Climatic Chamber Testing for the Automotive Sector: Concrete Examples

Types of Tests for the Automotive Sector

For testing batteries and accumulators, discover the battery test chamber, designed for testing under controlled conditions.

The automotive sector is a field of application in which product testing is practically endless.

Cars and means of transport in general are an integral part of our daily lives and must guarantee our total safety, with every use and in every possible circumstance.

Not only that: safety standards are not exclusively defined by the manufacturers and their subcontractors, but also by the regulatory bodies that must approve the homologation and therefore the subsequent sale of the finished vehicle.

In fact, there are several situations that may require testing in the automotive mechanical industry. These tests involve the various components that make up the automobile, such as:

• bodywork (crash test, road surface irregularity test, color test)
• engine (cooling, heating, engine oil, fuel, coolant, emissions)
• electronic and electromechanical components (such as EMC tests for electromagnetic compatibility 2004/104/EC, 2004/108/EC)
• Specific operation of the different parts (steering, wheels, brakes, gearbox, etc.) 

Car brands themselves created their own custom standards for specific internal tests, which over time became production standards. 

So, in addition to the well-known regulatory bodies IEC, ISO or ASTM, we can find a 50451 (Fiat) or a Volkswagen PV 1306.

Climatic Testing for the Automotive Sector: Introduction

Among the tests associated with the automotive sector, we certainly find various climatic tests, with controlled temperature and humidity.

The tests, as we have already seen for other applications, can concern both the various components that make up the finished product , and the actual finished cars

Climate tests for the automotive industry therefore concern not only the manufacturers directly, but also the suppliers of the individual components that will make up the car.

In the latter case, the climatic tests will concern everything from electronic boards to electric motors and lithium batteries. The most widespread standards governing these climatic tests are IEC 60068 , ISO 16750-4 , and IEC/EN 62133, which is specific for batteries.

In addition to these, as we mentioned before, many car manufacturers have developed their own test procedures, homologated to international standards.

However, in the case of the entire car, since we are dealing with large products, we will have to refer to walk-in chambers, already discussed here.

In both situations, however, the tests share similar characteristics, which in turn the automotive sector shares with the aeronautical, aerospace and military sectors which we have discussed here. 

But let's now look at the main features of the climate test for the automotive sector:

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Climatic Testing for the Automotive Sector: Features

Automotive climate testing takes into account three key variables: temperature, humidity, and lighting .

In most cases, the temperature range is very wide, generally from -40 to 180°.

This interval is due to the need for cars to be operational, without any kind of operational repercussions, in the different climatic zones of the globe, where they can also be subject to sudden changes in temperature (thermal shock).

These temperature ranges contribute to the realization of the so-called tests accelerated aging, which exacerbate the climatic conditions to speed up the aging process of the product under test.

To meet these requirements, climatic chambers automotive are always equipped with touch screen controllers, which allow the possibility of programming automatic temperature cyclesquickly and immediately.

Temperature uniformity and stability must have the lowest possible margin of error, even greater than in standard climate chambers. 

Humidity control is similar: a wide range, typically from 10 to 98%, serves to simulate all possible real-world conditions that the car, in all its components, will encounter throughout its life cycle.

The aging process is also simulated by corrosion simulation tests ( salt spray), rain simulation tests and sunlight simulation tests. 

Sunlight is simulated using UV lamps, according to standards such as ISO 4892-2 or ASTM D7356 .

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FDM and Climatic Testing in the Automotive Sector

Automotive companies are making increasing investments in climate control to ensure increasingly efficient and safe products.

Just think of the example of brands like Seat, which in 2020 invested 30 million euros in its own climate testing center.

FDM, in the industry since 1949, counts among its clients historic, high-quality brands such as Ferrari and Bridgestone. Here you'll find the customized solution we created for them.

Whether you need to test your tires, lithium batteries, or any component of your automobile, FDM will always have the solution for your requirement.

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Reference Standards

• ISO 16750 (series 1-5) — Road vehicles — Environmental conditions automotive
• SAE J1211 — Handbook for robustness validation of automotive electronic modules
• VDA 230-213 — German automotive component qualification
• IEC 60068 (series) — Base methods applicable to automotive components
• AEC-Q100/Q101/Q200 — Automotive Electronics Council qualification standards

Authoritative Sources

• SAE International — Global automotive standards body.
• VDA — Verband der Automobilindustrie
• AEC — Automotive Electronics Council

Frequently Asked Questions about Automotive Climatic Chamber Testing

Which climatic tests are mandatory for an automotive component?

The standard set according to ISO 16750-4 : operating temperature (-40°C÷+85°C cabin, +125°C engine bay), thermal shock (-40°C ↔ +85°C in damp heat cyclic (IEC 60068-2-30 Db or composite test IEC 60068-2-38), salt spray (72h according to ISO 9227), solar radiation (1120 W/m² for interiors), vibration (random according to ISO 16750-3). For electronics , AEC-Q100 with 1000h HTOL/HTSL is added

Temperature range for engine components vs. internals?

Three major ranges: Pressurized cabin -40°C/+85°C (ECU, internal sensors). Engine compartment -40°C/+125°C (engine ECU, injectors). Components near the exhaust up to +150°C continuously, peaks +200°C (lambda sensors, turbines). For electric vehicles , UN 38.3 battery qualification is added with a range of -40°C/+85°C in thermal cycle (IEC 62660-2).

What is the typical test profile for an automotive sensor?

Typical qualification dossier: (1) 1000h HTOL at Tmax, (2) 1000h HTSL high temperature in storage, (3) 500-1000 thermal cycles -40/+125, (4) 240h damp heat cyclic, (5) 1000h random profile vibration, (6) 96h salt mist, (7) 500h salt mist+humidity. Total duration 12-18 months. Each phase requires intermediate functional tests to verify parameter degradation (drift, offset, noise).

What changes for electric vehicles (EVs)?

EV components have additional constraints: lithium battery requires UN 38.3 plus IEC 62660 (-40/+60 thermal cycles, thermal shock, short circuit). Inverters and BMS follow ISO 16750 extended with greater emphasis on EMC (CISPR 25). High voltage connectors: LV 214 VDA with 1000+ thermal cycles and IP67/IP6K9K sealing. Entire battery pack: walk-in climate chamber validation with real mission profiles.