A method for testing a vehicle engine at the time of delivery

Abstract

A kind of automobile engine factory inspection test method, belong to engine power test technical field.The method will engine be installed to test bench, carry out appearance inspection, fluorescent agent addition, combustion chamber endoscopy and cylinder pressure detection in turn, then complete running-in test according to four-stage gradient working condition, monitor ECU operation data and listen to abnormal sound during running-in period, detect leakage using fluorescent flashlight after running-in, can be factory shipped after all detection is qualified.The present application effectively solves the problem that production line cannot detect by standard, complete bench test process, realizes comprehensive, efficient, stable engine factory inspection, and effectively improves engine factory shipment quality and detection reliability.

Description

Technical Field

[0001] This invention belongs to the field of engine power testing technology, specifically a factory testing method for automobile engines. Background Technology

[0002] As the core power component of a car, the quality of the engine directly determines the driving safety, power performance and service life of the entire vehicle. It is the core link of the overall vehicle quality control. The industry requires that 100% of the engines undergo full inspection before leaving the factory to ensure that every product meets the standards.

[0003] During the production line ramp-up phase or the immature cold / hot testing phase, it is impossible to perform factory inspections on engines. At this stage, full engine inspection mainly relies on engine bench testing, covering key aspects such as engine break-in, leak detection, abnormal noise troubleshooting, and electronic fuel injection system calibration, which can verify engine quality. Therefore, an optimized engine factory inspection technology and standard are needed to address the aforementioned deficiencies in existing production lines. Summary of the Invention

[0004] To address the problems existing in the background art, the present invention provides a factory testing method for automobile engines.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a factory testing method for automobile engines, the method comprising the following steps:

[0006] S1: Install the engine to be tested at the factory onto the test bench;

[0007] S2: Inspect the mating surfaces and triangular areas of the engine at various locations and take photos for record-keeping;

[0008] S3: Add fluorescent agent to engine oil;

[0009] S4: Remove the spark plugs, perform an endoscopy on the combustion chamber, and take photos;

[0010] S5: Perform cylinder pressure testing and retain cylinder pressure data;

[0011] S6: Restore the engine and prepare to begin the break-in period;

[0012] S7: Conduct a break-in test on the engine according to the preset four-stage gradient break-in conditions. During the break-in process, change the engine oil and oil filter as required, and check whether the engine oil is abnormal.

[0013] S8: During the break-in period, INCA software is used to monitor the engine ECU data throughout the process to ensure the engine operates normally;

[0014] S9: Listen for any abnormal noises while the engine is running;

[0015] S10: After the break-in period, use a fluorescent flashlight to check the mating surfaces and triangular areas of the engine to determine if there are any leaks, and take photos for record-keeping.

[0016] S11: After confirming that there are no abnormalities at each stage, the engine is removed from the test bench, packaged, and shipped out of the factory.

[0017] In step S3, a fluorescent agent is added to the engine oil at the normal filling volume, with an addition volume of 4 ml.

[0018] In step S4, the ignition coil is removed before removing the spark plug.

[0019] In step S6, after the engine is restored, the INCA software is connected to confirm that the ECU and engine status are normal.

[0020] The four-stage gradient break-in conditions in S7 are as follows: Stage 1: Engine speed 2000 r / min, output torque 30-40 Nm, continuous operation for 5 minutes. After the operation, change the engine oil and oil filter, and check if the engine oil is abnormal; Stage 2: Engine speed 2500 r / min, output torque 30-40 Nm, continuous operation for 10 minutes; Stage 3: Engine speed 3000 r / min, output torque 40-50 Nm, continuous operation for 10 minutes; Stage 4: Engine speed 4000 r / min, output torque 40-50 Nm, continuous operation for 10 minutes. After the operation, change the engine oil and oil filter again, and check if the engine oil is abnormal.

[0021] In S8, the ECU operating data monitored by the INCA software includes: engine fault codes, engine speed, water temperature, oil pressure, intake pressure, rail pressure, injection pulse width, ignition advance angle, air-fuel ratio, and actual phase tracking.

[0022] In S9, the listening locations for abnormal noises include the engine block, cylinder head, valve chamber, crankcase, timing system, pulley system, and connection points of various accessories.

[0023] In step S11, after confirming that there are no abnormalities at each stage, all test data are recorded and stored, and then the engine is removed from the test bench, packaged, and shipped out of the factory.

[0024] Compared with the prior art, the beneficial effects of the present invention are:

[0025] 1. It can complete the engine factory testing by relying on the test bench when the engine production line is ramping up or when the cold and hot test lines are not mature, thus solving the problem that the production line cannot carry out factory testing.

[0026] 2. Through bench testing, engine break-in, leak detection, abnormal noise troubleshooting, and electronic fuel injection system calibration can be completed in one go. The testing items are comprehensive and can effectively identify abnormalities in mechanical parts, sealing parts, and electronic control systems.

[0027] 3. By adopting standardized testing procedures and fixed break-in conditions, the testing process is stable and controllable, enabling 100% full inspection of engines before they leave the factory, thus improving testing efficiency and consistency.

[0028] 4. By using fluorescent agents in conjunction with fluorescent flashlights for detection, leakage problems can be accurately identified. Combined with preliminary inspections such as cylinder pressure testing and combustion chamber inspection, the defect detection rate can be further improved.

[0029] 5. Throughout the process, ECU data is monitored and abnormal noises are listened for using INCA software, allowing for real-time monitoring of engine operating status, timely detection of abnormalities, and prevention of substandard engines from leaving the factory.

[0030] 6. The testing process can retain complete data such as photos, cylinder pressure data, and operating parameters, enabling traceability of the testing process and ensuring stable and reliable product quality.

[0031] In summary, this invention effectively solves the problem of production line inability to perform tests through a standardized and complete bench testing process, achieving comprehensive, efficient, and stable engine factory testing, and effectively improving engine factory quality and testing reliability. Attached Figure Description

[0032] Figure 1 This is a break-in condition diagram of the testing method of the present invention; Detailed Implementation

[0033] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0034] This embodiment describes a factory testing method for automobile engines, which includes the following steps:

[0035] S1: Install the engine to be tested at the factory onto the test bench;

[0036] S2: Inspect the mating surfaces and triangular areas of the engine at various locations and take photos for record-keeping;

[0037] S3: Add fluorescent agent to engine oil;

[0038] S4: Remove the spark plugs, perform an endoscopy on the combustion chamber, and take photos;

[0039] S5: Perform cylinder pressure testing and retain cylinder pressure data;

[0040] S6: Restore the engine and prepare to begin the break-in period;

[0041] S7: Conduct a break-in test on the engine according to the preset four-stage gradient break-in conditions. During the break-in process, change the engine oil and oil filter as required, and check whether the engine oil is abnormal.

[0042] S8: During the break-in period, INCA software is used to monitor the engine ECU data throughout the process to ensure the engine operates normally;

[0043] S9: Listen for any abnormal noises while the engine is running;

[0044] S10: After the break-in period, use a fluorescent flashlight to check the mating surfaces and triangular areas of the engine to determine if there are any leaks, and take photos for record-keeping.

[0045] S11: After confirming that there are no abnormalities at each stage, the engine is removed from the test bench, packaged, and shipped out of the factory.

[0046] In step S3, a fluorescent agent is added to the engine oil at the normal filling volume, with an addition volume of 4 ml.

[0047] In step S4, the ignition coil is removed before removing the spark plug.

[0048] In step S6, after the engine is restored, the INCA software is connected to confirm that the ECU and engine status are normal.

[0049] The four-stage gradient break-in conditions in S7 are as follows: Stage 1: Engine speed 2000 r / min, output torque 30-40 Nm, continuous operation for 5 minutes. After the operation, change the engine oil and oil filter, and check if the engine oil is abnormal; Stage 2: Engine speed 2500 r / min, output torque 30-40 Nm, continuous operation for 10 minutes; Stage 3: Engine speed 3000 r / min, output torque 40-50 Nm, continuous operation for 10 minutes; Stage 4: Engine speed 4000 r / min, output torque 40-50 Nm, continuous operation for 10 minutes. After the operation, change the engine oil and oil filter again, and check if the engine oil is abnormal.

[0050] In S8, the ECU operating data monitored by the INCA software includes: engine fault codes, engine speed, water temperature, oil pressure, intake pressure, rail pressure, injection pulse width, ignition advance angle, air-fuel ratio, and actual phase tracking.

[0051] In S9, the listening locations for abnormal noises include the engine block, cylinder head, valve chamber, crankcase, timing system, pulley system, and connection points of various accessories.

[0052] In step S11, after confirming that there are no abnormalities at each stage, all test data are recorded and stored, and then the engine is removed from the test bench, packaged, and shipped out of the factory.

[0053] The working principle of this invention addresses the pain point of not being able to conduct online factory testing during the ramp-up phase or the immature cold / hot testing phase of automotive engine production lines. It integrates multi-dimensional testing methods through a standardized bench testing process to achieve comprehensive pre-shipment testing of engines. Its core logic is a three-tiered testing system: "static pre-inspection - dynamic break-in verification - precise leak detection," comprehensively covering all key quality control points of engine mechanical assembly, electronic fuel injection system, and sealing performance. First, the engine to be tested is fixed on the test bench. After basic installation, a visual pre-inspection is performed on all mating surfaces and triangular areas to identify visible assembly defects, dents, and initial leaks, avoiding subsequent invalid tests. Then, a fluorescent agent is added to the engine oil, utilizing the color development characteristics of fluorescent substances under specific light to... Subsequent leak detection provides visual markers, followed by combustion chamber inspection and cylinder pressure testing by removing spark plugs. Before engine operation, foreign objects inside the combustion chamber, poor valve sealing, and cylinder sealing defects are checked to prevent irreversible damage from engines with internal faults entering the break-in period. After engine restoration, it is operated according to a preset four-stage gradient break-in condition, gradually transitioning from low speed and low torque to high speed and high torque. This ensures a uniform and gentle initial break-in for all moving parts, including the engine piston and cylinder wall, crankshaft and bearings, camshaft and valves, avoiding abnormal wear or part damage caused by sudden changes in operating conditions. During the break-in process, the engine oil and oil filter are changed twice as required to promptly remove metal debris generated during break-in, preventing debris from scratching the surfaces of moving parts due to oil circulation. See the table below for specific break-in conditions:

[0054]

[0055] During the break-in period, the engine ECU (Electronic Control Unit) was continuously monitored and collected using INCA (Integrated Calibration and Application Tool, engine electronic control calibration software). The core operating data of the Electronic Control Unit (ECU), also known as the engine electronic control unit, is used to accurately capture parameter fluctuations caused by electronic fuel injection system malfunctions and mechanical abnormalities, ensuring that the engine always operates in a safe state. During continuous operation of the engine at different speeds and torque conditions, the sounds of each key component are monitored simultaneously. By using the sound characteristics transmitted by mechanical vibrations, early mechanical faults such as improper assembly clearances, loose parts, and damaged bearings are identified. After the break-in test is completed and the internal oil pressure and temperature of the engine reach a stable operating state, all sealed parts are illuminated with a fluorescent flashlight. At this time, after continuous operation at different speeds and torque conditions, the internal pressure of the engine has increased. Any tiny oil leak will carry fluorescent agent through the leak, showing a clear fluorescent trace under fluorescent illumination. This enables accurate identification of micro-leakage that is difficult to detect with traditional visual inspection. Finally, after confirming that there are no abnormalities in all inspection steps, all inspection data and image data are completely preserved. The engine is then removed from the test bench, packaged, and shipped out of the factory, preventing unqualified products from entering the market from the source and ensuring the consistency and stability of the engine's quality.

[0056] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of the equivalent features of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A factory testing method for automobile engines, characterized in that: The method includes the following steps: S1: Install the engine to be tested at the factory onto the test bench; S2: Inspect the mating surfaces and triangular areas of the engine at various locations and take photos for record-keeping; S3: Add fluorescent agent to engine oil; S4: Remove the spark plugs, perform an endoscopy on the combustion chamber, and take photos; S5: Perform cylinder pressure testing and retain cylinder pressure data; S6: Restore the engine and prepare to begin the break-in period; S7: Conduct a break-in test on the engine according to the preset four-stage gradient break-in conditions. During the break-in process, change the engine oil and oil filter as required, and check whether the engine oil is abnormal. S8: During the break-in period, INCA software is used to monitor the engine ECU data throughout the process to ensure the engine operates normally; S9: Listen for any abnormal noises while the engine is running; S10: After the break-in period, use a fluorescent flashlight to check the mating surfaces and triangular areas of the engine to determine if there are any leaks, and take photos for record-keeping. S11: After confirming that there are no abnormalities at each stage, the engine is removed from the test bench, packaged, and shipped out of the factory.

2. The factory testing method for automobile engines according to claim 1, characterized in that: In step S3, a fluorescent agent is added to the engine oil at the normal filling volume, with an addition volume of 4 ml.

3. The factory testing method for automobile engines according to claim 1, characterized in that: In step S4, the ignition coil is removed before removing the spark plug.

4. The factory testing method for automobile engines according to claim 1, characterized in that: In step S6, after the engine is restored, the INCA software is connected to confirm that the ECU and engine status are normal.

5. The factory testing method for automobile engines according to claim 1, characterized in that: In the S7, the four-stage gradient break-in condition is as follows: First stage: engine speed 2000r / min, output torque 30-40Nm, run continuously for 5min, after which change the engine oil and oil filter, and check whether the oil is abnormal. Second stage: Engine speed 2500r / min, output torque 30-40Nm, run continuously for 10 minutes; Third stage: Engine speed 3000r / min, output torque 40-50Nm, run continuously for 10 minutes; Fourth stage: Engine speed 4000r / min, output torque 40-50Nm, run continuously for 10 minutes. After the operation is completed, change the engine oil and oil filter again, and check if the engine oil is abnormal.

6. The factory testing method for automobile engines according to claim 1, characterized in that: In S8, the ECU operating data monitored by the INCA software includes: engine fault codes, engine speed, water temperature, oil pressure, intake pressure, rail pressure, injection pulse width, ignition advance angle, air-fuel ratio, and actual phase tracking.

7. The factory testing method for automobile engines according to claim 1, characterized in that: In S9, the listening locations for abnormal noises include the engine block, cylinder head, valve chamber, crankcase, timing system, pulley system, and connection points of various accessories.

8. The factory testing method for automobile engines according to claim 1, characterized in that: In step S11, after confirming that there are no abnormalities at each stage, all test data are recorded and stored, and then the engine is removed from the test bench, packaged, and shipped out of the factory.

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