POWERTRAIN ENGINEERING

TESTS and SERVICES(extract)

3 locations in France

D2T POWERTRAIN ENGINEERING - 11 rue Denis Papin - CS70533 - F-78190 Trappes Cedex - Tel.: +33 (0)1 30 13 07 07

www.d2t.com

Our test centersTrappes - Cesame - Mont Saint-Aignan

Powertrain EngineeringGeneral information

With more than 20 years of experience, D2T, which has partneredboth carmakers and equipment suppliers, is specialized in powertrain engineering, development and tuning of internal combustion engines.

D2TD2T: MAIN PRIV: MAIN PRIVAATE FRENCH R&D CENTERTE FRENCH R&D CENTER (after OEM)in the field of engines, powertrains and test systems.

GENERALGENERAL INFORMAINFORMATIONTIOND2T - DRECQ DANIEL TECHNOLOGIESHeadquarters and offices: Z.A de Trappes-Elancourt - 11 rue Denis Papin78190 TRAPPES - FRANCETél. : +33 (0)1 30 13 07 07 - Fax : +33 (0)1 30 13 07 10

www.d2t.comInformations: sales@d2t.com

President: André QUIGNODONManaging Director: Gaétan MONNIER

Company with a capital of 9 122 101 € - RC Versailles BSiret 400 286 688 00025 - APE 7112B - VAT: FR-76 400 286 688

Certification: UTAC SQ/11 38-S - ISO 9001 version 2008

CONTENTSCONTENTSENGINE ARCHITECTURE 4ENGINE CALIBRATION - Gasoline & Diesel 7ENDURANCE 8EMISSIONS AFTER TREATMENT 10CHASSIS DYNAMOMETER TESTING 11GEARBOX/TRANSMISSION TESTING 12SUBSYSTEM TESTS 13STANDARD TESTING FOR LUBRICANTS 15OTHER SERVICES 16

YOUR CONTYOUR CONTACTSACTSSales department: +33 (0)1 30 13 07 53

D2T is a strategic subsidiary of IFP Energies nouvelles

Engine architectureDynamometer

CHARACTERIZACHARACTERIZATION OF FUNCTIONSTION OF FUNCTIONS

ADJUSTMENT OF TURBO COMPRESSORS- Adjustment of dynamic turbo response time, e-turbo characteriza-tion, measurement of oil consumption of a turbo and its permeability.

CHARACTERIZATION OF ELEMENTS RESPONSIVE TO DYNAMICS- Characterization of functions (turbo response times and pumping,

lubrication circuit under strong transients, etc.

CHARACTERIZACHARACTERIZATION OF FUNCTIONSTION OF FUNCTIONS

CHARACTERIZATION OF DISTRIBUTION DRIVES- Measurement of belt flap and high-speed video analysis of

the interlocking responsible for the failures

MEASUREMENTS OF INSTANTANEOUS CONSTRAINTS- Measurement of instantaneous drive distribution torque,

accessories, etc.

OIL REMOVAL ADJUSTMENT- MAP of geometry of compressed air filters (oil removers) and

characterization of their efficiency

COMBUSTION MODEL RESETTING- Resetting of combustion models with regard to various points,

possibly resulting from an experimental design

INTERNAL AERODYNAMIC ADJUSTMENTEvaluation of the engine's internal aerodynamic solutions

Engine architectureEddy current brake

Engine architectureEddy current brake

VIBRAVIBRATIONALTIONAL CHARACTERIZACHARACTERIZATIONTION

OPERATIONAL DEFLECTED CURVE OF EXHAUST LINE- Operational deflected curve of exhaust line

OPERATIONAL DEFLECTED CURVE ON GMP (POWERTRAIN)

VEHICLE TRANSFER FUNCTION

VIBRATIONAL MEASUREMENT ON ENGINE ELEMENTS- Vibrational measurements on the elements of the engine

(e.g., alternator) to identify the level and frequencies of vibration

PRODUCTION COMPLIANCEPRODUCTION COMPLIANCE

BEDDING IN/BENDING

SPECIALSPECIAL FUELS TESTING (drums or tFUELS TESTING (drums or tank)ank)

AGING OF AFTERTREATMENT SYSTEMS- Accelerated aging of aftertreatment system or systems

EXPORT ENGINE CALIBRATION- Complete calibration for engine destined for export

KNOCK CALIBRATION

ROBUSTNESS OF ENGINE- Ability of engine to handle exotic fuel

ROBUSTNESS OF EXHAUST GAS TREATMENT- Ability of the engine's exhaust gas treatment system

to handle exotic fuel

EXHAUST GAS TREAEXHAUST GAS TREATMENT SYSTEMTMENT SYSTEM

ADJUSTMENT OF EGR SYSTEMS- Implementation and testing on diesel or gasoline

EGR systems, supercooled or not

THERMALTHERMAL

THERMAL BALANCE- Thermal balance: measurement of energy introduced by

the fuel and useful and lost energy totals

THERMOMANAGEMENT- Thermomanagement: Optimization of an engine's firing

with control of one or more thermostats

THERMOMETRY- Engine thermometry or engine operation.

Number of measurement pathways not unlimited.

Engine architectureEddy current brake + dynamometer

CHARACTERIZACHARACTERIZATION OF FUNCTIONSTION OF FUNCTIONS

MATCHING OF TURBOCOMPRESSORS- EGR/SUPERCHRG scanning under partial loads. Detection of

pumping line. Determination of compressor and turbine fields via scanning of gas flow/retention rates. Adjustment of bearings for TGV

CHARACTERIZACHARACTERIZATION TION OF THE LUBRICAOF THE LUBRICATION CIRCUITTION CIRCUIT

OIL CIRCUIT PERMEABILITY- Measurement of pressures at different points and of lubrication

circuit permeability

TESTING OF NUMERICALTESTING OF NUMERICAL MODELMODEL ADJUSTMENTADJUSTMENT

MODEL ADJUSTMENT- Generation of points with scanning of all engine control parameters

influencing combustion

MEASUREMENT OF OILMEASUREMENT OF OIL CONSUMPTIONCONSUMPTION

CHARACTERIZATION OF OIL CONSUMPTION OVER TOTALFIELD OF OPERATION- Measurement via radio-tracer method allowing immediate

identification of consumption at each operating point

MEASUREMENT OF FRICTIONMEASUREMENT OF FRICTION

FRICTION LOSS DURING COMBUSTION- Measurement of engine friction during combustion

(effect of the load, of crankshaft misalignment, etc.)

FRICTION LOSS DURING THERMAL TRANSIENTS- Measurements of losses due to friction when driven part to part or

on firing at the stabilized points of a cycle, during thermal transients

FRICTION LOSS WHEN DRIVEN- Measurement of total engine friction or part by part

Engine calibration- Gasoline & DieselDynamometer

Engine calibration- Gasoline & DieselEddy current brake

CALIBRACALIBRATION OF FUNCTIONSTION OF FUNCTIONS

ADJUSTMENT OF TORQUE STRUCTURE- Validation of torque structure

AIR LOOP ADJUSTMENT- Air loop MAP for a new turbo adaptation

COMBUSTION NOISE- Combustion noise over temperature rise

DESIGN AND CALIBRATION OF NEW STRATEGIES- New strategies

EGR ADJUSTMENT

INJECTION CALIBRATION- Validation of injector mapping

NEW FUEL- Switchover to a new fuel

PERFORMANCE ADJUSTMENT- Performances (full load and dynamic)

PF ADJUSTMENT- PF regeneration

SENSITIVITY- Sensitivity curves (counterpressure, temperature downstream of

exchanger, etc.)

SMOOTH-RUNNING ADJUSTMENT- Smooth-running/noise/reliability positioning

CALIBRACALIBRATION OF FUNCTIONSTION OF FUNCTIONS

ADJUSTMENT OF "FOOT LIFTING" STRATEGIES- Adjustment of strategy when lifting foot from pedal (injector

adjustment, retention of turbo speed, etc.)

SMOOTH-RUNNING PRECALIBRATION- Precalibration of smooth-running before driving

ENGINE CALIBRAENGINE CALIBRATIONTION

TESTING OVER CYCLES- Measurement of parameters (consumption, pollution, PMF)

over driving cycles.

Engine calibration- Gasoline & DieselEddy current brake + dynamometer

FUNCTIONFUNCTION

ENDURANCE OVER CYCLE- Testing of sensitive components during transients (turbos, PF, etc.)

COMPLETE ENGINECOMPLETE ENGINE

ENDURANCE OVER CYCLE- Driving simulation on cycle defined by the client based on vehicle data and driving cycle (speed and gear engaged based on time)

STOP & START ENDURANCE- Validation of engine equipped with Stop & Start function

FUNCTIONFUNCTION

AGING OF GASOLINE OR DIESEL CATALYTIC CONVERTERS

ALTERNATOR

BALANCER SHAFTS

COOLANT AGING

EGR CLOGGING

EXHAUST MANIFOLD

EnduranceDynamometer

EnduranceEddy current brake

CALIBRACALIBRATION OF FUNCTIONSTION OF FUNCTIONS

CMF (FRICTION MAP) CALIBRATION- Validation of friction map

EXHAUST GAS TREATMENT / SPECIFIC CONSUMPTION (SCP)POSITIONING- Positioning of the exhaust gas treatment/specific consumption field

EXPERIMENTAL DESIGN- Experimental designs to determine the numerical model

of the engine

EnduranceEddy current brake

FUNCTIONFUNCTION

INJECTOR CLOGGING

OIL AGING

SPARK PLUGS

TIMING AND ACCESSORY BELTS, HEATED OR NOT

TURBO- Possibility of feeding the turbo with an auxiliary lubrication circuit

to measure its consumption

TURBO CORROSION

VIBRATIONAL

COMPLETE ENGINECOMPLETE ENGINE

CLOGGING

ENDURANCE OVER CYCLE- Endurance on ECE/EUDC cycle; road cycle, urban cycle, etc.

WEAR BEHAVIOR- Measurement of wear behavior: endurance testing interspersed

with disassembly and measurement phases (roughness, geometry, etc.)

IDLE- Idle endurance

LUBRICATION

OVERSPEED

STICKING

THERMAL SHOCKS

WOT- Continuous wide-open throttle

Emissions aftertreatmentEddy current brake

CACATTALALYTIC CONVERTERYTIC CONVERTER

LIGHT OFF EFFICIENCY- Light off before/after aging

DeNOxDeNOx

ADJUSTMENT OF NOX TRAP

ADJUSTMENT OF SCR- Adjustment of SCR HC and/or NH3

DIESELDIESEL PPARTICULAARTICULATE FILTE FILTERTER

DPF ADJUSTMENT- Regenerability study, MSL, CPE characterization, etc.

DPF CHARACTERIZATION- Measurement of efficiency

DPF SOILING- Testing of DPF soiling with combustion residues

Chassis dynamometer testing48 " Chassis dynamometers - 2 and 4 wheel drive

PPASSENGER CARS ASSENGER CARS AND LIGHT DUTYAND LIGHT DUTY VEHICLESVEHICLES

DURABILITY / RELIABILITY- Development and realization of customized durability cycles:

catalyst aging, DPF durability, clutch durability, vehicle, engine or component validation

- Injector or cylinder head fouling cycles

COMPONENT TESTING IN HOT ENVIRONMENT- Alternator validation with several driving cycles

FUNCTIONAL DIAGNOSIS - Validation of engine control functions (EOBD) on regulatory

or customized cycles (NMVEG, Artemis, etc. ...)

EXHAUST EMISSIONS MEASUREMENT- EU, USA and Japan regulatory cycles- Low Temperature Tests (- 7 ° C) - Hybrid vehicles characterization

PERFORMANCE TESTS - Vehicle engine performance characterization

Gearbox/transmission testingHigh torque electric test bed - single or dual shaft

SUBSYSTEM & GEARBOX DURABILITYSUBSYSTEM & GEARBOX DURABILITY TESTSTESTS- Coupling validation

- Lubrication

- Screening

- Shifting mechanism validation

- Tooth, roller bearing and gear shift endurance tests

- Efficiency measurements

VIBRATORY CHARACTERIZATION OF THE GEARBOX UNDER TEST CONDITIONS- Tooth gear performance, bearings cycling

with vibration failure detection

Subsystem testsSubsystems, components, accessories

HEAHEATER UNITTER UNIT- Radiator testing- Measurements: air and coolant flow rate, temperature in and out

and air differential pressure across the radiator at different flow rates and temperatures.

- Motor driven fan tests

SHIFTING SERSHIFTING SERVICE - MANUALVICE - MANUAL GEARBOXGEARBOX- Synchronization tests- Lubricants tests- Selector fork tests- Mechanism tests

MANUALMANUAL GEARBOX FRICTIONGEARBOX FRICTION- Materials tests- Process tests- Lubricants tests

HEAD COMPONENTS TESTINGHEAD COMPONENTS TESTING- Materials validation- Tests: cam shafts, followers, tappets, rollers, water pump pulley,

injection pump pulley, timing belt

GASOLINE & DIESELGASOLINE & DIESEL INJECTION INJECTION CHARACTERIZACHARACTERIZATION TION - Durability tests- Wave of pressure measurements- Pressure and temperature cycling- Corrosion tests

EFFICIENCYEFFICIENCY MEASUREMENTSMEASUREMENTS- Miscellaneous transmissions tests- Engine friction loss tests

THERMOSTTHERMOSTAATS DURABILITYTS DURABILITY- Heat cycling

Subsystem testsSubsystems, components, accessories

AUTAUTOMAOMATIC & MANUALTIC & MANUAL GEARBOX FRICTIONGEARBOX FRICTIONDRDRYY & WET CLUTCHES& WET CLUTCHES- Clutch facing tests- Lubricant development testing

Principle of operationsA flywheel is accelerated to a given kinetic energy level and then stop-ped with an oil immersed clutch pack. Torque curve generated duringbraking, together with applied force on the clutch enable to producefriction coefficient traces which are characteristics of the lubricant andthe friction material. It is also possible to measure breakaway torquejust after dynamic engagement giving then access to clutch capacitydata.

DescriptionA electric motor accelerates a flywheel, inertia of which depends uponprocedures and customer requirements to produce appropriate kineticenergy. Maximum rotating speed is 6 000 rpm. A wet clutch is locatedon the same shaft as the flywheel and used to stop the system by appli-cation of a locking force with an air operated piston. Applied force, airpressure as well as torque force are recorded and friction coefficentsare calculated.A second electric motor, coupled to a worm gear drive can then startthe system and measure the force required to let the clutch slip andhence access the clutch capacity data with «static» friction coefficient.This type of test is commonly applicable to automatic transmissionfluids, and to clutch plates or friction material production control, forboth characterisation and endurance evaluation.

Control and data acquisition system: Labview.

Synchroniser testing machineDurability 3>4

SpeedForceCoefficientDisplacement

Standard testing for lubricantsAnti-wear and extreme pressure performances

LUBRICANT TRIBOMETERS LUBRICANT TRIBOMETERS - FZG machines, 4 ball, 4 ball EP, VKA KRL, Timken, Falex

FZG TestingThis machine is widely used in the lubricant industry for gear lubri-cants evaluation, covering anti-wear, anti-seizure, gear fatigue, shearstability… It is using a 4 square gear system (re-circulating power)with gears operating under controlled torque at variable speeds andtemperatures. Different gear profiles are available depending upon the test destina-tion and both liquid lubricants and greases could be tested on thismachine.The standardised test methods that cover this equipment:- CEC L-07-A-95, - DIN 51354-02,- ASTM D-5182,

4 ball lubricant Tests3 1/2 inch balls are blocked in a support cup, and a fourth is rotated(see drawing) with a controlled load applied. The scar diameter pro-duced at the contact between the rotating ball and the others iscontrolled by the lubricant and might characterise its anti-wear or anti-seizure properties.Depending upon the duration of the test, the temperature, and theload program, the test is referred to as 4 ball wear, or 4 ball E.P. (forExtreme Pressure).A number of methods exist and have been standardised by ASTM,ISO, AFNOR, DIN, IP, … and can be run on these machines.

Lubricant Shear StabilityKRL (Tapered Roller Bearing) procedure. The standardised testmethods are essentially the CEC L-45-A-99 or DIN 51350.This machine is using the 4 Ball apparatus, replacing the conventio-nal mandrel and cup with a tapered roller bearing operating at 60 °Cunder very high load.

Timken E.P. and WearTimken have developed a machine using bearing ring, rotated againsta steel block under load to investigate lubricant properties. Wear pro-tection provided by lubricating oils or greases and load carrying capa-city can be assessed by this equipment. Two such machines are avai-lable for testing (one for liquids and one for greases).The most current standards:- ASTM D-2782 for oils,- D-2509 for greases.

Other ServicesDesign, projects

ANALANALYSIS OF THE CONSEQUENCES YSIS OF THE CONSEQUENCES OF BLOW BYOF BLOW BY GASESGASES- Exhaust emissions measurement

CHANGE OF THE INJECTION SYSTEMCHANGE OF THE INJECTION SYSTEMfor an existing engine basis

ENGINE CALIBRAENGINE CALIBRATION - TION - Gasoline & DieselGasoline & Diesel- New strategies- Change of a new fuel- Switchover to a new fuel - EGR tuning- Intake air loop calibration for a new turbocharger adaptation- Emissions and acoustics- Performance (full load and transient)

DEVELOPMENT OF METHODOLOGIESDEVELOPMENT OF METHODOLOGIESfor an accelerated aging for gasoline and gas engine catalyst

DOE (DESIGN OF EXPERIMENT)DOE (DESIGN OF EXPERIMENT)on the factors influencing a manual gearbox characterization

EMISSIONS EMISSIONS AND DRIVEABILITYAND DRIVEABILITY CALIBRACALIBRATION TION & CALIBRA& CALIBRATION TION ADAPTADAPTAATIONTIONfor Euro 4 light duty vehicles with a robotised gearbox powertrain

ENGINE EXPERTISEENGINE EXPERTISE

IMPIMPACT OF OXYGENAACT OF OXYGENATED FUELSTED FUELSon non restricted exhaust emissions species

IMPIMPACT OF ACT OF ALCOHOLALCOHOL BASED BIOFUELSBASED BIOFUELSon corrosion of aluminium components

METHODOLOGYMETHODOLOGY AND DESIGNAND DESIGNfor a system which permits to characterize an acoustic insulation for an exhaust box

METHODOLOGYMETHODOLOGY DEVELOPMENT EGR DEVELOPMENT EGR exchanger validation

RUNNING TESTS ON ROADRUNNING TESTS ON ROAD

SIMULASIMULATION TION

STSTAATIC TIC ANALANALYSIS YSIS AND EXPERTISE AND EXPERTISE FOR ENGINE FOR ENGINE AND GEAR BOXAND GEAR BOX- Disassembly, metrology, analysis and photography,

study report and quote

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