Component TestsApplication DescriptionThe main goal of component testing is to test the various engine parts as regards their functionality and durability. AVL defines engine components like
- Valve gear (valve timing drive, valve train, variable valve timers, ...)
- High pressure injection system (fuel injection pumps, injectors, …)
- Media pumps or dosing devices (oil pumps, urea injection units, …)
- Cooling and lubricating circuits (flow distribution, pressure losses, heating up times, …)
- Turbo chargers (compressor, turbine, bearing assembly, ...)
- Exhaust components (diesel particle filters, catalysts, …)
Demands for Component TestingTime to market is required getting shorter and shorter whereby the complexity of internal combustion engine systems massively increase.
This conflict generates a massive time pressure on development teams involved in an engine development process. Usually the time available for sufficient and reliable testing of all components is very short and – due to cost cutting reasons – often the number of available prototype engines is not sufficient to test all relevant components.
Lots of simulation and modeling is done for reducing the testing work load at present. Nevertheless testing is required for a detailed understanding of specific effects and improvement of the model quality and boundary conditions.
Thus, components’ testing is an essential part of the engine development process and requires flexible and specific testing equipment to cover the whole band width of testing requirements.
Most of the testing tasks can be done on engine test beds with the complete combustion engine or with fractions of an engine such like a crank case front end. The engine can be fired or motored for test tasks like accessory drives evaluation instance for strip down friction testing.
Other tests require specific test rigs, simulating specific interfaces and load profiles to safe time and money like water pump test rigs or to ensure an isolated understanding of a complex device without restrictions in measurement or application like the turbo charger.
On the engine test rig the following standardized development tasks are carried out:- Measurement of speed and torque
- Measurement temperature and pressure
- Measuring vibration paths and adjustment travel
- Measurement of mechanical stress
- Testing of high and low cycle fatigue
- NVH evaluations
A particular challenge is the integration of the many sensors and various special measuring equipment.
Due to the variety of components that are tested, the test bed must be very flexible in its configuration, allowing easy adaptation.
Further information can be obtained in the chapter:
On a specific test rig such like the turbo charger test rig, the following tests can be carried out:- Turbine and compressor maps, surge detection
- Efficiency maps for turbine, charger and the complete turbo charger
- Testing of high and low cycle fatigue
- High temperature and over speed effects
- Thermo shock testing
- NVH evaluations
The challenge for these systems is to be found in the demanding thermodynamics as well as the reliability and high repeatability of measurement systems in use.
By the intelligent and highly integrated test rig architecture the experienced use as well as the turbo charger novice finds a mature tool which is prepared to completely cover all relevant testing procedures for turbo chargers.
The complete thermodynamic calculations and data post processing procedures down to the automized generation of result maps are already part of this testing solution and ensure a quick rise of productivity starting shortly after the delivery.
Further information can be obtained in the chapter:
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