Topic: Functional Testing

All relevant engine subsystems have to pass functionality tests under fired conditions. FEV is able to conduct these investigations on test benches and in vehicles. To ensure a high quality level, all details of these tests are defined in the FEV Test Catalog. The boundary conditions for installation and execution of the test are defined and the targets and limits are given. These values are obtained from FEV's well-known benchmarking database and the results of our calculations.

According to the requirements of the specific project, an individual test program is selected out of the FEV Test Catalog and completed according to the FEV - Quality Standards. FEV is also experienced in conducting customer-specific test programs.

The following is a list of some of the tests that are found in the FEV Test Cataloq (extract):

• Coolant/lubrication functional test (performed on the entire system under severe boundary conditions)
• Oil aeration test (measurement of solved and free air within the oil main gallery)
• Crankcase ventilation test (blow-by flow, crankcase pressure, oil pull over and oil separation)
• Hot/cold piston scuff test (investigation of piston and piston rings scuffing behavior)
• Hot idle test (valvetrain investigation under severe operating conditions)
• Engine inclination test (investigation against increased oil pull over / oil aeration on a special fired inclination test bench)
• Piston/valve temperature test (determination of maximum loads)
• General temperature test (measurement of material temperatures at different positions on the engine block, cylinder head, and other critical engine parts)
• Valvetrain and chain drive dynamics (dynamic validation test on fired engine)
• Overspeed test (verification of overspeed capabilities)
• Oil dilution test (investigation of fuel entrainment into the oil under different engine conditions)
• Deep thermo shock (extreme check of cylinder head gasket sealing behavior)