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Measurement
journal homepage: www.elsevier.com/locate/measurement
a r t i c l e i n f o a b s t r a c t
Article history: Paper deals with dynamic measurement of performance parameters for selected vehicles engines using
Received 17 January 2017 incremental sensor attached to the rest bed roller. Data collection was performed with an eight-
Received in revised form 11 July 2017 channel collector. The moment of the inertia is the result of the measurement, which can also be used
Accepted 13 July 2017
in the measurement of performance parameters. The external speed characteristics of the engine primar-
Available online 14 July 2017
ily resulting from the dynamic measurement is the absolute result of the measurement. It can be con-
cluded on the technical conditions of the motor vehicle based on the evaluation of external speed
Keywords:
characteristics of the engine. It is possible to maintain consistently good technical state of the motor
Moment of inertia of engine
Performance parameters
engine with an appropriate maintenance and contribute to the ecology and the economy of the vehicle
Roll test bed operation.
Ó 2017 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.measurement.2017.07.021
0263-2241/Ó 2017 Elsevier Ltd. All rights reserved.
12 M. Pexa et al. / Measurement 111 (2017) 11–17
Nomenclature
aabm acceleration of rollers of test bed during acceleration of av(n) acceleration of rollers of test bed during the acceleration
motors, all inertial masses are reduced to the roller cir- of combustion engine (full supply of fuel) (m/s2)
cumference, but without moment of inertia of motor dv(n) acceleration of rollers of test bed while the steps on the
(m/s2) clutch (m/s2)
aasm acceleration of rollers of test bed during acceleration of Fe the overall strength of the electric motors (N)
motors, all inertial masses are reduced to the roller cir- I moment of inertia of the engines (kg m2)
cumference (m/s2) ic overall gear ratio (–)
aav(1,2) acceleration of roller of test bed during acceleration of M(n) engine torque as a function of engine speed (Nm)
electric motors on the left (1) and right (2) side of the mbm mass inertia of the rotating masses reduced to the cir-
test bed (m/s2) cumference of rollers excluding an inertia of motor (kg)
adbm acceleration of rollers of test bed during deceleration of msm mass inertia of the rotating masses reduced to the cir-
motors, all inertial masses are reduced to the roller cir- cumference of rollers including an inertia of motor (kg)
cumference, but without moment of inertia of motor mv inertial mass of rollers of test bed reduced on the cir-
(m/s2) cumference (equal for left and right side of test bed) (kg)
adsm acceleration of rollers of test bed during deceleration of mv(1,2) inertial mass in the left roller (1) or right (2) side of test
motors, all inertial masses are reduced to the roller cir- bed reduced on the circumference (kg)
cumference (m/s2) n measured and calculated combustion engine speed
adsme acceleration of the roller during deceleration testing of (rpm)
electric motors (motors connected), all the inertial nm engine rpm (rpm)
masses are reduced to the roller circumference (m/s2), nv roll rpm (rpm)
adv(1,2) acceleration of roller of test bed during deceleration of P(n) engine power as a function of engine speed (kW)
electric motors on the left (1) and right (2) side of the rv circumference of rollers of test bed (m)
test bed (m/s2)
moment of inertia. In such cases, there are suitable several other of vehicle’s engine are defined by a reduction of measured values
ways, such as measuring of a vehicle acceleration on the road or in the overall speed ratio between vehicle’s engine and rollers of
on the roll test bed with loose rollers or on the roll test bed itself. the test bed.
The research of many authors describes the dynamic measure- Possibilities of the utilization of the roll test bed are extensive
ment of performance parameters of the combustion engines [6–10] and include the dynamic measurement of performance parameters
of road vehicles with the possibility of determining the moment of of engines of vehicles, the measurement of transmission ratios,
inertia. It turns out that the dynamic method of measurement measuring the dynamic braking forces. Data collection was per-
reaches a sufficient exactness and it is suitable for service measure- formed with an eight-channel collector, which ensures online data
ments above all. The dynamic method of performance parameters preprocessing and passes data to the operating computer type PC
measurement does not aim for substituting a current method of which is connected through the USB port.
the measurement with using dynamometers [11–15], which is pre- The procedure of finding performance parameters of the vehicle
scribed in directives (ČSN ISO 9249, ČSN ISO 789-1, ČSN ISO 789-5, engine is implemented in four steps, which are logically connected
ČS ISO 789-9) but it offers a service alternative to these homologa- and, if necessary, it is possible to print a protocol.
tion measurements [16,17].
The aim of the research is to use the dynamic method of perfor- (1) The first step is to measure a gear ratio between the engine
mance parameters measurement and subsequently compare and the rollers of the test bed for each vehicle. Revolutions of
gained data with the classic method. The research result is the ver- the roller test bed measured by an incremental sensor and
ified measuring method of vehicle and various machines operating revolutions of the engine measured by another external sen-
parameters which enables to perform timely and effective mainte- sor are compared. To measure the revolutions of the vehicle
nance interventions. The dynamic method of operating parameters engine, the diagnostic plug OBD is the most suitable to use.
measurement has a positive benefit for a development of service For instance, if a motor vehicle has 820 rpm, and rollers of
centres above all. test bed have 265 rpm, then the overall gear ratio is 3.094.
(Eq. (1))
2. Methodology
nm
ic ¼ ð1Þ
nv
A structural adjustment of the roll test bed, originally designed
only to check the brakes, consisted in the removal of gearbox and The second step is to measure all inertial masses, i.e. the mass of
connecting electric motors to frequency converters (this is not the engine, the transmission and wheels of the vehicle and rolls
strictly necessary). and other rotating masses of the test bed, reduced to the circum-
A detail of the test bed adjustments is shown in the Fig. 1, fre- ference of rollers. Frequency converters controlled by electric
quency converters are shown in the Fig. 2. An angular velocity and motors are used to measure and it is possible for them to change
an angular acceleration of the vehicle engine are calculated from the performance of approximately 15–30 kW (according to over-
the time recorded data of an incremental rotating speed sensor. load set on the converter). Given procedure, in view of the perfor-
The sensor (Fig. 3) gives 1024 pulses per revolution (with time mance characteristics of electric motors roll test bed, is different
accuracy within 20 ns) at this described specific application. The for engines of vehicles with low inertia mass (lower stroke volume,
sensor is attached to the rollers of the test bed. Required values approximately up to 1.4 l) and for vehicles with engines of higher
M. Pexa et al. / Measurement 111 (2017) 11–17 13
inertia mass (higher stroke volume more than 1.4 l and diesel engi- F e ¼ msm ðaasm adsm Þ ð4Þ
nes). A prerequisite for this and other parts of the measurement is
msm ðaasm adsm Þ ¼ mv1 ðaav1 adv1 Þ þ mv2 ðaav2 adv2 Þ ð5Þ
that electric motors are pushing with a constant force (or the pre-
dictable course of power) and the inertial mass of the roller test
mv1 ðaav1 adv1 Þ þ mv2 ðaav2 adv2 Þ
reduced to its own circumference is known. The constant power msm ¼ ð6Þ
is provided by attached frequency convertors. The electric power ðaasm adsm Þ
is calculated by starting parameters of electric motors according (b) It is not enough electric power to accelerate the testing of all
to Eq. (2). rotating masses of the idling speed revolutions for vehicles’
F e ¼ mv1 ðaav1 adv1 Þ þ mv2 ðaav2 adv2 Þ ð2Þ engines with larger inertial mass. At first the vehicle on
the rollers is started by using its own engine to a speed of
14 M. Pexa et al. / Measurement 111 (2017) 11–17
Torque (Nm)
mv1 ðaav1 adv1 Þ þ mv2 ðaav2 adv2 Þ
Power (kW)
msm ¼ ð7Þ
ðadsme adsm Þ
50 35
In the third step it is essential to set the optional selected gear.
Then the gear is accelerating with a full supply of fuel to the pre- 40 28
selected speed (over engine speed, the maximum permitted speed
limiter). When reaching the pre-set speed, the fuel pedal is 30 torque 2° 21
released while the steps on the clutch. Performance parameters
are calculated after stopping the rollers of the test bed depending torque 3°
20 14
on the achievement of the acceleration and the deceleration. The power 2°
resulting performance figures are the sum of these values at speci-
10 power 3° 7
fic speeds (Eqs. (8) and (9)).
rv 0 0
MðnÞ ¼ ðmsm av ðnÞ mbm dv ðnÞÞ ð8Þ
ic 1000 2000 3000 4000 5000 6000
RPM
MðnÞ n p
PðnÞ ¼ ð9Þ
30000 Fig. 4. Performance parameters of motor 1.0 dm3 of car Peugeot 107, measured by
shifted 2nd and 3rd speed.
In the fourth step it is necessary to determine the inertial mass
of all rotating parts except for the engine and the relevant parts of
the gearbox. The procedure is the same as in the second step, but (55 kW), (3) 1.4 MPi Seat Cordoba (44 kW). The observed moment
no gear is shifted. The calculation is performed according to Eq. of inertia of each motor (Eq. (13)) is Škoda 0.17 kg m2, Peugeot
(12). 0.1 kg m2 and Seat 0.14 kg m2. The measured values of perfor-
F e ¼ mbm ðaabm adbm Þ ð10Þ mance parameters of Škoda and Seat vehicles match tabular data.
Peugeot motor vehicles did not reach the tabular values (power
mbm ðaabm adbm Þ ¼ mv1 ðaav1 adv1 Þ þ mv2 ðaav2 adv2 Þ ð11Þ drop by about 10%).
The measurement procedure can be applied to any passenger Measurements of diesel vehicles are usually complicated and
road vehicle. Restrictions are only related to the fact that the vehi- results do not comply with measure on a dynamometer. Firstly,
cle cannot be measured with a four-wheel drive with automatic there is the influence of forced induction. Turbocharger’s boost
transmission and the vehicle whose speed would have exceeded pressure at low engine speeds is inefficient and on the other hand
140 km/h at the selected gear. There is no limitation of the roller high engine speeds can exceed the desired value. Therefore, it is
test bed due to the dynamic principle of the measurement (the possible to reach higher performance compare to short-term nom-
energy is dissipated by its own inertia of the running engine). inal performance.
The maximum torque is not reached during measurement,
3.1. Vehicles with spark-ignition engine because this maximum is at low engine speeds. The maximum
value can be almost achieved when a higher gear is shifted. It is
The measurement of petrol vehicles is usually easier and results shown at Fig. 6.
better reflect the reality. Turbocharged engines, which are primar- Fig. 7 shows a behaviour of the performance parameters of
ily diesel, are the exceptions. The measurement of turbocharged engine (1) 2.0 HDi Citroen Xantia (88 kW after chiptunning), (2)
engines is described for measurements of diesel engines. 2.0 TDi Škoda Octavia II (103 kW), (3) 1.9 TDi PD Volkswagen Golf
It is necessary to keep in mind that the control unit to run the V (77 kW). The observed moments of inertia of the engines (Eq.
engine reaches higher speeds than diesel engines during measure- (13)) are Citroen 0.30 kg m2, Škoda 0.32 kg m2 and Volkswagen
ments. It is therefore necessary to subtract the measured inertia at 0.25 kg m2.
higher engine speeds, which already does this intervention. An incongruity of the performance parameters of the engine
The engine controls unit, introduced in the lower gear, allows Citroen is quite apparent according to these behaviours. Achieved
only a limited torque in rare cases. Measurements have to be made power should be 88 kW. However, it reached only 57 kW. The vehi-
to a higher gear in this case. An example of such measurements is cle has a defect in the intake or turbocharger. The failure of the
shown in Fig. 4. intake was confirmed by the diagnostics - faulty air weight. The
Fig. 5 shows a behaviour of output parameters of engine (1) motor vehicle Škoda and Volkswagen had a typical behaviour of
1.6 MPi Škoda Octavia II (75 kW), (2) 1.4 MPi Peugot 206 the performance parameters for this method of measurement.
M. Pexa et al. / Measurement 111 (2017) 11–17 15
160 80
140 70
120 60
Torque (Nm)
100 50
Power (kW)
80 40
60 30
40 20
0 0
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
RPM
Fig. 5. Engine performance parameters: (1) 1.6 MPi Škoda Octavia II, (2) 1.4 MPi Peugeot 206, (3) 1.4 MPi Seat Cordoba.
350
300
250
Torque (Nm)
200
150
100
Fig. 6. Influence of choice of shifted gear on turbocharger pressure during the dynamic measurement of performance parameters.
Whole methodology to evaluate the accuracy of the measure- motors do require a removal of the other units, possibly requiring
ment is theoretically possible in several ways, the only one is prac- additional signal such as ABS, ASR and from similar systems.
tically feasible without major problems:
Check on a roller dynamometer – This would theoretically con- 4. Accuracy of measurement
sist in measuring the performance parameters of the vehicle on a
roller dynamometer and comparing with results obtained by the Tabular check – This method of the accuracy detection is based
methodology described above. Unfortunately, this option is not on the measurement of larger number of vehicles which are guar-
possible, because the precision of cylindrical dynamometers is typ- anteed by the producer that engine performance parameters reach
ically 10%, and extremes can be up to 20%. certain values. It is a vehicle with mileage kilometers - maximally
Check the engine station – This method would be based on 30–40,000 km. Thus, the observed initial accuracy is around 5.5%.
measuring of performance parameters of the engine mounted on However, it is necessary to measure the number of larger vehicles.
a braking motor system and comparing with results obtained by Table 1 shows measured values of selected new vehicles.
the methodology described above. The accuracy of the method is The moment of inertia is one of the necessary input data for the
sufficient, but unfortunately the engine cannot be easily removed diagnostic non-assembling acceleration measurement. The correct
and placed on a braking motor system, because some (modern) and accurate detection is usually the main problem of these
16 M. Pexa et al. / Measurement 111 (2017) 11–17
300 120
250 100
200 80
Torque (Nm)
Power (kW)
150 60
100 40
0 0
1000 1500 2000 2500 3000 3500 4000 4500 5000
RPM
Fig. 7. Performance parameters of engine: (1) 2.0 HDi Citroen Xantia, (2) 2.0 TDi Škoda Octavia II, (3) 1.9 TDi PD Volkswagen Golf V.
Table 1
Accuracy of measurement method.
Vehicle Škoda Octavia II – 1.6 MPI 31000 km Škoda Fabia I – 1.4 16 V 27000 km
Tabular data Measured values Accuracy (%) Measured values Tabular data Accuracy (%)
Torque (Nm) 148 147 0.7% 126 120 -4.8%
At (rpm) 3800 4007 3800 3754
Power (kW) 75 75 0.0% 55 58 5.5%
At (rpm) 5600 5666 5000 5083
Vehicle Peugeot 107 6000 km Hyundai i20 7000 km
Tabular data Measured values Accuracy (%) Measured values Tabular data Accuracy (%)
Torque (Nm) 93 89 4.3% 118.6 115 3.0%
At (rpm) 3600 3676 4000 4130
Power (kW) 50 52.5 5.0% 57.2 57 0.3%
At (rpm) 6000 6067 6000 6230
Table 2
Comparison of measured and tabular data of spark-ignition engines performance parameters.
measurements. There are several options for finding the moment accuracy is evaluated primarily according to the limitations of
of inertia, however, there are not always easily feasible. these vehicles with mileage 40,000 km. Overall, it is achieved
The moment of inertia of all parts (rotating with the engine in 5.5% of measurement error. Fig. 5 shows performance parameters
neutral) can be obtained by the procedure described above. This of engines 1.6 MPi Škoda Octavia II (75 kW) 1.4 MPi Peugeot 206
is not a moment of inertia of the engine by itself, but for the pur- (55 kW) 1.4 MPI Seat Cordoba (44 kW), compared with the tabular
poses of measuring the acceleration performance parameters is data which are shown in Table 2. The Peugeot car does not achieve
not misleading. These are precisely those masses which are accel- the nominal values due to increased resistance to the intake or
erating during the acceleration measurement. exhaust (see Table 3).
The proposed method is suitable for cases where it is available Performance parameters of diesel engines have been counter-
the roll test bed, even with low power. The method provides a acted by the Citroen Xantia 2.0 HDi (88 kW), 2.0 TDi Skoda Octavia
specific value of the moment of inertia of the rotating masses of II (103 kW) and 1.9 TDI PD, Volkswagen Golf V (77 kW). The motor
the vehicle engine and immediately after it provides its basic per- vehicle and Volkswagen’s Škoda has a typical behaviour for tur-
formance characteristics. bocharged engines. The nominal torque is not reached at low speed
The measurement of non-turbocharged gasoline engines is and on the other hand the nominal power is exceeded at high
reliable and the results correspond to the reality. Therefore, the speeds. At Citroen car the defect (later diagnosed as faulty air
M. Pexa et al. / Measurement 111 (2017) 11–17 17
Table 3
Comparison of measured and tabular data of diesel engines performance parameters.