Testing: Valvetrain Systems For Combustion Engines
Testing: Valvetrain Systems For Combustion Engines
Publication VVV
Produced by:
INA-Schaeffler KG
91072 Herzogenaurach (Germany)
Mailing address:
Industriestrasse 13
91074 Herzogenaurach (Germany)
by INA 2003, October
All rights reserved.
Reproduction in whole or in part
without our authorization is prohibited.
Printed in Germany by:
Frankendruck GmbH, 90025 Nrnberg
Bucket tappets
Oil aeration
Switchable tappets
Dynamic behavior
Crosshead tappets
Torsional vibrations
Roller tappets
Acceleration
Rocker arms
Ball stroke
Finger followers
Pressures
Hydraulic
chain tensioners
Roller slip
Rotation
Torque
Forces
Check valves
158 075
Velocities
158 074
Pivot elements
Special designs
Wear
Friction
158 076
Misfire
Rattling
Fatigue load
158 077
Displacement
Elementary
investigations
Switching process
Durability
158 078
Functional tests
Testing Overview
Testing Overview
158 079
158 080
158 081
Drive motor
Measuring
flange
Thermal
insulation
Temperature
Cylinder head
Oil pressure
Gallery
Oil temperature
Gallery
Oil temperature
Inlet
Frictional torque
Speed
Oil pressure
Inlet
Inlet
Return
Oscilloscope
Booster
Oil unit
Oil heater
Regulator
Oil temperature
Booster
Oil temperature
Oil tank
158 082
External
temperature
control unit
Oil return
Oil inlet
Measuring
amplifier
Test Types
Fatigue Tests I
10
Fatigue Tests I
Load (log)
ND
Probability of
survival
10%
50%
100
10 000
1 000 000
Cycles N (log)
158 037
90%
Double (oscillation)
amplitude
Force F
Upper load
Center load
Lower load
1
Number of cycles N
158 038
Preload
0
158 039
11
Fatigue Tests II
12
Fatigue Tests II
8500
8000
7500
7000
B
D
6500
B
D
B
D
B
D
B
D
B
D
B
D
B
D
6000
5500
5000
10
15
20
25
30
158 040
1% failure probability
First sample
M3 sample
M4 sample
fail-safe
margin
Force / N
158 041
Density of distribution
13
14
158 042
158 043
123
67
45
15
16
B
A
0
1
2
3
4
5
Incremental encoder
Fy
A Wheatstone bridge
B DC - measuring-force amp.
C DMS - measurement points
C
Computer with A/D converter
C
A
158 044
2
Laser Vibrometer
Sensors
Acceleration / m/s
0
-3 000
-6 000
0
15
30
Cam angle /
45
60
75
90
105
120
135
150
165
180
158 045
Velocity / m/s
Stroke / mm
18 000
12
10
8
6
4
2
0
-2
-4
-8
-10
-12
Cam angle /
Force
Cam
contact
pressure
158 046
Speed / 1/
mm
Force / N
17
Functional Tests I
18
Functional Tests I
High pressure
chamber
158 047
Oil supply
from engine
158 048
Signal evaluation
Noise evaluation
Diagram
Documentation
158 049
Test Stand
19
Functional Tests II
Standard tests are used to simulate the critical operating conditions in the
engine:
Cold start down to 40 C ambient
(drained oil supply, delayed oil pressure increase, thick oil,
high oil pressure, etc.)
Hot idle test
30 min. operation at idle speed after sustained operation at high engine
speeds and associated temperatures
(thin oil, low oil pressure, oil aeration, sharp drop, etc.)
40 short stop-start tests (taxi tests)
(draining of oil passage, leakdown of the hydraulic elements in the
three minute downtime phase, air transport to the hydraulic elements
during startup, only brief test run of 10 sec)
Temperature-cycle tests
(temperature variations up to 50 C max. lead to draining effects due to
the heat expansion of oil and air in the oil supply)
20
Functional Tests II
Signal strength
Time
Signal strength
Time
Start-cycle no.
158 050
Signal strength
21
Misfire Tests I
22
Misfire Tests I
Valve elongation
due to heat
generation
Danger
that the valve
remains slightly
opened
158 051
st
au
xh
e
t
Ho C
0
0
8
Crankshaft speed
Time
158 052
TDC 1. Cyl.
23
Misfire Tests II
In the U.S. and Europe, on-board diagnostics (OBD) are required by law.
The emission-related components must be continuously monitored.
The malfunction indicator lamp (MIL) and fault codes set in the engine
control computer indicate the presence of emission related problems.
If the same reoccurring emission problem is found in 5% of the vehicles
of the same type, production must be corrected at the expense of
the responsible manufacturer.
Compared to what the driver can perceive, the electronic monitoring
of misfire is very precise, and malfunctions can be detected long before
the driver notices them. Tests can be conducted to determine whether
the hydraulic lash adjusters are causing misfire events.
Various procedures are used to monitor the engine:
Crankshaft speed variations are measured, the ionization current in
the exhaust gases is measured, etc.
To determine what safeguards exist that ensure that misfires detection is
not activated, tests are performed on vehicles having the manufacturers
diagnostic systems. Here, misfire detection signals are compared with
the current limiting values.
24
Misfire Tests II
60s
Full load
Id
30s
60s
Full load
Id
le
Full load
30s
le
60s
Id
Time
30s
le
Speed
Crankshaft revolutions
158 053
Engine
started at -25
Signal strength
Rotational speed
Time
158 054
Misfire - signal
Rotational speed
Misfire - signal
Time
158 055
Signal strength
25
Switching Tests I
26
Switching Tests I
Switching
Unlocked (low valve lift)
158 056
Locking
pin
27
Switching Tests II
28
Switching Tests II
Time / sec
158 057
Switching signal / V
Lift detection / V
100 %
360
158 058
Switches within
this revolution
0%
15.2
14.8
14.4
14
13.6
13.2
12.8
12.4
12
11.6
11.2
10.8
10.4
10
3000
10
60
2000
1000
Temperature / C
90 550
158 059
16
15.6
Switching time / ms
29
30
Simulation Models
1
158 060
31
32
Sensor
Sensor
support
Cap
Stroke / mm
Calculation
Measurement
0.12
0.08
0.04
0.00
0.0
72.0
144.0
216.0
288.0
360.0
158 062
-0.04
33
Special Investigations I
34
Special Investigations I
158 063
Housing
Oil supply bore
closed
Spacer block
Piston
Disk springs
Displacement sensor
Adjustment disk II
Turn locking
158 064
Adjustment disk I
35
Special Investigations II
Some of the special investigations that have been performed include the
following:
Measurement of the rotation of hydraulic bucket tappets (TSTH)
Quantification of oil aeration in the TSTH reservoir
Measurement of TSTH ball opening behavior
Measurement of the pressure within a high pressure chamber
of a hydraulic lash adjuster (HLA)
Measurement of valvetrain friction with roller bearing and plain bearing
supports
Measurement of rotational speed of rocker arm rollers
Over time, many special investigations have evolved into standard tests or
measurements.
These investigations have contributed greatly to improving the reliability
of our products in the engine.
36
Special Investigations II
Strain gauges
158 065
4:1
Telemetry
Antenna
Strain gauged
chain link
158 066
Amplifier and
transponder
37
38
Chain
blade
Chain
guide
158 083
Hydraulic
tensioner
Crankshaft sprocket
Intake
Exhaust
F-KSH
Chain guide
p-oil
Chain blade
Amplifier
Plotter
Intake
Exhaust
Speed
Speed
Rotec
158 068
Crankshaft
39
40
Oil supply
Pressure
transducer
158 069
Pressure
transducer
mm
KSH stroke
Cam speed
Time
158 070
Resonance
= Force overload
Intake, 8. Ord.
Intake,16. Ord.
Intake, 4. Ord.
41
Wear Tests
Wear tests are conducted to verify the resistance of parts against material
abrasion.
Metal pieces sliding against each other under mixed friction conditions
produce abrasive and adhesive wear processes. Both of these wear
mechanisms as well as fatigue wear, which leads to surface pitting,
often cause the sliding contact partners to fail completely. Wear can also
result from several types of corrosion.
Parameters that have an effect on wear include:
Materials
(material pairing, heat treatment, coating, etc.)
Contact geometry
(macro/microgeometry, geometric accuracy, roughness,
supporting surface, etc.)
Load
(forces, moments, Hertzian pressure, etc.)
Kinematic design
(relative speed, hydrodynamic speed, contact pressure, etc.)
Lubrication
(oil, viscosity, quantity, additives, contamination, aging, etc.)
42
Wear Tests
158 072
158 073
43
Summary
As you can see, INA has world class testing capabilities to complement
any product development program. Of course, a highly skilled staff of
professionals is required to bring it all together. INA has that with ample
resources available in Germany and a growing staff in North America.
Working jointly with you, the customer, sound solutions can be obtained
for your product optimizations.
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45
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47
91072 Herzogenaurach
Internet www.ina.com
Email
[email protected]
In Germany:
Phone
0180 / 5 00 38 72
Fax
0180 / 5 00 38 73
From Other countries:
Phone
+49 / 9132 / 82-0
Fax
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INA-Schaeffler KG