DRIVETRAIN TESTING

Denis Long, Manager

Drivetrain Engineering Section
Vehicle and Driveline Research Department
Phone: (210) 522-6599 Fax: (210) 522-5720

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 Powertrain Facilities

u 240 Dynamometers
u 176 Engine Stands
u 33 Transmission
u 34 Emission Stands
u 9 Axle Test Stands

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Automatic Transmission Technology By The
Numbers

u 12 Years Transmission Hardware

u 25 Years Transmission Fluid
u 6 250/375 KW Double Ended DC Dyno Stands
u 5 15KW Spin Stands
u 104 Transmission/Transaxles/CVT’s Tested
u 93 Conversion
u 1.6-8.0L Engine Applications
u 96 Pumps
u 21 Invention Disclosures
u 28 SAE Papers, Technical Articles

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Comprehensive Transmission Services

u Reverse Engineering
u Fixture Design
u Fixture Fabrication
u Vehicle Parameter Testing
u Test Matrix Development
u Pump, Converter and Transmission Testing
u Gearbox Loss Determination
u Power Path Analysis
u Inertia Value Testing
u Data Analysis
u Statistical Analysis
u Data Regression 4
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Dynamometer Test Facility

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CVT Testing and Development

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 Preproduction Hybrid Electric/Belt-Type CVT
Certification Testing
SwRI conducted a 41 test validation program of a passenger car CVT. The testing
was conducted using 7 different dynamometer and laboratory test stands.
n Spin Loss n Cold Start Up
n Efficiency-Assembly n Oil Level-Pitch
n Pump Efficiency n Oil Level-Roll
n Torque Converter Efficiency n Oil Level-Temperature Effects
n Lockup Clutch Capacity n Breather Function
n Lubrication-Bearing
n Lockup Clutch Torsional
n Lubrication-Pulley/Sheave
n Dynamic Belt Capacity
n Static Belt Strength
n Durability-Constant Speed n Static Sheave Strength
n Durability-Variable Speed n Static Parking Brake Strength
n Durability-Variable Ratio n Cycling-Belt
n Durability-Variable Load-Positive n Cycling-Sheave Shaft
n Durability-Variable Load-Reversing n Cycling-Parking Brake
n Durability-Towing n Cycling-Shift Selector
n Durability-Differential Output Low n Cycling-Hydraulic Circuit
Speed n Cycling-Case Stress
n Durability-Differential Output High n Load Testing-Bosses/Mounting
Speed n Deformation-Case
n Durability-Differential Output Speed n Leakage –Internal
n Durability –Final Drive n Leakage-Sealing Surfaces
n Leakage- Seals
n Steady State Hot
n Contact Pressure-Seal Surface
n Transient Hot 7
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Transmission Testing

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Transaxle Testing

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Transmission Assembly Torque Loss
2nd Gear

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 SwRI Defined Industry Variation of
Transmission Assembly Torque Loss

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Best of Class Gearboxes

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Torque Converter Test Stand

u Efficiency
u Capacity Determination
u Endurance
u Lockup Clutch Dynamics
u Distortion

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Multiple Torque Converter Efficiencies

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Torque Converter Damper Clutch Dynamics

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Pump Testing

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Overall Pump Efficiency Comparison

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Spin Loss Testing

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Clutch Pack Drag Test Stand

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 Clutch Pack Drag Testing

u Variable Speed
u Variable Differential Speed
u Variable Differential Direction
u Flow Rate
u Variable Temperature
u Effects of Clutch Pack Clearance
u Effects of Friction Material Groove Pattern

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Groove Configuration Effect

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Groove Pattern Torque Loss

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A Breakdown of Clutch Pack Losses

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Performance Variability Associated With
Manufacturing Processes

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Engine Driven Transmission Testing

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Drivetrain Component Testing

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 Testing Modes

u 2 WD
u 4 WH
u 4WL

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2H Efficiency Surface

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 4WD System Testing
DC Dyno Driven/Absorbing

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 4WD System Testing
DC Dyno Driven/Absorbing

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Fatigue/Ultimate/Environmental Testing

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 Failure Analysis

u NDE u Gear Teeth

u Die Penetrate u Tooth Contact
u Nital Etch u Pressure Angle
u Ultrasound u Diametral Pitch
u Tooth Profile
u Pitch Diameter
u Hardness

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Multiple Input/Output Gearboxes

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