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09 Drivetrain Testing

The document discusses drivetrain testing facilities and capabilities at a vehicle research organization. It has 240 dynamometers and over 300 engine and transmission test stands. Automatic transmission testing includes efficiency testing of pumps, torque converters, and lockup clutches over various operating conditions and loads. Transmission durability testing verifies components over millions of cycles. Capabilities also include clutch pack analysis, engine-transmission integration testing, and 4WD system evaluation. Failure analysis uses techniques like dye penetrant and metallography to evaluate gear wear and contact.

Uploaded by

Ravi Harper
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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45 views

09 Drivetrain Testing

The document discusses drivetrain testing facilities and capabilities at a vehicle research organization. It has 240 dynamometers and over 300 engine and transmission test stands. Automatic transmission testing includes efficiency testing of pumps, torque converters, and lockup clutches over various operating conditions and loads. Transmission durability testing verifies components over millions of cycles. Capabilities also include clutch pack analysis, engine-transmission integration testing, and 4WD system evaluation. Failure analysis uses techniques like dye penetrant and metallography to evaluate gear wear and contact.

Uploaded by

Ravi Harper
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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DRIVETRAIN TESTING

Denis Long, Manager


Drivetrain Engineering Section
Vehicle and Driveline Research Department
Phone: (210) 522-6599 Fax: (210) 522-5720

1
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Powertrain Facilities

u 240 Dynamometers
u 176 Engine Stands
u 33 Transmission
u 34 Emission Stands
u 9 Axle Test Stands

2
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Automatic Transmission Technology By The
Numbers

u 12 Years Transmission Hardware


u 25 Years Transmission Fluid
u 6 250/375 KW Double Ended DC Dyno Stands
u 5 15KW Spin Stands
u 104 Transmission/Transaxles/CVT’s Tested
u 93 Conversion
u 1.6-8.0L Engine Applications
u 96 Pumps
u 21 Invention Disclosures
u 28 SAE Papers, Technical Articles

3
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Comprehensive Transmission Services

u Reverse Engineering
u Fixture Design
u Fixture Fabrication
u Vehicle Parameter Testing
u Test Matrix Development
u Pump, Converter and Transmission Testing
u Gearbox Loss Determination
u Power Path Analysis
u Inertia Value Testing
u Data Analysis
u Statistical Analysis
u Data Regression 4
H
Dynamometer Test Facility

5
H
CVT Testing and Development

6
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Preproduction Hybrid Electric/Belt-Type CVT
Certification Testing
SwRI conducted a 41 test validation program of a passenger car CVT. The testing
was conducted using 7 different dynamometer and laboratory test stands.
n Spin Loss n Cold Start Up
n Efficiency-Assembly n Oil Level-Pitch
n Pump Efficiency n Oil Level-Roll
n Torque Converter Efficiency n Oil Level-Temperature Effects
n Lockup Clutch Capacity n Breather Function
n Lubrication-Bearing
n Lockup Clutch Torsional
n Lubrication-Pulley/Sheave
n Dynamic Belt Capacity
n Static Belt Strength
n Durability-Constant Speed n Static Sheave Strength
n Durability-Variable Speed n Static Parking Brake Strength
n Durability-Variable Ratio n Cycling-Belt
n Durability-Variable Load-Positive n Cycling-Sheave Shaft
n Durability-Variable Load-Reversing n Cycling-Parking Brake
n Durability-Towing n Cycling-Shift Selector
n Durability-Differential Output Low n Cycling-Hydraulic Circuit
Speed n Cycling-Case Stress
n Durability-Differential Output High n Load Testing-Bosses/Mounting
Speed n Deformation-Case
n Durability-Differential Output Speed n Leakage –Internal
n Durability –Final Drive n Leakage-Sealing Surfaces
n Leakage- Seals
n Steady State Hot
n Contact Pressure-Seal Surface
n Transient Hot 7
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Transmission Testing

8
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Transaxle Testing

9
H
Transmission Assembly Torque Loss
2nd Gear

10
H
SwRI Defined Industry Variation of
Transmission Assembly Torque Loss

11
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Best of Class Gearboxes

12
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Torque Converter Test Stand

u Efficiency
u Capacity Determination
u Endurance
u Lockup Clutch Dynamics
u Distortion

13
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Multiple Torque Converter Efficiencies

14
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Torque Converter Damper Clutch Dynamics

15
H
Pump Testing

16
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Overall Pump Efficiency Comparison

17
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Spin Loss Testing

18
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Clutch Pack Drag Test Stand

19
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Clutch Pack Drag Testing

u Variable Speed
u Variable Differential Speed
u Variable Differential Direction
u Flow Rate
u Variable Temperature
u Effects of Clutch Pack Clearance
u Effects of Friction Material Groove Pattern

20
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Groove Configuration Effect

21
H
Groove Pattern Torque Loss

22
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A Breakdown of Clutch Pack Losses

23
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Performance Variability Associated With
Manufacturing Processes

24
H
Engine Driven Transmission Testing

25
H
Drivetrain Component Testing

26
H
Testing Modes

u 2 WD
u 4 WH
u 4WL

27
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2H Efficiency Surface

28
H
4WD System Testing
DC Dyno Driven/Absorbing

29
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4WD System Testing
DC Dyno Driven/Absorbing

30
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Fatigue/Ultimate/Environmental Testing

31
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Failure Analysis

u NDE u Gear Teeth


u Die Penetrate u Tooth Contact
u Nital Etch u Pressure Angle
u Ultrasound u Diametral Pitch
u Tooth Profile
u Pitch Diameter
u Hardness

32
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Multiple Input/Output Gearboxes

33
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