Electric vehicle (EV) battery endurance testing laboratory for battery simulation and life cycling at Millbrook

Automotive Electronics Testing

Millbrook’s automotive electronics testing laboratory offers an extensive range of high- and low-voltage vehicle electrical component tests. These ensure that all electrical systems continue to work even after being subjected to harsh environmental or mechanical conditions or when issues are experienced with the electrical power supply.

What is Automotive Electronics Testing?

The average vehicle on the road today relies on many electrical and electronic components and control units, which can often be the point of failure in a vehicle and throw up intermittent problems. Development within the automotive industry such as increasing connectivity, self-driving technology and electrification further contribute to the growing number of sensors and electronics on vehicles. Automotive electronics testing is conducted in a laboratory environment. It ensures that a system or component, such as an electric vehicle battery or a vehicle seat wiring harness, continues to work after being subjected to harsh conditions that a vehicle might experience while in use, and comply with the relevant standards and regulations, such as the UN ECE Regulation 10 and UN ECE Regulation 100.


Engineer assessing battery mechanical impact and shock through sled pulse data at Millbrook

Automotive Electronics Test Laboratory

Millbrook conducts mechanical tests on electrical vehicle components including:

  • Automotive electronics vibration test
  • Resonant frequency test
  • Shock test
  • Drop test
  • Crush test
  • Terminal push out test
  • Connector to connector engagement and dis-engagement force
  • Connector abuse
  • Locking force
  • Fretting
Vehicle environmental testing in a large climatic chamber at Millbrook Proving Ground

For many electrical components, Millbrook offers environmental tests, including:

  • Power temperature cycles
  • High temperature degradation
  • Low temperature test
  • Thermal fatigue
  • Thermal shock and water splash
  • Humidity test
  • Salt mist
  • Salt spray
  • Dust test
  • Immersion test
  • Water spray
  • Water freeze
  • Sugar water function impairment test
  • Solar load test
Engineer plugging electric vehicle into chargers outside Millbrook main office

Electrical tests include:

  • Continuity test
  • Jump start
  • Reverse polarity
  • Over voltage
  • Under voltage
  • State change waveform characterisation
  • Ground path inductance sensitivity
  • Parasitic and dark current
  • Power supply interruptions
  • Battery voltage drop out
  • Sinusoidal superimposed voltage
  • Pulse superimposed voltage
  • Intermittent short circuit
  • Continuous short circuit
  • Open circuit
  • Ground offset
  • Overload
  • Isolation resistance
  • Insulation checks

Millbrook also offers a range of shakers, actuators and environmental chambers for testing electronic elements of a seat, including wiring harnesses and heating systems.

Millbrook’s electric vehicle battery testing capabilities cover life, safety and abuse of battery cells, modules and packs.