Season 3 Challenges

REWARD - ₹ 3,00,000
Ferous Oxide

Remanufacturing process involves dismantling old engines, inspection of parts, salvaging  and re-machining of these parts to re-building specs. These parts are then assembled to convert into remanufactured Engines. These engines range from single cylinder to multi cylinder type with capacities varying from 0.6 litre to 8 litres. Post assembly, these engines need to be tested on dynamometer test beds to ascertain conformance to performance in accordance with the designed specs and detect any inherent defects that may manifest as rejection at the test bed.

The tests that are carried out are primarily running load cycle testing, performance load testing, leakage testing and vibration testing etc. In these tests, external loads are applied to simulate the on-road conditions. The engine is run at different RPMs (speed) and loading conditions.  Amongst all the equipments that are used for testing and capturing data, dynamometer is the most important and often used equipment. The testing consumes a lot of power and fuel.

Through these tests, various commonly occurring problems are checked such as:

  • abnormal rise in temperature
  • abnormal noise generation
  • oil pressure abnormalities (low or high oil pressure)
  • internal casting punctures
  • coolant and oil leakages
  • coolant and oil mixing
  • piston seizure
  • engine bearing damage
  • premature wear and tear of various moving and non-moving parts etc.

It takes a lot of time, effort and a skilled operator to set up the engine for these tests and carry out testing cycle for detection of abnormalities. The cost of the equipments and the test rig to do these tests is very high.  This limits the speed and efficiency of testing. Scaling up is not an easy option as installing a new test rig involves a lot of capital expenditure and also requires skilled and trained operators.

Solutions are invited for an alternative low cost setup that can perform efficient and quick testing of remanufactured engines.

The solutions have to meet the following criteria:

  1. It should allow an integrated inspection and testing of the engines. The tests to be carried out by the setup are:
    • Running load testing
    • Performance load testing
    • Leakage testing
    • Noise and vibration testing
    • Damage to internal parts like engine bearing
    • Oil and coolant mixing
  2. It should be cost-effective i.e  The cost has to be substantially lower than that of the test rigs that are currently available in the market.
  3. It should reduce the time, effort and cost to carry out the complete test cycle.
  4. It should eliminate the need for high skill levels to perform foolproof engine testing and detecting all possible defects on the test bed or rig.

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