热门搜索:

  • /?12
  • 下载费用:5 金币 ?

High_Speed test with idle.doc

关?键?词:
HIGH_SPEED TEST WITH IDLE
资源描述:
draft C CORPORATE ENGINEERING TEST PROCEDURE TITLE: High Speed Test with Idle CETP: 03.00-L-3xx(21)(I) Supersedes: None 200308 Page 1 of 12 1.0 INTRODUCTION 1.1 The purpose of this test is to investigate the system-to-system interaction durability of a diesel engine (and/or component parts) at maximum rated engine power. It should be recognised that the test cycle may not adequately represent expected customer usage for some sub-systems and is not to be regarded as a catch-all durability test. Contact Diesel Core Group Test Methodology for more information about the derivation of the test cycle. 1.2 COMMONALITY. This is a CONTROL TEST and can be used to qualify vehicles or components throughout the world. The test may be conducted at any location having the necessary equipment and facilities. Proposed revisions to this procedure must be submitted per FAP03-179. 2.0 INSTRUMENTATION 2.1 As specified in CETP 03.00-L-603 Standard Operating Practice – Installation of Diesel Engines and also instrumentation to measure the following parameters: Parameter Units Tolerance Notes Engine coolant inlet temperature oC +/- 2 Exhaust gas temperature pre- turbine oC +/- 2 Turbocharger metal temperature oC +/- 2 See requesting engineer for exact location (Boost) Inlet manifold air temperature oC +/- 2 Coolant flow L/sec Indication only Situate flow-meter in suitable straight section of coolant system pipe work Fuel pump inlet/outlet pressures or depressions Pa +/-1% FIE suppliers to confirm acceptable levels Coolant pressure above coolant level in header tank kPa +/-1% Primary drive tension using Clavis gauge or equivalent Hz +/-1% As applicable Front end accessory drive belt tension using Clavis gauge or equivalent Hz +/-1% Hardware torque Nm +/-10% Cylinder pressure bar +/-1% During cycle prove-out Exhaust gas recirculation vacuum (If applicable) kPa +/-1% Combustion gases in coolant Indication only Engineering Standards & Systems Engineering (ESSE) Printed copies are uncontrolled.draft C CORPORATE ENGINEERING TEST PROCEDURE TITLE: High Speed Test with Idle CETP: 03.00-L-3xx(21)(I) Supersedes: None 200308 Page 2 of 12 2.2 All test measurement equipment must be calibrated and maintained per FAP03-015, Control, Calibration, and Maintenance of Measurement and Test Equipment 2.3 All applicable safety guidelines and procedures must be followed. 3.0 EQUIPMENT AND FACILITIES 3.1 As specified in CETP 03.00-L-603, Standard Operating Practice – Installation Diesel Engines. 3.2 Any Ford approved Engineering Dynamometer facility to be shown capable of running the test cycle. 3.3 The volume of lubricant in the dynamometer circuit must be the same as in-vehicle volume to facilitate effective control over its temperature. 3.4 Fuel, lubricant and coolant used throughout the test are specified in the Test Request. 3.5 Fuel, lubricant and coolant temperatures to be controlled to +/- 2oC. 3.6 Any cell or facility failure that leads to loss of either coolant or engine lubricant must be recorded and Test Engineer notified immediately. A permanent preventive action must be made in a timely manner.Engineering Standards & Systems Engineering (ESSE) Printed copies are uncontrolled.draft C CORPORATE ENGINEERING TEST PROCEDURE TITLE: High Speed Test with Idle CETP: 03.00-L-3xx(21)(I) Supersedes: None 200308 Page 3 of 12 4.0 SAMPLE PREPARATION 4.1As specified in CETP 03.00-L-603, Standard Operating Practice – Installation of Diesel Engines with the following additions: 4.1.1 On turbocharged engines the exhaust system should be flexible to avoid undue loads on the turbocharger mounting hardware. The exhaust down-pipe fixing should simulate vehicle configuration wherever possible. If not possible, document in the engine log/report. 4.1.2 EGR systems should be supported as per the vehicle configuration to ensure representative loading. Contact EGR component engineer for further information. 4.1.3 Install thermocouple on turbo housing. See Test Request for exact position. 4.1.4 Install oil/water catch jar on air intake circuit between the vent system and the turbocharger compressor, unless specified in the Test Request. 4.1.5 Ensure that the alternator charging strategy is the same as the vehicle application. The power assisted steering circuit should be set up for residual flow only. The air conditioning compressor is not loaded during this test. 4.1.6 Conduct engine break-in to local procedure specified on the Test Authorisation. 4.1.7 Conduct test to CETP 03.11 L 402 Crankshaft Torsional Vibration Survey Petrol and Diesel Engines. 4.1.8 Conduct blow-by checks to CETP 03.08-L-405, Crankcase Blow-by Test. See appendix 3 for set points unless specified in the Test Request. Ensure blow-by is within required limits as specified in the Test Request. 4.1.9Ensure dynomometer cell fuel filtering is vehicle representative. 4.1.10 Carry out any additional pass-off tests if specified on the Test Request. 5.0 OPERATION 5.1 Preliminary Checks. 5.1.1 Record version or level of calibration and confirm with Requesting Engineer that this is correct. 5.1.2 Fit new air filter element. 5.1.3 Drain sump and fill with new lubricant. Flush out cooler and associated pipe work. Fit new oil filter. Check lubricant is to maximum level on the dipstick, if not, fill to maximum mark. 5.1.4 Check/Reset fan belt tension.Engineering Standards & Systems Engineering (ESSE) Printed copies are uncontrolled.draft C CORPORATE ENGINEERING TEST PROCEDURE TITLE: High Speed Test with Idle CETP: 03.00-L-3xx(21)(I) Supersedes: None 200308 Page 4 of 12 5.1.5 Cooling system to be inlet pressured as close as possible to the water pump inlet. Degas hose(s) should vent to header tank above coolant level and run horizontal or upwards for their whole length. 5.1.6 Ensure coolant system produces in-vehicle representative flows around each part of the engine by using baffles and valves to represent vehicle components not used in dyno, eg, cabin heater. See coolant component engineer for further information. 5.1.7 Check that the correct performance correction factor is being used – see Test Request. 5.1.8 Orientate dynamometer cell cooling fans to direct airflow on to turbo housing. See Test Request for Turbo housing temperature limit. 5.1.9Set engine shut down fail-safes on the following key operating parameters: Fail-safe parameters a) Engine Speed b) Torque c) Coolant temperature d) Lubricant temperature e) Exhaust temperature f) Lubricant pressure g) Boost pressure h) Turbo housing temperature i) Boost Temperature j) Fuel Temperature k) Fuel Pressure l) exhaust back-pressure m) Air cleaner depression 5.1.10Conduct functional check on EGR at idle by measuring air-flow and checking it conforms to calibration requirements.Engineering Standards & Systems Engineering (ESSE) Printed copies are uncontrolled.draft C CORPORATE ENGINEERING TEST PROCEDURE TITLE: High Speed Test with Idle CETP: 03.00-L-3xx(21)(I) Supersedes: None 200308 Page 5 of 12 5.1.11Check that the following basic test conditions are within limits as specified on the Test Request and adjust where necessary: Preliminary check parameters a) Engine performance at full load speeds b) Maximum no load speed c) Exhaust back pressure d) Fuel inlet depression e) Fuel inlet temperature f) Boost temperature g) Boost Pressure h) Air intake depression i) Coolant flow at idle and maximum power j) Cylinder pressure k) Oil prime, time to rise, time to 50kPa and stabilise l) Time to start 5.1.12Check for leaks and record, correct as necessary. Clean down engine. 5.1.13Run five cycles of the main durability test and monitor to ensure that all specified torque, speed and liquid temperatures are met within limits. Review with Diesel Test Methodology Engineer. 5.1.14Ensure that all pre-durability tests, checks and performance results are reviewed and agreed by Requesting Engineer before commencing durability. 5.2 Durability test. Set Point Duration (min) RPM Load (%) Oil Temp. (oC) Coolant Out Temp. (oC) Comments 1 1 Idle 0 125 105 2 10 Maximum power rated speed 100 125 105 Max Power point. See test request for exact test point. 20 sec ramp from idle to max power. 20 sec ramp from max power to idle. 5.2.1 Repeat cycle to accumulate time indicated on Engine Test Request.Engineering Standards & Systems Engineering (ESSE) Printed copies are uncontrolled.draft C CORPORATE ENGINEERING TEST PROCEDURE TITLE: High Speed Test with Idle CETP: 03.00-L-3xx(21)(I) Supersedes: None 200308 Page 6 of 12 5.2.2 During each durability cycle monitor parameters as mentioned in Appendix One of this procedure. The test facility must offer the capability of recording one full cycle for the parameters listed. 5.2.3 The Maintenance Schedule is contained in Appendix Two and should be followed throughout the test. Note: the order of completion of the final checks is discretionary. However the Nitrogen Pressure Test must be conducted after all engine running is completed. 6.0 GENERAL INSTRUCTIONS 6.1The Requesting Engineer is to be advised of any component failures and major leaks prior to rectification. Minor faults should be rectified at routine service periods. Photograph any failures and major leakages. 6.2Before disturbing any components note the relative positions of all affected components. Measure the residual torque of all affected hardware by the “crack-off and back-to-mark“ method. 6.3If any “back-to-mark“ torque drops below 30% of its nominal specification the Requesting Engineer is to be informed. 6.4Primary toothed belts must never be re-tensioned. If removal is necessary record the cold tension and the direction of rotation. Refit to as-found tension or to Requesting Engineer's instructions. 6.5After prolonged shut down, warm engines at 2000rpm half (50%) load for 5 minutes prior to resuming durability running. 6.6 The engine should be cleaned down after any service or repair work so that new lubricant and coolant leakage points may be readily identified. 6.7 The exact timing of checks and tests may be changed by up to 3 hours to accommodate facilities and manpower availability, provided that the test results are not adversely affected. This does not apply to lubricant and filter changes. 7.0 PRESENTATION OF DATA Engineering Standards & Systems Engineering (ESSE) Printed copies are uncontrolled.draft C CORPORATE ENGINEERING TEST PROCEDURE TITLE: High Speed Test with Idle CETP: 03.00-L-3xx(21)(I) Supersedes: None 200308 Page 7 of 12 7.1As specified in CETP 03.00-L-604 Standard Operating Practice (Presentation of Data) Diesel Engines, with the following additions: 7.1.1 Lubricant additions to be recorded in the engine log. 7.1.2 Plot corrected performance, BMEP, SFC, oil pressure, oil additions, blow-by and any other requested parameters against elapsed durability hours. If any significant change occurs investigate immediately and/or inform Requesting Engineer. 7.1.3 Record location, nature, severity and hours-to-initiation of leak or failure. 8.0 REFERENCES 8.1 CETP 03.11-L-402, Crankshaft Torsional Vibration Survey Petrol and Diesel Engines. 8.2 CETP 03.00-L-422, Maximum Performance Test ('C' Curve) Diesel Engines. 8.3 CETP 03.00-L-603, Standard Operating Practice – Installation of Diesel Engines. 8.4 CETP 03.00-L-604, Standard Operating Practice, Presentation of Data Diesel Engines 8.5 CETP 03.02-L-413, Oil Pressure Curve – Gasoline and Diesel Engines 8.6 CETP 03.00-L-405, Cylinder Compression Test – Gasoline Engines 8.7 CETP 03.01-L-702, Cylinder Head Gasket Nitrogen Pressure Test – Gasoline and Diesel Engine. 8.8 CETP 03.08-L-405, Crankcase Blow-by Test. 8.9 FAP03-015, Control, Calibration, and Maintenance of Measurement and Test Equipment.Engineering Standards & Systems Engineering (ESSE) Printed copies are uncontrolled.draft C CORPORATE ENGINEERING TEST PROCEDURE TITLE: High Speed Test with Idle CETP: 03.00-L-3xx(21)(I) Supersedes: None 200308 Page 8 of 12 9.0 RECORD OF REVISIONS See metadata field “Previous Review Notes“. (ESSE responsibility) Version Date Record of change Changed by A1 16/09/03 Updates after review with program office E. Nicklin B 01/04 Cycle change to 10/1 min. Small wording changes prior to release to DPC committee. First maintenance check time shortened. Oil change interval. Oil temperature. E. Nicklin C 27/02/04 Valve clearance check change interval. Blow-by check interval and content E. Nicklin Engineering Standards & Systems Engineering (ESSE) Printed copies are uncontrolled.draft C CORPORATE ENGINEERING TEST PROCEDURE TITLE: High Speed Test with Idle CETP: 03.00-L-3xx(21)(I) Supersedes: None 200308 Page 9 of 12 APPENDIX ONE - PARAMETERS TO BE RECORDED C o n t in u o u s ly (1 H z o r b e t t e r ) E v e r 3 0 c y c le s (a p p r o x 5 h r s ), a n d r e c o r d e d o n t e s t lo g Parameters Units x x Corrected power kW x x Corrected torque Nm x x Engine Speed RPM x Exhaust smoke Bosch smoke units x x Fuel delivery mg/stroke x x Intake air temperature °C x x Ambient air temperature °C x x Lubricating oil pressure kPa x x Lubricating oil (sump) temperature °C. x x Coolant outlet temperature °C. x x Coolant inlet temperature °C. x x Fuel inlet temperature °C. x x Fuel outlet temperature °C. x x Fuel inlet pressure kPa x x Fuel outlet pressure kPa x x Cylinder pressure (for selected cycles) kPa x x Turbo housing skin temperature oC x x Combustion gases in the coolant x Intake manifold pressure kPa x Air filter element depression(s) kPa x Exhaust back pressure kPa x Exhaust temperature (downpipes) °C. x Exhaust temperature (pre turbo) °C. x Coolant pressure kPa x Coolant flow l/sec x Pre-filter oil pressure – where possible kPa x Post-filter oil pressure kPa x Other parameters in any stages if specified on the Test Authorization. Engineering Standards & Systems Engineering (ESSE) Printed copies are uncontrolled.draft C CORPORATE ENGINEERING TEST PROCEDURE TITLE: High Speed Test with Idle CETP: 03.00-L-3xx(21)(I) Supersedes: None 200308 Page 10 of 12 APPENDIX TWO - MAINTENANCE AND CHECK SCHEDULE N u m b e r E v e r y 7 5 c y c le s (1 5 h r s a p p r o x ) E v e r y 3 0 0 c y c le s (6 0 h r s a p p r o x ) E v e r y 1 5 0 0 c y c le s (2 7 5 h r s a p p r o x ) F in a l c h e c k s 1 x X x x Stop engine and immediately remove oil filler cap. Turn engine to No1 T.D.C. and wait 2 minutes from engine stop. Dip oil, add oil to restore the oil level to the maximum on the dipstick. Record all oil additions. 2 x X x x Check and top up coolant if required. Record amount added 3 x X x x Review engine performance using readings from full load stages. Discontinue testing and inform the Requesting Engineer if power differs by more than ±5% from the nominal power rating 4 x x x x Examine whole engine for leaks and any other signs of failure. Record nature, position and magnitude of all leaks. If leak found, record, and inform Requesting Engineer. Clean down afterwards i
? 汽车智库所有资源均是用户自行上传分享,仅供网友学习交流,未经上传用户书面授权,请勿作他用。
0条评论

还可以输入200字符

暂无评论,赶快抢占沙发吧。

关于本文
本文标题:High_Speed test with idle.doc
链接地址:http://www.autoekb.com/p-9416.html
关于我们 - 网站声明 - 网站地图 - 资源地图 - 友情链接 - 网站客服客服 - 联系我们

copyright@ 2008-2018 mywenku网站版权所有
经营许可证编号:京ICP备12026657号-3?

收起
展开