An engine automatic break-in test system

Abstract

The present application relates to the technical field of engine running-in test, and particularly relates to an automatic engine running-in test system, which comprises an engine bench, a dynamometer, a data acquisition subsystem, a test execution and regulation subsystem, a data processing and output subsystem and an abnormality diagnosis and alarm subsystem. The present application realizes full-process, unattended automatic test, improves test efficiency and consistency, shortens the test rhythm of a single engine, eliminates accidental errors caused by human operation, guarantees the high consistency and repeatability of the test process and results, creates the optimal test environment through intelligent boundary condition dynamic regulation, has high data quality and engine qualification rate, enhances the safety and reliability of the test process, prevents the engine from continuously running in an abnormal state, effectively avoids equipment damage and waste of test resources, and also realizes deep management and efficient use of test data, reduces operation difficulty and labor cost.

Description

Technical Field

[0001] This invention relates to the field of engine break-in testing technology, specifically to an automatic engine break-in testing system. Background Technology

[0002] As the core power unit, the break-in and performance testing of the engine before it leaves the factory is a crucial step in ensuring quality and detecting early faults. Traditional engine break-in testing heavily relies on manual operation and experience-based judgment. Testers need to manually operate the dynamometer, setting speeds and loads in stages for cold and hot break-in, and manually recording various parameters. During performance testing (such as external characteristic testing), the operating conditions must be adjusted point by point, and data must be manually recorded after parameters stabilize. This process is cumbersome, time-consuming, and the consistency of test cycles and results is easily affected by human factors.

[0003] More importantly, to ensure the accuracy and comparability of test data, engine testing needs to be conducted under stable and standardized boundary conditions, such as constant oil temperature, coolant temperature, and intake air conditions. In existing technologies, these boundary conditions (such as coolant temperature, intake air temperature, and pressure) are mostly controlled roughly by operators observing instruments and manually adjusting coolant valves, intercooler systems, or external air sources. This manual adjustment mode is slow to respond and has low precision, making it difficult to quickly stabilize boundary conditions within the target range, and even more difficult to cope with dynamic disturbances caused by changes in engine conditions during testing. This leads to an unstable testing environment, directly affecting the accuracy of performance data and the determination of engine pass rates, and also creating difficulties for subsequent quality traceability and performance analysis.

[0004] In recent years, some test benches have introduced automated data acquisition functions, but these are mostly limited to data recording and transmission. Systematic solutions are still lacking for the two core pain points: "fully automated execution of the break-in process" and "real-time, accurate, and adaptive closed-loop control of test boundary conditions." Insufficient automation and intelligence in the testing process has become a major bottleneck in improving engine testing efficiency, data quality, and consistency. No solutions have yet been proposed to address these technical issues. Summary of the Invention

[0005] To address the problems in related technologies, this invention proposes an automatic engine break-in testing system to overcome the aforementioned technical issues in existing technologies. The purpose of this invention is to achieve fully automated, unattended testing, improve testing efficiency and consistency, shorten the testing cycle of a single engine, eliminate random errors caused by human operation, ensure high consistency and repeatability of the testing process and results, create an optimal testing environment through intelligent boundary condition dynamic control, achieve high data quality and high engine pass rate, enhance the safety and reliability of the testing process, prevent the engine from running continuously under abnormal conditions, effectively avoid equipment damage and waste of testing resources, and also achieve in-depth management and efficient utilization of test data, reducing operational difficulty and labor costs.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an automatic engine break-in testing system, comprising: An engine test bench is used to mount the engine being tested. A dynamometer, connected to the engine, is used to apply a load to the engine and measure its speed and torque; The data acquisition subsystem is used to collect multi-dimensional parameters of the engine and test environment in real time. The data acquisition subsystem includes a CAN card data acquisition unit and a sensor group. The CAN card data acquisition unit is used to obtain internal engine operating data from the engine ECU. The sensor group includes a flow sensor, a pressure sensor and a temperature sensor. The pressure sensor and temperature sensor are used to measure the parameters of the engine intake and exhaust system, and the flow sensor is used to measure the flow rates of fuel, engine oil and coolant. The test execution and control subsystem includes an automated operation test module and an intelligent boundary condition dynamic control module. The automated operation test module is communicatively connected to the dynamometer and the data acquisition subsystem, and automatically executes a preset break-in test process, which includes at least cold break-in, hot break-in, and performance testing. The intelligent boundary condition dynamic control module is communicatively connected to the data acquisition subsystem and the automated operation test module, and dynamically adjusts the test environment based on real-time acquired boundary parameters through a built-in control algorithm. The boundary parameters include at least engine oil temperature, coolant temperature, intake air temperature and pressure, fuel temperature, intercooler pressure difference, and smoke opacity. The data processing and output subsystem includes a data return server, a data preprocessing and archiving module, and a test report automatic generation module. The data return server is used to receive and store all test data from the data acquisition subsystem. The data preprocessing and archiving module is used to perform structured processing on the stored test data to form a digital file for each engine. The test report automatic generation module automatically generates a standardized test report based on the digital file.

[0007] Preferably, the test execution and control subsystem further includes an automatic water temperature control module and an automatic intercooler back pressure control module. The intelligent boundary condition dynamic control module adjusts the engine cooling system through the automatic water temperature control module and adjusts the engine intake system through the automatic intercooler back pressure control module to stabilize the corresponding boundary condition parameters within the target range.

[0008] Preferably, the intelligent boundary condition dynamic control module adopts one of the adaptive PID algorithm based on real-time feedback and the fuzzy PID algorithm.

[0009] Preferably, it also includes an anomaly diagnosis and alarm subsystem, which includes an automatic alarm module for abnormal data. The automatic alarm module for abnormal data is communicatively connected to the data acquisition subsystem and the data processing and output subsystem, respectively. The anomaly diagnosis and alarm subsystem monitors the test data in real time and compares it with preset break-in completion judgment criteria, performance target values ​​and various alarm limits. It also automatically determines whether the current test stage is completed and whether the performance meets the standards, and provides real-time warnings for abnormal data or over-limit states. The abnormal data includes at least one of the following: power surge, excessive emissions, fuel consumption deviating from the target value, abnormal oil pressure, and excessive water temperature leakage.

[0010] Preferably, when performing performance testing, the automated operation test module automatically tests and captures data points of the external characteristic curve and load characteristic curve within the entire speed range of the engine, and automatically records them.

[0011] Preferably, the test execution and control subsystem further includes an automatic smoke detection module, which is used to automatically measure and report the exhaust status of the engine during the test.

[0012] Preferably, the data processing and output subsystem further includes an engine information automatic input module, used to input the identity information and configuration parameters of the engine under test before the test begins.

[0013] Preferably, the structured database in the data return server supports the tracing, comparison, and analysis of historical test data.

[0014] Compared with the prior art, the beneficial effects of the present invention are: (1) This invention is an automatic engine break-in test system. By setting up an automated operation test module, it can seamlessly connect and automatically execute the entire process from cold break-in, hot break-in to complete performance test. It realizes automatic and continuous testing and data capture of performance curves such as external characteristics and load characteristics in the full speed range of the engine. It completely changes the traditional manual point-by-point operation mode, greatly shortens the test cycle of a single engine, eliminates the random errors caused by human operation, and ensures the high consistency and repeatability of the test process and results. (2) This invention is an automatic engine break-in test system. By setting up an intelligent boundary condition dynamic control module, it breaks through the limitations of traditional fixed or manual adjustment of boundary conditions. It can monitor key boundary conditions such as engine oil temperature, coolant temperature, and intake parameters in real time. Through intelligent algorithms, it dynamically and accurately controls the water temperature automatic control module and the intercooler back temperature and back pressure automatic control module, so that the engine always operates under the preset optimal working conditions. This provides a fundamental guarantee for obtaining accurate and reliable performance data, thereby effectively improving the first-time pass rate of the engine. (3) The present invention is an automatic engine break-in test system. By setting up an abnormal diagnosis and alarm subsystem, it can monitor and automatically judge the break-in completion status, performance compliance status, and key parameters such as power, emissions, fuel consumption, and oil pressure in real time based on preset judgment criteria and alarm limits. Once abnormal data or over-limit status is detected, the system can immediately issue an early warning to help testers quickly identify potential faults or assembly problems, prevent the engine from running continuously in an abnormal state, and effectively avoid equipment damage and waste of test resources. (4) This invention is an automatic engine break-in test system. By automatically uploading and archiving all test data, a unique and complete digital file for each engine is formed. Combined with the functions of historical data tracing and comparative analysis, it not only provides detailed basis for the quality judgment of a single engine, but also builds a powerful data analysis platform, providing valuable data support for batch quality analysis, performance optimization, failure mode research and process improvement of engines. (5) This invention is an automatic engine break-in test system. It integrates complex test processes, data acquisition, environmental control and report generation into one system. It is centrally managed through an intuitive software interface. The automatic entry of engine information and the automatic generation of test reports greatly reduce the data processing burden of test personnel, reduce the dependence on the professional experience of operators, and realize the standardization and simplification of test operations. Attached Figure Description

[0015] Figure 1 This is a schematic diagram illustrating the overall principle of the present invention. Detailed Implementation

[0016] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0017] Example Please see Figure 1 This invention proposes a technical solution for an automatic engine break-in testing system: an automatic engine break-in testing system, comprising: An engine test bench is used to mount the engine being tested. The dynamometer, connected to the engine, is used to apply a load to the engine and measure its speed and torque. Specifically, the dynamometer is connected to the output end of the engine crankshaft via a coupling. Its core functions are: ① as a load unit to simulate the real resistance of the engine operation; ② as a measurement unit to measure the engine speed and torque under different operating conditions with high precision, which is a direct data source for calculating power and plotting characteristic curves. The data acquisition subsystem is used to collect multi-dimensional parameters of the engine and test environment in real time. This subsystem includes a CAN card data acquisition unit and a sensor group. The CAN card data acquisition unit obtains internal engine operating data from the engine ECU. The sensor group includes a flow sensor, a pressure sensor, and a temperature sensor. The pressure and temperature sensors measure parameters of the engine's intake and exhaust systems, while the flow sensor measures the flow rates of fuel, engine oil, and coolant. Specifically, the CAN card data acquisition unit acts as an interface with the engine's internal network, directly acquiring speed and torque (as determined by the ECU) by parsing CAN bus messages sent by the engine ECU. The system calculates a wealth of internal operating data and status information, including fuel injection quantity, intake air pressure (MAP / MAF), combustion status of each cylinder (such as misfire detection), and fault codes. This method of data acquisition is direct and has good real-time performance. The sensor group serves as the sensing unit for external environmental parameters. Pressure and temperature sensors are installed at key locations such as the engine intake manifold, exhaust manifold, before and after the turbocharger, and before and after the intercooler to accurately measure key boundary parameters such as intake air pressure / temperature, exhaust back pressure, and pressure difference before and after the intercooler. The flow sensors include fuel flow meters, oil flow meters, and coolant flow meters, which are used to measure fuel consumption rate, monitor oil circulation, and evaluate the cooling system's heat dissipation capacity, respectively. The test execution and control subsystem includes an automated operation test module and an intelligent boundary condition dynamic control module. The automated operation test module is communicatively connected to both the dynamometer and the data acquisition subsystem, automatically executing a preset break-in test procedure, which includes at least cold break-in, hot break-in, and performance testing. The intelligent boundary condition dynamic control module is also communicatively connected to both the data acquisition subsystem and the automated operation test module. Based on real-time acquired boundary parameters, it dynamically adjusts the test environment using a built-in control algorithm. These boundary parameters include at least oil temperature, coolant temperature, intake air temperature and pressure, fuel temperature, intercooler pressure difference, and smoke opacity. Specifically, the automated operation test module embeds a standardized test program sequence. Operators only need to select the test specification (e.g., according to national or enterprise standards) during the initialization phase. The automated operation test module then automatically sends instructions to the dynamometer, executing the following sequence: "Cold break-in (low speed, no load or low load operation) → Hot break-in (gradually increasing load to rated operating conditions) → Performance testing." The entire process is automated, with the test module directly controlling the test's progress and pace. The intelligent boundary condition dynamic control module receives boundary parameters (such as oil temperature, coolant temperature, intake air temperature / pressure, and intercooler pressure difference) from the data acquisition subsystem in real time and compares them with preset target values ​​(e.g., coolant temperature target 85℃±2℃, intake air temperature target 25℃±3℃). Through built-in advanced control algorithms (such as adaptive PID algorithm or fuzzy PID algorithm), it calculates precise control quantities. The data processing and output subsystem includes a data return server, a data preprocessing and archiving module, and a test report automatic generation module. The data return server receives and stores all test data from the data acquisition subsystem. The data preprocessing and archiving module performs structured processing on the stored test data to create a digital archive for each engine. The test report automatic generation module automatically generates standardized test reports based on the digital archives. Specifically, the data return server receives and massively stores time-series data from all testing processes, forming a raw database. The data preprocessing and archiving module performs structured processing on the stored test data to create a digital archive for each engine. The test report automatic generation module automatically generates standardized test reports based on the digital archives. Specifically, the data return server receives and massively stores time-series data from all testing processes, forming a raw database. The data preprocessing and archiving module performs structured processing on the stored test data to create a digital archive for each engine. The file module performs operations such as cleaning, alignment (timestamp synchronization), and feature extraction (e.g., calculating average power and fuel consumption under specific operating conditions) on the raw data, and then archives the processed data in a structured manner according to the engine's unique identifier (e.g., VIN code or test serial number), forming a digital archive of each engine's entire lifecycle from installation to completion of testing. The automatic test report generation module has built-in report templates and can automatically extract key data, performance curves (e.g., external characteristic curves, universal characteristic diagrams), judgment results, etc. from the digital archive, and generate a PDF or Word format test report that meets the specifications with one click, greatly reducing the workload of manual report writing.

[0018] Please see Figure 1 As shown, the test execution and control subsystem further includes an automatic water temperature control module and an automatic intercooler back pressure control module. The intelligent boundary condition dynamic control module adjusts the engine cooling system through the automatic water temperature control module and adjusts the engine intake system through the automatic intercooler back pressure control module to stabilize the corresponding boundary condition parameters within the target range.

[0019] In this embodiment, the automatic water temperature control module consists of a three-way regulating valve, an electronic actuator, and related pipelines. When the intelligent boundary condition dynamic control module determines that the coolant temperature is too high, it will instruct the automatic water temperature control module to open the valve leading to the external radiator to increase the coolant flow and thus lower the water temperature; conversely, it will reduce the opening to allow the water temperature to rise. Through this continuous fine-tuning, the engine coolant temperature can be stably controlled within the target range. In the automatic control module for intercooler temperature and back pressure, temperature regulation can be achieved by setting an electronically controlled throttle valve or bypass valve in the intake manifold to adjust the airflow through the intercooler, or by controlling the flow rate of the intercooler cooling medium (such as refrigerant or cooling water) to achieve precise control of the intake air temperature after intercooling; back pressure regulation can be achieved by installing an electronically controlled variable back pressure valve at the exhaust end, and by adjusting the valve opening to simulate different exhaust pipe resistances, so that the engine exhaust back pressure is stabilized at the value required by the test specifications.

[0020] Furthermore, the intelligent boundary condition dynamic control module adopts one of the adaptive PID algorithm based on real-time feedback and the fuzzy PID algorithm.

[0021] In this embodiment, the nonlinearity and time-varying nature of engine testing can be effectively addressed. For example, during the hot break-in phase, the engine heat generation increases dramatically, and the cooling system load changes dynamically. Traditional PID parameters are fixed, and the control effect may be poor. However, adaptive PID can identify changes in system characteristics online and automatically adjust the proportional, integral, and derivative coefficients to ensure that the water temperature can be quickly and without overshoot to the target value throughout the entire dynamic process. Fuzzy PID, on the other hand, transforms precise quantities such as temperature deviation and its rate of change into fuzzy rules by simulating expert experience, and then outputs precise control quantities, which have good robustness to the control of complex systems.

[0022] Please see Figure 1As shown, further, it also includes an anomaly diagnosis and alarm subsystem. The anomaly diagnosis and alarm subsystem includes an automatic alarm module for abnormal data. The automatic alarm module for abnormal data is communicatively connected to the data acquisition subsystem and the data processing and output subsystem, respectively. The anomaly diagnosis and alarm subsystem monitors the test data in real time and compares it with preset break-in completion judgment criteria, performance target values ​​and various alarm limits. It also automatically determines whether the current test stage is completed and whether the performance meets the standards, and provides real-time warnings for abnormal data or over-limit states. The abnormal data includes at least one of the following: power surge, excessive emissions, fuel consumption deviating from the target value, abnormal oil pressure, and excessive water temperature leakage.

[0023] In this embodiment, the automatic alarm module for abnormal data acquires raw data from the data acquisition subsystem and preprocessed data provided by the data processing subsystem in real time. The automatic alarm module for abnormal data has multiple levels of judgment rules set up internally, as follows: Process rules: For example, the criteria for determining "break-in completion" may be "power and fuel consumption fluctuations of less than 1% for 3 consecutive minutes at rated speed"; Performance rules: Compare the measured external characteristics, such as maximum power, maximum torque, and minimum fuel consumption, with the target values ​​(such as design values ​​or benchmark values ​​of the same model) and set a qualified tolerance zone (such as ±3%). Safety alarm limits: Set hard safety limits for various parameters, such as "oil pressure below 0.2MPa alarm", "coolant temperature above 105℃ emergency shutdown", "exhaust temperature above 750℃ alarm", etc.

[0024] The system continuously performs comparisons, and once it detects: If a certain break-in data meets the "completion" criterion, the completion time will be automatically recorded, and the process will trigger the next testing phase.

[0025] If the performance data exceeds the acceptable tolerance zone, it is judged as "performance unacceptable" and marked prominently in the report.

[0026] If any parameter touches the safety alarm limit, the system will take immediate action: ① A red flashing alarm will pop up on the operation interface with an audible and visual prompt; ② All data snapshots for 1 minute before and after the abnormal moment will be recorded for analysis; ③ Depending on the severity level, different contingency plans can be selected, such as "alarm only", "request operator confirmation to reduce load" or "execute automatic emergency shutdown".

[0027] Furthermore, when performing performance tests, the automated operation test module automatically tests and captures data points of the external characteristic curve and load characteristic curve within the entire engine speed range, and automatically records them.

[0028] In this embodiment, the automated operation test module completely overturns the traditional manual mode when performing performance tests such as external characteristics or load characteristics. Its specific working process is as follows: the module controls the dynamometer to automatically increase the engine speed from idle speed to the maximum speed according to a preset speed step size (e.g., 200 rpm). At each speed point, the automated operation test module will: ① Instruct the dynamometer to be loaded to the maximum torque (or specified load rate) that can be achieved at this speed.

[0029] ② Through the coordinated operation of the intelligent boundary condition dynamic control module, wait and ensure that all boundary conditions (water temperature, oil temperature, air intake status, etc.) are stable within the target range.

[0030] ③ Data acquisition is only carried out at this time, and all parameters (speed, torque, power, fuel consumption, emissions, smoke opacity, etc.) under this stable operating condition are recorded in high density.

[0031] ④ The system automatically determines the validity of the data at a given point (e.g., stability criteria), stores the point upon confirmation of validity, and automatically jumps to the next speed point. The entire process requires no manual intervention, enabling the automatic mapping and recording of performance curves across the entire speed range.

[0032] Please see Figure 1 As shown, the test execution and control subsystem further includes an automatic smoke detection module, which is used to automatically measure and report the exhaust status of the engine during the test.

[0033] In this embodiment, the automatic smoke detection module consists of an opaque or filter paper smoke meter, a sampling probe, an air pump, and a control unit. During performance testing or specific loading processes, the automatic smoke detection module automatically extracts sample gas from the exhaust pipe for measurement and feeds back the smoke value (such as FSN or light absorption coefficient) to the data acquisition subsystem in real time to evaluate the combustion status and emission level of the engine.

[0034] Please see Figure 1 As shown, the data processing and output subsystem further includes an engine information automatic input module, which is used to input the identity information and configuration parameters of the engine under test before the test begins.

[0035] In this embodiment, the engine model, serial number, production date, ECU software version and other information can be automatically entered into the system by scanning the QR code or RFID tag on the engine body with a barcode scanner. This information is then automatically associated with subsequent test data, eliminating manual input errors and enabling data flow between the production and testing stages.

[0036] Furthermore, the structured database in the data return server supports the tracing, comparison, and analysis of historical test data.

[0037] In this embodiment, the structured database in the data feedback server not only supports querying data for a single engine, but also supports the tracing, comparison, and analysis of batch data. For example, quality engineers can quickly filter out the break-in fuel consumption distribution chart for a certain batch of engines, or compare the impact trends of different ECU calibration versions on full-load smoke opacity, providing a powerful data mining platform for engine performance optimization, quality control, and problem troubleshooting.

[0038] Working principle of the invention: Initialization and Information Association Phase: Before testing begins, the operator installs the engine under test onto the test bench and connects it to the dynamometer. After system startup, the engine information automatic entry module in the data processing and output subsystem (e.g., scanning QR codes / RFID) automatically acquires and binds the engine's unique identification information (model, serial number, ECU version, etc.). This step establishes a unique traceability identifier for all subsequent test data, achieving precise association between the physical engine and its full lifecycle digital archive. The operator then selects a preset test program (e.g., based on national standard GB / T 18297 or enterprise standards) on the interactive interface of the automated test module, and the system completes its initialization preparation.

[0039] The fully automated testing process execution phase: The automated test module acts as the "commander-in-chief," taking over the entire testing process. It strictly follows the preset program logic, automatically sending control commands to the dynamometer to drive the engine to sequentially perform stages such as cold break-in, hot break-in, and performance testing.

[0040] Cold break-in: The automated operation test module instructs the dynamometer to run the engine at a low speed (e.g., 800-1200 rpm), low load or no load, so that the various moving parts can initially cooperate.

[0041] Hot break-in: Gradually increase the speed and load to make the engine run under conditions close to actual operation, and promote the optimal matching state of each component.

[0042] Performance Testing: This is a crucial step. The automated test module automatically plans the speed-load matrix according to the test specifications. For example, during external characteristic testing, the automated test module controls the engine to start from idle speed and gradually increase to the rated speed in preset steps (e.g., 200 rpm). At each target speed point, the automated test module instructs the dynamometer to apply the maximum permissible torque at that speed and enters a critical "steady-state waiting and data acquisition" sub-process.

[0043] Intelligent boundary condition dynamic closed-loop control phase: This phase runs parallel to and is deeply integrated with the test process, and is crucial for ensuring high-quality test data. The intelligent boundary condition dynamic control module is the core controller of this process.

[0044] Real-time sensing: The data acquisition subsystem operates synchronously at any moment during engine operation. The CAN card data acquisition unit obtains internal data from the engine ECU; sensor groups (pressure, temperature, and flow sensors) located in key locations such as the intake manifold, exhaust manifold, before and after the intercooler, oil passages, and water passages measure external environmental parameters in real time. All these boundary parameters (oil temperature, coolant temperature, intake air temperature / pressure, pressure difference before and after the intercooler, smoke opacity, etc.) are collected in real time by this module.

[0045] Intelligent decision-making: The module compares the real-time values ​​of the collected boundary parameters with the preset target values ​​and tolerance ranges (such as the target cooling water temperature of 85℃±2℃) and calculates the deviation.

[0046] Precise execution: The module uses a built-in adaptive PID algorithm or fuzzy PID algorithm to calculate the optimal control quantity (such as valve opening adjustment) in real time based on the deviation and its changing trend, and sends the command to the corresponding actuator. Automatic water temperature control module: Adjusts the opening of the three-way valve to change the flow rate of coolant through the external radiator, thereby achieving rapid and precise control of the engine coolant temperature.

[0047] Intercooler back temperature and back pressure automatic control module: controls the intake temperature by adjusting the intake bypass valve or the flow rate of the intercooler cooling medium; controls the exhaust back pressure by adjusting the opening of the exhaust back pressure valve.

[0048] Closed-loop stability: The actions of the actuators alter the engine's operating environment, causing environmental parameters to change and be sensed again by sensors, which then feed back to the control module, forming closed-loop control. Through this continuous and dynamic fine-tuning, the system can quickly stabilize various key boundary conditions within the target range even when engine operating conditions change drastically (such as during the instant of hot break-in loading), creating an optimal and consistent steady-state environment for performance testing.

[0049] Real-time diagnostics and safety monitoring phase: The anomaly diagnosis and alarm subsystem operates as an independent "safety officer" throughout the entire process. Its automatic alarm module for abnormal data monitors all input data streams in real time and makes intelligent judgments based on preset multi-level rules. Process monitoring: Based on rules (such as "power and fuel consumption fluctuation rate is less than X% for N consecutive minutes"), the system automatically determines "break-in complete" and triggers the process to enter the next stage.

[0050] Performance assessment: The measured performance data (such as maximum power and torque) are compared with the target value and tolerance zone to automatically draw a preliminary conclusion of "qualified / unqualified".

[0051] Safety Warning: Strictly monitor safety limits (lower limit of oil pressure, upper limit of water temperature, upper limit of exhaust temperature, etc.). Once any parameter exceeds the limit, the system immediately activates a tiered warning mechanism: from audible and visual alarms on the operating interface and recording abnormal data snapshots, to requesting operator intervention, and finally instructing the dynamometer to perform automatic emergency load reduction or shutdown, ensuring comprehensive protection of equipment and personnel safety.

[0052] Data stream processing and knowledge output phase: All massive amounts of time-series data generated during the testing process are uploaded in real time to the data feedback server for raw storage through the data acquisition subsystem.

[0053] Data structuring: The data preprocessing and archiving module cleans, aligns timestamps, and calculates feature values ​​for the raw data. Then, based on the engine's unique identifier, the processed data is associated with engine information, test program information, alarm events, etc., and structured and archived to form a complete digital file for the engine.

[0054] Report Automation: Once the entire testing process is complete, the automatic test report generation module is triggered. It automatically extracts key data, performance graphs, and judgment results from the digital archive, fills them into a standardized report template, and generates a well-formatted and detailed test report (PDF / Word format) with one click.

[0055] Deep Data Utilization: Digital profiles of all engines are stored in a structured database on the server. This database supports powerful query, traceability, and comparative analysis capabilities. Engineers can perform data mining across engines and batches, such as analyzing the distribution patterns of break-in quality and studying the impact trends of different calibration parameters on emissions, providing data-driven decision support for continuous product improvement and quality control.

[0056] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An automatic engine break-in testing system, characterized in that, include: An engine test bench is used to mount the engine being tested. A dynamometer, connected to the engine, is used to apply a load to the engine and measure its speed and torque; The data acquisition subsystem is used to collect multi-dimensional parameters of the engine and test environment in real time. The data acquisition subsystem includes a CAN card data acquisition unit and a sensor group. The CAN card data acquisition unit is used to obtain internal engine operating data from the engine ECU. The sensor group includes a flow sensor, a pressure sensor and a temperature sensor. The pressure sensor and temperature sensor are used to measure the parameters of the engine intake and exhaust system, and the flow sensor is used to measure the flow rates of fuel, engine oil and coolant. The test execution and control subsystem includes an automated operation test module and an intelligent boundary condition dynamic control module. The automated operation test module is communicatively connected to the dynamometer and the data acquisition subsystem, and automatically executes a preset break-in test process, which includes at least cold break-in, hot break-in, and performance testing. The intelligent boundary condition dynamic control module is communicatively connected to the data acquisition subsystem and the automated operation test module, and dynamically adjusts the test environment based on real-time acquired boundary parameters through a built-in control algorithm. The boundary parameters include at least engine oil temperature, coolant temperature, intake air temperature and pressure, fuel temperature, intercooler pressure difference, and smoke opacity. The data processing and output subsystem includes a data return server, a data preprocessing and archiving module, and a test report automatic generation module. The data return server is used to receive and store all test data from the data acquisition subsystem. The data preprocessing and archiving module is used to perform structured processing on the stored test data to form a digital file for each engine. The test report automatic generation module automatically generates a standardized test report based on the digital file.

2. The automatic engine break-in testing system according to claim 1, characterized in that, The test execution and control subsystem also includes an automatic water temperature control module and an automatic intercooler back pressure control module. The intelligent boundary condition dynamic control module adjusts the engine cooling system through the automatic water temperature control module and adjusts the engine intake system through the automatic intercooler back pressure control module to keep the corresponding boundary condition parameters stable within the target range.

3. The automatic engine break-in testing system according to claim 2, characterized in that, The intelligent boundary condition dynamic control module adopts one of the adaptive PID algorithm or the fuzzy PID algorithm based on real-time feedback.

4. The automatic engine break-in testing system according to claim 1, characterized in that, It also includes an anomaly diagnosis and alarm subsystem, which includes an automatic alarm module for abnormal data. The automatic alarm module for abnormal data is communicatively connected to the data acquisition subsystem and the data processing and output subsystem. The anomaly diagnosis and alarm subsystem monitors test data in real time and compares it with preset break-in completion judgment criteria, performance target values ​​and various alarm limits. It also automatically determines whether the current test phase is completed and whether the performance meets the standards, and provides real-time warnings for abnormal data or over-limit states. The abnormal data includes at least one of the following: power surge, emissions exceeding standards, fuel consumption deviating from the target value, abnormal oil pressure, and water temperature leakage exceeding the standard.

5. The automatic engine break-in testing system according to claim 1, characterized in that, When performing performance tests, the automated operation test module automatically tests and captures data points of the external characteristic curve and load characteristic curve across the entire engine speed range, and automatically records them.

6. The automatic engine break-in testing system according to claim 1, characterized in that, The test execution and control subsystem also includes an automatic smoke detection module, which is used to automatically measure and report the exhaust status of the engine during the test.

7. The automatic engine break-in testing system according to claim 1, characterized in that, The data processing and output subsystem also includes an engine information automatic input module, which is used to input the identity information and configuration parameters of the engine under test before the test begins.

8. The automatic engine break-in testing system according to claim 1, characterized in that, The structured database in the data return server supports the tracing, comparison, and analysis of historical test data.

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