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Overview:

A Chinese car manufacture required a fully automatic engine hot test system. Hot Testing was desired to provide our customer engine max power, torque, and thermo-start open or close status. Multiple models needed to be supported, including two intake manifold variations, two crank sensor positions, two wiring harnesses, and two complete ECU units from different ECU manufactures. Available time for testing was limited to four minutes part to part. So the ability to maximize time utilization was imperative. Our data handling performance was significant due to the large quantity of engine test data requiring trending analysis and reporting.

Values & Benefits:

• Turn key test system providing single point accountability
• Able to test a variety of engine models and variations
• Able to test power, torque, and thermo-start status where Cold Test methods cannot
• Able to perform SPC analysis including trending on all engine data acquired

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Solution:

• Fully Load Hot test capable of measuring Maximum engine torque and power.
• Pallet Delivery System With RFID For Tracking, fully Automatic.
• Oscar Data Management System Capable of managing multiple years worth of engine data, including SPC analysis capabilities was provided.
• Centralized hot water system for quick cycle time (four minute part to part).
• Two ECU system with Automatic switching.
• Exhaust Gas analysis, CO, CO2, HC, NOx.
• Use of dummy electrical harness with automatic probing.
• Ability to disengage drive line in mid cycle for Idle stability test.
• Oil, water and Fuel Evacuation System at End of cycle.
• Connectivity to ATW OSCAR host system (also used for cold test) for production and SPC analysis.

Highlights:

• Palletized Engine delivery system.
• Fully automatic engine engagement.
• Multiple models needed to be supported Full analysis of all components fit and function through advanced waveform analysis techniques.