Engine Testing Lab
Based on technical knowledge and cooperation with international engine Test in the worlds, IPCO engine testing is able to perform many engine validation. These tests are included durability, performance, Functional, combustion and engine mapping tests. The targets of these tests are as follows:
Component assessment tests
As usual, component tests are performed before the sample engine is ready to reduce time and product development costs and increase the level of design reliability. Component tests are divided into three categories based on a classification: static, pulsed and dynamic. One of the capabilities of the engine testing is to perform some of important part tests and analyze the results in relation to the actual working conditions. List of some capabilities of the engine testing department in conducting part tests and cooperation with domestic manufacturers in product:
- Spark plug test
- Ignition coil test
- Piston cooling jet (PCJ) test
- Fuel injector test
- Belt characteristic test
- Oil filter test
- Radiator test
- Cabin heater test
In some of these tests, the component should be tested on engine and real condition.
Engine functional tests
Investigation of engine systems and component functionality is the main scope of functional tests. These tests evaluate the initial performance of each system based on its defined task in different conditions. For example, the initial performance of cooling system is measured and validated in a test that called the “cooling test”. Functional tests are performed by limitation of boundary conditions and with the help of advanced test equipment. Some of these tests are:
- Cooling functional test
- Lubrication functional test
- Friction test
- Crankcase ventilation test
- Hot/ cold piston scuffing test
- Tilting test
- CVVT functional tests
- Hydraulic tappet functional tests
Engine durability tests
In durability tests, the ability and performance of the engine or any of the systems for its useful lifetime in different conditions under thermal and mechanical loads are evaluated. Therefore, after finishing the test, all engine parts and components were disassembled and evaluated in an activity that named Rating. These tests are performed after the functional tests. Some of the durability tests that are performed are listed below:
- 800 hrs standard test: The test is main test is to check the mechanical durability of engines. This test involves of high-frequency component failure.
- 200 hrs standard test : The test is suitable for quick identification of major friction problems, critical parts and wear
- 400 hrs thermal change cycle test: This test is for all engine parts, especially test and sample parts. Because it puts the engine in life time cycles with sever cooling changes and the engine is severely pressurized.
- 500 hrs general endurance tests: The test is suitable for developing parts and testing them in more difficult conditions in transient states. This test has been designed on the theory of high frequency failure.
- 250 hrs resonace durability test: The target of this test is the performance of test parts or connections during operation at engine resonance points. These points are determined by installing acceleration sensors on the components and frequency analysis. Long time of the test are determined according to material and function of each component (approximately 10 million cycles) at its resonant frequency.
- deep thermal shock test (172 and 400 hrs): This test is performed for validation of cylinder head gaskets, cylinder heads and related parts. At this test mixture cooling of engine will be heated up and cooled down suddenly, then largest expansion difference will occurs between the cylinder head and the body, therefor the cylinder head gasket must sealed. This test is performed based on the type of engine, design and requirement of engine manufacturers, including 172 hours and 400 hours.
- 110 hrs endurance test: This test is performed to validate valve train and crank train systems in dynamic and critical conditions.
- Accessory belts characteristics test: These tests are designed to validate the front end accessory drive (FEAD) systems in the resonance conditions (critical cycles) and heat in the worst possible condition. Critical cycles are defined the cycles the belt oscillations are greatest.
- Timing belts characteristics test: The purpose of this test is to evaluate the durability of the timing belt system during engine operation in transient engine speed and load conditions, especially critical cycles. These speeds are determined in a pre-test that called specification Test before starting main endurance test
- Catalyst aging test: Catalyst Aging Test: This test is performed for evaluating the lifetime, performance and determining time of replacing to achieve pollution standards. According to the European pollution standard 5, the car must be guaranteed up to one hundred thousand kilometers.
Engine performance tests
The maximum performance of any engine in fully open throttle mode at different speeds is investigated in performance test. Important parameters of this test are:
- Engine power and torque
- Fuel consumption
- Blow-by flow rate
- Air/fuel ratio (Lambda)
Performance tests In addition to rapidly assessing the condition of the engine in achieving the desired targets in engine development stages, is one of the standard tests in confirming the conformity of production engines (COP) with prototypes and approved by the standard. IPCO engine test has worked extensively with a wide range of manufacturers. Including:
- Modiran Khodro
In these tests, the combustion quality of the engine in different operating conditions is checked. These tests are performed in two times and in two ways:
1) Combustion development tests: At the beginning of engine development and in order to evaluate the engine capability for achieving the main targets (maximum power and torque, fuel consumption, pollution,), these tests are performed. At this stage, the gas exchange process, compression ratio, fuel supplying and ignition system and … are reviewed and their designed were improved.
2) Combustion investigation tests (combustion system validation): These tests are performed in the last stage of engine development to evaluate the engine calibration or on production line engines that combustion parts system have changed and In the other words, it validates the changes of affect combustion indicators.
Engine mapping tests
In these tests, all hardware and software of the intelligent car management system are adjusted carefully in order to be able provide customer satisfaction and environmental regulations at the same time. These tests are performed on engine and car also.