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What is engine test and Why Do We Use Them?

Jul. 21, 2025

What Are The Different Types of Pressure Tests for Engine Test ...

Did you know that companies spend hundreds of millions of dollars on research and development for off-highway vehicle engines? A portion of the R&D goes into developing specialized engine test stands to ensure that the engines are functioning properly.

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Engine test stands are complex, engineered systems designed to measure, control and record parameters during the different engine manufacturing stages. OEMs use engine test stands for testing certain variables of the engine in preset conditions and for verifying the engine’s accuracy prior to delivery to the customer.

Due to increasingly strict regulations and demand for higher quality in certain applications, many engine test stands today contain pressure sensors. There are many types of pressure tests conducted within an engine test stand, such as:

Oil Pressure

Proper oil pressure is necessary in an engine to ensure that all moving parts are properly lubricated to prevent any component failures or engine seizures.
Pressure Type: Gauge

Coolant Pressure

Engine temperature is a key component in prolonging the life of engine components. The coolant system is responsible for distribution of coolant during the test.
Pressure Type: Gauge

Fuel Line Pressure

Internal combustion engines use different fuels to make them run, monitoring the fuel line pressure allows for calculations for efficiency and control of fuel delivery.
Pressure Type: Gauge

Cylinder Compression

Allow for detection of any defects in piston rings, bores & valves during testing.
Pressure Type: Gauge

Pressure Decay

Overall system leak-rate test to ensure there are no missing O-rings, gaskets or any other valve issues or system leaks.
Pressure Type: Gauge

Manifold Vacuum Pressure

This measures the amount of restriction of airflow through the engine. Accurate measurements enable calculations to see the unused power capacity in the engine.
Pressure Type: Vacuum

Dry Airflow

Measuring the back pressure in the engine while knowing the crankshaft position, enables the test stand to recognize missing main bearings or plugged oil cavities.
Pressure Type: Differential

Barometric Reference

Barometric sensors play a key role in the data gathered by a test stand. The sensor reads real-time barometric pressure that can be used for calculations and performance comparisons.
Pressure Type: Absolute & Barometric

Testing of engines | ZwickRoell

For fatigue testing on crankshafts, you can use a Vibrophore or a servo-hydraulic testing machine. In the case shown, the S-N curve is determined to DIN . Due to the relatively low frequency of 10 to 30 Hz, a servo-hydraulic testing machine was used. Fatigue occurs through flexural loading in which the mounting table and tools are arranged so that all of the crankshaft's segments can be checked by reclamping them. A fatigue limit of approximately N = 3 x 106 cycles is assumed here. Force-controlled sinusoidal cycles are performed according to the staircase method. Fatigue testing via torsional loading can also be performed using the same machine.

Combustion engines consist of the three main components: the engine block (cylinder housing), crankshaft drive, and timing assembly. The cylinder block can be made up of just one unit or individual cylinders. It consists of one or several castings, in which cast iron, or increasingly also lightweight metal, for example, aluminum or light metal alloys of aluminum/magnesium are used. The cylinder block is subject to many loads, such as moments of inertia, torque, or forces from the transmission of the gas forces from the cylinder head to the crankshaft bearings.

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Vibrophores are available to help determine the fatigue properties of individual chain components in series production. The fatigue properties and limits of endless chains as well as individual chain components (for example, chain bridges) can be determined with a testing frequency of up to 50 Hz. ZwickRoell's control electronics were developed specifically for chain testing and allow you to even measure chains with large changes in damping. They can also be readily adapted to company-specific testing standards.

Because of how they are used, camshafts must withstand high, continuous torsional loads. Torsion testing machines can be used for production-related quality control. The torque acting on a camshaft at which component connections begin to loosen is determined. Camshaft sections are gripped horizontally in the machine and a torque load of up to Nm is increasingly applied. Especially interesting is the elastic and plastic deformation of the camshaft components. ZwickRoell's optical laser extensometer measures the rotational angle without making contact.

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