products Complete Systems for Quality Assurance in Production AVL offers its customers complete quality assurance systems for engine production – starting with consultancy and planning right through to turn-key testing systems. 3 4 F o c u s ted ‘hot’ on the one hand depends on the application segment (light duty, medium duty or heavy duty). It also depends on how mature the manufacturing process is. I.e. after starting a new engine series, up to 100 percent of the engines undergo a cold (function) test and a hot test. Once the manufacturing quality has been assured, the percentage that undergoes hot testing is very low – about 5 percent. Regardless of that, 1 to 3 percent of the engines are always subjected to a quality audit on the test bed,” says Arnold Berger. A large number of globally active car and engine manufacturers have already chosen AVL production test systems for their production sites around the world. “We offer our customers comprehensive solutions to assure product and process quality – from concept to turnkey test systems. In addition, the on-site support, which our global AVL network and our local subsidiaries are able to provide customers around the globe at all of their production locations, is a tremendous advantage,” concludes Gabriele Lo Schiavo. < For assuring process and product quality in engine production, AVL can offer its customers a fitting quality concept solution whatever the task at hand. The system portfolio comprises cold test beds (engine is motored) and hot test systems (engine is fired briefly) as well as quality audit test beds. Being part of the production equipment, the demands on the test systems are tough, so high robustness and availability are imperative. “Our end-of-line test systems satisfy these requirements to a very high degree. Added to this are the ease of operation and the convenient options to adjust the systems if any product changes are made to the engines to be tested,” explains Arnold Berger, Business Segment Manager for Endof Line Hot Test Systems. AVL’s end-of-line test system and plant & production-engineering experts are already able to advise customers on the concept of their production plant early on in the planning stage. “Almost every customer has different, very specific surrounding conditions such as transport system, interface to unit under test, etc. This means that despite its predefined functionality, the production test system is made to measure for each customer,” Arnold Berger adds. “Cold testing is a firmly established process in engine production, applied by almost all manufacturers with very few exceptions. With the engine only being motored for a short period of time, it is possible to test up to 1000 engines ‘cold’ per day and test bed. This makes it possible to test the quality of the assembly process at a very early stage,” points out Gabriele Lo Schiavo, Global Business Segment Manager for EOL Cold Test Systems. During the cold test that takes between 90 and 140 seconds (including loading time), sensors determine the values (pressure, temperature, vibration, electrical signals, torques, etc.) which are then compared with statistical reference values in order to detect any mistakes in the assembly or engine components. Usually, a production involves combining cold testing with the hot testing of a certain number of engines. “Exactly how many engines are tes- > AVL End-of-Line Hot Test System Foto: AVL
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