GB/T 19055-2024 PDF English
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Reliability test methods for motor vehicle engines
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GB/T 19055-2024: PDF in English (GBT 19055-2024) GB/T 19055-2024
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.060.01
CCS T 11
Replacing GB/T 19055-2003
Reliability test methods for motor vehicle engines
ISSUED ON: MAY 28, 2024
IMPLEMENTED ON: DECEMBER 01, 2024
Issued by: State Administration for Market Regulation;
Standardization Administration of the People’s Republic of China.
Table of Contents
Foreword ... 3
1 Scope ... 6
2 Normative references ... 6
3 Terms and definitions ... 6
4 Test engine ... 7
5 General test requirements ... 7
6 Control of general test conditions ... 7
7 Adjustment of engine accessories and systems during the test ... 8
8 Working procedures ... 9
9 Reliability test specifications ... 11
10 Recommended inspection and maintenance ... 15
11 Test result evaluation ... 17
12 Test report ... 18
Appendix A (Normative) Reliability assessment methods for motor vehicle engines 20
Reliability test methods for motor vehicle engines
1 Scope
This document specifies the general reliability test methods and reliability assessment
methods for motor vehicle engine bench test.
This document applies to M and N category motor vehicle engines, which are
reciprocating, rotary type, excluding free piston type.
2 Normative references
The following documents are referred to in the text in such a way that some or all of
their content constitutes requirements of this document. For dated references, only the
version corresponding to that date is applicable to this document; for undated references,
the latest version (including all amendments) is applicable to this document.
GB/T 1883.1, Reciprocating internal combustion engines - Vocabulary - Part 1:
Terms for engine design and operation
GB/T 15089, Classification of power-driven vehicles and trailers
GB/T 17754, Tribology terminology
GB/T 18297, Performance test code for road vehicle engines
3 Terms and definitions
For the purpose of this document, terms and definitions given in GB/T 15089, GB/T
1883.1, GB/T 17754 and GB/T 18297, as well as the following apply.
3.1
rated speed
The engine speed at rated power.
Note: The rated power is specified by the manufacturer, and the rated speed is
generally lower than the maximum power speed under full load.
3.2
speed of maximum net torque
nM
By GB/T 18297, the speed at which the engine with a full set of vehicle accessories
outputs the maximum effective torque.
3.3
rated net power
By GB/T 18297, the corrected effective power output of the engine with a full set of
vehicle accessories at rated speed and full load.
4 Test engine
The three test engines (numbered A, B, and C) shall comply with the product technical
standards of the engine manufacturer.
5 General test requirements
The accuracy of the instruments used in the test, the measurement locations and the
calculation of the test data shall be in accordance with the provisions of GB/T 18297.
6 Control of general test conditions
6.1 Air intake status
It is recommended to control the air intake temperature within the range of 25 ℃ ±
10 ℃.
6.2 Fuel
The fuel designation shall be in accordance with the regulations of the engine
manufacturer. The gasoline temperature shall be controlled at 25 ℃ ± 5 ℃; the diesel
temperature shall be controlled at 40 ℃ ± 5 ℃; the temperature of other fuels shall be
controlled in accordance with the regulations of the engine manufacturer.
Fuel pressure shall be controlled in accordance with the engine manufacturer's
regulations.
6.3 Engine oil
The engine oil designation shall be in accordance with the regulations of the engine
manufacturer. The engine oil temperature shall not exceed the permissible temperature
specified by the engine manufacturer, otherwise a forced cooling device shall be used.
6.4 Coolant
Use the coolant specified by the engine manufacturer. The coolant outlet temperature
shall be controlled at 95 ℃ ± 3 ℃ or the temperature specified by the engine
manufacturer; during the hot and cold shock test, the coolant temperature shall be
controlled according to the provisions of Table 5.
7 Adjustment of engine accessories and systems during the
test
7.1 Air intake system
Use a standard vehicle intake system or an equivalent laboratory intake system (under
full speed and full load conditions, the resistance difference with the standard intake
system is within ±5%). The intake temperature after intercooling of a supercharged
intercooled engine shall meet the product technical standard requirements of the engine
manufacturer, and the resistance of the intercooler or intercooler simulator under full
speed and full load conditions of the engine shall be equivalent to that of the vehicle
intercooler.
7.2 Exhaust system
Use a standard exhaust system installed on the vehicle or a laboratory exhaust system
with equal resistance (under full speed and full load conditions, the back pressure
difference with the standard exhaust system is within the range of ±2 kPa).
7.3 Cooling system
According to the technical requirements of the engine manufacturer, the maximum
power fan for the vehicle is selected (for the clutch fan, the clutch shall be locked to
achieve the effect of direct connection to the fan), and an external blower can be used
to blow the engine. The vehicle cooling system components or other equivalent
components shall be installed, and the cooling system pressure, radiator resistance and
coolant flow value shall meet the product technical standards of the vehicle and engine
manufacturer. The thermostat shall be set to the fully open position.
7.4 Ignition system
The ignition angular advance of the spark-ignition engine shall be in accordance with
the regulations of the engine manufacturer.
7.5 Power generation system
The vehicle-mounted generator, voltage regulator and battery (if any, fully charged) etc.
shall be installed and in working condition.
7.6 Accessory system
Test the net power (or total power), piston leakage and oil consumption in accordance
with the provisions of GB/T 18297, and select test conditions in accordance with the
provisions of the engine manufacturer.
8.4 Reliability test
Proceed as per Chapter 9.
8.5 Performance retest
Repeat 8.3.
8.6 Disassembly and inspection
Dismantle and inspect engine A, engine B and engine C:
a) Detect the attenuation of the tightening torque decrement of fasteners (such as
bolts, nuts, etc.), that is, when the fasteners are re-tightened, the difference
between the torque at which the fasteners start to rotate and the tightening torque
before the test is the torque decrement;
b) Dismantle, inspect and analyze performance-related assembly parts according
to the control requirements of the engine manufacturer;
c) Take local clear photos of the surface of the main friction pairs, which includes
the journal, bearing, cylinder barrel (hole) (the reversal point of the upper and
lower dead points of a ring), piston (skirt), piston ring, cam, tappet, rocker arm,
valve, valve seat, etc.;
d) Take magnified photos of the overall appearance of the failed parts, the fracture
surface and the cracks;
e) Take photos of the upper and lower surfaces of the piston top, the spark plug
ceramic body and electrode, and the injector;
f) Take photos of the deposits, sludge and paint films on the oil pan, cover, cylinder
head upper surface, piston and cam surfaces;
g) Take photos of leaking seals such as cylinder gaskets, intake and exhaust pipe
gaskets, exhaust pipes and oil seals.
The parts referred to in e), f) and g) shall not be cleaned before taking photos, and
instructions shall be provided under each photo.
8.7 Precision measurement after testing
Repeat 8.1.
10.2.1 Apply data acquisition and control system; set alarm or shutdown limit at each
step; monitor the main monitoring parameters of the test throughout the whole process.
The recommended value of alarm limit is ±5% of normal stable operation condition,
and the recommended value of shutdown limit is ±10% of normal stable operation
condition.
10.2.2 The alarm and shutdown functions shall be operational when the engine is
running.
10.2.3 If an alarm or emergency shutdown occurs, handle and maintain it. If it is an
engine failure, it will be counted as a failure shutdown. Record the operating time, cause
and handling of the shutdown.
10.2.4 Monitor the abnormal noises from the engine's moving parts (such as the crank-
connecting rod mechanism and valve mechanism, etc.) and take measures when
necessary.
10.2.5 Record engine speed, torque, power, fuel consumption, oil pressure and
temperature and other parameters in a timely manner every hour.
10.3 Inspection and maintenance every 20 h ~ 30 h
10.3.1 Check the engine for inward and outward oil, water and air leakage, such as
cracks in the exhaust pipe, air leakage at the flange connection, oil emulsification and
gas leakage into the cooling system caused by cylinder gasket seal failure, etc. Keep
the engine and its surroundings clean so that leaks can be discovered in time.
10.3.2 Inspect the engine and test equipment, and check the fasteners, connectors and
pipelines, especially hoses; check the belt tension.
10.3.3 Check all fluid levels and, if necessary, the engine oil consumption.
10.4 Regular inspection and maintenance (according to the time interval specified
by the engine manufacturer)
10.4.1 Check the oil level of the engine oil. If necessary, take oil samples at the time
interval specified by the engine manufacturer to measure the viscosity, percentage of
insoluble matter, total acidity, total alkalinity, metal element content, grinding
morphology, etc.
10.4.2 Measure valve clearance (if applicable) and determine whether to adjust
according to the manufacturer's regulations.
10.4.3 Replace the spark plug; check the injector opening pressure, spray and dripping,
etc.
10.4.4 Replace the engine oil and oil filter.
10.5 Replacing the air filter and fuel filter elements
Replace the air filter and fuel filter elements at the appropriate time according to the
engine manufacturer's regulations.
10.6 Reliability test final inspection
Take an oil sample and measure the oil consumption, cylinder compression pressure,
valve clearance (if applicable) and valve depression (the routine inspection and final
inspection can be performed together when the time is close).
11 Test result evaluation
11.1 Running time
Based on the actual engine operation duration (h), the parts replaced during operation
and their time (h), carry out assessment in accordance with A.1.1.
11.2 Performance stability
11.2.1 Compare the performance curves and main parameters of the initial test
(according to 8.3) and the retest (according to 8.5). Evaluate according to the limits of
A.1.3, A.1.4 and A.1.5.
11.2.2 Draw the relationship curve between the corrected maximum net torque,
corrected maximum net power, rated net power and running duration (h) recorded in
10.2 during the reliability test, and analyze the performance change trend of the
reliability test.
11.3 Damage to parts
Record the operating time (h) and maintenance operation conditions of fault shutdown,
loose fasteners, seal failure, rubber aging, blockage, deformation, cracks, fractures, and
component damage; provide photos of damaged parts, cracks, fractures, and leakage
marks; use precise measurement data to analyze deformation. The evaluation of
components shall be carried out according to A.2.
11.4 Wear of components
11.4.1 Based on the analysis results of the engine oil sample, determine the wear of
components and the quality of the engine oil.
11.4.2 Organize the precise measurement data, and determine the wear amount of the
main friction pair in 8.6c).
11.4.3 Distinguish the forms of wear on components; determine the severity of wear;
provide photos of wear; make assessments according to A.2.3.
11.4.4 Describe the contact conditions of the friction pair surfaces and provide photos;
evaluate according to A.2.4.
11.5 Deposits on the surface of parts
Describe the status of the deposits on the surface of the parts and provide photos;
evaluate according to A.2.5.
12 Test report
The test report shall at least include the following contents.
a) Introduction: Explain the origin of the test task.
b) Purpose.
c) Test object: The technical parameters of the test engine shall be filled in
according to the contents of the "Main parameters table of ignition engine" or
"Main parameters table of compression ignition engine" in GB/T 18297, and
attached with graphics, photos and necessary explanations.
d) Test equipment and instruments: The name, manufacturer, model, accuracy,
calibration date and measuring location of the main equipment and instruments
shall be stated.
e) Test conditions, accessories of the test engine, adjustment and test procedures of
each system: indicating the test standard and its number, and explaining any
differences from the standard.
f) Test results: Process the original test data and express them with curves as far as
possible; tabulate important data; compile according to the requirements of
Chapter 11.
g) Conclusion: Based on the test results and the evaluation method in Appendix A,
make a pass or fail conclusion on the reliability of the engine; for engines that
fail, suggestions for improvement and additional testing shall be made. Pass
conditions:
1) Whole machine: If the requirements are met according to A.1 and there is no
damage (crack or breakage) to the parts related to the engine's safety,
regulations, environmental protection, etc., then the whole machine is judged
to have passed; otherwise, it is judged to have failed;
2) Parts: Evaluate with reference to the provisions of A.2. Those that meet the
requirements of Category A and Category B in Table A.1 ~ Table A.5 are
considered to have passed; those that meet the requirements of Category D in
Table A.1 ~ Table A.5 are considered to have failed; those that meet the
Appendix A
(Normative)
Reliability assessment methods for motor vehicle engines
A.1 Whole machine assessment
A.1.1 In order to provide a consistent assessment basis for engine reliability, a small
number of parts may be replaced without major structural damage, and the assessment
shall be conducted only when the operating duration (h) reaches the requirements of
Table 1. If the replaced parts do not reach the designed life during the test, the reliability
of the parts is unqualified.
A.1.2 The engine shall not leak oil or water inward or outward; air shall not penetrate
into the engine negative pressure system; there shall be no gas in the engine that leaks
into the oil or water channels, or oil and water mixing, etc.
A.1.3 During operation, the decrease in the corrected maximum net torque, corrected
maximum net power and rated net power shall not exceed 5% of the initial value.
A.1.4 The oil/fuel consumption ratio at rated speed and full load shall not exceed 0.2%.
A.1.5 The maximum piston leakage (Bmax) of a four-stroke engine at full load shall not
exceed the limit (BL). The leakage limit is calculated according to Formula (A.1):
Where:
C – coefficient (0.8% for compression ignition engine and 0.6% for spark ignition
engine);
Vt – the theoretical intake volume of a four-stroke engine at rated speed under standard
conditions, in liters per minute (L/min), i.e., the charging coefficient = 1;
VH – engine displacement, in liters (L);
nr – rated speed, in revolutions per minute (r/min);
rr – pressure ratio of the booster at rated speed and full load, that is, the ratio of the
compressor outlet absolute pressure P0 to the compressor inlet absolute pressure Pi
(rr=P0/Pi), for non-boosted compressors, rr =1;
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.
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