Walk-In Temperature and Humidity Chamber Solution for In-Vehicle Systems

Tailored for Large-Scale Automotive Systems: How TEMAK’s Customized Walk-In Temperature and Humidity Test Chamber Solves the Reliability Verification Challenges

In the field of automotive electronics reliability verification, one increasingly common challenge is how to perform precise and consistent environmental stress screening for large, structurally complex automotive-grade electronic systems.

As traditional floor-standing test chambers can no longer accommodate these "behemoths," the performance requirements for walk-in chambers have reached unprecedented levels. These chambers must not only provide ample space but also replicate the precision, uniformity, and stability typically achieved by normal floor-standing models.

The customized walk-in temperature and humidity test chamber we recently delivered to a leading global automotive manufacturer is a perfect example of this philosophy.The client's test subject was a large automotive electronic integration system, measuring 2×1.6×0.5 meters and weighing approximately 500kg.

Their core requirement was to simulate global temperature and humidity conditions to accurately verify the system’s performance, particularly focusing on the impact of condensation under extreme environmental conditions.

Instead of providing a standard product, TEMAK deeply engaged with the client to create a fully customized reliability solution tailored to their specific challenges.

I.Precision Insights: From Client Needs to Tailored Technical Specifications

The client’s testing objectives directly influenced the technical core of the equipment.

Based on their focus on "whole package testing" and "condensation research," we collaboratively defined the following key technical requirements, which significantly exceeded those of conventional walk-in chambers:

Temperature Range

-40°C to +120°C — Covering everything from extreme cold to the high temperatures found in engine bays.

Critical Precision

Temperature fluctuation ≤ ±0.5°C, Temperature uniformity ≤ 2.0°C — Ensuring that all test points within the chamber provide consistent and comparable conditions.

Humidity Control

Range 10% to 98% RH, Fluctuation ≤ ±2.5% RH — Laying the foundation for precise condensation testing at critical thresholds.

Dynamic Variation

Average temperature change rate ≥ 1°C/min — Meeting the demand for rapid temperature cycling tests that can effectively trigger potential failures.

During this process, we identified that temperature and humidity testing for automotive electronics PCBs, especially under high precision requirements, demands advanced design and technical control of the test equipment.

To meet this demand, Temak ensured that every detail of the design is meticulously tailored to match the customer's stringent standards, guaranteeing the reliability and consistency of test data.

II. TEMAK’s Customized Solution: How Core Technologies Address Critical Pain Points

To meet the above specifications, Taimiko implemented several highly targeted design modifications in the KTM-WTHE412 walk-in temperature and humidity test chamber.

1. 3D Wind Field Design for Large-Scale UniformityThe client’s sample size required a chamber volume of 15m³

   
   In such a large space, traditional designs risked creating dead spots that would lead to invalid test data.

   
   Our solution involved integrating a "high and low-temperature multi-winged circulating fan" combined with "adjustable airflow guides" to create a 3D, circumferential wind field system.

   
   This system was optimized using CFD fluid dynamics simulations to ensure that the air circulates evenly and gently throughout the entire chamber, even in hard-to-reach areas like the sample’s back and bottom.

   
   This innovation was key to achieving temperature uniformity ≤ 2.0°C and meeting strict humidity uniformity requirements.

2. Robust Cooling System for Extreme Temperature and High Heat Load

   
   Large electronic systems generate substantial heat during testing, creating a significant thermal load while requiring stable operation at -40°C.

   
   Our solution was to use a German Bock semi-hermetic compressor in a dual-refrigeration system, paired with efficient plate-type heat exchangers and shell-and-tube condensers.

   
   This system was not simply about adding power but was carefully tailored to the client’s anticipated heat load, ensuring robust cooling performance while maintaining stable internal heat regulation. This design guarantees the system can withstand long-term testing without compromising performance.

   
   

3. Precise Condensation Testing Control

   
   Condensation testing was the core of this project, and it required ultra-precise control of both temperature and humidity, particularly in terms of the rate of change.

   
   To achieve this, we equipped the chamber with an ARM-based embedded industrial controller (TMK-THS200) and Class A PT100 sensors to achieve 0.01°C temperature resolution and 0.1% RH humidity resolution.

   
   By using advanced technologies like non-contact pulse width modulation (P.I.D + P.W.M + S.S.R), we can adjust the execution components with millisecond precision, maintaining temperature fluctuation within a narrow ±0.5°C range.

It is also worth noting that, similar to thermal shock test chamber for automotive parts, temperature shock testing plays a critical role in verifying the reliability of automotive components in high temperature and high humidity environments.

With its superior performance in precise temperature and humidity control, TEMAK ensures that test results meet the most stringent quality standards without compromising testing efficiency.

III. TEMAK’s Commitment — Your Challenge, Our Solution

This walk-in temperature and humidity test chamber, delivered to a global automotive giant, stands as a prime example of Taimiko’s “customized solution” philosophy. It demonstrates that, when faced with the challenges of reliability verification for large, high-value products, working closely with an environmental test equipment supplier to co-develop a device that truly understands your testing needs is far more efficient and reliable than simply purchasing a standard product.

The above outlines the temperature and humidity testing solution for automotive systems. Before entering mass production, both vehicles and components must undergo a series of rigorous environmental tests, including the automobile body salt spray test requirements.

At TEMAK, we believe that the best equipment is not just about building a test chamber; it’s about creating a device that perfectly aligns with your R&D objectives. We don’t just manufacture chambers; we strive to be a trusted partner in your reliability engineering process.