 - 136 . The climate control system may be configured to adjust environmental conditions in the test chamber(s), like  111 - 116 , during the testing. The climate control system may further control temperature/humidity distribution and/or air flow in the test chamber(s). The environmental conditions controlled by the climate control system to may include at least one of temperature and humidity. 
     Infra structure modules  221 - 223  can be seen as one module so module arrangement comprising three parallel sub-modules  221 - 223  or comprising three different modules. 
     Referring to  FIGS. 1-2 , regarding the those parts of the climate control system that are at the infra structure module  221 - 223 , there is provided a water chiller  240  and it is supported on top of the infra structure module  222  so on the roof of the transportable container, like  232  of the infra structure module  222 . In the embodiment of  FIG. 1 , the water chiller/cooler  240  has six dual elements. In  FIG. 1 , also on top of the roof of container  232  of the infra structure module  222  there is also provided a reservoir  290  for water and one or more pumps  291 - 292  for the cooling water. The cool water from water chiller  240  is used for cooling of the frequency converter/battery cycler FC, FC 1 -FC 12  that is inside the transportable containers  231 - 233  of the infra structure modules  221 - 223 . 
     In an embodiment, one or more parts  240 ,  250 ,  290 ,  291 - 292  of the climate control system is supported on top of the transportable container  232  of the infra structure module  222 , and one or more other parts  280 ,  281 ,  282  of the of the climate control system is supported on top of the transportable container  131  of the test module  121 . In an embodiment, one or more of the following is supported on top of the transportable container  232  of the infra structure module  222 : water chiller  240 , water filtering device  250 , reservoir  290  for water, pumps   291 - 292  for water, and one or more of the following is supported on top of the transportable container  131  of the test module  121 : outdoors unit  280  of the climate control system, compressor  281  of the outdoors unit  280  of the climate control system, cooling cell  282  of the outdoors unit  280  of the climate control system. 
     In  FIG. 2 , FC 1 -FC 12  refers that at infra structure module  221 - 223 , there are 12 battery cycler elements FC 1 -FC 12  for six test modules  121 - 126 . Each two battery cycler elements, like battery cycler elements FC 1 -FC 2  are assembled their back walls against each other, each set of two battery cycler elements are servicing their dedicated test module. 
     Additionally, regarding parts of the climate control system, at the infra structure module(s)  221 - 223  inside the transportable container, like container  231 - 233 , there is provided a water filtering device  250  such as demineralization device  250 . The role of the demineralization device  250  at the infra structure module is to produce filtered water via connecting element CE 2  for the humidifier  255  that is at the test module like at the test module  121  as shown in  FIG. 3 . 
     Regarding parts at the test module, like test module  121 , also the test module comprises some parts regarding the climate control system. Those parts so the climate control arrangement at the test module, like test module  121 , comprises outdoor unit  280 , humidifier  255  so a steam generator  255  and an internal unit  256 . Outdoor unit  280  is operatively connected to humidifier  255  so steam generator, which in turn is operatively connected to the internal unit  256 . 
     Outdoor unit  280  is on top the container  131  of the test module  121  and comprises compressor  281  for cooling and a honeycomb-type cooling cell  282 . Humidifier  255  so steam generator  255  is preferably inside the test module container  131 , preferably inside so at the control room R which can also be called a device room R. Internal unit  256  is at the test chamber  111  and the role of the internal unknit  256  is to circulate the air inside the test chamber  111 , and for that purpose he fan motors M 1 -M 3  are used. Humidifier  255  so steam generator  255  and the internal unit  256  are at the opposite sides of the internal wall IW between the test chamber  111  and the control room R so device room R. Cool air for the  testing chamber  111  is produced by the compressor  281  and the cooling cell  282 . Hot air for test chamber  111  is produced at the internal unit  256  with heating element such as a heating resistor. 
     In addition to outdoor unit  280 , on top of the test module  121 , there can be electrical isolators IS 1 , IS 2 . 
     Regarding  FIG. 2  and relating also to  FIGS. 4 and 1 , the infra structure module  221 ,  223  comprise bushings/openings like OP 1 , for bringing connecting elements like CE 1 , CE 2  from the infra structure module  221 ,  223  to test modules  121 - 126 . Additionally, the infra structure module comprises doors like to DR 1  so as to close the pathways like pathway D 1  at the test module  121 . 
     Regarding  FIGS. 1 and 3 , humidifier  255  is at the control room R of the test module  121  so inside the transportable container  131  of the test module  121 . The humidifier  255  such as steam generator device is connected to internal unit  256  within the test chamber  111  for delivering the humidity (water vapour/steam) to the test chamber  111 . Humidifier  255  and internal unit  256  are those parts of the climate control systems that are accommodated by the test module  121 . 
     Referring to  FIG. 2 , the internal wall IW divides test module  121  to a test chamber  111  and to a control/device room R. D 1  refers to a pathway D 1  to be closed with a door that is at the nearby infra structure module. D 2  refers to door between control room R and the test chamber  111 . D 3  refers to door at the end of the test chamber  111 . Control room R so device room may also comprise additional elements such as electrical cabinet E 1 , automation system cabinet E 2  and switching box E 3  for the battery to be tested at the test chamber  111 . 
     As an alternative to above discussed location (at the control room R) of the humidifier  255 , the humidifier  255  so the steam generator  255  can be at the outdoors unit  280 , especially when the test arrangement is not subjected to cold outdoors temperature. 
     Connecting element CE 1  between the test system at the infra structure module  211  and the test module  121  may comprise one or more electrical cables. Connecting element CE 2  between the part of the climate control system at infra structure module  231  and the test module  121  may comprise one or more tubes  for delivering water from infra structure module  231  to test module  121 , for example for delivering filtered water from water filtering device  250  at the infra structure module  233  to the humidifier  255  at the test module  121 . 
     In an embodiment, the transportable container of the infra structure module further accommodates one or more of the following: fire safety system, building automation system, infra structural support system. 
     Referring to  FIG. 2 , regarding fire safety system, one or more pump  261  is accommodated by the infra structure module, like module (sub-module)  223  inside the transportable container  233 . Referring to  FIG. 1 , regarding infra structural support system, the transportable container  233  of the infra structure module (sub-module)  223  accommodates a ventilation machine  270  on top of container  233  of the infra structure module (sub-module)  223 . Referring to  FIG. 2 , a building automation system (BAS) element  265  is inside the container  232  of the infra structure module  222 . 
     Referring to  FIG. 4 , in an embodiment the arrangement may comprise release element for releasing the test system connection element CE 1 , for facilitating moving away of the infra structure module and/or the test module. Additionally, in an embodiment, the arrangement may comprise release element for releasing the climate control system connection element CE 2 , for facilitating moving away of the infra structure module and/or the test module. Release elements make it easier to have one move the test module and or infra structure module in the event of fire or explosion. 
     Referring to  FIG. 1 , in an embodiment, the arrangement further comprises a power bank module  300 , said power bank module  300  being arranged for balancing the electrical transfer in relation to external power network and/or for providing a power resource in the event of external power network shut-down. Power bank may replace one test module, such as test module  126  in  FIG. 1 . 
     In an embodiment, the power bank module  300  comprises a transportable container  331  which in an embodiment transportable container of the power bank module is a standard-size freight container. 
     In an embodiment, the vehicle component C to be tested is a vehicle battery, and wherein the test system at the infra structure module is arranged to input charge cycles and/or discharge cycles to the vehicle battery at the test module. In a further specified embodiment the test system at the infra structure  module is arranged to guide (arranged to control) a loaded battery at a test module, like test module  121 , to discharge the load thereof to be used for loading another battery at another test module like test module  122 . For the above mentioned purposes, the infra structure module comprises a frequency converter FC (battery cycler, FC 1 -FC 12 ) and the related rectifiers inside the transportable containers  231 - 233  of the infra structure modules  221 - 223 . 
     In an embodiment, the frequency converter may be water cooled Unico Ltd. Battery simulator (battery cycler) with 1100V voltage and 700 A electric current settings. 
     The transportable container of the infra structure module comprises a door DD arranged to provide access to the internal space of the infra structure module from exterior of the transportable container of the infra structure module. 
     Referring to  FIGS. 5-6 , most of the elements in the second embodiment are similar than as discussed regarding  FIGS. 1-4 . Therefore in  FIGS. 5-6  the test arrangement comprises infrastructure module ISM having sub-modules  6221 - 6223  having transportable containers  6231 - 6233 . Furthermore, the test arrangement comprises test modules  6121 - 6122  having transportable containers  6231 - 6232 . The major difference, compared to  FIGS. 1-3 , is that in  FIGS. 5-7  the arrangement comprises a monitoring room MR (control room) in the transportable container of the infra structure module. In  FIGS. 1-3  the corresponding element (control room R) is within a test module. Alternatively, monitoring room (control room) could be in a separate monitoring module that is a transportable container. 
     Referring to  FIGS. 5-7 , supported on top (roof) of the container of the test module  6121 , there is an outdoors unit  6280  (like  280  in  FIGS. 1-3 ) of the the climate control system, having compressor (like compressor  281  in  FIGS. 1-3 ) and a cooling cell (like cooling cell  282  in  FIGS. 1-3 ). In addition to outdoors unit  6280 , on top of the test module  6121 , there can be electrical isolators  6 IS 1 ,  6 IS 2 . However, in some embodiments the electrical isolators can alternatively be on top of the infra structure module(s).  
     Referring to  FIGS. 5-6 , likewise as was discussed referring to in  FIGS. 1-3 , supported on top (roof) infrastructure module, there are elements of the climate control system. Those elements comprise water chiller  6240  (like water chiller  240  in  FIGS. 1-3 ), water filtering device (like device  250  in  FIGS. 1-3 ), reservoir (like reservoir  290  in  FIGS. 1-3 ) for water, pumps (like pumps  291 - 292  in  FIGS. 1-3 ) for water. 
     Referring to  FIGS. 5-6 , in an embodiment, the monitoring room MR comprises monitoring equipment ME for receiving test data and or other data from the test module and/or from the infra structure module. The monitoring to equipment ME comprises elements like test Automation cabinet, test automation PC (computer), building automation system cabinet, Fire detection system central unit, as were discussed relating to  FIGS. 1-3 . 
     Referring to  FIG. 7 , in an embodiment, the arrangement comprises a concrete foundation CF for supporting one or more infra structure module  6221 - 6223  and the two or more test modules  6121 - 6122 . In a further embodiment, the concrete foundation CF comprises one or more recesses RE for accommodating one or more test system connection element CAB or other cable between the modules of the arrangement. 
     The invention relates also to a method for for setting up (method for building) an arrangement for testing vehicle components. The method comprises the following steps: 
     Forming a concrete foundation CF on ground outdoors. This can be done in well known traditional way. 
     Supporting on the concrete foundation an infra structure module ISM,  6221 - 6223  comprising a transportable containers  6231 - 6233  for accommodating test system equipment  6 FC 1 ,  6 FC 2  (in containers  6231 - 6232 , because third container  6233  of the infra structure module is the container for the monitoring room MR.  
     Supporting on the concrete foundation two or more test modules  6121 - 6122  in such way that the test modules are next to the infra structure module  6231 - 6233  on different sides of the infra structure module so that the infra structure module is between the test modules, each test module  6121 - 6122  comprising a transportable container  6131 - 6132  comprising the test chamber for the vehicle components to be tested. 
     Using test system connection elements CAB (CE 1 ) for operatively connecting the test system equipment  6 FC 1 ,  6 FC 2  (FC, FC 1 -FC 12  in  FIGS. 1-3 ) at to the infra structure module ISM to the test modules  6121 - 6122  ( 121 - 126  in  FIGS. 1-3 ). 
     In the method, a suitable movable lifting vehicle is used for lifting and placing the modules on the concrete foundation CF. 
     Before supporting the infra structure module ISM,  6221 - 6223  and the test modules  6121 - 6122  on the concrete foundation CF, the test system connection elements CAB or other cables between the modules of the arrangement are laid on the recesses RE on the top surface of the concrete foundation CF. 
     Regarding the elements of the climate control system, the connection is established between those elements on top the infra structure module and those elements on top of the test modules. This can be done with suitable tubes and cables or other connecting elements. 
     It will be obvious to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims.