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Friction power test bench - dynamometer for testing the friction power of engine components

Two dynamometers have been developed to investigate the effects of various engine component design features on engine friction performance. These test benches can test individual components or complete 6-cylinder engine blocks and are equipped with torque measurement, speed control and data acquisition. The systems have an output of 47 kW and an oil supply unit that supports temperatures from 20 °C to 135 °C. They are designed for three-shift operation. They are designed for three-shift operation and offer a wide range of measurement and control options.
1990

Task:

These Dynamometers are used to investigate the influence of different design features of engine components on the friction performance of the engine. For this purpose, individual engine components (valve train, camshaft, crankshaft drive, etc.) are mounted on a test specimen holder and driven by an engine.

Both individual parts and a complete 6-cylinder engine block can be assembled.

The torque is determined using a torque measuring shaft. The test specimen can be tested from an idling speed up to a drive speed of 7000 rpm. In manual mode, the speed can be changed directly via potentiometer or via four preselectable ramps. In automatic mode, a speed program can be specified by the computer. The measured speed and torque values can be evaluated and saved by the computer.

The power of the drive motor is 47 kW. The test benches include an oil supply unit that can be plugged in as an option. It supplies the test specimen with oil at a temperature of 20 °C to 135 °C.

 

Solution:

Two different Friction dynamometers which can be controlled centrally via a control panel. The main differences lie in the drive power and the mechanical design. While one friction dynamometer has a mounting plate that is infinitely adjustable in height over 400 mm, the other has a fixed mounting plate. The accuracy of the clamping plate corresponds to DIN 876, quality 3. The dimensions are 800 mm x 600 mm.

The control unit takes the following operating and fault messages into account:

Fault messages:

  • Oil level
  • Temperature limiter
  • Pressure switch
  • Circulation pump
  • Oil pump
  • Oil filter
  • Inlet pressure switch
  • Cooling water pressure switch
  • Overall fault message on the test benches

 

All fault messages lead to the system being switched off during normal operation.

The following is measured using digital technology and a display:

  • Operating hours counter
  • Temperature (circulation pump or test sample flow)
  • Feed pressure
  • Temperature test specimen
  • Speed
  • Torque

 

Test bench/computer interface:

  • Manual/Automatic
  • Test item start
  • Drive speed
  • Malfunction
  • Measured values
  • Speed
  • Torque
  • Test specimen temperature
  • Oil pressure

 

Engine Friction Rig:
Torque: 50 Nm at 3500 rpm.
Speed: 100 to 7000 rpm.

Valve Train Rig:
Torque: 130 Nm at 3500 rpm.
Speed: 100 to 7000 rpm.

The torque measuring device has an accuracy class of 0.2. The components of the calculator are assembled according to customer requirements.

 

Structure of the climatic chamber of the dynamometer

 

climatic chamber structure friction dynamometer

 

Structure of the air conditioning unit

The circulating air temperature control unit consists of a compact cabinet. The cooling unit is located in the lower section, while the air conditioning section is installed in the upper section. The connection to the test chamber is made via flexible, insulated hoses. The test chamber consists of 120 mm thick insulated wall elements that are fixed to the test stand and can be retrofitted. The temperature control unit is designed for a heating rate of 2 °C/min. and a cooling rate of 1 °C/min. for 60 kg test specimen mass.

 

Control panel

The separate operating rack (19″) is connected to the chest with a plug-in cable (20 m). It contains the temperature controller with digital setpoint device and digital actual value display as well as ON/OFF switch, function indicator lamps and fault indicators.

 

Technical data

Type: UTA 1500/30-120 DU
Unit dimensions:
- Height approx. 1850 mm
- Width approx. 1500 mm
- Depth approx. 1000 mm
Test chamber capacity: approx. 950 l
External dimensions:
- Height approx. 1400 mm
- Width approx. 1100 mm
- Depth approx. 1200 mm
Temperature range: -30 °C to +120 °C
Temperature stability: +/- 2.0 °C
Water-cooled cooling unit: 6 kW
Refrigerant (Frigen): R 502
Mains connection: 220/380 V / 50 Hz
Connected load: approx. 25 kVA