Unlocking the Future of Automotive Testing for Electric Vehicles

The transition to electric vehicles (EVs) is transforming the automotive landscape, and commercial vehicles are no exception. From long-haul trucks to EV delivery vans, these vehicles demand rigorous testing to ensure durability, safety, and peak performance under extreme conditions.

For over 110 years, Modine has been at the forefront of vehicle testing innovation. Starting with the Ford Model-T, the company has developed advanced testing facilities and methods to push automotive technology to its limits. Today, as the EV era accelerates, Modine’s state-of-the-art Racine, WI campus is leading the charge, validating pre-production commercial EV platforms with cutting-edge facilities and expertise.

Here are three ways Modine is paving the way for reliable, durable, and innovative EV technologies:

Extreme Condition Testing

Commercial EVs must perform reliably in a wide range of environments, from subzero temperatures to sweltering heat. Modine’s climate-controlled wind tunnels and climatic chambers are designed to replicate these extremes with precision. They can test vehicles as large as city buses at temperatures as low as -40°F or as high as 120°F, with humidity levels ranging from 10% to 90%.

This technology allows Modine to simulate real-world scenarios and evaluate how EV components perform under stress. For example, battery performance during both operation and charging can be validated in controlled environments. By testing these critical systems under extreme conditions, Modine ensures EVs meet durability and safety standards before they hit the road.

Innovating Beyond Traditional Testing

Unlike ICE vehicles, EVs present unique challenges that often lack established testing protocols. Modine engineers thrive in these situations, leveraging their expertise to find innovative solutions for new technologies.

For instance, a client once brought a pre-production EV to Modine’s wind tunnel equipped with custom flow meters, only to find they were incompatible with the data acquisition system. Modine’s team collaborated quickly to troubleshoot the issue, resolve the integration challenge, and keep testing on schedule. Charging infrastructure can also be a hurdle for early-stage EVs. When external chargers fail or prove incompatible, Modine engineers deploy creative alternatives, such as using a dynamometer to replenish vehicle batteries via regenerative charging. These flexible approaches keep testing moving forward, no matter the obstacles.

Data-Driven Validation

Data is the foundation of modern vehicle testing, and Modine excels at collecting and analyzing it to inform better vehicle design. By managing CAN-Bus data and integrating it into OEM R&D systems, Modine provides manufacturers with critical insights into vehicle performance.

Modine’s data-driven approach ensures that every vehicle and component meets rigorous performance standards, from validating cooling capacity and battery longevity to testing durability on a rumble track. This commitment to precision improves vehicle reliability and helps manufacturers optimize their designs for real-world conditions.

The Modine Advantage

Modine’s expertise doesn’t stop at testing protocols. It’s about creating solutions for the EV frontier, where traditional methods fall short. Their testing teams act as both engineers and innovators, ensuring that even the most cutting-edge EV technologies are ready for real-world conditions.

As OEMs and EV startups bring their latest designs to Racine, WI, Modine continues to set the standard for vehicle testing excellence. With its advanced facilities and a history of innovation, Modine is helping manufacturers deliver safe, reliable, and high-performing EVs that meet the demands of a sustainable future.

Want to learn more about Modine’s legacy in vehicle testing and how we’re shaping the future of EV technology? Read the full blog here: Advanced Testing Facilities Unlock the Future of Commercial EVs - Modine Electric Vehicle