engine dyno development in utem from single cylinder to multi cylinder engine performance test Capable of testing engine on test bed and analyze the engine mapping which include Power (kW/ Hp / Bhp) , Torque (Nm), Fuel Consumption (BSFC) Emission (NOx, CO, CO2, HC) engine cylinder pressure and temperature mapping

1. Engineering Knowledge Transfer Units to Increase
Student´s Employability and Regional Development
The European Commission's support for the production of this publication does not constitute an endorsement of the contents, which
reflect the views only of the authors, and the Commission cannot be held responsible for any use which may be made of the
information contained therein. 598710-EPP-1-2018-1-AT-EPPKA2-CBHE-JP
Engineering Knowledge Transfer Unit
UTeM UNITED
FUTURE FUEL DESIGN TRAINING CENTER
[Universiti Teknikal Malaysia Melaka]
1st Introduction to Engine Dyno Testing
06 Sept 2021, Zoom (online)
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Prof Ts Dr Noreffendy Tamaldin
Professor Mechanical Engineering -
Automotive
Centre of Adv Research on Energy CARe
Universiti Teknikal Malaysia Melaka, UTeM

2. Tentative Schedule
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Introduction for Engine /Dynamometer Testing

3. Presentation Contents
1.Introduction- Why Perform Dynamometer Test ?
2.Engine Dyno Checklist:
1. SET TESTING GOALS
2. PREPARE THE ENGINE FOR TRANSPORTING
3. ENGINE SPECS
4. TEST COMPONENTS
5. HEADERS & EXHAUST
6. SPARE PARTS
7. FUEL & LUBRICANTS
8. TOOLS
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4. WHY DYNO TEST AN ENGINE?
• It is easier and cheaper to test and tune an engine on the dyno than on the
road/track. In the long-run, the money spent will pay off as you optimize your
engine configuration and identify any problems before they become a
catastrophic failure.
• Engine dyno testing allows you to:
• Safely break-in a new engine.
• Optimize your torque, horsepower, and air-fuel ratio.
• Set your ignition timing, oil pressure, carb, lash and cam timing and test supporting
systems.
• Detect leaks, vibration, noise, and test the effectiveness of cooling, lubrication, and
controllability.
• Compare engine output with different engine components.
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5. Engine Dyno Checklist
1. SET TESTING GOALS
2. PREPARE THE ENGINE FOR
TRANSPORTING
3. ENGINE SPECS
4. TEST COMPONENTS
5. HEADERS & EXHAUST
6. SPARE PARTS
7. FUEL & LUBRICANTS
8. TOOLS
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6. 1. SET TESTING GOALS
• Why do you want to perform dyno test?
• What is the key elements you wish to get? Expected output ?
• Write down ambiguous vs clear test goals
• Racing, competitions, F1, SAE etc
• Maybe to break in a new engine build
• Destructive vs non-destructive testing.
• Reliability testing
• Testing/ tuning to new components; camshafts, carbs, header, air induction system, fuel
blends, gasket.
• Check for noise & vibration
• Setting timing & optimize for specific fuel
• Testing the effectiveness of cooling system
• Cheaper/cost effective, controlled environment & safer on dyno vs road test.
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7. UTeM Experiences
• Proton Green Mobility 2012- convert to electric, cooling sys
• Perodua Eco Challenge 2010,11,13,14, go cart to Myvi fuel saving
• MPOB- biofuel B5,B7, B10, B20, B30
• Component Testing- eleastomer-fuel line, pump, injector
• MTUN Biodiesel higher blend B70,B80, B90, B100- engine
performance+emission
• HHO Sg Melaka- H2 enrichment into marine engine
• Patented HHO system- fuel improvement, emission, CO Cleaner
• RON 95 vs RON97 study- engine performance+emission
• Proton Underfloor catalyst, EHC – Lotus tech
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8. 2. PREPARE THE ENGINE FOR TRANSPORTING
• Cooling system may have Trapped air- inaccurate T reading, lead water
pump cavitation
• Purge air out-radiator cap off/lever vent radiator cap
• Exhaust port, carb flange, securely strapped.
• Engine mounting
• Crate, cargo
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9. 3. ENGINE SPECS- ELABORATED LATER
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• Fundamental
• Proof of Principles
• Single cylinder
• Limited parameters/DAQ
• Specific/Focus measurements
• Assumptions
• R&D Stage
• Hardware in Loop Simulation-HILS
• Applied Testing
• Manufacturing reliability
• Burn in test- destructive
• Service life estimations
• Real world engine test
• New model/model improvement
• Extensive measurements
• Simulation of real environments
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10. 4. TEST COMPONENTS
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• Piston, rings, liner
• Combustion chamber design
• CAM & Valve design
• Gasket reliability
• Fuel delivery system
• Intake / Induction system
• Exhaust / aftertreatment system
• Fuel blend testing
• Efficiency
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11. 5. HEADERS & EXHAUST
• Use Standard spec unless test focus
on them
• Intake runner design – may requires
various config
• Exhaust port design also need
variations for optimization
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12. 6. SPARE PARTS
• Depending on type of testing
• Some component testing
need multiple spare parts
esp. for destructive testing
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13. 7. FUEL & LUBRICANTS
• Pre testing preparation
• During Testing monitoring
• Post Testing preparation
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14. 8. TOOLS
• Very much depends on
type of testing
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15. IntRo ICE- Internal Combustion ENGINE
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Module : Introduction
• History of ICE
• Fundamental ICE
• 4 Stroke engine Cycle
• Basics Forced Induction
Technology
• Basics- engine cooling system
Module : Instrumentation &
Commissioning
• Test Bed Instrumentation
• Thermocouple & Pressure sensor
• Instrumentation Points
• Additional Measuring eqmnt
• Test Cell Alarm system.
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16. Introduction to ICE- What is ICE ?
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17. Fundamental ICE & 4 Stroke cycle
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19. Observe 4 stroke Engine cycle
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Basics – forced induction vs naturally aspirated engine

21. Basics of Forced Induction
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22. Turbocharged mechanism
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23. Supercharged mechanism
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24. Performance with Forced Induction
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25. BASICS- ENGINE cooling system
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26. Modern/advanced cooling system
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27. SF cooling system
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29. Research Activities
Engine Performance & Emission
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2013
2014
2015
2016
2017-
Present
Petrol
Diesel
Hybrid
EV
RON 95 vs 97
Palm oil
BioDiesel
BioDiesel
From Waste
B5 –> B100
BioDiesel
BioDiesel
Storage
Impact
BioDiesel
Emission
BioDiesel
Engine
Performance
BioDiesel
Tribology
Active Safety
Passive Safety
Engine
Performance
Emission
ETB HILS
Cylinder
Deactivation
BioDiesel
Additive
Autonomous
Auto Lane
detection
Hydrogen
enrichment
Draft
NAP2010
Fluidic
lubrication
Dry
lubrication
ICE HCCI
BioDiesel
Nanolubricant

30. Dyno Test Facility
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2007
2014
2015
2017
2000 HP
Eddy-Current
500 HP
Eddy-Current
125 HP AC
30 HP AC
800 HP
Eddy-Current
Real-Time Gas
Analyzer
Cylinder Pressure
Mapping Kit
50 HP
Eddy-Current

31. 2014
2017
Flowbench Test Facility
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SuperBench
Swirl & Tumble Meter
 For intake and exhaust development
 Engine displacement range: 600cc to 2700cc

32. Emission Measurement Equipments
• Diesel euro5 (2009) compliance vs Euro6-2015
• Petrol euro3 (2001) compliance vs Euro5-2015
• Malaysian emission standard,
• 8 yrs(diesel) & 14yrs(petrol) behind industry std
• Marketing Opportunity-Locally
• Global market need more stringent compliance
• Promote better environment for future
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33. Tribology Facilities
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FACILITIES
4-ball
tester
Pin-on-disc
tribometer
Bomb calorimeter FTIR
Thermographic
camera
Rotational
viscometer
UV Spectrometer
Flash Point Tester
Optical
microscope
Gas
Chromatography
Surface
Roughness
Tester
Ultrasonic
homogenizer
Densitometer

34. CARe-FKM-UTeM Committed
with Proton Research Collaboration
34
Supported by:
•UTeM internal
grant
•PJP/2017/FKM-
CARE/S01564-
RM30k
•Final year student

35. 35

36. ERASMUS Contents
1.Introduction- EU Erasmus Project
2.About UTeM-Facts
3.Gap Analysis
4.Objectives United, NAP
5.Methodology
6.Expected Results-EKTU
7.Conclusions & Way forward
8.Acknowledgement
598710-EPP-1-2018-1-AT-EPPKA2-CBHE-JP
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37. 1.Introduction
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38. 1.About UTeM- Fast Facts
• 1st Technical Univ in Malaysia Est Dec 2000 - Practice&
application oriented
• Celebrated 20 years in Dec 2020
• QS Asian Univ Ranking #401-450
• UI Green Metrics World Univ ranking #8 Asia & #109 World
• Location UNESCO World Heritage Site- City of Melaka
• Public Univ Student population ~11,051 with 846 international
students (from 34 countries~>70% Postgrad). Academics ~793.
• 8 Faculties - 4 Engineering + 4 Technology- Specialized
Engineering Program
• 10 Engineering Technology Program
• Offer Diploma, Bachelor, Master, PhD, EngD, DIT, DTM.
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39. 3.SEA Gap analysis -Automotive
• Part of Work Package 1: Politechnico Di Torino (PTT)
• Automotive Industry needs, from European to
South East Asia countries.
• Gap Analysis for Malaysian, Indonesian & Thailand
Automotive Industries.
• Key findings :
• Mismatch expectation from Automotive Industry
vs University graduates
• AE program separately from ME program
• Lack of high skill workers in Automotive Industry towards Autonomous &
sustainable IR4.0
• Lack of specialised courses in emerging Automotive with hands on training
• Lack of facilities for business cooperations with Automotive industries.
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40. 4. Objectives- United
• Capacity Building Higher Education CBHE
• Automotive Engineering Knowledge
• Technology Transfer EU to SEA- Through EKTU
• Increase Student Employability
• Automotive Industry - Regional Development
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41. 5.Methodology- Training
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42. 6.Expected - Results
• UTeM Responsibility WP 4 : EKTU Establishment & Operations
• Engineering Knowledge Transfer Units (EKTU) established in each SEA
partners.
• Malaysia focus on Hybrid Trainer and Fuel Management System
• Thailand focus on Hybrid Power train and simulation
• Indonesia focus on Electric, Hybrid & Fuel Cell vehicle
• Expected to Increase Automotive Student Employability
• To supply knowledgeable and well-trained Automotive Engineer for the future.
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43. Engineering Knowledge Transfer Units to Increase
Student´s Employability and Regional Development
The European Commission's support for the production of this publication does not constitute an endorsement of the contents, which
reflect the views only of the authors, and the Commission cannot be held responsible for any use which may be made of the
information contained therein. 598710-EPP-1-2018-1-AT-EPPKA2-CBHE-JP
UTeM UNITED
FUTURE FUEL DESIGN TRAINING CENTER
Engineering Knowledge Transfer Units
Project Leader : Noreffendy Tamaldin
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44. Objectives of UTeM EKTU
1. Develop expertise in academic
to support National Automotive
Policy in Malaysia.
2. Develop training module for
commonrail injection system for
improved engine performance
3. Incorporate the designed
EKTU into academic curriculum
(B. Eng & M. Eng module) &
offer the program to Academia,
Industry and Gov agencies.
Target Group
• Academic
• Student B. Eng, M.Eng
• Lecturer, Teaching Engineer,
Technician
• Colleges Instructor, High School
Teacher
• Industry
• Automotive
• Proton, Dreamedge, Mazda,
Nissan, Bosch, Denso
• Fuel Supplier-
• Petronas, MPOB, Biofuel
Manufacturer
• Government Agency/
Enforcement
• SIRIM, JPJ, Puspakom, DOE,
MARii, MITI, MIROS, MRC Data
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45. UTeM EKTU Training Program
1. Fundamental- Fuel Delivery System
(FDS)
2. Components in FDS- Fuel Injection
3. Working Principle of Fuel Injection
System
4. Typical test in fuel injection system
5. Parametric identification in fuel
injection system-Spray pattern, pulse,
response time
6. Automatic Test vs Manual Test
1. Programming of Fuel Injection
parameter
2. Demonstration of Fuel Injection
System
3. Analysis of fuel injection system
performance
4. Synthesize the fuel injection
optimization
5. Leak test & Coding
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46. 6.Expected - Results _ UTeM EKTU
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UTeM EKTU - multimedia

48. 7.Conclusions & Way Forward
• With EKTU established- Increase university business
cooperation with Automotive industry.
• The curriculum developed align with the IR4.0
development especially in automotive industries.
• Graduate produced meet the automotive industry
expectation.
• University become the centre of reference for state of
the art automotive technology.
• Sustainability of EKTU operations as mean of income
generation to the university.
• Closing the gap between academia and automotive
industry of the future.
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49. 8.Acknowledgement
1. FH Joanneum, Austria- as European Partners for allowing UTeM to participate in this Erasmus+
CBHE United Programme.
2. FH Aachen - as liaison EU partners for UTeM, Train of Trainers, Quality & Ethics.
3. Politechnico Di Torino, Italy - for the Automotive Gap Analysis- Industry needs
4. UTeM, Malaysia for supporting the entire United Program
5. UPM, Malaysia- Cross Countries Exchange Conferences
6. Dreamedge, M’sia Sdn Bhd- for Malaysian automotive partner on EKTU
7. Atipong Motor, Thailand - as Thailand automotive partner on EKTU
8. USU, Indonesia- for Dissemination & Visibility Initiative promotive United project
9. UNUD, Indonesia, CKU, MSU, Thailand for continuous supports and sharing of best practices in
Automotive Engineering
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50. The
End !
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51. • Q & A
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52. Engineering Knowledge Transfer Units to Increase
Student´s Employability and Regional Development
The European Commission's support for the production of this publication does not constitute an endorsement of the contents, which
reflect the views only of the authors, and the Commission cannot be held responsible for any use which may be made of the
information contained therein. 598710-EPP-1-2018-1-AT-EPPKA2-CBHE-JP
https://www.facebook.com/unitederasmus/
https://united-erasmus.usu.ac.id/
N.Tamaldin © 2021