Electric Vehicle
Component Testing

Test Benches by Poppe + Potthoff


Test Stands for Electric Vehicle Components

Pressure Cycle Test Bench | Function Test Stand | Automotive Testing | Burst Test Stand | Leak Test Bench | Pressure Pulsation

In order to prove the quality of Media-leading automotive parts, drive units (electric motors), valves, cooling and heating systems, hose lines, pipes, pressure vessels and other components are pressurized. Whether for dynamic pressure change tests, static pressure-holding tests, flow measurements or classic burst pressure tests, Poppe + Potthoff Maschinenbau offers you a solution individually tailored to your requirements. In addition to the pressure and durability tests, PPM’s test benches offer the opportunity to carry out a functional test on live components. The main focus here is on efficient energy management and performance under changing temperature conditions.

All tests are precisely measured and documented in order to optimally design the components for specific applications.
It goes without saying that our systems can be specifically configured to customer requirements and are built to UL or CE standards as required. In addition, we offer you service and support locally. Typical test norms involve VW8000 or BMW Group Standard GS95024-3-1 Test: M-07 pressure pulsation test of the cooling circuit, including pulsation testing in climate chambers, vacuum testing, and more.

Pressure Test Rigs for HVCH, PTC Heaters, Cooling Circuits

At Poppe Potthoff Maschinenbau we offer pressure cycle test rigs that enable coolant (glycol) flow, environmental temperature simulation through climate chambers, as well as heating and cooling the test fluid. In addition, the component, such as a high voltage coolant heater, can be accessed with a wire harness to simulate operation.

Pressure Pulsation Test Stand with Climate Chamber

Pressure change test

Function test bench with closed test chamber for automotive heating and cooling units and battery simulation

Function test benches

Pressure Load Change Test Bench for Automotive Components with two test chambers and climate chamber

Pressure-change test benches
for automotive components

Burst Test Stand up to 4000 bar with closed test chamber and Siemens PLC System

Burst-test benches
for e-mobility components

Component Testing Service

Automotive Testing | Thermal Management | Pressure Tests of Metal and Plastic Components | Battery Simulation

In general, we also offer the above-mentioned tests in various pressure areas as a service. Whether for research and development or series applications, please contact us with your testing requirements for a non-binding offer.

For different E-Mobility devices, click the following applications:

Pressure Pulsation test bench for air conditioning components tests at -40 to +140 degrees Celsius

Pressure test at -40 to +140 degrees Celsius

The test medium used is water-glycol mixture or pure glycol (for example Glysantin® G40, G44, G48). The refrigeration cycle is tested in the temperature range from -40 to +20 degrees Celsius, and in the heating circuit from +20 to +140 degrees Celsius. The development of alcohol-containing vapors (danger of explosion) is avoided by means of specially-developed closed-circuit test equipment with the help of pressure. Optionally, an additional air-conditioning chamber can also be used to generate environmental simulation.
The volume flow of the test medium can vary from 3 to 30 l/min at a pressure of 0.2 to 10 bar (max 12 bar). The load changes are freely programmable with sinusoidal or trapezoidal rise in a test frequency of 0.2 to 1 Hz. The test system can be used to test complete systems as well as individual assemblies made of various plastics, metals and sealants. With the aid of realistic simulation, the weak points in the material composite are precisely determined – for example in the area of a weld seam – and can be optimized early in the development process.



  • Medium: water – glycol mixture/pure glycol
  • Medium temperature control: Refrigeration circuit: + 20 ° C to -40 ° C
    • Cooling capacity up to -30 ° C 5 kW
    • Cooling capacity up to -40 ° C 2 kW
  • Medium temperature heating circuit: + 20 ° C to + 140 ° C
    • Heating power: 12 kW
  • Flow rate control: 3 to 30 l/min
  • Ambient temperatures: -40 ° C to + 140 ° C
  • Dynamic pressure changes: 0.2 to 10 bar
  • Frequency: 0.2 Hz
  • Ramp shape: trapezoid & sine
  • Static pressure drop test: up to 12 bar
  • With PPM FdrV, any pressure curve up to 12 bar can be programmed

Functional test bench puts heating and cooling units for e-mobility to the test

Performance test at changing temperatures

The test specimen is inserted into the test chamber and connected to the test medium circuit. To simulate battery operation in an electric vehicle, a low voltage (0 to 20VDC/5A) or high voltage (0 to 600VDC/150A) power supply is available. The test medium (water-glycol mixture or pure glycol, for example Glysantin® G40, G44, G48) circulates at a freely controllable temperature of -35 to +100 degrees Celsius and a volume flow of 3 to 30 l/min. Optionally, the test can also be carried out in an air-conditioning cabinet at -40 to +140 degrees Celsius to simulate changing ambient temperatures.

A meaningful long-term test usually takes 20 days. The temperature and volumetric flow of the test medium as well as the ambient temperature will vary around the clock according to the programmed test cycles if the test takes place in the climatic chamber. The temperature of the test medium at the inlet and outlet of the test specimen and the ambient temperature are continuously measured. The flow, pressure and pressure drop as well as current and voltage in the high and low voltage range are also documented. The focus is on the thermal and electrical performance of the heating and cooling unit under varying environmental conditions.

Test medium: water-glycol mixture or pure glycol

  • Medium temperature: -35 ° C to +100 ° C
    • Cooling capacity: 15 kW at -35°C
    • Heating power electrical.: 25 kW
  • Ambient temperature control: -40 ° C to + 140 ° C (optional)
  • Flow rate control: 3 to 30 l/min
  • Battery simulation:
    • High Voltage: 0 to 600VDC/150A
    • Low Voltage: 0 to 20VDC/5A
  • Measurement data:
    • Temperature medium DUT inlet and outlet
    • Ambient temperature
    • Flow
    • Pressure
    • Pressure drop
    • Electric power
    • Thermal performance
    • Voltage HV and LV
    • Current HV and LV
    • Maximum value HV

Pressure Load Change test benches for automotive components

For impulse testing with subsequent long-term pressure and burst testing, our systems offer two chambers in which up to ten test specimens can be tested simultaneously at an ambient temperature of -60 ° C up to 180 ° C or room temperature. Separate control circuits supply 100% glycol or various oils at room temperature up to + 160 ° C. Thus, tests are possible at very large temperature differences, which are rare in reality, even in endurance tests on the race track of the Nürburgring, in the Siberian tundra or in the deserts of Africa.

Various servo-hydraulic pressure intensifiers, optimally designed for each test area, allow very precise control of the pressure. Pulse-pressure tests can be carried out with a frequency of 0 – 10 Hz (usually 0.5 – 2.5 Hz) with a trapezoidal curve of 4 – 25 bar and 0 – 160 bar. For the sinusoidal curve with a frequency of 0 – 10 Hz, pressures of 0 – 6 bar are possible. The maximum bursting pressure is 500 bar. Metering and visualization is done with National Instruments LabVIEW applications. All test procedures and data are automatically stored on the system and can be exported to the network for evaluation.


  • 3 different load change tests
  • 3 different media (each with double tank system)
  • additional burst pressure test: up to 500 bar
  • additional leak test: up to 100 bar (long-term test)
  • Frequency: 0.5 to 2.5 Hz (10 Hz max.)
  • Medium temperature control: RT to + 160 ° C
  • Ambient temperature control: -60 ° C to + 180 ° C
Pressure Cycle Test Bench with large Environmental Chamber and Computer System
Pressure cycling test stand with climate chamber

Temperature ambient:

-40°C to +150°C with rate of change 3,5 K/min

Temperature fluid:

-40°C to +140°C

Test chamber:

with Ex protection for pressure test with coolant (ATEX)

Size of test chamber:

1,500 x 1,000 x 1,000 mm (W x H x D)

Flow rate coolant:

0,5 l/min up to 30 l/min adjustable

Test pressure:

dynamic 0,2 to 6 bar with sinus- and trapezoidal curve


up to 2 Hz (further frequencies upon request)

Pressure drop test:

up to 1,000 mbar

Static pressure test:

up to 20 bar with compressed air and adjustable pressure increase

Leak rate test:

0,5 cm3/min

Vacuum testing:

Pressure variation between atmosphere and 18 mbar abs.

Burst-test benches for e-mobility components

In electric vehicles, media-carrying components are exposed to extreme conditions. The load capacity of pumps, pressure vessels, hose and pipes made of metal or plastic is proven by dynamic and statistical pressure tests.
The specimens can be easily adapted via quick couplings. Furthermore, a quick-change device is possible to perform the mounting of the specimen by hand outside the test chamber.

For the burst test two test circles with different working methods are available. Up to 50 bar, a very precise increase in pressure is possible due to the wear-free fine-control method. The other test circuit uses a pneumatically-driven pressure intensifier with which a pressure of up to 400 bar can be generated. The test medium normally is mains water or test oil. The test bench can also be equipped with a hand-held scanner to identify the components so as to assign the bursting pressures to each component. The system is controlled via a PLC with serial interface for data exchange. The entry of the test requirements is done via a touch panel.


  • Bursting pressure up to 400 bar
  • 0 – 50 bar fine pressure control
  • Tests with different media and temperature control

Your request

Contact us

Johannes Montag


Frank Baudler


Philip Claussen


+49 3631 46221022


Philip Claussen

Poppe + Potthoff Maschinenbau America

+1 617 250 7668

For further testing solutions, click the following product areas:

Pipes, (flexible) Hoses, Tubes und Connectors, A/C components and various other pressure vessels need to be tested and simulated in the EV industry.

 Play EV Component Testing Pressure Test Bench Movie

Poppe + Potthoff Maschinenbau is part of the Poppe + Potthoff Group
18 locations in 9 countries.

Poppe + Potthoff Gruppe has 18 production plants and sales offices in 9 countries. The name Poppe + Potthoff always indicates the highest quality – a promise to which our customers rely on, regardless of which Poppe + Potthoff location they work in.

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