上海华依科技集团股份有限公司

TECHNICAL
PRINCIPLE OF
COLD TEST

- Cold test is a method of quality inspection, which performs comprehensive test of assembled engines
without combustion process. Cold test is usually performed at the end of engine assembly line.

- Partly assembled status
Intake manifold not installed
Exhaust manifold not installed
Wiring harness not installed

- Fully assembled status
Intake manifold installed
Turbocharger installed
Wiring harness installed

- The engine flywheel is connected with cold test Equipment via an AC servo motor ,then the engine is driven
and tested at different RPM under PC control.

- IPC collect various signals via sensors. Test software processes the signals via special test algorithm
and compare with the accelerometer to judge if the engine is assembled correctly, if the components are
qualified.

step1   harness test/sensor static test/actuator dynamic test/static ignition test
step2   start torque test
step3   safe oil pressure test/high pressure fuel leakage test/crankshaft cam timing test
step4   high speed oil pressure test/high speed NVH test/VVT test/turbocharger test
step5   intake vacuum test/fuel system dynamic test
step6   low speed oil pressure test/low speed NVH test/discharge pressure test/running
           torque test
step7   throttle test

CHARACTERISTICS OF COLD TEST TECHNOLOGY

User is able to find out engine assembling defects and component quality failures in advance via cold test technology to promote engine quality.

Cold Test

- No fuel consumption,low cost
- No coolant needed,No emission,Low
test noise level
- Short test cycle（Min.60s）
- Small floor area,online test is supported
- Components of unqualified engine can
be recycled
- Few support engineers

Hot Test

- Huge consumption of fuel，high cost
- Coolant needed，Exhaust collection
   facility needed
- High test noise，sound proof room
   needed
- Long test cycle（at least 5 minutes）
- Huge floor area，isolated test room
   needed
- Components of unqualified engine can
   not be recycled
- More support engineers

With cold test, user can not only perform comprehensive test of engine assembly, but also test quality of engine components.

Cold test technology has many advantages, such as short test cycle, high efficiency, high test accuracy, more test items, no fuel needed, no combustion, low noise, no emission, components of defect engine can be recycled，and so on.

ENGINE DEFECT MAPPING

HUAYI MADE COLD TEST EQUIPMENT ADVANTAGE

- 15 years of engine cold test development and manufacturing experience. Technology and reliability is adopted and recognized by world famous automotive manufacturers and we already own many references in China;
- We have test technology experts from all over the world to provide advanced cold test equipment to meet requirements of modern automobile industry, and follow the international advanced cold test technology to keep updating ours;
- We own cold test patented technology completely. Provide more convenient and efficient communication with customers during the whole life cycle of the cold test equipment;
- Fast local after-sales service;
- Equipment investment is much lower than that of foreign manufacturers. Provide all sets of spare parts, after-sales service and equipment updating with higher cost-efficiency.

KEY ACCOUNT

- W-Ibeda’s products have been widely used in various large automobile and engine manufacturers around
   the world. Our main customers are: Shanghai Automotive Industry Corporation (SAIC), China First Auto
   Works Group (FAW), General Motors(GM), Dongfeng Group, Changan Group, Beijing Automotive
   Group(BAIC), Mazda, Ford, Jianghuai Auto(JAC), Chery Automobile, Nissan (Brazil), Meidensha (Japan),
   Weichai Power, etc..

CLASSIFICATION OF COLD TEST EQUIPMENT- LAYOUT

SYSTEM OF COLD TEST EQUIPMENT- TEST BENCH SOFTWARE SYSTEM

Test Module
Engine Rotation Control	Engine Qualification Judgement
Engine Actuators Control	Test Log
Engine Data Acquisition	PLC Monitor
Data Processing	Test Curves Display

SYSTEM OF COLD TEST EQUIPMEN- DATA QUERY AND STORAGE SYSTEM

- Repair Software
Online engine test data query
Historical engine test data query
Repair suggestion
Waveform overlaying
Test waveform display
Test data print
Network connection diagnosis

- Report Software
Test parameter normal distribution report
Limits setting
Scatter diagram report
Tendency chart report
TOP10
Top100 default parameter report
Test first-pass rate report
Test parameter report

COLD TEST PROJECT

Mechanical
Test

Electrical
Test

Continuous
Monitoring

- Start torque test
- High speed oil pressure test
- Low speed oil pressure test
- NVH test
- Intake vacuum test
- Discharge test
- Running torque test
- VVT test
- Turbocharger test
- Fuel rail leakage test

- Wiring harness test
- Static high pressure ignition test
- Static low pressure ignition test
- Crankshaft cam timing test
- Sensors static test
- Throttle test
- Fuel system dynamic test
- Injector motion test

- Torque monitor
- Oil pressure monitor
- NVH monitor

Crankshaft Cam Timing Test Check： Crank / cam phase tooth machining error Crank / cam position sensor fault Cam crank timing error Others		VVVT Test Check： OCV oil gallery block OCV electrical fault VVT phaser stuck VVT open angle error VVT open not stable Others
	Low Speed Oil Pressure Test Check： Crankshaft oil gallery leakage／block Camshaft oil gallery leakage／bloc Crankshaft / Camshaft oil hole machining error Oil pump fault ...		Injector Motion Test Check： Injector open stuck Injector control solenoid valve fault Injector not closed tightly / leakage Others
Discharge Pressure Test Check： Discharge valve gap out of tolerance Discharge valve broken Spark plug loose/missing Crankshaft Cam timing error Others		Static Ignition Test Check： Spark plug gap out of tolerance Ignition coil short／open High voltage wiring broken Spark plug electrode fault Others
	NVH Vibration Test Check： Foreign matter in combustion chamber Rotary parts interference Rotary parts unbalance Others		Turbocharger Test Check： Turbocharger outlet pressure abnormal Turbocharger rotation not stable Turbocharger exhaust by-pass valve stuck Turbocharger intake by...