Case Study Title: Multi-Protocol Validation of 400 W electric Water Pump
Client Type: Leading Manufacturer of fluid Power and Power Transmission Solutions
Scope and Capabilities:
This project delivered comprehensive testing services for 400W electric water pumps to verify performance, leakage resistance, and long-term durability under a range of environmental and operational conditions. The program included air leakage verification, performance mapping, low- and high-temperature endurance, and cycling durability, all executed in accordance with major OEM validation standards. Testing environments were tightly controlled, with fluid and air temperatures ranging from –20°C to +120°C, a 60/40 ethylene glycol–water mixture, and 1 Bar system pressure. Test protocols incorporated varying PWM duty cycles, valve restrictions, and supply voltages to replicate real-world operating scenarios. All voltage measurements were taken with active Sense leads, and pumps were evaluated within an electrically grounded test enclosure to ensure safety and measurement integrity. Testing was performed on a single Ensure eWP test platform, enabling consistent execution and compliance with rigorous automotive validation requirements.
Key Features:
The testing program included air leakage evaluations with 4 Bar pressurized air at 23 ± 5°C, held for five minutes to measure pressure decay. Performance mapping was conducted using a 77-point matrix that captured the effects of temperature, PWM duty cycle steps, and valve opening percentages. Low-temperature endurance testing was performed at –20°C over a 48-hour period with varying voltage and PWM combinations, while high-temperature durability testing extended up to +120°C across 2,000 hours with staged voltage profiles. Cycling durability testing replicated 250,000 on/off cycles over approximately 972 hours to simulate long-term use. All testing was carried out in compliance with Ford, VW, and GM OEM specifications. Data collection was provided in metric units, with both raw and averaged results delivered in CSV format. Safety measures included an electrically grounded test enclosure and active Sense lead voltage monitoring to ensure accurate and reliable operation.
Deliverables:
The project included completion of multiple test types, such as air leakage, performance mapping, low- and high-temperature endurance, and cycling durability. Both pre-durability, post-durability, and spare pump samples were tested in accordance with OEM specifications, ensuring full coverage of the validation scope. All evaluations were conducted under controlled and repeatable test environments to guarantee consistency and reliability. Data collection encompassed both raw and averaged results, provided in metric units and delivered in CSV format. Selected samples were removed mid-test for evaluation to assess durability progression, while all testing was performed in compliance with the specified standards and procedures.
