Engine R&DApplication DescriptionBasic engine research and development tasks include:
- function tests required as part of the mechanical development of the engine
- tuning of mechanical parts such as spark plugs
- steady-state engine mapping and calibration
- specific emissions measurements
- thermodynamic/combustion analysis
- performance and fuel consumption development
Demands on the Test BedDue to the diverse nature of the testing tasks carried out on engine R&D test beds, a great number of different types of peripheral instrumentation and tools must be integrated into the automation system.
At the same time it must be ensured that the engine under test can be rapidly exchanged and the next unit quickly installed, without loss of signal quality.
For effective calibration work it is essential that thermodynamic measurements as well ECU signals are fully integrated into the automation system and time-synchronised.
Due to the large number of interfaces it is essential to keep the operation of the test cell via the automation system as easy as possible, as only very experienced operators will have an overview of the complete test landscape. Typically the test cell is used over several shifts – as the operating personnel is changed the smooth running of the test bed must be ensured. Stability of the data acquisition system instrumentation is essential to enable unmanned operation
It is advantageous to have the same operator interface in all test cells and a clear, standardised procedure for quickly recognising and dealing with errors must be implemented.
Standard Test Bed ComponentsThe AVL SolutionThe fact that AVL offers a broad range of products which can be cleverly combined with each other is particularly advantageous for the variety of tasks within this area of testing.
- AVL understands the relationship between test cell sub-systems, ensuring rapid integration and stable operation of the systems
- You have just 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
- The integration of AVL Indicating systems within the automation system PUMA Open provides synchronised thermodynamic calculations for base calibration
- The combination of the automation system PUMA Open with AVL's calibration tool CAMEO allows fast engine mapping with graphic visualisation
- AVL's automation system offers standardised, pre-tested and reusable test runs in graphical form, allowing a high level of standardisation in the work process, and throughout a test facility
- At the same time more complex test runs can be flexibly created for tasks such as multi-parameter variations.
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. Of particular interest is AVL's fast, exchangeable pallet system.
Standard mechanical components for an engine test bed 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
DynamometerThe base calibration of the engine takes place in steady-state mode, which means that a passive dynamometer such as the AVL DynoPerform Eddy Current Dyno, can be used. This dyno type is also suitable for steady-state heavy-duty driving cycles.
For much of the work carried out on engine R&D test beds, transient test cycles are used, which means that an active dynamometer is required – the AVL DynoExact APA Series or the AVL DynoRoad AFA Series are both suitable for light duty engines or smaller.
Product Description
Data Acquisition, Automation and Control- The AVL automation system PUMA Open functions as an integration platform, to ensure that all sub-systems are interconnected, stable and available for use.
- The graphical user-interface makes PUMA Open easy to use.
- A particular highlight of the system are the libraries, in which application-specific test run components are stored. AVL provides pre-configured test runs within these libraries, or they can be easily assembled offline, prior to the test.
For dyno control AVL offers the BME 400. If the test requires the control of the engine – in the case of dynamic applications – AVL offers the EMCON 400 system, integrated within the automation system PUMA Open.
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.
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 for legal driving cycles
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 InstrumentsA wide variety of instruments are used on the engine R&D test bed. AVL offers many of the required systems, and integrates them all in the cell.
ServiceTo round off the AVL solution we offer a range of services to ensure reliability and availability of your AVL test cell.
- 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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