Engine Test Stands

AUTOMOTIVE

Engine Test Stands

Engine testing is an essential step in the production process, intended to guarantee the product quality. To achieve this goal in a cost-effective manner and within a reasonable time, a constant development of test-related methods and systems is absolutely necessary. In the space of a few years, the engine testing standards may be even subject to radical changes with a view to reducing inspection costs and time.

Simpro is a leading company in designing and manufacturing test rooms for endothermic engines, always keeping abreast of the engineering progress of customers and suppliers as well as of the technological innovation and the most advanced professional standards.

Simpro is capable of designing and installing different types of systems: hot and cold test stands, each of which being used to detect different faults in accordance with the customer’s economical and functional requirements.
But that’s not all. Simpro also designs and installs specific systems to test engine leaks or transmission performances.
Therefore, each design solution is conceived and developed to the last detail in order to provide the customer with a product complying with his own production requirements.
Such machinery and systems are turnkey supplied and, where required, a full customer service including a 24-hour assistance in case of failure, personnel training and periodic maintenance will be provided.

Hot test

Hot test is defined as a variety of tests performed in order to check the production quality with a view to obtaining type-approvals and certifications.
Compared to the cold test, this type of test takes a longer time, as engine should reach the required thermal conditions before testing.

The test duration as well as the type of measurement and stress applied to the engines will change according to the nature of the test itself (global performance, simulation of “vehicle conditions”, long-run test, C.O.P.).

Containerized Cell

For an easy handling of their own installations, SIMPRO has developed and manufactured a system where all test bench components are arranged in self-supporting, movable containers. The ventilation and exhaust circuits, the fire-fighting equipment as well as the fluids systems and the data control and management system are integrated with the test bench in such a way as to occupy the smallest space and to be as functional as possible.

In doing this, it is possible to provide the customer with an efficient and flexible system easy relocatable in other production sites.

Cold test

Cold test is defined as a set of procedures required to test the dynamic, electrical or fluids performances of the engine without being started. Such procedures are needed to verify the proper execution of the engine assembly process by attesting its conformity with the next assembly steps.

The short duration of the cold test (about two minutes) allows a considerable reduction of the production time and a consequent increase in performance and productivity. In so doing, the total costs of the production chain are reduced accordingly.

Trasmission test

In addition to the test of the engine itself, a further test is required to check the conformity of the whole set of members, whose purpose is to transfer the energy produced by the engine to the wheels, i.e. the transmission test.

The range of possible tests is very wide, and can include the torque transmissibility test or the reduction gear inspection, up to the analysis of clutchless gearshift ratios with relevant clutch load measurement and gear selection check.

Leak test

Leak test is defined as a test performed on each engine by introducing dried compressed air in the engine cooling and lubrication circuit. In so doing, after measuring the air pressure drop, it is possible to detect any leak through the analysis of data acquired by means of ATEQ instruments.

To carry out the test, the external cavities of the engine circuits are insulated through specific plugging units integrated in the system.

The duration of this test cycle is approximately one minute, a part of which is destined to ATEQ measurements.

The test stations are capable of running in a fully automated manner, they are provided with pallets coming from the conveyor lines in the testing area.

CSS

Over the last few years, SIMPRO has developed the CSS, i.e. an operating system integrated into their own systems for a complete management of the engine test benches.
It is a constantly updated product, modular and widely customizable, being the result of years of experience in the manufacture of engine test benches and installations for the major car manufacturers worldwide.

The CSS architecture has been developed to create a system capable of meeting the specific customer’s requirements in its own production process. Further, it can give rise to long-life installations through an easy updating to keep them in line with the tested product.

The system is provided with several interfaces connectable with the relevant hardware devices as a function of the required performances.

The CSS is suitable for being used in no-load engine starting test benches, in fully automatic in-line test benches, as well as in special-purpose manual and automatic benches for specific analyses on engine performances.

By using just one user interface, it is possible:
to configure and adjust the test cycle parameters;
to check and view the measurements carried out during the cycle in real time;
to create reports for a thorough analysis of data collected during the test, having the possibility of exporting them in formats compatible with the most widespread analysis systems.

Facilities

Facilities are meant as any subsidiary structure of the testing system itself, their purpose is to make the working process efficient and compliant with the most stringent safety regulations.

Simpro supplies turnkey products, complete with lighting and ventilation systems, soundproof cells, fire-extinguishing devices, lifting and handling equipment (hoists and bridge cranes) as well as thermofluid systems intended for feeding and draining any fluid used in the test benches (system supply fluids, coolants, drippings).

These structures are directly connected to the factory supply mains as to cooling water, compressed air, overheated air, drain fluids, diesel/gasoline. So, the test bench is completely automated, also with regard to fluid feeding and draining: this results in a considerable time reduction of engine loading and unloading operations, as well as in an increase of productivity.

Auxiliary devices

Simpro also supplies all those auxiliary components required for the proper functioning of its own systems, for maintenance or for handling of materials.

Actually, repair benches are provided for engines failing the test, special-purpose conveyor systems designed according to the specific requirements of the main system (pallets, friction rollers, fly-rollers), or special trolleys.

As any other component manufactured by Simpro, the auxiliary devices also comply with the most advanced safety standards and with the regulations in force in the country where they are installed.