汽车耐久性试验技术_图文
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Gasket, Block (deck
RPM RPM RPM
RPM RPM Coolant Temp.
Load Range RPM Range Test Pattern
Test Duration
Idle to Full Load
Idle to Peak Power
45
2
3 1
8 7 6
Time
9 10
90 ±3°C (195 ±5°F)
90 ±3°C (195 ±5°F)
50 gly / 50 H20 mix Orifice plates to match vehicle
backpressure Pending
Derived from Volvo test procedure.
50 gly / 50 H20 mix Orifice plates to match vehicle
390.5 hrs running = 273.8 h Max: 532.0 hrs total =
437.2 hrs running = 273.8 h
Cycle Description
Oil Sump Temp Coolant Temp Coolant Type Exhaust Setup Last CETP Rev.
Idle, No load and Full load Idle to Power Peak + 12%
34 5
6
2
1
Time
Car/Light Truck: 50 x 106 WOT engine cycles (100 x 106 WOT revs) Over 8500 GVW Truck: 75 x 106 WOT engine cycles (150 x 106 WOT revs)
Total cycle = 60 minutes
140°C (284°F) max.
140°C (284°F) max.
140 °C Max (284°F Max) (but must be > coolant temp)
Cycles between 12 ±3°C (54 ±5°F) and 95 ±3°C (203 ±5°F)
high speed operation.
are loaded and engine coolant is force-
drive cycle.
torsional vibration amplitudes.
cooled.
System Test
Structural / System Test
Structural Fatigue
Blocks, Cylinder Heads, Lubrication,
Piston&Rod, Crankshaft
Lubrication, Valvetrain, Piston & Rod,
Camdrive
Valvetrain, Piston&Rod, Crankshaft,
Crankshaft, Bearings
Power Peak WOT
Time
All: 180 test hours (60 cycles)
All: 100 test hours
No Load to Full Lo Idle to Power Peak +
Repeat 7 times
12 12 3 2
Time Time depends on heat-up tim Min: 485.3 hrs total =
5) 1 min 12 sec - Power Peak/ No Load Total cycle = 9 hours
5) 3 hr 45 min, Power Peak / WOT
6) 3 min - Normal Idle
(includes 1 hour soak)
6) 2 hr, Power Peak+6% / WOT
1000 test hours = 890 hours running (1000 cycles)
Idle, 20%, 40%, 60%, 80%, WOT
(Peak Tq-500) to (Peak Hp+10%)
Cycle includes the following speed/load pts:
Cylinder Head Joint Ke (KLT)
Test Purpose
Test Classification Components On Test*
To evaluate the durability and reliability To investigate the durability and reliability To investigate the structural integrity of an To evaluate the durability of
M. R.
E. R.
公共道路数据
客户调查
失效及统计分析
14
试验场试验 极端客户 CAE/试验 室试验
15
16
强度试验 结构耐久性试验
PT耐久性试验 抗腐蚀性试验
零部件 系统 整车
17
18
19
20
21
22
23
Road Cycle Dynamometer Durability Test
loads typical of customer use. Accessories load conditions derived from an Autobahn load conditions.
with maximum crankshaft
parts) at high engine speeds.
Dearborn-Cologne Durability Cycle - No Thermal Overlay
FIE Dynamometer Test
Crankshaft Durability Test
180 Hour High Speed Durability Cycle
100 Hour High Speed Endurance
3) 15 min - 110 km/hr equivalent
above are used to make up the 250 points. 3) 20 min, Pwr Peak+6% / No Load
4) 3 min - Power Peak WOT
4) 10 min, Pwr Peak+12% / No Load
Bearings
To generate high mileage/tim failure modes associated with head joint and gasket service yr/150,000 mile lifespan.
Thermal Fatigue Cylinder Head (surface), Cy
50 gly / 50 H20 mix
Minimum exhaust pressure
May, 2005 Known as the Ford International
Engineering (FIE) cycle. 50x106 WOT Cycles for Car & Light
Truck 75x106 WOT Cycles for O/8500 Truck
汽车耐久性试验技术_图文.pptx
2
3
客户需求
设计
设计验证 CAE 试验室 道路
公共道路
客户关联
整车
系统
载荷谱采集
道路（试验场）试验 试验室试验
部件
CAE分析
里程累积试验
定义客户需求 制定DVP
执行Dຫໍສະໝຸດ BaiduP
1. 产品寿命 2. 驾驶习惯 3. 路面 4. 环境
1. 设计 2. 材料 3. 加工制造 4. 质量控制
RPM Idle
Pk Tq - 500 Pk Tq
1/2(PkTq+PkPow) Pk Pow
Pk Pow + 10%
Percent of WOT Torque N/L 20% 40% 60% 80% WOT X
XXXXX XXXXX XXXXX XXXXX
XX
Car/Light Truck: 675 test hours = 596.2 hours running (75 cycles) over 8500 lb Truck: 990 test hours = 874.5 hours running (110 cycles)
Determine RPM of highest crankshaft torsional vibration and run continuously at that RPM WOT. Measure and adjust RPM every 20 hours.
1) 17 min - Idle 2) 60 min - Power Peak WOT 3) 3 min - Max. Intermittent Spd WOT 4) 17 min - Power Peak WOT 5) 60 min - Max. Continuous Spd WOT Total cycle = 180 minutes
Notes
1) 3 min - 60 km/hr equivalent
Cycle contains 250 speed/load points and 1) 30 min - Idle / No Load
2) 4 min 12 sec - Torque Peak WOT
a 1 hr soak period.. The speed/loads listed 2) 5 hr 45 min, Torque Peak / WOT
To investigate the structural fatigue
To investigate the endurance quality of
characteristics of an engine at speeds and of the entire engine system at speed and engine at sustained high speed and high engine components while running durability of an engine (and/or component an engine and/or component parts at
backpressure December, 2005 Also called "DCDC" test. Based on Autobahn driving from Cologne to Kassel to Frankfurt to Cologne. All emission controls that are integral with the engine must be installed and functional.
Full load Peak Torsional
Peak Crankshaft Torsional RPM WOT
Time
All: 100 test hours
Idle and Full load Idle to Max. Intermittent Spd
5 2 3434 3 1
Time
Full load Power Peak
7
8
R客e户qu需ir求ed 设T计e验st证
设计
客户需求 设计验证 设计验证
9
客户需求 设计验证 设计
客户需求 设计验证 设计验证
✓
10
采集样车 公共道路 客户需求 设计强度 验证方法
客户1 客户2 客户3 客户???
… …
11
12
13
开发运转工况及进行试验场测量
试验场程序
S. R.
Structural Fatigue
Structural Fatigue
Structural Fatigue
All
ALL, this is an engine system test Blocks, Cylinder Heads, Intake Manifold, Piston & Rod, Crankshaft,
7) 3 min 36 sec - 105 km/hr equivalent
Total cycle = 12.5 hours
8) 15 min - 120 km/hr equivalent
9) 5 min 24 sec - High Idle (forced cooling)
10) 6 min 36 sec - Cold Soak (12°C/54°F)
RPM RPM RPM
RPM RPM Coolant Temp.
Load Range RPM Range Test Pattern
Test Duration
Idle to Full Load
Idle to Peak Power
45
2
3 1
8 7 6
Time
9 10
90 ±3°C (195 ±5°F)
90 ±3°C (195 ±5°F)
50 gly / 50 H20 mix Orifice plates to match vehicle
backpressure Pending
Derived from Volvo test procedure.
50 gly / 50 H20 mix Orifice plates to match vehicle
390.5 hrs running = 273.8 h Max: 532.0 hrs total =
437.2 hrs running = 273.8 h
Cycle Description
Oil Sump Temp Coolant Temp Coolant Type Exhaust Setup Last CETP Rev.
Idle, No load and Full load Idle to Power Peak + 12%
34 5
6
2
1
Time
Car/Light Truck: 50 x 106 WOT engine cycles (100 x 106 WOT revs) Over 8500 GVW Truck: 75 x 106 WOT engine cycles (150 x 106 WOT revs)
Total cycle = 60 minutes
140°C (284°F) max.
140°C (284°F) max.
140 °C Max (284°F Max) (but must be > coolant temp)
Cycles between 12 ±3°C (54 ±5°F) and 95 ±3°C (203 ±5°F)
high speed operation.
are loaded and engine coolant is force-
drive cycle.
torsional vibration amplitudes.
cooled.
System Test
Structural / System Test
Structural Fatigue
Blocks, Cylinder Heads, Lubrication,
Piston&Rod, Crankshaft
Lubrication, Valvetrain, Piston & Rod,
Camdrive
Valvetrain, Piston&Rod, Crankshaft,
Crankshaft, Bearings
Power Peak WOT
Time
All: 180 test hours (60 cycles)
All: 100 test hours
No Load to Full Lo Idle to Power Peak +
Repeat 7 times
12 12 3 2
Time Time depends on heat-up tim Min: 485.3 hrs total =
5) 1 min 12 sec - Power Peak/ No Load Total cycle = 9 hours
5) 3 hr 45 min, Power Peak / WOT
6) 3 min - Normal Idle
(includes 1 hour soak)
6) 2 hr, Power Peak+6% / WOT
1000 test hours = 890 hours running (1000 cycles)
Idle, 20%, 40%, 60%, 80%, WOT
(Peak Tq-500) to (Peak Hp+10%)
Cycle includes the following speed/load pts:
Cylinder Head Joint Ke (KLT)
Test Purpose
Test Classification Components On Test*
To evaluate the durability and reliability To investigate the durability and reliability To investigate the structural integrity of an To evaluate the durability of
M. R.
E. R.
公共道路数据
客户调查
失效及统计分析
14
试验场试验 极端客户 CAE/试验 室试验
15
16
强度试验 结构耐久性试验
PT耐久性试验 抗腐蚀性试验
零部件 系统 整车
17
18
19
20
21
22
23
Road Cycle Dynamometer Durability Test
loads typical of customer use. Accessories load conditions derived from an Autobahn load conditions.
with maximum crankshaft
parts) at high engine speeds.
Dearborn-Cologne Durability Cycle - No Thermal Overlay
FIE Dynamometer Test
Crankshaft Durability Test
180 Hour High Speed Durability Cycle
100 Hour High Speed Endurance
3) 15 min - 110 km/hr equivalent
above are used to make up the 250 points. 3) 20 min, Pwr Peak+6% / No Load
4) 3 min - Power Peak WOT
4) 10 min, Pwr Peak+12% / No Load
Bearings
To generate high mileage/tim failure modes associated with head joint and gasket service yr/150,000 mile lifespan.
Thermal Fatigue Cylinder Head (surface), Cy
50 gly / 50 H20 mix
Minimum exhaust pressure
May, 2005 Known as the Ford International
Engineering (FIE) cycle. 50x106 WOT Cycles for Car & Light
Truck 75x106 WOT Cycles for O/8500 Truck
汽车耐久性试验技术_图文.pptx
2
3
客户需求
设计
设计验证 CAE 试验室 道路
公共道路
客户关联
整车
系统
载荷谱采集
道路（试验场）试验 试验室试验
部件
CAE分析
里程累积试验
定义客户需求 制定DVP
执行Dຫໍສະໝຸດ BaiduP
1. 产品寿命 2. 驾驶习惯 3. 路面 4. 环境
1. 设计 2. 材料 3. 加工制造 4. 质量控制
RPM Idle
Pk Tq - 500 Pk Tq
1/2(PkTq+PkPow) Pk Pow
Pk Pow + 10%
Percent of WOT Torque N/L 20% 40% 60% 80% WOT X
XXXXX XXXXX XXXXX XXXXX
XX
Car/Light Truck: 675 test hours = 596.2 hours running (75 cycles) over 8500 lb Truck: 990 test hours = 874.5 hours running (110 cycles)
Determine RPM of highest crankshaft torsional vibration and run continuously at that RPM WOT. Measure and adjust RPM every 20 hours.
1) 17 min - Idle 2) 60 min - Power Peak WOT 3) 3 min - Max. Intermittent Spd WOT 4) 17 min - Power Peak WOT 5) 60 min - Max. Continuous Spd WOT Total cycle = 180 minutes
Notes
1) 3 min - 60 km/hr equivalent
Cycle contains 250 speed/load points and 1) 30 min - Idle / No Load
2) 4 min 12 sec - Torque Peak WOT
a 1 hr soak period.. The speed/loads listed 2) 5 hr 45 min, Torque Peak / WOT
To investigate the structural fatigue
To investigate the endurance quality of
characteristics of an engine at speeds and of the entire engine system at speed and engine at sustained high speed and high engine components while running durability of an engine (and/or component an engine and/or component parts at
backpressure December, 2005 Also called "DCDC" test. Based on Autobahn driving from Cologne to Kassel to Frankfurt to Cologne. All emission controls that are integral with the engine must be installed and functional.
Full load Peak Torsional
Peak Crankshaft Torsional RPM WOT
Time
All: 100 test hours
Idle and Full load Idle to Max. Intermittent Spd
5 2 3434 3 1
Time
Full load Power Peak
7
8
R客e户qu需ir求ed 设T计e验st证
设计
客户需求 设计验证 设计验证
9
客户需求 设计验证 设计
客户需求 设计验证 设计验证
✓
10
采集样车 公共道路 客户需求 设计强度 验证方法
客户1 客户2 客户3 客户???
… …
11
12
13
开发运转工况及进行试验场测量
试验场程序
S. R.
Structural Fatigue
Structural Fatigue
Structural Fatigue
All
ALL, this is an engine system test Blocks, Cylinder Heads, Intake Manifold, Piston & Rod, Crankshaft,
7) 3 min 36 sec - 105 km/hr equivalent
Total cycle = 12.5 hours
8) 15 min - 120 km/hr equivalent
9) 5 min 24 sec - High Idle (forced cooling)
10) 6 min 36 sec - Cold Soak (12°C/54°F)