Engine Testing

Typical tasks

  • Durability testing and engine development work
  • Advanced development of new products
  • Complete product development up to series production
  • On-line piston temperature measurements
  • Investigation of friction power losses on a specialized friction test bed
  • Turbocharger testing
  • NVH investigations
  • Combustion failure detection, e.g. engine knock
  • Fast oil consumption measurement (cylinder selective, transient)
  • Cavitation measurement in cylinder liners of HD diesel engines
  • Development of special measurement procedures
  • Trouble shooting of in-service problems

MAHLE Powertrain in Northampton, UK

  • Climatic and ambient transient test cells, capable of -40 to +50 °C
  • 10 steady-state test cells
  • 2 transient test cells
  • Transient dynamometers rated to 250 kW, 530 Nm
  • 15 absorbing dynamometers up to 700 kW
  • Motoring dynamometers up to 400 kW
  • Horiba 7000 emissions analyzers (gasoline)
  • Horiba 9100 DEGR emissions analyzer (diesel)

  • Combustion DMS500 analyzers for particulate mass and number
  • Battery simulator for hybrid system development
  • Wide range of alternative fuels including CNG, LPG and biofuel blends
  • Analysis, specialized measurement, emissions equipment and fully automated control

Rapid changeover engine test cell

Palletized engine modules

  • On pallet heat exchangers for pre check in hot test
  • Fluid heating for rapid engine warm-up
  • On pallet transducers with signal conditioning
  • 64 temperature channels, 32 pressure channels, 16 current / voltage channels
  • CAN communication protocols
  • AVL Indiset combustion measurement with continuous monitoring
  • Fully automated testing and EMS optimisation

 Combustion air conditioning

  • Combined temperature / humidity control
  • Barometric compensation unit
  • Intake air delivery at up to 2,500 m3 / hour
  • Boost temperature control system

 Chilled coolant system for continuous cold start test cycles

  • 500 kW external refrigeration unit
  • Continuous 5 °C fluid supply
  • Configurable HD camera system for monitoring and event investigation
  • AVL PUMA test automation system

MAHLE Powertrain in Farmington Hills, USA

19 test cells for dynamometer testing of gasoline, diesel and alternative fuel engines:

  • 7 heavy duty diesel capable dynamometers (including transient / motoring)
  • 5 medium duty diesel / gasoline capable dynamometers
  • 7 light duty diesel / gasoline capable dynamometers
  • Exhaust emissions measurements including CVS
  • Smoke meter
  • Real time oil consumption measurement systems

  • Inlet air temperature and humidity control (variable)
  • High speed data acquisition
  • In-cylinder pressure, temperature & strain analysis

MAHLE Powertrain in Jundiai, Brazil

  • 13 test cells for dynamometer testing of gasoline, diesel and alternative fuel engines
  • Durability tests:
    • 4 Heavy duty diesel capable dynamometers (including transient)
    • 4 light - medium duty diesel / Otto capable dynamometers
  • Functional and performance tests:
    • 1 Heavy duty diesel capable dynamometer
    • 2 light - medium duty diesel / Otto capable dynamometers
  • Emissions tests:
    • 1 light duty transient engine test bed for Otto and diesel
    • Gaseous emission measurement system AVL AMA i60 (pre & post catalyst)
    • ESC/ETC cycles (THC, CO, NOx, CO2, O2, CH4)
    • Combustion air conditioning
    • Altitude simulation (from sea level to 700m)
    • Oil consumption meter AVL 406
    • Smoke meter and opacimeter
    • Particulates measurement (smart sampler)
  • NVH semi anechoic testing:
    • 1 medium - light duty diesel / Otto capable dynamometer
    • 1 medium - light duty diesel / Otto capable dynamometer
    • Fully equipped cell to measure and analyze noise, vibration and harshness (NVH)
    • Cell cut-off 100Hz only
    • Temperature control

MAHLE Powertrain in Shanghai, China

  • Medium / heavy duty testing:
    • High accuracy AC dynamometer 600 kW, 4400 Nm:
    • Blow-by and oil consumption instrumentation
    • Durability testing
  • Light duty testing
    • High sped eddy current dynamometer 330 kW, 600Nm
    • Blow-by and oil consumption instrumentation
    • Engine component and system test

  • Component / material testing
    • SPECTROLAB metallurgical analyzer
    • Scanning electron microscope
    • Energy-dispersive X-ray spectroscope
    • Variable air flow test rigs
    • Leakage test rigs
    • Pulsation tester
    • Climate chamber test
    • Salt spray chamber
    • 3D scanning meter

MAHLE Powertrain in Stuttgart, Germany

  • 32 engine test beds:
    • 14 test rigs for passenger car engines
    • 11 for diesel truck engines
    • 3 for small two-stroke engines
    • Friction measurement test bed
    • Cold test chamber
    • Anechoic chamber
  • Eddy current brakes (160 - 250 kW)
  • AC dynos (200 - 800 kW)
  • Water whirl brakes (400 - 1200 kW)
  • AVL PUMA OPEN automation systems