ANALYSIS IN DETAIL
UNIQUE ENGINE AND COMPONENT TESTING RIGS PUT EVERY ELEMENT OF YOUR ENGINE AND COMPONENTS TO THE TEST, SO CHALLENGE US TO DELIVER THE ANALYSIS YOU NEED.
Many of our specialist test rigs have been developed in-house and can be adapted exactly to your requirements for in-depth analysis of fuel systems, radiator core performance, pneumatic and steel valve spring behaviour or clutch and launch systems.
Our cam rig for air and valve spring measurement can run up to 22,000rpm engine speed with an 110Kw electric motor. A 70-channel measurement system, six-channel laser system and high-speed camera provide full valve motion analysis.
The adjustable radiator wind tunnel runs at realistic air speeds up to a maximum of 12m/s for lifelike analysis of radiator core performance.
A port development flow bench - a very rare example - provides low pressure exhaust measurement and valve shape optimisation, complete with Particle Image Velocimetry (PIV) analysis.
A unique fuel system testing facility incorporates the most comprehensive analyses available, including a fuel pump test rig, fuel rail calibration rig and single injector test and development rig.
Heat rejection and friction analysis is a particular speciality while the latest technology is utilised to provide incredibly detailed data on individual components.
High-speed cameras and lasers deliver incredible accuracy, as does the military-grade thermal camera on our 10,000rpm clutch development rig, which requires a specific permit from the authorities.
Additionally, we offer Horiba exhaust gas analysers, Malvern laser system for fuel spray characterisation, fast flame ionization detection and rapid in-cylinder sampling.
REAL RESULTS FROM A VIRTUAL WORLD
TMG’S ENGINE CALCULATION SPECIALISTS USE THE LATEST TECHNOLOGY TO UNDERSTAND IN PRECISE DETAIL EXACTLY WHAT IS HAPPENING UNDER THE COVERS OF A HIGH-PERFORMANCE ENGINE.
With a varied and powerful suite of software, our experts will bring to life the internal processes of any engine to allow specific analysis and development programmes.
Virtual development delivers concrete performance advantages by optimising all aspects of an engine’s behaviour – even those normally impossible to monitor on a test bench. For optimal heat management, gas exchange and performance, combustion or multi-phase flow, TMG has the answer.
Using high-performance computing power, we specialise in manifold design and tuning, valve profile and timing optimisation, intake and exhaust port development, 3D multi-cylinder and drive cycle simulation. In addition, we offer advanced combustion and injection simulation.
Optimisation of all aspects of engine behaviour is our speciality. For example, fine-tuning of intake valve lifting and timing will result in increased engine performance, improved torque, reduced fuel consumption and less valve train friction.
TMG is also experienced in exhaust gas recirculation (EGR) technology, with advanced multi-cylinder simulations allowing significant improvements to the intake system.
We can harness the power of several specialist software applications for each individual project, ensuring clear, verifiable analysis and development. And by coupling data from separate software models, you benefit from a solution derived from the most accurate information available.
Our structural and dynamic calculation group has developed wide-ranging techniques to improve virtually every aspect of engine performance, ensuring absolute efficiency in every area.
A wide range of calculation techniques - from multi-body simulation, hydrodynamic (HD) and elastohydrodynamic (EHD) oil film analysis to non-linear finite element analysis - is comprehensively covered at TMG.
The areas of potential development using these techniques are too numerous to list in their entirety but one look at some examples demonstrates how wide-ranging this technique is.
Piston development features thermomechanical reliability studies, crown tuning, pin bore trumpet shape and pit weight reduction and circlip shape tuning. When it comes to conrod optimisation, detail is the key so bolt thread lay-outs, bolt heads and bearing fretting are among the advanced procedures offered.
To produce the most efficient valvetrain, the lay-out and tuning of springs and dampers plays a vital role while gear train and belt tuning, friction and wear reduction or variable valve timing dynamics will deliver tangible results.
These computer-aided engine engineering techniques have been tried and tested in the extremely demanding world of top-level motorsport, where every tiny detail counts, delivering an exceptionally accurate correlation between virtual results and actual running data.
UNDERSTANDING ENGINE PERFORMANCE
OUR ENGINE DYNAMOMETERS SUITE HAS A PROGRAMME FOR EVERY PROJECT, FROM ROAD CAR TO HIGH-PERFORMANCE AND HYBRID ENGINE ANALYSIS.
TMG’s distinct varieties of dynamometer can meet all your performance testing needs, from high-power internal combustion engines to smaller electric or hybrid units, so whatever engine you are working with, TMG has a testing solution.
The TMG experts have experience of various sectors within the engine development and analysis industry while TMG-modified software gives greater flexibility to our clients.
Our complex car model allows virtual simulation and hardware in the loop system are customisable to suit virtually any vehicle, ensuring entirely repeatable tests linked directly to your specific requirements.
With various dynos available, all accurate to less than 1%, plus certification to utilise aviation fuel, TMG has the capacity and flexibility to meet the engine or motor analysis requirements of most industries.
We have the capability to test hybrid or e-motor systems, with single-component and full powertrain test benches dedicated to hybrid development.
The extremely accurate single-cylinder dyno is designed for minute analysis of single cylinders from high-performance engines or complete small capacity engines of around 100PS. With no neighbouring cylinders, there is less outside influence on results while a greater variety of tests can be carried out.
POWER AND PERFORMANCE
Our multi-function high-dynamic dyno accurately simulates road or track driving conditions based on a defined plan, with up to 22,000rpm engine speed, 3,000rpm wheel speed and 800kW engine power. Among its various uses, the dynamic dyno is also ideal for exhaust reliability studies and launch development.
The standard dyno monitors behaviour at constant speed for endurance and performance analysis as well as engine calibration. It is the perfect way to confirm engine characteristics at constant speeds.
An additional 320km/h, two-axle rolling road dyno allows in situ testing of a complete car, with 550kW power per axle and a maximum axle load of 2,400kg. Suitable for manual and automatic transmissions, this specialist test rig allows evaluation of drivability, reliability and fuel consumption.
Fully conditioned air, water, lubricants and fuel promote reliable test performance and you can be sure of complete confidentiality during your time at TMG, with private workshops and offices available to allow discreet development.
Take a look below for a summary of the most common tests available:
- Endurance testing
- Playback of specific scenarios
- Powertrain development
- Gear shift control development
- Drivability tuning
- Fast in-cylinder sampling
- Exhaust gas analysis
- Fuel efficiency tuning
- Calibration and mapping
- Lubricant endurance testing
- ECU development
- Pressure indication
- Heat and friction analysis