When a Standard Enclosure. Isn´t Enough: How We Developed a Custom Rack System for Battery Testing
27. 2. 2026
At the end of 2025, EUROSOFT - Control s.r.o. successfully completed a project involving four atypical modules for 19" rack enclosures. Today, these units are used for test control and data acquisition from battery cells for a major electric vehicle manufacturer.
From the outset, the project was defined by high technical complexity, limited installation space, and strict IP6x protection requirements.
Key Technical Challenges
1. High IP6x Protection Without Compromise The specifications demanded superior protection against dust and external influences. However, the prescribed connectors did not inherently meet the required protection level. We designed structural modifications that maintained full functionality while ensuring the necessary sealing. The result is a safe, long-term reliable solution tailored to a demanding testing environment.
2. Heat Dissipation Without Active Ventilation The required IP rating made the use of fans impossible. It was therefore necessary to design a system with fully passive cooling. The solution included:
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Optimization of power component layout.
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Design of efficient passive cooling elements.
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Detailed thermal analysis to verify long-term stability. Every element was engineered to ensure the system operates reliably even under continuous load.
3. Constrained 19" Rack Dimensions Spatial constraints were strict; every millimeter mattered. We positioned the components with a focus on:
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Minimizing electromagnetic interference (EMI).
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Operational safety.
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Service accessibility.
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Future system expandability.
4. Detailed Technical and Risk Analysis The entire solution was backed by a comprehensive technical and risk analysis. This verified not only the functionality but also the long-term operational reliability of the equipment under rigorous testing regimes.
The Result: Four Types of Custom Rack Enclosures
The project culminated in the development and production of four distinct types of rack modules currently serving:
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Precise control of battery cell tests.
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Stable and secure data acquisition.
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Long-term operation without the need for active cooling.
What did this project reaffirm?
For custom enclosures and technologically demanding applications, success is determined by a combination of: ✔ Precise technical design ✔ Manufacturing expertise ✔ Attention to detail ✔ The ability to find solutions where standard procedures fall short
Planning a Challenging Electrical Project?
If you are dealing with enclosure manufacturing or electrical engineering for specific or technologically advanced applications, we would be happy to discuss collaboration opportunities.
Contact us today, and together we will find a solution for your project.
