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

Aims and Objectives

Objective

  • Meeting the needs of our stakeholders,
  • Bringing certification capability to our country,
  • Enabling R&D activities to take place domestically,
  • Meeting the latest technological and regulatory requirements,
  • To be a laboratory that produces reliable data by performing maintenance and calibration of all systems and measuring devices.

Objectives

  • Becoming a focal center for certification tests that will increase our inspection and control capability on vehicles and engines entering our country.
  • To have systems that comply with the most up-to-date regulations on certification tests to be performed on all test systems and to follow the regulations.
  • To meet the demands of manufacturers in a reliable manner without deviating from confidentiality policies.

Working Areas

  • Electric Motor Performance Tests
  • Passenger Car 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
  • Powertrain and Vehicle Control Unit Development Tests
  • Passenger Cars and Light Commercial Vehicles Performance and Emission Tests
  • Diesel/Gasoline/Hydrogen Combustion Concept Development Tests in Single Cylinder Engines
  • Passenger Cars and Light Commercial Vehicles Emission Certification Tests
  • Heavy Commercial and Off-Road Vehicle Engine Emission Certification Tests

Infrastructure

  • The Engine Center 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 the active dynamometers of different power, torque and speed, development and certification tests of electric and internal combustion engines used in passenger cars, light commercial vehicles, heavy commercial vehicles and high-powered vehicles can be performed. The technical specifications of the dynamometers in the 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 very suitable for dynamic tests due to its low inertia and is used in electric motor tests. A 250 kW DC power supply with 1,200 V 800A and a connection panel for the electric motor drive is located in the room.

Engine Dynamometer-2

2 test chambers with 440 kW and 934 Nm torque dynamometers are used in performance and emission development studies of passenger car, light commercial and off-road vehicle engines. Both test chambers are equipped with measurement and conditioning devices for conditioning and measuring the intake air of the engine, conditioning the fuel and measuring fuel consumption, conditioning the charge air, conditioning the engine oil and water. In addition, blow-by devices for measuring gases escaping into the crankcase, soot measurement devices (smokemeter, microsoot, opacimeter), raw emission measurement device for continuous emission measurement before and after catalyst, sensors and interfaces on the engine that measure temperature and pressure from many points, and all engine parameters can be measured. There is also a system in the room for measuring in-cylinder pressure and making calculations.

In a room specifically for emission certification tests of heavy commercial and off-road vehicle engines, the necessary emission measurement equipment has been added, and thanks to the automation software, emission type approval tests of heavy commercial vehicles at Euro VI and off-road vehicle engines at Phase V level are carried out. An FTIR device that measures urea specific to SCR system engines is also used in the tests.

Engine Dynamometer-3-4

With the 500 kW power and 3,000 Nm torque dynamometer, the engines of vehicles used in the heavy commercial and military armored carrier vehicle class can be developed, and performance and emission calibrations can be performed. In this test room, there are devices that condition all air, fuel, engine oil and water of the engine, as well as development-specific emission measurement devices.

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)
*Values in brackets are the values that the engines have.

Engine Dynamometer-6

This hybrid dynamometer system, which can operate in tandem, includes an AC electric motor dynamometer with a power of 1,100 kW and a hydraulic dynamometer with a power of 2,100 kW. The system, which is connected to each other via coupling, reaches a total power of 3,300 kW and 20,000 Nm of torque, while it is possible to connect motors to both ends of the system, which provides ease of operation. In this system, which enables the development of high-power engines, the intake air flow rate, fuel consumption, blow-by and temperature/pressure values of the engine can be measured, and the engine's oil and cooling water and filling air can be conditioned.

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

It is a system consisting of 6 dynamometers and used in the development of powertrains (gearboxes, transmission, differential, axles, etc.) and control units of both passenger cars and off-road vehicles such as tractors. The system reaches 35,000 Nm torque on each of the front wheels and 60,000 Nm torque on each of the rear wheels with a gearbox connected to the output of 4 dynamometers with 290 kW power connected to the axle outputs of the vehicle. In the powertrain where there is no engine, the system is driven by a 160 kW dynamometer, while the PTO output can be loaded with a 160 kW dynamometer with a torque of 2,000 Nm. In the dynamometer automation system, the vehicle model is created, wheel loads are calculated on the defined road profile and instantaneously applied to the powertrain connected to the dynamometer.
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