Engine dynamometer




POWERLINK engine dynamometer is a powerful tool for engine and component research and development, enabling OEMs and suppliers to remain innovative and competitive. With an engine dynamometer, engineers can eliminate confounding variables and focus on how their product or process affects the combustion event.

For development of components such as injectors, valves, pistons, and manifolds to systems for control, EGR, and intake systems, engine dynamometer can help discern the impact on power, fuel economy, emissions and other performance criteria. In addition to the engine, the specification, design and performance of the entire supporting test cell systems shape the utility and effectiveness of the tool.



Engine dynamometer for durability test

 

The engine dynamometer can meet the requirements of routine test, engine performance and reliability test of gasoline engine and diesel engine, as well as the research on power, economy, emission, etc.

This engine test bench is reliable and practical. The accuracy of measurement control parameters can meet the national and professional standard requirement such as QCT 524-1999 Automotive engine performance test methods and GBT 18297-2001 Automotive engine performance test methods. The operation of the test process, monitoring, data processing can achieve full computerization.

 

Engine dynamometer

 

Overview of engine durability test

 

  • CAN field bus communication protocol uses international standards ISO 11898 (CAN)
  • Engine performance test is in line with QCT 524-1999 Automotive engine performance test method
  • GBT 18297-2001 Automotive engine performance test method
  • Engine reliability test is in line with GBT 19055-2003 Automotive engine reliability test method
  • The engine test bench is arranged as a whole. The engine test bench can perform multiple functions
  • The test bed puts the priority on mature and reliable design, technology and equipment

 

Engine dynamometer endurance test items

 

  • Engine idle test
  • Total engine power test
  • Net engine power test
  • Engine load characteristics test
  • Universal characteristics test
  • Cylinder work uniformity test

 

Engine dynamometer

 

Test control accuracy

 

  1. Engine speed (JC series torque sensor, ±1 rpm)
  2. Engine power (real-time calculated value, ±0.5%, ± 1 digit)
  3. Engine torque (JC series torque sensor, measurement ±0.1% FS)
  4. Engine fuel consumption (FC2210 fuel consumption meter, measurement ≤0.4% FS)
  5. Engine oil flow
  6. Crankcase blow-by
  7. Fuel temperature (PT100, -10-200 ℃, ±5 ℃)
  8. Exhaust main manifold temperature (K thermocouple, 0-1200 ° C, ±2 °C)
  9. Exhaust branch manifold temperature (K thermocouple, 0-1200 ℃, ±2 ℃)
  10. Pre-catalyst exhaust temperature (K thermocouple, 0-1200 ℃, ±2 ℃)
  11. Post-catalyst exhaust temperature (K thermocouple, 0-1200 ℃, ±2 ℃)
  12. Oil passage temperature (PT100, -10-200 ℃, ±5 ℃)
  13. Engine oil temperature (PT100, -10-200 ℃, ±5 ℃)
  14. Engine water inlet temperature (PT100, -10-200 ℃, ±5 ℃)
  15. Engine water outlet temperature (PT100, -10-200 ℃, ±5 ℃)
  16. Pre-air-filter intake temperature (PT100, -10-200 ℃, ±5 ℃)
  17. Supercharger air intake temperature (K thermocouple, 0-1200 ℃, ±2 ℃)
  18. Intercooler air intake temperature (K thermocouple, 0-1200 ℃, ±2 ℃)
  19. Intercooler air outlet temperature (PT100, -10-200 ℃, ±5 ℃)
  20. Exhaust manifold pressure (pressure transmitter, 0-100KPa, ±0.25% FS)
  21. Pre-catalyst pressure (pressure transmitter, ±0.25% FS)
  22. Post-catalyst pressure (pressure Transmitter, ±0.25% FS)
  23. Pre-turbocharger air intake pressure (pressure transmitter, 0-100KPa, ±0.25% FS)
  24. Intercooler air intake pressure (pressure transmitter, 0-250 KPa, ±0.25% FS)
  25. Intercooler air outlet pressure (pressure transmitter, 0-250 KPa, ±0.25% FS)
  26. Post-throttle pressure (pressure transmitter, -100-0KPa, ±0.25% FS)
  27. Oil passage pressure (pressure transmitter, 0-1000KPa, ±0.25% FS)
  28. Pre-filter engine oil pressure (pressure transmitter, 0-1000KPa, ±0.25% FS)
  29. Engine water inlet pressure (pressure transmitter, 0-350KPa, ±0.25% FS)
  30. Engine water outlet pressure (pressure transmitter, 0-350KPa, ±0.25% FS)
  31. Fuel supply pressure (after fuel regulator) (pressure transmitter, 0-600KPa, ±0.25% FS)
  32. Crankcase pressure (pressure transmitter, -10-10 KPa, ±0.25% FS)
  33. Air intake conditioning system temperature, pressure, flow monitoring (digital or analog channel input)
  34. Cooling water conditioning system temperature and pressure monitoring (pressure transmitter, control: ±2 °C)
  35. Engine oil conditioning system temperature and pressure monitoring (pressure transmitter, control: ±2 ℃)

 

 

Sensors and analog input signals comply with specifications

 

  1. Voltage and current input (0-5V, 4-20mA, accuracy ±0.1%)
  2. Thermal resistance input (PT100, accuracy ±5 ℃)
  3. Thermocouple input (K thermocouple, accuracy ±2 ℃)
  4. Switch output (relay contact, 2A-30V or 0.5A-220V)
  5. Switch input (L ≤3V, H = 5-30V)




Engine dynamometer for performance test

 

The engine transient performance test rig consists of a complete set of AC dynamometer and automatic measurement and control system for engine test. This engine dynamometer is mainly used for vehicle engine research and development processes. Both transient test and steady-state test can be taken. The test items include:

 

Engine dynamometer

 

  • Engine steady-state and transient performance tests of engine full load and partial load
  • Engine universal characteristics test
  • Engine friction loss test
  • Engine cylinder uniformity test
  • Engine piston blow-by test
  • Engine combustion analysis test
  • Catalytic efficiency test
  • Engine emission tests (ESC, ELR, R49, R24, China9, ETC, engine tests for off-road vehicle, emissions test for heavy-duty gasoline engine, etc.)
  • Engine electronic control system calibration, matching and optimization tests
  • User-defined development test and work conditions

 

Integration and control of third party equipment like direct sampling and analysis equipment, AVL415, AVL439, air flow meter, transient fuel consumption meter, etc.

 

Applicable standards for engine transient performance test

 

  • GBT 6072.1-2000 Reciprocating internal combustion engines performance – Part 1: standard reference conditions, declarations of power, fuel and lubricating oil consumptions, and test methods
  • GBT 17692-1999 Measurement methods of net power for automotive engines
  • GBT 18297-2001 Performance test code for road vehicle engines
  • GBT 19055-2003 Reliability test methods for motor vehicle engines
  • GB 1105.1-87 Performance test methods for reciprocating internal combustion engine standard ambient conditions and declarations of power, fuel consumption and lubricating oil consumption
  • GB 1105.2-87 Performance test methods for reciprocating internal combustion engine test methods
  • GB 17691-2005 Limits and measurement methods for exhaust pollutants from compression ignition and gas fueled positive ignition engines of vehicles (III, IV, V)
  • GB 14762-2002 Limits and measurement methods for exhaust pollutants from positive ignition (P.I.) engines of vehicles and vehicles equipped with P.I. engines
  • GB 14762-2008 Limits and measurement method for exhaust pollutants from gasoline engines of heavy-duty vehicles (III, IV)
  • GB 3847-2005 Limits and measurement methods for exhaust smoke from C.I.E. (Compression Ignition Engine) and vehicle equipped with C.I.E.
  • GBT 8190.1-1999 Reciprocating internal combustion engines exhaust emission measurement – Part 1: Test-bed measurement of gaseous and particulate exhaust emissions
  • GBT 8190.4-1999 Reciprocating internal combustion engines – Exhaust emission measurement – Part 4:Test cycles for different engine applications
  • ESC, ELR for Euro II, Euro III, Euro IV, Euro V emissions
  • Automated programmable control of the ERSC test cycle in accordance with the EU Directive 97-68-EC (Revised as 2002-88-EC)
  • Automatic process control tests in accordance with ECE, R24, visible contaminants and ISO 8178.4 test cycles

 

Control and measurement accuracy for engine dynamometer

 

Engine dynamometer

 

  1. Torque (HBM torque flange, measurement ≤0.1% FS, control ≤0.2% FS)
  2. Speed (1024 ppr encoder, measurement: ±1 rpm, control: ±2 rpm)
  3. Power (real-time calculated value, ± 0.5% ± 1 digit)
  4. Throttle opening (throttle actuator, 0-100%, reaction speed 0.12 seconds)
  5. Fuel consumption (fuel consumption meter, 0.2% FS)
  6. Engine oil pan temperature (PT100, 0 ~ 200 °C, ±1 °C)
  7. Engine oil passage temperature (PT100, 0 ~ 200 °C, ±1 °C)
  8. Engine water inlet temperature (PT100, 0 ~ 200 °C, ±1 °C)
  9. Engine water outlet temperature (PT100, 0 ~ 200 °C, ±1 °C)
  10. Pre-intercooler temperature (PT100, 0 ~ 200 °C, ±1 °C)
  11. Engine air intake temperature (PT100, 0 ~ 200 °C, ±1 °C)
  12. Post-intercooler temperature (PT100, 0 ~ 200 °C, ±1 °C)
  13. Fuel inlet temperature (PT100, 0 ~ 200 °C, ±1 °C)
  14. Fuel return temperature (PT100, 0 ~ 200 °C, ±1 °C)
  15. Pre-air-filter temperature (PT100, 0 to 200 ° C, ±1 ° C)
  16. Post-air-filter temperature (PT100, 0 ~ 200 °C, ±1 °C)
  17. Pre-supercharger temperature (K-type thermocouple, 0 ~ 1000 °C, ±5 °C)
  18. Post-supercharger temperature (K-type thermocouple, 0 ~ 1000 °C, ±5 °C)
  19. Pre-turbocharger temperature (K-type thermocouple, 0 ~ 1000 °C, ±5°C)
  20. Engine exhaust temperature (K-type thermocouple, 0 ~ 1000 °C, ±5°C)
  21. Pre-turbocharger pressure (relative pressure, 0 ~ 400 kPa, ±0.25% FS)
  22. Post-turbocharger pressure (relative pressure, 0 ~ 400 kPa, ±0.25% FS)
  23. Pre-intercooler pressure (relative pressure, 0 ~ 250 kPa, ±0.25% FS)
  24. Post-intercooler pressure (relative pressure, 0 ~ 250 kPa, ±0.25% FS)
  25. Engine oil pressure (relative pressure, 0 ~ 1 MPa, ±0.25% FS)
  26. Engine water inlet pressure (relative pressure, -100 ~ 25 0KPa, ±0.25% FS)
  27. Engine water outlet pressure (relative pressure, 100 ~ 250 KPa, ±0.25% FS)
  28. Engine exhaust back pressure (relative pressure, 0 ~ 100 KPa, ±0.25% FS)
  29. Engine expansion water tank pressure (relative pressure, 0 ~ 250 KPa, ±0.25% FS)
  30. Fuel pressure (relative pressure, 0 to 600 KPa, ±0.25% FS)
  31. Ambient pressure (barometer, 80 to 120 kPa, ±0.25% FS)
  32. Environmental relative humidity (0 to 100% R.H., ±3% F.S.)
  33. Ambient temperature (0 to 50 °C, ±0.5 °C, crankcase pressure)
  34. Precise relative pressure (-100 ~ 100 kPa, ±0.25% FS)
  35. Engine inlet pressure (-100 ~ 100 KPa)

 

 

Sensors and analog input signals comply with specifications

 

  1. Voltage input (±5V, accuracy ±0.1%, 16 channels)
  2. Thermocouple input (PT100, accuracy ±0.1%, 6 channels)
  3. Thermocouple input (K-type, accuracy ±0.1%, 8 channels)
  4. Switch output (relay contact, 2 channels, 2A-30V or 0.5A-220V)
  5. Digital input (L ≤3V, H = 5-30V, 4 channels)





Engine dynamometer for engine impact test

 

Engine impact test bench is mainly used to determine the engine thermal cycle durability parameters. Accelerated performance testing is not exactly the same as what the customer is in use, but it primarily achieves similar cumulative damage from the car using every day. The operating parameters of the engine dynamometer is related to the application of the engine to be tested.

In general, the test equipment should be similar to the environment in which the engine is located. The engine correction is to minimize the test error.

 

Engine dynamometer

 

Specification of engine impact test

 

FC2422 Engine thermal shock controller in the engine test bench makes engine the large actual alternating mechanical load and heat load, and increase the unit time in alternating times in order to assess the engine in a short period of time.

The test method is according to GBT 19055-2003 Automotive engine reliability test method.

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About dynamometer

 

 

Parameter selection and curve download

 

 

Application description download