Test Planning & Preparation
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.
Work closely with design, powertrain, and thermal teams to establish performance targets and define testing parameters for range and efficiency validation.
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.
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).
Test Execution
- Thermal System Testing
Assess the impact of thermal management on energy efficiency and vehicle range, identifying potential improvements to maximize battery life and vehicle performance.
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.
- Range & Efficiency 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.
Plan and execute range testing under various driving conditions (city, highway, mixed) and load scenarios, both in controlled environments and on- road testing.
Ensure that testing adheres to regulatory standards for electric vehicles, including WLTP (Worldwide Harmonized Light Vehicles Test Procedure), EPA, and NEDC.
Data Analysis & Reporting
Generate comprehensive validation reports for internal stakeholders and regulatory compliance documentation.
Identify trends, performance deviations, and areas for improvement, providing detailed technical reports with insights for optimizing thermal management and energy efficiency.
Analyze test data using tools like MATLAB, Python, or Excel to assess thermal behavior, energy efficiency, and range performance across various test conditions.
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.
