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:
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: