Engine Laboratory Remodel : modification of the Bench Test for the Adaptation of the SISU 420 DWRIE and Opel Z16XEP Engines

Engine testing is a tool to compare the performance of different states of tune and different types of engines. The aim of this thesis is to remodel the engine laboratory in Technobothnia so that the engine testbed can operate in optimal conditions with two different engines, these being SISU 420 DWRIE, a diesel engine, and Opel Z16XEP, a gas-operating engine. The thesis reviewed a range of different things that could be changed in the engine laboratory, including the dynamometer, the shape of the testbed, the mountings and the coupling between the engine and the dynamometer. As a result, it was found that the engine laboratory could be arranged such as it could test the two different engines on the same testbed. This was accomplished by enlarging the structure from 740mm to 855mm and replacing one side of the bed with two beam assemblies where the SISU engine will lie. This model was simulated using Siemens NX, giving a maximum deformation of 0.004mm, which is correct for the operation. The dynamometer was replaced by a Lanmec DW250 which can reach the Opel maximum (6500rpm) and the SISU maximum torque (503Nm). The mountings were also replaced, using for each engine a model that isolates the vibrations at idle speeds. The coupling also needed to be replaced as the current coupling could not be used for both engines. This is because of the SAE size, being the Opel engines’ flywheel 7 ½ and the SISUs’ 11 ½. To solve this, the coupling was substituted for the CENTAX-TEST, which can operate with both engines and the critical speeds of the shaft are 262.45rpm for the SISU engine and 244.05rpm for the Opel engine, which are both below the idle speeds of the engine, which is correct for the operation. The overall cost of the laboratory remodel would be 22720€, which is within the 30000€ budget cap