Component Testing

Appropriate component testing provides a cost-effective verification of the results of the calculations and a capable validation of the engine's subsystems. A significant advantage of component testing is its role in reducing the time required to complete the development process. This reduction in time is due to the possibility of starting the testing without the complete engine being available.

FEV distinguishes between the following tests:

• Static component testing
• Pulse testing
• Dynamic rig testing

One example of static component testing that AFEV performs is a static cylinder liner bore distortion measurement, which is performed under cold and hot conditions. The detailed procedure for this test - as for all other investigations - is outlined in the FEV Test Catalog. Additional static component tests that FEV performs include bolt preload, bolt residual load, lubricant level, bearing distortion, Fuji paper, nitrogen gasket leakage, Fax film, piston cooling jets and surface roughness.

Component tests, such as pulse testing, are an essential part of the entire engine development process. FEV also offers these investigations as stand-alone activities in terms of fundamental analysis or troubleshooting. Pulse tests are typically conducted on such components as the cylinder head, crankcase, connecting rod, crankshaft and exhaust manifold (thermo pulsing).

Early comparisons between calculations and measurements, such as those concerning valvetrain dynamics, require specific test rigs if running engines are not yet available. Under these conditions, FEV is well prepared to provide human and technical resources, such as laboratories and workshops. Additional dynamic rig tests are set up fort such items as the timing drive (chain, belt and gear), accessory drives, cooling flow distribution and friction behavior.

The FEV Acyclism Generator is one example of a unique solution that allows action on early specimens with the typical angular vibration of a combustion engine without firing. Different numbers of cylinders can be simulated using this device. Depending on the current speed, the angular deviation is adjusted automatically.