The customer's problem
The customer needed to qualify several pump variants in accordance with industry standards within a short timeframe. As part of a comprehensive validation project, AUCOTEAM tested six electrically powered oil pumps for use in modern high-voltage vehicle systems. The goal was to provide robust evidence of reliability, safety and service life under realistic conditions in accordance with relevant automotive standards. Evidence was required across the entire thermal operating range, including rapid temperature changes, defined flow rates and pressure profiles, IP protection ratings and leak tests, as well as mechanical and climatic stresses. The results were to be documented in an audit-proof manner and be usable for approval decisions; reference standards included LV124, VW80000, and Volvo STD, encompassing requirements for electrical and thermal properties, EMC performance and environmental resistance.
Solution by AUCOTEAM
We developed a custom-built multi-test bench featuring end-to-end automation, oil conditioning and an integrated safety chain. This modular test bench was designed for the simultaneous testing of six pumps. The electrical supply provides up to 800 V DC and up to 30 kW per test station. A central oil conditioning system covers a range from −40 °C to +140 °C and enables stable setpoints, ramps and temperature jumps. High-speed CAN and LIN were integrated for control and diagnostics; residual bus simulation, flash and diagnostic routines are incorporated. A combined software and hardware safety control system with insulation monitoring (insulation monitor), interlocks and HV/LV separation ensures test safety.
The test program included electrical tests in accordance with customer requirements and LV124 derivatives, IP protection class tests to verify resistance to dust and water ingress, climate and corrosion tests, mechanical shock and vibration profiles, as well as stone impact tests. In addition, we conducted long-term tests such as PTC (Performance under Thermal Cycling) and HTOE (High Temperature Operating Endurance) to assess performance throughout the product lifecycle. All measurement channels are recorded synchronously with timestamps; automatic plausibility checks and standardized reports ensure traceability.
Key Features of the AUCOTEAM Solution
Testing multiple variants in parallel reduces validaion time and sample costs. The reusable test architecture with standardized sequences increases reproducibility and shortens setup times. The combination of oil conditioning, residual flow simulation and safety chain replicates realistic operating conditions and enables early fault detection, for example in cases of leaks, startup surges or cavitation tendencies. Audit-ready reports with references to test plans, limits as well as calibration and traceability records support robust approval decisions and design optimizations.
