Foreword to the Fourth Edition
About the Authors
Introduction
Chapter 1. Test Facility Specification, System Integration, and Project Organization
Introduction: The Role of the Test Facility
Part 1. The Specification of Test Powertrain Facilities
Part 2. Multidisciplinary Project Organization and Roles
Summary
Chapter 2. Quality and H&S Legislation and Management, Type Approval, Test Correlation, and Reporting of Results
Test Facility Efficiency and Quality Certification
Management Roles
Work Scheduling
Health & Safety (H&S) Legislation, Management, and Risk Assessment
Common Hazards in All Powertrain Facilities
Risk Analysis
Management and Supervision of University Test Facilities
Use and Maintenance of Test Cell Log Books
Test Execution, Analysis, and Reporting
Determination of Cause and Effect
Key Life Testing
Vehicle and Vehicle Systems Type Approval, Homologation, and Confirmation of Production
Cell-to-Cell Correlation
End-of-Life Vehicles (ELV) Directive
Power Test Codes and Correction Factors
Statistical Design of Experiments
Useful Websites and Regulations
Further Reading
Chapter 3. The Test Cell as a Thermodynamic System
Introduction
The Energy Balance of the Engine
Diversity Factor and the Final Specification of a Facility Energy Balance
Common or Individual Services in Multi-Cell Laboratories?
Summary
Further Reading
Chapter 4. Powertrain Test Facility Design and Construction
Part 1. Cell Types, Sizes, and Layout
Part 2. Cell Contents and Fittings
Part 3. Test Cell Roles and their Special Features
Part 4. Fire Safety and Fire Suppression in Test Facilities: European Atex Codes Applied to Engine Test Cells
Useful Websites
Chapter 5. Electrical Design Requirements of Test Facilities
Introduction
The Electrical Engineer’s Design Role
General Characteristics of the Electrical Installation
Physical Environment
Electrical Signal and Measurement Interference
Earthing System Design
The Layout of Cabling
Integration of AC Dynamometer Systems
Supply Interconnection of Disturbing and Sensitive Devices
Power Cable Material and Bend Radii
Electrical Power Supply Specification
Electrical Cabinet Ventilation
European Safety Standards and CE Marking
Safety Interaction Matrix
Useful Texts on EMC Suitable for Electrical Engineers Involved with Test Facility Design
Chapter 6. Ventilation and Air-Conditioning in Powertrain Test Facilities
Part 1. Test Cell Ventilation Strategies
Part 2. Design of Ventilation Ducts and Distribution Systems
Part 3. Combustion Air (Ca) Treatment and Climatic Cells
Summary
Notation
Further Reading
Chapter 7. Test Cell Cooling Water and Exhaust Gas Systems
Part 1. Cooling Water Supply Systems
Part 2. Exhaust Gas Systems
Part 3. Turbocharger Testing
Chapter 8. Fuel and Oil Storage, Supply and Treatment
Introduction
Bulk Fuel Storage and Supply Systems
Decommissioning of Underground Fuel Tanks
Auditing of Fuel Use
Fuel Pipes
Storage and Treatment of Residual Fuels
Storage of Biofuels
Reference Fuel Drums
Natural Gas (NG), Liquefied Natural Gas (LNG), and Compressed Natural Gas (CNG)
Liquefied Petroleum Gas (LPG)
Fuel Supply to the Test Cell
In-Cell Fuel Systems
Engine Fuel Pressure Control
Engine Fuel Temperature Control
Engine Oil Cooling Systems
Properties of Gasoline and “Shelf Life”
Properties of Diesel Fuels
Fuel Dyes and Coloring
Safety Principles in Handling and Storing Volatile Fuels
Further Reading
Chapter 9. Vibration and Noise
Part 1: Vibration and its Isolation
Part 2: Noise and its Attenuation in Test Facilities
Useful texts
Further Reading
Chapter 10. Dynamometers
Introduction
Trunnion-Mounted (Cradle2) Dynamometers
Measurement of Torque Using In-Line Shafts or Torque Flanges
Calibration and the Assessment of Errors in Torque Measurement
Torque Measurement Under Accelerating and Decelerating Conditions
Measurement of Rotational Speed
One, Two, or Four Quadrant?
Dynamometer Torque/Speed and Power/Speed Characteristics
Pushing the Limits of Dynamometer Performance
Water Quantity Required to Absorb a Given Power in Water Brakes
Engine Cranking and Starting
Choice of Dynamometer
Classification of Dynamometer Types and their Working Principles
Chapter 11. Rigging the Engine and Shaft Selection
Part 1. Rigging of Electrical and Fluid Services Plus Engine Mountings
Part 2. Selection of a Suitable Dynamometer Connecting Shaft
Part 3. Flywheels and Engine Starting Systems
Notation
Further Reading
Chapter 12. Test Cell Safety, Control, and Data Acquisition
Part 1. Machinery and Control System Safety: Stopping, Starting, and Control in the Test Cell
Part 2. Open- and Closed-Loop Control of Engine and Dynamometer
Part 3. Test Control Software, Choosing Supplier, and Sequence Editing
Part 4. Data Acquisition and the Transducer Chain
Further Reading
Chapter 13. Data Handling, the Use of Modeling, and Post-Test Processing
Part 1. Data Collection and Transmission
Part 2. Management of Data: Some General Principles
Chapter 14. Measurement of Fuel, Combustion Air, and Oil Consumption
Introduction
Part 1. Measurement Instruments for Liquid Fuel Consumption
Part 2. Measurement of Air Consumption and Gas Flows
Notation Used in Air Consumption Calculations
Further Reading
Chapter 15. The Combustion Process and Combustion Analysis
Introduction
Single-Cylinder Research and “Optical” Engines
Fundamental Influences on Combustion
Total and Instantaneous Energy Release
Cyclic Energy Release—Mean Effective Pressure (Indicated, Gross, and Pumping)
Instantaneous Energy Release
Computerized Engine Indicating Technology and Methodology
Basic Circuit and Operation of Pressure Measurement Chain
Ground Loops in Indication Equipment
“Exact” Determination of True Top Dead Center Position
Combustion Analysis Roles in IC Engines for Hybrid Vehicles
Integration of Combustion Analysis Equipment within the Test Cell
High-End Engine Calibration Cells
Occasional use of Combustion Analysis in Test Cells
Engine Indicating Pressure Transducers (EIPTS)
Fuel Rail Pressure and “Shot Volume” Measurement
Speed/Crank Angle Sensors
Calculation for Combustion Analysis Test Results
Notation
Further Reading
Chapter 16. Engine Exhaust Emissions
Emission Legislation, Certification, and Test Processes
Auxiliary Engine-Driven Units, Fitted or Omitted for the Emissions Test
Legislation Classifications
After-Market Emission Legislation
Fuel Standards
Basic Chemistry of Internal Combustion Engine Emissions
Emissions from Spark-Ignition Engines
Emissions from Diesel Engines
Principles of Particulate Emissions Measurement
Principles of Measurement and Analysis of Gaseous Emissions
Exhaust “After-Treatment” Catalysts and Filters, Operation and Testing
Testing of Post-Combustion Exhaust Systems and Devices
Integration and Management of Exhaust Emission Instrumentation
Calibration, Span Gases, Storing Gas Distribution System
Gas Analyzers and “Emission Benches”
Constant-Volume Sampling (CVS) Systems
Health and Safety Implications and Interlocks for CVS Systems
Temperature Soak Areas for Legislative Testing
The European Exhaust Emissions Test Procedure (Passenger Cars)
The US Federal Light-Duty Exhaust Emission Test Procedure (FTP-75)
Heavy-Duty Test Procedures
Exhaust Emissions of Marine Propulsion Diesel Engines
ISO 8178 and Testing Emissions of Non-Road Vehicle Engines
Vehicle Evaporative Emissions
Implications of Choice of Site on Low-Level Emissions Testing
Abbreviations
References
Further Reading
Useful Addresses
Chapter 17. Chassis or Rolling-Road Dynamometers
Introduction
Genesis of the Rolling-Road Dynamometer
The Road Load Equation
Calibration, Coast-Down, and Inertia Simulation
Brake System Testers
Tire-Testing Dynamometers
Rolling Roads for In-Service Tuning and Assessment
Rolling Roads for End-of-Line (EOL) Production Testing
Chassis Dynamometers for Emissions Testing
The Emission Dynamometer Cell and Environs
Mileage Accumulation Facilities
NVH and EMC Chassis Dynamometers
Special Features of Chassis Dynamometers in Climatic Cells
Flat-Track Chassis Dynamometers
Independent Wheel Dynamometers
Articulated Chassis Dynamometers
Robot Drivers or Shifters
The Installation of Chassis Dynamometers
Chassis Dynamometer Cellar or Pit Design and Construction Details
Design and Installation of Variable-Geometry (4 × 4) Dynamometers
Drive Cabinet Housing
Offloading and Positioning Chassis Dynamometer Units
Tire Burst Detectors
Loading and Emergency Brakes
Vehicle Restraints
Guarding and Safety
Roll Surface Treatment
Road Shells and Bump Strips
Driver’s Aids
Fire Suppression
The Effect of Roll Diameter on Tire Contact Conditions
Limitations of the Chassis Dynamometer
Solar Heat Load Testing in Chassis Dynamometer Environmental Cells
Chapter 18. Anechoic Test Cells
Introduction
Part 1. NVH Testing and Acoustic Test Facilities
Part 2. Electromagnetic Compatibility (EMC) Test Facilities
Further Reading
Chapter 19. The Pursuit and Definition of Accuracy
Introduction and Terms
Analog Versus Digital
Example: Measurement of Exhaust Temperature of a Diesel Engine
Some General Principles
Definition of Terms Relating to Accuracy
Statements Regarding Accuracy: A Critical Examination
Instrumental Accuracy: Manufacturers’ Claims
Uncertainty
Traceability
Combination of Errors
The Number of Significant Figures to be Quoted
Absolute and Relative Accuracy
The Cost of Accuracy: A Final Consideration
Further Reading
Chapter 20. Tribology, Fuel, and Lubrication Testing
Introduction
Calorific Value of Fuels
Gaseous Fuels
Lubricant Classification and Certification
Tribology
Oil Characteristics
Fuel Contamination of Lubrication Oil
Reference Fuels and Lubricants
Designated Engines and Test Regimes in Fuel and Lube Testing
Biofuels (see chapter 7 concerning storage of biofuels)
Further Reading
Chapter 21. Thermal Efficiency, Measurement of Heat, and Mechanical Losses
Introduction
Ideal Standard Cycles: Effect of Compression Ratio
The Energy Balance of an Internal Combustion Engine
Measurement of Mechanical Losses in Engines
Summary
Notation
APPENDIX 1. Martyr’s Laws of Engineering Project Management
Index
