testing
Environmental Testing of Automotive Generator
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Project overview
Incotech delivered a complete solution for environmental testing of automotive generators, enabling manufacturers to perform Performance Acceptance Tests (PAT) under extreme conditions.
The challenge was to replicate real-world “under bonnet” conditions, ranging from -30 °C (cold climates) to +120 °C (hot traffic scenarios), while maintaining precise control over the unit under test (UUT).
the solution
Our specialist team designed and installed a suite of three identical test machines, fully engineered for harsh environmental testing:
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Modified Environmental Chambers – Adapted to house the UUT and maintain extreme temperature conditions.
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Stainless Steel Fixtures – Durable fixtures to prevent corrosion from high humidity and temperature variations.
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External Drive Motors – Drive motors placed outside the chamber to reliably operate the UUT under test.
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Temperature Control – Chiller units maintain the UUT at safe operating temperatures while simulating real-world conditions.
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Integrated Machine Control – LabVIEW software manages the UUT, drive motors, CANbus communication, and auxiliary systems for fully coordinated testing.
Key Benefits
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Extreme Condition Testing: Accurate replication of real-world temperature ranges for reliable PAT results.
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Reliability: Robust construction ensures continuous operation in harsh environments.
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Integrated Control: LabVIEW coordination allows precise control and monitoring of all systems.
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Safety: Chiller and fixture design protect the UUT while simulating extreme conditions.
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Project Delivery: Incotech led the full project from design to installation, providing a turnkey solution.
SEE WHAT OUR CUSTOMERS THINK
"Working with Incotech Ltd has been consistently positive. Their professionalism, flexible scheduling, and adaptability make collaboration seamless. As a trusted HYMH partner, their technical expertise, customer service, and teamwork set them apart in the testing equipment field. I highly recommend them to any organization seeking reliable engineering solutions and support."
DARREN FLETT: SYSTEMS LEAD, DRIVE TRAIN
‘I just wanted to send you a message to thank all at Incotech for their support and dedication to the leak test fixture that you have delivered against our very difficult timing plans. The customer was very pleased with the fixture that you produced and we had good feedback on our process. Once again thank you all at Incotech for their hard work on this.’
MARC PIDGEON - COMMODITY BUYER
‘I want to personally thank you all for your efforts and the work that has been completed both on the test stand design, implementing the great changes to the current rig design process, the validation of the test stand, both within India, and the UK. As well as the smooth transport and installation in India.’
‘I just wanted to thank you very much for the excellent response to our ‘plea for help’. Your swift response to repair our Middlemarch Dyno, meant we were able to carry out some extra testing for our crucial customer deadline on a Friday evening. This made a huge difference to the data we submitted and I am very grateful for your support to achieve this.’
MIKE DOWSETT - SENIOR MANAGER
‘Incotech is known to us as a very well experienced engineering company providing hi-tech special purpose machinery and test equipment. They were engaged in the design and manufacture of highly sophisticated electrical and hydraulic test rigs for our domestic and commercial water products. We are very pleased with the final result and thank their dedicated team with their client oriented approaches and transparent technical practices.’
NURCAN SIPAHI - MANUFACTURING ENGINEER