FEV Dauerlaufprüfzentrum : Endurance & functional testing center

The combination of state-of-the-art testing equipment, established processes in all areas and highly qualified 24/7 operations results in efficient and high-quality endurance and functional testing, significantly reducing development and testing time for our customers using the operation around the clock.

The basis for successful and efficient endurance and functional testing is the state-of-the-art equipment of the individual 48 engine and powertrain test benches. In addition, we breathe into utilise the capacities within the FEV Group with more than 180 test benches of various types and configurations. At our location in Brehna, these include:

• Asynchronous machines for simulating drive and output in a power class ranging from 180 to 600 kW by producing electricity used for running the facility in a sustainable way
• Highly flexible automation system with in-house development expertise
• Conditioning of the test cell, coolant, oil and intake air
• Automated safety monitoring of defined shutdown limits (>> 200 channels) including vibration control to prevent from test object damages
• 48V, high-voltage capability and battery simulation of all test equipment
• Cold test benches for dedicated heating and cooling gradients
• Documentation accurate to any second and transparency in processing
• Read access from anywhere in the world, online to the test bench around the clock

Our standardised and professional approach to endurance and functional testing, combined with the ability to test both transverse and longitudinal engines in a vehicle-like environment, including the original exhaust system, forms the basis for engine performance type testing.

For the expanded area of homologation, our test benches have been audited by DEKRA Automobil GmbH and all engine test benches have been certified in accordance with UNECE Regulation 85 (ECE-R 85).

On this basis, we can now carry out type approvals for engine-vehicle combinations worldwide. Thanks to our established 24/7 operation, we ensure that the approval process can be carried out highly efficiently and in the shortest possible time.

On the one hand, we are present for our customers with FEV locations on all continents and in automotive hotspots worldwide. On the other hand, we support our customers in all challenges arising from the decentralisation of testing.

These include, among others:

• Global on-site support for commissioning, testing and trial runs.
• Central project management of global activities via a single point of contact in Germany
• Remote access for efficient completion of testing tasks
• Assumption of responsibility for transport and shipping, including worldwide on behalf of customers
• Advice on tax law issues and customs regulations in connection with the above tasks

The FEV Testing Centre will be happy to advise and support you with any questions you may have about national and international testing. Please contact us.

To ensure short turnaround times and documentation of the highest quality, we have established standardised processes tailored to our customers’ needs. The basic procedure for diagnosis always follows a defined sequence:

• Disassembly of the entire drive system, recording the loosening/retightening torques of all screws
• Measurement of individual components
• Re-measurements during disassembly
• Visual diagnosis and evaluation of all components
• Definition of abnormalities or damage
• Comprehensive photo documentation
• Summary of all information from the endurance or functional testing and the results of the assessment in report form

Since the quality of documentation is a fundamental part of the entire development process, we have continuously improved the quality of our photographic documentation, thereby exceeding the requirements of our customers. The scope of this amounts to more than 400 photos per motor available on your network.

Duravelopment™ stands for the combination of development testing and endurance testing in a single process. One example is the 12/12/7 principle: during regular working hours, engine-specific data is adjusted in collaboration with the customer. In the evenings and at night, 24/7 operations take over testing, validation and evaluation, so that results are available the next morning. This saves time and shortens development cycles by shifting road tests to the test bench (road-to-rig). In addition to the potential and necessity for further developing ‘classic’ test strategies, we at FEV Dauerlaufprüfzentrum GmbH strive to advance Duravelopment™ in all areas. This includes, for example:

• Early damage detection systems to prevent engine and component damage
• In-house development of test bench peripherals (conditioning units, auxiliary unit loads, etc.)
• Qualified interruption and interim assessment of engines, including trend analysis and outlook
• Remote access to test bench, diagnostic and application tools
• Adaptation of data sets and hardware configuration to ensure functionality in close consultation with the customer

Together with our customers, we strive to create specific solutions for a wide variety of problems in order to enable time-optimised and customer-oriented testing. Please contact us if you have any questions.