Quality Assurance & Production TestsApplication DescriptionQuality assurance tests are hot tests (where the engine is ignited) carried out on a certain sample of production engines to ensure that the specifications are met in regard to:
- functional quality
- legislative emissions limits
- performance, engine speed, torque, specific fuel consumption, injection rate
Production tests on the other hand are fast functional tests of the whole engine batch. These tests may be either hot or cold tests and can be as short as 1 minute per engine, with set up times of only a few minutes.
Demands on the Test BedIn a production environment time is of the essence. This necessitates optimised logistics, very fast engine set-up on the test bed and a minimum test time. Flexible test configuration is important, as different engine types may be tested - "mixed line" testing. The ability to exchange engines using exchangeable palette systems and the usage of fast measuring systems is also paramount.
In addition to the time factor, reliability is vital. Test systems must remain highly accurate over long periods of use – normally over 3 shifts - and on all test beds, and results must be reproducible. Measuring conditions must be therefore exactly defined and maintained which makes the use of conditioning systems and a stable dyno control very important.
As various sub-systems are used in the cell, integration is an important issue. The more homogenous the environment, the easier the integration of test systems in to the automation system and the more reliable the operation.
Particularly for production tests, the actual test procedure must be standardised and easy to carry out for the operator, yet flexible for the system administrator.
Restbus-Simulation is also required to simulate the various vehicle control systems that are not present on the engine test bed.
As many thousands of engines are tested per year the test system must be able to cope with and archive large amounts of test data. Also, operating data must be archived for production control and cost transparency.
Statistical test result evaluation needs to take place automatically and to be passed on quickly to the relevant person. This necessitates a host solution.
Standard Test Bed ComponentsThe AVL Solution- A quality assurance test bed from AVL has the unique advantage that the sub-systems and instruments come from one partner and can be easily integrated with each other. This eliminates many typical sources of error from the outset and means you have one point of contact.
- The exchangeable pallet system ensures fast engine change without loss of signal quality as it includes both the mechanical set-up as well as conditioning and data acquisition systems
- Test runs can be easily parameterised centrally and sent to the specific test cell where they can be carried out without further alteration. This ensures test standardisation.
Test automation is integrated into logistic and production processes, thus optimising the quality assurance process.Mechanical ComponentsAVL offers a wide range of mechanical equipment for test bed operation. Proven standard solutions cover many automotive applications. In addition AVL provides tailor-made systems, including exchangeable pallet system concepts.
Standard mechanical components are:
- AVL Cable Boom and Boom Box FEM or AVL Wallbox FEM
- AVL Drive Shaft System
- AVL Engine Mounting System
- AVL Intermediate Bearing
- AVL Intermediate Frame
- AVL Isolated Base Plate
- AVL Pallet System
- AVL Shaft Guard
DynamometerQuality tests are usually steady-state tests for which a passive dynamometer is suitable. AVL offers the AVL DynoPerform eddy-current dynamometer in various sizes. For larger engines ( 1,000 – 10,000 kW) AVL offers the OMEGA Series hydraulic dynamometer. Beyond this size AVL can provide large hydraulic dynos.
Product Description
Data Acquisition, Automation and ControlAVL PUMA Open Test Bed Automation is offered in a configuration suitable for quality assurance testing, including the following highlights:
- Automatic acquisition and archive of operating data, synchronous to the test
- Restbus-Simulation via CAN interface
- ECU interface
- Standardised test runs in graphical form that can be administered centrally via the network
- Hierarchical structure of user rights allowing flexibility for the system administrator but limiting the operator to the primary tasks
The AVL PUMA Host solution provides a networked environment that statistically evaluates result files for further analysis.
The proven AVL Front End Modules (FEMs) have been developed for data acquisition because they can be positioned in the cell, close to the unit under test, maximising signal quality. They can be positioned on the pallet system to enable fast test cell logistics.
Product Description
Actuators and SensorsThe following sensors can be provided as required:
- Ignition timing systems
- Temperature Sensors
- Air Mass Flow Meters
- Humidity measurement systems
The following throttle actuator may be required for certain test applications:
- AVL Throttle Actuator THA 100 - Adjustment of the throttle valve or injection pump
Media Conditioning EquipmentAVL provides media conditioning equipment for the units under test and the media – coolant, oil, combustion air, fuel.
- AVL 553 Coolant Conditioning System
- AVL 554 Oil Conditioning System
- AVL Combustion Air Conditioning System
- AVL Dynamic Combustion Air Conditioning System
- AVL Fuel Temperature Control
- AVL Boost Air Conditioner
- AVL Exhaust Back Pressure Adjustment Kit
Operating Panels and CabinetsDepending on the available space and the test equipment required, AVL offers a range of easily adaptable modular system cabinets and operating consoles. Where only limited space is available, special compact solutions are available.
- AVL Test Commander Operating and Control Desk
- AVL Test System Operating and Control Cabinet
- AVL Test System Operating and Control Desk
- AVL Compact Cabinet – wall mounted 19" cabinet
- AVL Console for the operating panel AVL P400
Other InstrumentsServiceTo round off the AVL solution we offer a range of services to ensure reliability and availability of your AVL test cell and to fully support you in the case of unforeseen stoppages.
- AVL eSpares online spare part procurement ensures rapid ordering and delivery of standard spare parts
- Hotline for fast and personal response to your queries
- Training, to ensure that you make the most of your AVL system
- Software Care Packages
- Full maintenance and repair service
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