1. [1]
Internship at laboratory ‘Kolbenmaschinen’
Hochschule Heilbronn
Abdulaziz Kadri
ID#: 2011105023
Internship duration:
14.04.2015 – 31.08.2015
20 weeks
Supervisor
Prof. Dr.-Ing. Karsten Wittek
Exchange officer at GJU
Dr. Ala’aldeen Al-Halhouli

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Table of Contents
1. Preface............................................................................................................................. 3
2. Introduction to the laboratory ......................................................................................... 3
2.1 Laboratory Activities...............................................Error! Bookmark not defined.
2.1.1 Applications.............................................Error! Bookmark not defined.
2.1.2 Feautsures ................................................Error! Bookmark not defined.
3. Internship .......................................................................Error! Bookmark not defined.
3.1 Tasks .....................................................................Error! Bookmark not defined.
3.2 Working conditions ..............................................Error! Bookmark not defined.
3.3 Challenges.............................................................Error! Bookmark not defined.
3.4 Experience ............................................................Error! Bookmark not defined.
4. Internship task................................................................Error! Bookmark not defined.
4.1 Preparation of test engines for dyno testing.........................
4.2 Preparation of testing room
4.3 Doing the dyno test
5. Internship evaluation......................................................Error! Bookmark not defined.
6. conclusion ......................................................................Error! Bookmark not defined.
7. Refrences........................................................................Error! Bookmark not defined.
8. Zusammenfassung..........................................................Error! Bookmark not defined.

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1. Preface
I am a Bachelor’s degree student of Mechanical Engineering. School of Applied
Technical Sciences, at the German Jordanian University in Madaba, Jordan.
This internship is considered as an important part in my study plan at the German
Jordanian University (GJU), and it is obligatory for all the students.
The reason of being excited to do my internship in Germany is that I want to learn and to
gain experience. After following an internship in Nuqul Service Center in Madaba,
Jordan, during my studies, I wanted a new challenge. Doing my internship in Germany
helps me to learn, improve and develop new sets of skills and experiences. One of my
main targets is to improve my skills, expand my knowledge in the area of mechanical
engineering and to improve my German language.
The GJU was a very good chance for me to learn German by having German courses in
my study plan for three years. And it is a good step for me, to live in Germany, talk to
people and work with them, in order to improve my language and learn the German
culture, since the German culture is so different from the Jordanian culture. I was very
interested in getting a stronger knowledge of this culture and to know how people live
and how do they connect their studies or personal life with work.
In this internship report I will describe and discuss my experiences and challenges during
my internship period. The internship report contains a detailed overview of the internship
company and the activities, tasks that I have worked on during my internship.
2. Introduction to the Laboratory ‘KOM’
Labor Kolbenmaschinen (KOM) (Combustion Engines Laboratory) is one of the
laboratories at the Hochschule Heilbronn (HHN) in Sontheim Heilbronn, Germany. It is
one of the largest laboratories of testing engines at the HHN. The laboratory was started
by Prof. Herbert Windisch in 1990.
KOM’s core speciality is developing and testing piston engines, in a fully equipped lab.
Developing the engines includes the theory part (Which comes out of the Professor and
the Students) and the mechanical part (Buliding the engine starting from its very base
until it goes to the testing room).
Testing the engines is occured in a fully equipped testing room under certain conditions
(Dyno test).

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KOM has cooperations with German automotive industrial companies for example,
Bosch, Wurth, Porsche and Audi.
And the engines to be developed and tested are most of the time (Porsche, Audi) engines.
Since 1992, students have their own projects in the KOM lab. And they write their
graduating projects (Diplom, Bachelor’s or Master degrees) in such different areas. There
are the students of Formula 1 projects, Measurement students, Design students, Students
working on different speciality in cars (Engines in general, Pistons, Brakes). All in the
field of Mechanical Engineering.
2.1 Laboratory Activities
2.1.1 Applications
 Friction power
 Cylinder Heads
 Crank mechanisms
 Function VCR components
 Thermo management
2.1.2 Equipments
 Wirbelstrombremsen (Eddy current brakes)
 Electrical Machine
 Menzel-Electric motors
Pmax = 19 kW ; nmax = 6.000 min-1
 AVL(ELIN)
Pmax = 63 kW ; nmax = 9.000 min-1
 Torque Detection
 HBM
T40B (±200Nm, Repro.: ±0,06Nm)
T40 (±1000Nm, Repro.: ±0,10Nm)
 Conditioning Resources (Self-Built Units)
 Oil:
Pressure: 0 < p < 10 bar
Temperature: 30 < T < 130 °C
 Cooling water:
Volume Power: 0 <Q <100 RPM
Temperature: 30 < T < 110 °C

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 Testing bench Control
 National Instruments
Software: LabView
Hardware: SCXI-Series, PCI-Series
 Motor Control
 No Limits Motorsport (UMC2).
Free-Programmable (+clutch adjust)
 Series ECU’s (Electronic Control Units)
With INCA interface
 Measurement instruments
 Fuel Balance
Sartorius Combics 1
Dynamic AVL Fuel Balance (7131-06)
 Restbussimulation
Vector VN8970
 Exhaust emission measurement
HORIBA EXSA-1500L
2.2 Laboratory design
The laboratory is well designed to give the workers more space and freedom of
movement and work. And it consists of three working-cages and four testing rooms.
The laboratory is secured by a high quality with high standards of safety systems.
All of the three cages are provided with electricity, air-blow guns and some special
materials for every cage.
The first cage contains cabinets for bolts, working tools and electrical materials.
Engine holder

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The second cage contains lathe machines for making the needed special parts or bolts
either for the engines or the testing rooms.
The third room contains drawers and shelves for the special bolts and tools, and also
some measurement tools, and a disc for making/fixing the electrical cables.

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3. Internship
The internship was directly in the laboratory, my job was to learn and assist in several
research projects, and in the following tasks:
3.1 Tasks
 Preparation of test engines for Dyno testing
 Test-Bench set-up
 Preparation of testing procedure
 Execution of test and test evaluation
3.2 Working Conditions
The obligatory internship period was for 20 weeks. The typical working day was 8 hours
and it was flexible.
3.3 Challenges
The main challenge while doing my internship in the Laboratory was the language.
My German language skills were okay for talking and communicating with people. But
when it came to technical terms and explanations, it was hard at the beginning.
But during the internship, the communication between me and the team was only in
German, Which helped me a lot to improve my listening and talking skills in the German
language. So that, to understand the technical terms.
And the team was very helpful in this topic. They were explaining things if I did not
understand, most of the time in German. I have noticed also that my German language
became way better after doing my internship, and my German colleagues also noticed
that.
Some of the challenges also during the internship were the lack of knowledge and
experience in the area of Combustion Engines.
Of course, and because it is considered as my first time working in such a department, it
was a serious challenge for me. But with the team I worked with, I got over this
challenge. They were explaining everything, and I was free to ask anything in anytime.
They were just keeping giving me information and also asking me about things, so if I
don’t know it they would tell me about it, to make sure that I fully understand what is
going on.

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3.4 Experience
Of course, working in a new environment, in a different country, with different culture
and with new people has its ups and downs. This internship has allowed me to gain an
insight into the following areas:
 Cultural Difference
 Time & Commitment
 Team spirit
 Innovative thinking
4. Internship task
Prof. Dr.-Ing. Karsten Wittek was my supervisor, and there were students and co-workers
supervised also by Prof. Wittek as the team of KOM.
The task of my internship is to work with the team on research projects. In these projects,
we do tests on engines/ engine heads. We build the engine in the laboratory and prepare it
then we test it by “dyno test”.
4.4.1 Preparation of test engines for Dyno testing
The first step is to build up the engine. All the needed measuring materials, working tools
and engine parts (engine block/parts) are provided in the laboratory. So we build it step
by step from the base.
We start building the engines in the first cage, where I got familiarized to several kinds of
engines (single cylinder “test-engines”, 4-cylinder engines, v6 engines, box-engines).
First we install the engine on an engine holder and make sure it’s fixed. After that we
clean the engine from dust or oil and remove the rubber glue of the gasket.
Then we install all the parts on the engine.

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For this step, all the working tools were provided in a tools-cart, clean, oriented and in a
perfect quality and conditions.
Some special materials for carrying or moving the engine from a place to another are a
crank and an electrical vehicle.
And here is an example of a 4-cylinder engine with its first and last step of building.

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4.4.2 Preparation of testing room
The testing rooms are well isolated, which when its closed, there is no heat or mass
transfer between in/out the room.
In the testing room there is a testing-bench, which we can fix the engine head on. And
then we connect the engine to the testing room’s features, which are:
oil (in/out), intake and exhaust air, cooling water, fuel, electrical wires, sensors (pressure,
temperature).
Control canbinet presseure sensor Oil pump & tubes
But first, in the case of a cylinder head, we install it on a base, which allows the oil to
flow in/out of it, and then we connect it to an electrical motor, which gives it a torque to
operate.
electrical motor connecting rod
Cylinder head base

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In order to adjust the camshaft to rotate in the same rotational angle of the electrical
motor, we use an adjustment laser device.
This device contents of sender, receiver and a smart screen controlling device. We install
the sender and the receiver in parallel on the electrical engine and the cylinder head,
respectively. The sender sends laser lights to the receiver, and when we rotate the rod
manually, the smart screen shows us how many degrees/millimeters we should move the
cylinder head in order to have a systematic rotation between the electrical motor and the
camshaft.
smart screen sender/ receiver
I have faced some barriers while preparing the testing room in some cases.
In one case, a special part was needed to be made, in a design allows it to connect several
electrical tubes together. One of the team members explained the case, and after a quick
brain storming, we had an idea of the design of that part. I picked up the right material
with the right size, and by coordination with a lathing specialist in another laboratory in
HHN, the part has been made in the needed time of the preparation.

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In another case, there was a strong vibration in the testing-bench, which affects the
accuracy of testing.
The solution was to install a supporting rod, from the testing-bench’s base to the bench
itself. And that was done by picking up the raw material, cutting it using the automatic
metal-cutting machine, welding its parts and painting it before installing it in the room.
Before starting the test, we should make sure that the room and the working place is
clean. All the materials and tools should be in its place. There should be no extra
cables/tubes on the floor. It should be either connected or in the cabinets. We should
make sure also that the safety system and fire systems are working well, just in case of
any accident and to stay under a high standard of safety.
4.4.2 doing the dyno test
What is dyno testing?
A dynamometer or "dyno" for short is a device for measuring force, torque, or power. For
example, the power produced by an engine, motor or other rotating prime mover can be
calculated by simultaneously measuring torque and rotational speed (RPM).

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A dynamometer can also be used to determine the torque and power required to operate a
driven machine such as a pump. In that case, motoring or driving dynamometer is used. A
dynamometer that is designed to be driven is called an absorption or passive
dynamometer. A dynamometer that can either drive or absorb is called a universal or
active dynamometer.
Electric motor/generator dynamometer
Electric motor/generator dynamometers are a specialized type of adjustable-speed drive.
The absorption/driver unit can be either an alternating current (AC) motor or a direct
current (DC) motor. Either an AC motor or a DC motor can operate as a generator that is
driven by the unit under test or a motor that drives the unit under test. When equipped
with appropriate control units, electric motor/generator dynamometers can be configured
as universal dynamometers. The control unit for an AC motor is a variable-frequency
drive, while the control unit for a DC motor is a DC drive. In both cases, regenerative
control units can transfer power from the unit under test to the electric utility. Where
permitted, the operator of the dynamometer can receive payment (or credit) from the
utility for the returned power via net metering.
In engine testing, universal dynamometers can not only absorb the power of the engine,
but can also drive the engine for measuring friction, pumping losses, and other factors.