Vehicle Components

Evaluation, Research, and Development

From headlight to tailpipe, Southwest Research Institute (SwRI) evaluates virtually all vehicle components and systems, electrical and mechanical, as well as their associated fluids. The Institute's testing, research, and development program covers the broad issues of:

• Durability and reliability
• Performance
• Electromagnetic compatibility
• New materials and coatings

Components and systems evaluated include:

• Engines
• Bearings
• Transmissions and transaxles
• Hydraulic systems and components
• Exhaust systems and catalysts
• Fuel injectors, pumps, and delivery modules
• Suspensions
• Powertrains
• Brakes
• Air, oil, and fuel filters

The Institute's vehicle components evaluation program also determines adherence to government regulations and documents component quality, equivalency, and demonstration to original equipment manufacturer (OEM) or regulatory agency specifications.

Vehicle components and systems work in concert. Changes to one component or fluid may affect a myriad of other components and systems. The Institute's broad-based, world-renowned vehicle, engine, fuels, and lubricants program -- providing a full range of testing, research, design, and development services -- is uniquely qualified to solve problems. SwRI conducts evaluation programs for vehicle manufacturers and suppliers to:

• Determine performance, efficiency, and durability
• Reduce noise and vibrations
• Help certify components
• Improve existing component quality and reliability
• Substantiate performance claims
• Evaluate materials
• Demonstrate economy
• Develop new design criteria
• Assure quality
• Document equivalency to original
• Evaluate emissions effects
• Compare, analyze, document, and issue reports
• Evaluate electromagnetic compatibility

One-third of the Institute's research program involves engines, fuels, lubricants, drivetrain components, and related areas such as electronics, manufacturing, and materials. The scope of activity is substantial, with more than 200 drivetrain test facilities devoted to vehicle component evaluation. Laboratory bench tests, dynamometer tests, field evaluations, and combinations of these establish automotive component performance.

Durability and Reliability

The Institute evaluates the durability and reliability of engines and drivetrain parts prior to manufacture and qualifies outsourced engine parts. The Institute conducts evaluations for diesel, gasoline, and alternative-fuel cars, trucks, buses, and farm tractors. SwRI tests:

• Rings
• Pistons
• Liners
• Valves
• Turbochargers
• Seals
• Pumps
• Injectors
• Filters
• Torque converters
• Axles
• Gear boxes
• Microcomputers
• Suspensions

Using radioactive tracer technology, the Institute provides cost-effective, highly useful data about lubricant properties, component designs and materials, air and oil filter effectiveness, and general wear tendencies in response to external and internal operating environments.

Structural reliability

SwRI evaluates various vehicle components for reliability and durability under a variety of conditions. Salt spray, humidity, cold, heat, and other conditions are simulated in conjunction with vibration and other dynamic tests. The Institute conducts shock and vibration tests to determine the reliability of shift selectors. Vehicle suspension systems are tested under dynamic loads to establish the load transfer function of suspension components, including the shock absorbers and the structure itself.

Automotive natural gas storage tanks are constructed of glass fiber/epoxy composite wrapped over an aluminum core. SwRI is studying the long-term fracture behavior of the composites exposed to roadway hazards and weathering.

Advanced wear technology

Component wear in internal combustion engines significantly affects engine performance, service life, maintenance, and exhaust emissions. Extreme temperature gradients can result in component failures. Advanced instrumentation and sophisticated techniques address these reliability issues. Radioactive tracer technology measures component wear, in real-time, in operating engines. SwRI developed a sophisticated telemetry system to measure piston temperature gradient characteristics and ring motion to address design reliability issues.

With fleet testing, the Institute evaluates automotive components, fuels, and lubricants.

Using outboard engines, the Institute certifies two-stroke oils and the durability of engine and lower unit components.

Performance

Driven by consumer and governmental requirements, today's vehicles must meet increasingly high standards of performance to lower emissions, improve fuel economy, and enhance driveability. These high standards spur performance improvements for virtually every component and system under the hood of a car. To improve fuel economy, manufacturers must increase powertrain efficiency by improving the thermo-dynamic efficiency of the engine, reducing friction losses in the engine and transmission, and incorporating advanced energy regenerative systems in the brake and suspension systems. To reduce emissions, the Institute evaluates various exhaust catalysts. To enhance driveability, fuel injectors are developed to resist fouling, powertrain control modules are developed for smooth shifting, and air, fuel, and oil filters are developed to maintain powertrain performance.

Transmission/Transaxle Evaluations

Automotive transmission and transaxle evaluation requires precise control and acquisition of test data. SwRI has developed precision electric dynamometer test stands to evaluate automatic and manual transmission and transaxle performance for engine applications ranging in size from 1.6-8 L, with capabilities of:

Speed 0-6,000 rpm, ± 1 rpm
Torque 0-4,750 ft-lb, ±1 ft-lb

Using computer control and automatic data acquisition, the Institute evaluates the performance of a variety of transmissions and transaxles on dual DC dynamometer test stands.

Standard Tests

• Constant coast drive
• Constant input torque
• Stall
• Road load
• Spin losses
• Coast neutral
• City traffic

Specialized Tests

• Formula One racing simulation
• Shift logic analysis
• Shift feel
• Accelerated endurance
• Transmission and torque converter performance and efficiency mapping
• Transmission pump performance and efficiency mapping
• Clutch pack drag torque
• Torque steer

Engines Research

SwRI designs and develops advanced engines and engine technologies for passenger cars, heavy-duty trucks and buses, off-highway equipment, generator sets, and locomotives. Engine research and development activities focus on maintaining performance while meeting stringent emissions regulations, utilizing alternative fuels, improving fuel economy, reducing oil consumption, and increasing engine durability.

The Institute has six locomotive engines available for research and development methods. Using this large engine test facility, SwRI investigates methods of converting diesel locomotive engines to run on natural gas.

During the engine development process, SwRI utilizes state-of-the-art diagnostic tools including combustion system visualization, flame propagation measurement, knock and misfire detection, in-cylinder air flow and fuel-air mixing measurement, real-time oil consumption measurement, piston and ring motion measurement, and computer simulation. The Institute's engine design, research, and development program focuses on:

• Natural gas engines
• Locomotive/industrial engines
• Heavy-duty diesel engines
• Gasoline engines
• Ethanol/methanol engines
• Alcohol (methanol/ethanol) fuel engines
• Ultra-low emissions engines
• Engine control systems

Using an SwRI-developed fiber-optic spark plug ionization head gasket (SPION) data acquisition system, engineers measure flame propagation to help develop emissions reduction techniques.

SwRI has developed several diagnostic tools to assist in the engine development process, including:

• Flame kernel development and propagation models
• Fuel-air mixture preparation techniques
• Mixture preparation techniques for spark-ignition engines
• Real-time oil consumption measurement technology
• Friction measurement technology

SwRI develops electronic control systems for a variety of engines.

Exhaust Catalysts

Using special facilities, the Institute evaluates the performance of catalysts under a variety of conditions and operations. Programs include evaluating:

• Combustion efficiency in terms of the level of pollutants emitted from the tailpipe
• Cold-start engine performance
• Alternative high-temperature substrates, catalyst washcoats, and catalyst formulations
• Oxygen sensor performance over time
• Unconventional catalysts for small engines used in recreational and utility vehicles

For more than 25 years, teams of SwRI chemists and engineers have conducted exhaust aftertreatment research, continuously improving capabilities and facilities to meet the demands of evolving emissions technology.

The Institute also develops improved catalyst systems, such as new NO_x reduction catalysts for use under lean-burn conditions.

Hydraulic Systems and Components

Hydraulic fluid power systems produce unparalleled levels of power with tremendous flexibility and minimal size and weight requirements. In conjunction with component and system evaluations, SwRI performs computerized analyses to predict component and system performance, to identify and solve problems, and to optimize designs for industry and government. The Institute evaluates the efficiency and durability of hydraulic components, such as:

• Hydraulic pumps
• Hydraulic motors
• Hydrostatic transmissions
• Control valves
• Actuators
• Accumulators

Complete systems are evaluated at various loads under simulated environmental conditions. Systems evaluated include:

• Steering
• Active suspension
• Hydraulic regenerative braking
• Off-highway equipment
• Industrial motion control

To isolate an instability problem, SwRI conducts laboratory tests for a proportional control valve for off-highway equipment.

Injector Improvements

Fuel injector design affects injector fouling, sticking, and performance. Using several methods, SwRI evaluates gasoline injector performance and tolerance to deposits while maintaining proper atomization and delivery.

Engine Bearing Performance

SwRI evaluates bearing performance using advanced instrumentation.

Air, Oil, and Fuel Filter Performance

Air, oil, and fuel filters for all types of vehicles protect internal combustion engines and provide cleaner environments for passengers. Using Society of Automotive Engineers (SAE) bench test procedures, SwRI evaluates air, oil, and fuel filter performance for prescribed particle sizes and concentrations of contaminants. Engine or road testing exposes components to actual contaminants.

Air filters and air cleaner systems are tested to national, international, governmental, and industrial codes, standards, and specifications. In addition to testing, the Institute provides basic and applied research ranging from media development to vehicle systems integration and special applications.

The Institute's oil filter test stand is computer-controlled to monitor its temperature, safety features, automated sampling, and inlet, outlet, and differential measurement systems.

Brake Systems

SwRI is involved in brake system performance testing for vehicles ranging from motorcycles to heavy-duty multi-unit trucks. Design and development programs help correct braking problems or develop new systems. Vehicle and brake performance data are collected and analyzed using advanced statistical analysis techniques, both on site and from remote locations. SwRI offers extensive data storage and manipulation capabilities.

Using advanced data acquisition and analysis techniques, SwRI collected data from more than 250 vehicles at 17 remote sites. The resulting 2.5 gigabyte data bank will provide the client with braking performance and maintenance information for operation and design activities for years to come.

Electromagnetic Compatibility

The Institute provides electromagnetic compatibility (EMC) services, from design consultation to testing, for automotive systems, ranging from components to whole vehicles. The tests are conducted for, or in conjunction with, government and industry. Extensive electromagnetic compatibility experience includes:

• Vehicular system/subsystem radio-frequency (RF) emissions and immunity testing to SAE, U.S., and international manufacturer standards
• RF susceptibility testing
• EMC consulting services
• Electric and magnetic shielding evaluations
• Special-purpose RF instrumentation and test procedures
• Test, evaluation, and design of vehicle electronics
• Computer-controlled, multi-channel electromagnetic measurement systems
• Measuring electric and magnetic fields for compliance with national and international regulations and standards
• Determining the susceptibility of electronic systems to RF energy
• Evaluation and modifications of equipment and systems to meet applicable regulations and standards

Whole Vehicle and Component Design Evaluation

The Institute conducts EMC testing in accordance with SAE, U.S., and international EMC automotive industry standards. In connection with these services, SwRI provides consultation at the component, circuit, and system levels to aid the client in bringing designs into compliance. These timely, cost-effective services are available from initial concept to final product stages.

The Institute performs the following categories of electronic tests:

• Conducted emissions
• Conducted susceptibility
• Electrostatic discharge
• Radiated emissions
• Radiated susceptibility

Immunity Testing

The SwRI staff uses Tri-plate-line (TPL), bulk current injection (BCI), and transverse electromagnetic (TEM) techniques to determine the frequencies and levels of electromagnetic susceptibilities of components and subsystems. These computer-controlled tests provide accurate, repeatable, and cost-effective results.

Using pneumatics, engineers remotely controlled this vehicle without interference from the radiated electric field.

Using its computer-controlled TPL facility, SwRI evaluates the radiated immunity of electronic components over the frequency range 1-1,000 MHz, at an electronic field intensity up to 200 V/m. Larger systems and subsystems are tested in SwRI's RF anechoic chamber, large volume semi-anechoic shielded enclosure, or open area test site. Testing is performed according to a wide variety of government, European, and industrial specifications and standards.

Under manual operation or computer control, SwRI performs radiated immunity testing of automotive components using a Tri-plate-line. This technique is used to evaluate vehicular modules, sensors, and subsystems with associated wire harnesses for radiated susceptibility.

New Materials and Coatings

The Institute has an extensive program in the research, development, and evaluation of advanced materials, such as ceramics, composites, and polymers. These materials, which are currently found in many aircraft and race car engines, will become increasingly important in the high-performance engines of the future.

Emissions researchers are studying the gas adsorption properties of various materials. Here, an ethylene molecule is trapped in a silicalite zeolite. Studying the relative diffusion of various hydrocarbons in zeolite has contributed to an Institute program investigating cold-start emission control methods.

Institute scientists are using preceramic polymers to produce heat-resistant composites in complex shapes without damage to the reinforcing fibers. The resulting materials, which are increasingly found in turbine engines, will be critical in future, fuel-efficient automotive engine applications.

Advanced surface treatment

Using ion beam processes, the Institute can treat automotive components and develop new solutions to wear, friction, and corrosion problems. Hard, lubricious diamond-like carbon, titanium nitride, and other compounds can be deposited, providing coatings that are amorphous, harder than tungsten carbide, and exhibit very low friction coefficients. Derivatives incorporating silicon have even better tribological properties, acting as smooth, tough, solid lubricants.

The Institute operates the largest facility in the U.S. to modify the surface of materials using ion beams. New materials, such as ceramics, metals, and composites, may require surface treatment to reduce friction. Ion implantation and ion beam-assisted deposition can be used in conjunction with other surface treatments, such as nitriding, carburizing, electrodeposition, and CVD or thermal spray, for optimized performance.

Ion beam processes are completely free from environmental hazards or impact and may replace less acceptable surface treatments. Studies indicate that ion beam systems can be scaled up with the ensuing benefits of high throughput and low unit cost. The Institute can design full-scale production equipment incorporating long-life ion guns and automated workpiece handling.

Additional Services

Government Compliance

Some engines, vehicles, or components need government approval prior to sale. The Institute conducts required testing including:

• EPA emission certification
• NATO qualification
• European Economic Community noise and smoke testing
• U.S. Army Qualified Products List testing
• Mine Safety and Health Administration testing

Quality Audit

Through quality audits, parts quality, equivalency, and demonstration, engines and components are evaluated to ensure compliance with OEMs or regulatory specifications. SwRI conducts engine emissions performance evaluations for heavy-duty diesel, alternative-fuel, and gasoline engine manufacturers.

Environmental testing

SwRI conducts laboratory tests to evaluate how vehicle components operate in adverse physical environments. These tests simulate expected service conditions or determine if a component meets commercial or governmental specifications. SwRI tests components such as turbochargers, shift selectors, filters, and air conditioner compressors under:

• Shock and vibration loading
• High, low, and ramped temperatures
• High and low humidity exposure
• Salt spray and other environmental conditions

The Institute integrates temperature and vibration tests for this catalytic converter to more realistically simulate the operating environment.

SwRI designs special test fixtures and environments combining various factors to most effectively and realistically recreate service conditions. For example, catalytic convertors and oil filters receive simultaneous thermal and vibration loading. SwRI simulates road conditions to test vehicle suspension systems under dynamic loading to determine component wear effects on performance and to establish shock and vibration levels.

Noise emission, transfer

Noise is produced by dynamic components and can be transferred or intensified by inactive components (structure-borne noise). SwRI evaluates the noise emissions of components such as air conditioner compressors, manifolds, and other mechanical equipment and recommends design modifications to reduce noise. Engineers characterize noise using sound pressure or sound intensity measurements and evaluate recommended design changes with boundary and finite element analyses.

Applied Statistics

SwRI uses carefully planned experimental designs and sophisticated data analysis techniques in testing and evaluating vehicle components and systems. Proper experiment design results in efficient tests that better quantify the relationships between variables. Using innovative analysis techniques, SwRI ensures the proper measurement of the experimental variation and of the relative effects of various experimental factors. Services offered include:

• Experimental design
• Data analysis
• Statistical methodology application
• Statistical process improvement
• Regression and response surface modeling
• Reliability and failure analysis
• Sampling plan development

This brochure was published in May 1996. For more information about vehicle components, contact Mike Ladika, Phone (210) 522-2122, Fax (210) 522-3496, Engine, Emissions and Vehicle Research Division, Southwest Research Institute, P.O. Drawer 28510, San Antonio, Texas 78228-0510.

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