FEV Dauerlaufprüfzentrum : Endurance and functional testing center

The combination of state-of-the-art testing equipment, established processes in all areas, and highly qualified 24/7 operations enables efficient and high-quality endurance and functional testing. This significantly reduces development and testing times for our customers through continuous round-the-clock operation.

The foundation for successful and efficient endurance and functional testing is the state-of-the-art equipment of our 48 engine and powertrain test benches. In addition, we leverage 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 drivetrain performance and output in a power range from 180 to 600 kW, generating electricity that is fed back for sustainable facility operation
• 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 (more than 200 channels) including vibration monitoring to prevent damage to the test object
• 48 V, high-voltage capability, and battery simulation across all test equipment
• Cold test benches for dedicated heating and cooling gradients
• Time-accurate documentation with full transparency in data processing
• Global 24/7 online read access to test bench data from anywhere in the world

Our standardized 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 extended field of homologation, our test benches have been audited by DEKRA Automobil GmbH. All engine test benches are certified in accordance with UNECE Regulation 85 (ECE-R 85).

On this basis, we are able to carry out type approvals for engine-vehicle combinations worldwide. Our established 24/7 operation ensures that the approval process is executed efficiently and in the shortest possible time.

On the one hand, we support our customers through FEV locations on all continents and in key automotive hotspots worldwide. On the other hand, we assist in addressing all challenges arising from the decentralization of testing activities.

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 execution of testing tasks
• Responsibility for transport and shipping, worldwide on behalf of our customers
• Advisory services on tax-related matters and customs regulations in connection with the above activities

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

To ensure short turnaround times and high-quality documentation, we have established standardized processes tailored to our customers’ needs. The basic diagnostic procedure always follows a defined sequence:

• Disassembly of the entire drive system, including documentation of all loosening and tightening torques of fasteners
• Measurement of individual components
• Re-measurements during disassembly
• Visual inspection and evaluation of all components
• Definition of abnormalities or damage
• Comprehensive photographic documentation
• Consolidation of all results from endurance and functional testing, including assessment outcomes, into a final report

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

Duravelopment™ combines development testing and endurance testing into a single integrated 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, ensuring that results are available the next morning.

This approach saves time and shortens development cycles by shifting road tests to the test bench (road-to-rig). In addition to the potential and necessity of further developing traditional test strategies, FEV Dauerlaufprüfzentrum GmbH is committed to advancing Duravelopment™ across 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 load units, etc.)
• Qualified interruption and interim evaluation of engines, including trend analysis and outlook
• Remote access to test bench systems, diagnostic and application tools
• Adaptation of data sets and hardware configurations to ensure functionality in close consultation with the customer

Together with our customers, we develop tailored solutions for a wide range of challenges, enabling time-optimized and customer-oriented testing.
Please feel free to contact us if you have any questions.