EV Battery Testing Requirements & Industry Challenges
Before mass production, EV battery packs go through rigorous thermal management validation. Test equipment runs battery packs through thermal shock, temperature cycling, and long-term stability tests across a range from -40℃ to +150℃ — sometimes even -60℃ to +200℃ in extreme cases. These tests directly impact battery safety, lifespan, and performance in real-world use.
The circulation media used in testing — thermal oil, ethylene glycol solution, or deionized water — undergo drastic viscosity changes with temperature. At the cold end, viscosity can climb to several thousand cP. At the hot end, it drops close to water levels. This viscosity swing puts serious pressure on pump adaptability.
Conventional industrial pumps hit multiple problems under these extreme conditions. Mechanical seals fail under repeated thermal expansion and contraction, creating leakage risks. Flow output fluctuates with temperature, throwing off test accuracy. Gear pumps and centrifugal pumps generate excessive noise at high viscosity, disrupting the test environment. Some pumps simply can't handle rapid temperature changes, leading to high equipment downtime.
Core Challenges
Extreme temperature range operation
High viscosity fluid handling
Zero leakage requirement
Continuous operation stability
Low noise operation
Critical Pump Requirements for EV Battery Thermal Testing
Extreme Temperature Capability: -60℃ to +250℃
Battery test chambers need pumps that hold stable performance through cryogenic-to-high-temperature cycles without seal degradation or flow loss. That means pump body materials, sealing structures, and bearing systems all have to be matched to wide-temperature-range operation.
The Aulank MDC-K gear pump series covers -60℃ to +250℃. Pump bodies use specialty stainless steel or alloy materials. Sealing structures are optimized for thermal expansion and contraction. At the cold end, ceramic isolation sleeves and PEEK components prevent brittleness. At the hot end, Hastelloy components and high-temperature mechanical seals keep things running reliably long-term.
High Viscosity Handling: 1~20,000 cP
Thermal fluids shift viscosity by several orders of magnitude across the temperature range. Centrifugal pumps lose efficiency sharply at high viscosity — some won't even start. Positive displacement gear pumps form sealed chambers through gear mesh, pushing out a fixed volume per revolution regardless of viscosity.
The MDC-K gear pump handles 1 to 20,000 cP. Even when the media hits 8,000 cP in cold conditions, the pump maintains steady flow output — whether the media is high-viscosity cold or low-viscosity hot. That consistency keeps test circulation flow controlled and accurate.
Zero Leakage & Dual-Seal Design
Test media often contains ethylene glycol, thermal oil, or other chemicals. Some applications involve flammable or toxic media. Any leakage creates safety hazards and environmental risks. Single-seal pumps fail under high or low temperature stress and can't meet zero-leakage requirements.
The MDC-K gear pump uses a dual-seal structure: primary mechanical seal as the first barrier, secondary seal chamber for backup. Even if the primary seal develops minor seepage under extreme temperatures, the secondary seal keeps the media contained. For higher safety levels, Aulank also offers magnetic drive versions that transmit torque through magnetic coupling, eliminating shaft penetration entirely for true zero leakage.
Low Noise: ≤70 dB
Test facilities are typically in lab or workshop environments with clear noise limits. Conventional spur gear pumps generate significant impact noise during gear mesh, affecting the test environment and operators.
The MDC-K gear pump uses helical gear technology. Gear mesh shifts from point contact to line contact, making the engagement process smoother and cutting pulsation and noise significantly. Combined with optimized bearing systems and vibration damping design, overall pump noise stays at or below 70 dB. Some models test as low as 68 dB — suitable for sound-sensitive test locations.
Aulank MDC-K Gear Pump Solution for EV Testing
Technical Specifications
Flow Range: 4~630 ml/rev
Viscosity Range: 1~20,000 cP
Temperature Range: -60℃ to +250℃
Pressure: Up to 35 bar
Noise Level: ≤70 dB
Key Technologies
Helical Gear Technology
Helical gears reduce pulsation and noise through continuous angled engagement. Compared to the instantaneous impact engagement of spur gears, helical gears engage more progressively and smoothly. Flow output curves stay closer to constant, reducing system pressure fluctuation. This matters especially in temperature cycling tests where stable flow is essential.
Dual-Seal Design
The primary mechanical seal uses imported precision components, with seal faces specially treated to handle temperature changes. The secondary seal chamber includes a safety valve core that automatically relieves pressure when system backpressure gets too high, protecting the seal structure from damage. Dual-layer protection keeps media contained even under thermal shock, rapid heating and cooling, and other harsh conditions.
Wide-Temperature Material Matching
Pump bodies are cast from specialty stainless or alloy steel. Gears use 42CrMo specialty steel with surface hardening treatment — hardness and wear resistance both meet industrial standards. Critical components like isolation sleeves use ceramic materials, impellers use PEEK engineering plastic, and Hastelloy is used for parts contacting corrosive media. These material combinations keep the pump from getting brittle at -60℃ or thermally deforming at +250℃, maintaining structural stability through long-term operation.
Gas-Liquid Mixed Transport Capability
During testing, the system may develop negative pressure from rapid cooling, or gas may enter from media evaporation. Conventional pumps cavitate easily under gas-liquid mixed conditions, causing flow to drop sharply or stopping entirely. The MDC-K gear pump optimizes gear clearances and pump chamber design to maintain stable transport under gas-entrained conditions, reducing cavitation risk. Strong negative-pressure self-priming and high startup reliability.
API Standard Structural Design
The pump body uses modular design with interface dimensions meeting API standards, making integration into test equipment systems straightforward. Flanges, pipe connections, and motor mounting can be adjusted based on customer equipment layout, shortening on-site installation time. During maintenance, seals or gears can be quickly disassembled and replaced, minimizing downtime.
Application Case: Automotive New Energy Testing Equipment
A leading EV manufacturer's battery pack testing line required test equipment capable of thermal shock and temperature cycling from -40℃ to +150℃. The circulation medium was ethylene glycol solution with wide viscosity variation. The customer specified three core requirements: zero leakage, low noise, and continuous operation stability.
Solution
Aulank supplied multiple MDC-K gear pumps customized for extended temperature range based on actual operating conditions. Pump body material was corrosion-resistant stainless steel. Dual-seal configuration eliminated leakage risk. Helical gear design kept continuous operation noise below 68 dB, meeting lab environment requirements.
After installation and commissioning, the pumps have run continuously and stably for over 12 months, going through thousands of temperature cycles with no leakage or downtime incidents. Maintenance record: zero. Customer feedback indicated flow stability and reliability significantly exceeded their previously used imported brand products.
Why Choose Aulank for EV Testing Pump Solutions
17 Years of Industrial Pump Engineering
Founded in 2008, Aulank focuses on industrial pump R&D and manufacturing, with extensive experience in extreme operating conditions.
Proven Extreme Temperature Capability
Product portfolio covers -196℃ to +400℃ operating range. Technology path is long-term validated with reliability assurance.
ODM Customization Capability
For specific test protocols, media characteristics, and installation space requirements, we provide customization of voltage/frequency, explosion-proof ratings, material configuration, and performance parameters.
On-Site Technical Support
Full-process technical support including installation commissioning, operation training, and troubleshooting. Fast response.
