Customer Stories

Rain-Test Protocol for New-Energy Electric Vehicles

Purpose of the Plan

The rain‑exposure test protocol for new‑energy electric vehicles is designed to assess and evaluate the vehicle’s sealing and waterproofing performance. This test simulates driving conditions in rainy weather by exposing various models to simulated rainfall, thereby determining whether components such as windows, door seals, and sunroofs can effectively prevent water ingress. In addition, the rain‑exposure test for new‑energy vehicles helps evaluate the effectiveness of the exterior design and the wipers.

Scheme Introduction

Passenger Car Rain-Exposure Test Plan

New Energy Electric Vehicle Rain-Test Plan – Reference Diagram

This test procedure is based on the national standards QCT 476–2007, “Test Method for Rain‑Proof Sealing of Passenger Vehicles,” and QC/T 476–2007, “Limit Values and Test Methods for Rain‑Proof Sealing of Passenger Vehicles.” It employs a spray‑type method to apply rain‑simulating water at a specified intensity onto the vehicle’s window surfaces. The test is conducted in a rain‑test chamber, where the testing conditions closely mimic natural outdoor conditions, thereby verifying the vehicle’s water‑tightness.

【Rain‑Test Zone】 Water is sprayed onto the vehicle’s windows from both the side and the top, eliminating dead zones and ensuring that spray pressure and flow rate meet national standards for all vehicle components. The rain‑test chamber features a frame structure that is both rust‑proof and vibration‑resistant while maintaining a sleek, aesthetically pleasing design. The entire system is easy to operate and facilitates convenient inspection and maintenance of its components.

[Rainfall Intensity] Top: 8–10 mm/min; other areas: 6–8 mm/min (adjustable)

【Sprinkler System】 Equipped with adjustable plastic nozzles. The spray pattern is a solid cone with a cone angle of 60 degrees. The spray angle is set such that the top nozzle is perpendicular to the horizontal plane, and the nozzle design complies with national standards. The nozzles are arranged in a grid pattern, ensuring no dead zones within the sprinkler coverage area. The nozzles can be adjusted as needed to optimize the spray angle.

Solution Value

This test procedure is a critical step in the automotive manufacturing process. It verifies the sealing and waterproofing performance of passenger cars, while also replicating full‑vehicle rain‑exposure conditions to assess the vehicle’s water‑tightness. The system incorporates an integrated water‑storage and filtration unit, which accelerates testing and enables continuous rain‑exposure operations, significantly increasing the daily throughput compared with conventional methods. Moreover, by adjusting the rainfall intensity, the setup can simulate a variety of precipitation scenarios, yielding more realistic test results and allowing evaluation of the vehicle’s protective capabilities under different levels of exposure—providing valuable insights for design and process improvements.

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