R&D

Laboratory and Testing Group

The Laboratory and Test Group, which operates under TÜBİTAK RUTE Alternative Energy Technologies Department, carries out testing activities that verify R&D activities with its internal combustion and electric engine, powertrain and vehicle test systems, conducts and coordinates engine and vehicle level certification processes, and ensures the execution of Industrial Service processes for the use of infrastructures to meet all public and private sector needs. As a result of the activities carried out, for the first time, Turkey and Europe Euro 6 emission type approval tests of a light commercial class vehicle and Phase V emission type approval tests of an off-road engine were carried out in Turkey. The studies are carried out at the Engine Center of Excellence Laboratory.

R&D

Purposes and Objectives

Purposes

To be a laboratory that meet the needs of our stakeholders,
Obtain certification capabilities for our country,
Enable R&D activities to take place domestically,
Meet the latest technology and regulatory requirements,
Produces reliable data by performing maintenance and calibration of all systems and measuring instruments.

Objectives

To become a focal centre for certification tests that will increase our inspection and control capability on vehicles and engines entering our country.
To possess systems compliant with the latest regulations for certification tests conducted on all test systems and to keep abreast of regulations.
To meet the demands of the producers in a reliable manner without deviating from confidentiality policies.

Working Areas

Electric Motor Performance Tests
Passenger and Light Commercial Vehicle Engine Performance and Emission Tests
Heavy Commercial and Off-Road Vehicle Engine Performance and Emission Tests
High Power Engine Development Tests
Power Transmission Systems and Vehicle Control Unit Development Tests
Passenger and Light Commercial Vehicle Performance and Emission Tests
Diesel/Gasoline/Hydrogen Combustion Concept Development Tests in Single-Cylinder Engines
Passenger and Light Commercial Vehicle Emission Certification Tests
Heavy Commercial and Off-Road Vehicle Engine Emission Certification Tests

Infrastructure

The Engine Centre of Excellence Laboratory has the most powerful R&D and certification test infrastructure in Turkey. The test systems in the laboratory infrastructure are as follows:

Engine Dynamometers

With various active dynamometers in the center, featuring different power, torque, and speed, development and certification tests for electric and internal combustion engines used in passenger, light commercial, heavy commercial, and high-power vehicles can be conducted. The technical specifications of the dynamometers located in 6 test rooms are as follows:

Engine Test Chamber	Nominal Power	Nominal Torque	Highest Speed
Engine Dynamometer-1	370 kW	785 Nm	8,000 rpm
Engine Dynamometer-2	440 kW	934 Nm	10,000 rpm
Engine Dynamometer-3-4	500 kW	3,000 Nm	5,800 rpm
Engine Dynamometer-5	56 kW	180 Nm	8,000 rpm
Engine Dynamometer-6	3,300 kW (1,100+2,200)	20,000 Nm (5,000+15,000)	4,000 rpm

Engine Dynamometer-1

With 370 kW and 785 Nm torque, this dynamometer is highly suitable for dynamic tests due to its low inertia and is used for electric motor tests. In the chamber, there is a DC power supply and connection panel with a power of 250 kW, 1,200 V, and 800A to supply power to the electric motor drive.

Engine Dynamometer-2

The two test rooms equipped with dynamometers with 440 kW and 934 Nm torque are used for the performance and emission development studies of passenger, light commercial, and off-road vehicle engines. Both test rooms are equipped with measurement and conditioning devices to condition and measure the intake air, condition the fuel and measure fuel consumption, condition the charge air, and condition the engine oil and water. Additionally, there are measurement and conditioning devices for measuring blow-by gases escaping into the crankcase, smoke measurement devices (smokemeter, microsoot, opacimeter), continuous emission measurement devices for pre- and post-catalyst emissions, and sensors with interfaces on the engine for measuring temperature and pressure at multiple points. The room also contains a system for measuring cylinder pressure and performing calculations.

Especially for emission certification tests of heavy commercial and off-road vehicle engines, one room has been equipped with the necessary emission measurement equipment. Thanks to the available automation software, emission type approval tests for heavy commercial vehicles at Euro VI level and off-road vehicle engines at Phase V level are conducted. In these tests, an FTIR device is used for urea measurement, specifically for engines equipped with SCR systems.

Engine Dynamometer-3-4

With a dynamometer that has 500 kW power and 3,000 Nm torque, engines used in heavy commercial and military armored carrier vehicles can be developed, and performance and emission calibrations can be performed. In this test room, there are devices conditioning all air, fuel, engine oil, and water of the engine, along with emission measurement devices specific to development.

Engine Dynamometer-5

This dynamometer is a compact system with single cylinder diesel/gasoline/hydrogen research engines with a power of 56 kW and a torque of 180 Nm, which includes all the conditioning equipment. With the single-cylinder research engines, the details of which are shown below, in-cylinder pressure measurement is carried out inside the combustion chamber, while the inside of the cylinder is visualized and the combustion process is recorded with a high-speed camera system. The test system, which enables the development of combustion concepts, is used for academic studies and to examine the effects of different fuels on engines.

Single Cylinder Engines	Cylinder Diameter	Stroke	Cylinder Volume
Diesel Engine	75-110 mm (106)	80-130 mm (127)	0,4-1,2 L (1,12)
Gasoline/Hydrogen Engine	65-100 mm (82)	60-95 mm (86)	0,2-0,75 L (0,454)

*The values within parentheses represent the specifications of the engines.

Engine Dynamometer-6

This hybrid dynamometer system, with the capability to operate in tandem, consists of an AC electric motor dynamometer with a power of 1,100 kW and a hydraulic dynamometer with a power of 2,100 kW. Connected to each other through a coupling, the system reaches a total power of 3,300 kW and 20,000 Nm of torque. Both ends of the system can be connected to motors, providing operational convenience. In this system enabling the development of high-power motors, parameters such as the intake air flow, fuel consumption, blow-by, and temperature/pressure values of the motor are measured. Additionally, the motor's intake air, fuel, and blow-by can be conditioned with oil and cooling water.

Dual Axle Climatic Chassis Dynamometer

The dual-axle climatic chassis dynamometer enables the performance and emission testing of passenger and light commercial vehicles. With an electric motor of 200 kW power on each axle, the system allows testing of 4X4 vehicles with a total power of 400 kW. The dynamometer system is equipped with a movable axle system, adjustable within a range of 2,100 mm to 4,700 mm. Operating in a climatic environment adjustable between -10°C and +40°C, the dynamometer system can reach a maximum speed of 250 km/h. Integrated with a dilution tunnel and emission system, it is utilized for certification and compliance tests in accordance with the latest emission standards. Additionally, electric vehicle range and energy consumption tests are conducted with expert test drivers following specific driving cycles.

Powertrain Dynamometer

This system, comprised of 6 dynamometers, is utilized for the development of powertrain (gearboxes, transmissions, differentials, axles, etc.) and control units for both passenger vehicles and off-road vehicles like tractors. The system is connected to the axle outputs of the vehicle, achieving torque of 35,000 Nm on each front wheel and 60,000 Nm on each rear wheel through a gearbox connected to the outputs of four dynamometers with a total power of 290 kW. In the absence of an engine, the powertrains are driven by a dynamometer with a power of 160 kW, and the PTO output can be loaded with a dynamometer with a power of 160 kW and a torque of 2,000 Nm. The dynamometer automation system generates a vehicle model, calculates wheel loads based on the defined road profile, and applies them in real-time to the powertrains connected to the dynamometer.

Corporate

Fields of Activity

R&D Departments

PRODUCTS

TRACS-GP-E5000 Rail Vehicle Traction System Power Platform

TRACS-GP Power Platform for Electric Locomotives

TRACS-GP-D Power Platform for Diesel Locomotives

TRACS-GP-HRT Power Platform for Urban Rail Vehicles

AUTHENTIC 8V160B

E5000 - Electric Mainline Locomotive Traction Motor Design

TRACS CM - Traction Motor for Urban Rail Vehicles

Magnetic Flux Leakage Sensor

Ground Movements Monitoring and Recording System

Railway Interlocking Systems

Line ATC System

Traffic Control Center

R&D