POWERTRAIN ENGINEERING

ACTIVITIES ON D2T SITESOur human & technical resources

D2T POWERTRAIN ENGINEERING - 11 rue Denis Papin - CS70533 - F-78190 Trappes Cedex - Tel.: +33 (0)1 30 13 07 07

www.d2t.com

D2T: your partnerTrappes - Cesame - Mont Saint-Aignan

Powertrain EngineeringGeneral information

With more than 20 years of experience, D2T, which has partnered bothcarmakers and equipment suppliers, is specialized in powertrain engineering, development and tuning of internal combustion engines.

D2TD2T: MAIN PRIV: MAIN PRIVAATE FRENCH R&D CENTERTE FRENCH R&D CENTER (after OEM)in the field of engines, powertrains and test systems.

GENERALGENERAL INFORMAINFORMATIONTIOND2T - DRECQ DANIEL TECHNOLOGIESHeadquarters and offices: Z.A de Trappes-Elancourt - 11 rue Denis Papin78190 TRAPPES - FRANCETél. : +33 (0)1 30 13 07 07 - Fax : +33 (0)1 30 13 07 10

www.d2t.comInformations: sales@d2t.com

President: André QUIGNODONManaging Director: Gaétan MONNIER

Company with a capital of 9 122 101 € - RC Versailles BSiret 400 286 688 00025 - APE 7112B - VAT: FR-76 400 286 688

Certification: UTAC SQ/11 38-S - ISO 9001 version 2008

CONTENTSCONTENTSENGINE ARCHITECTURE 4ENGINE CALIBRATION - Gasoline & Diesel 7ENDURANCE 8EMISSIONS AFTER TREATMENT 10CHASSIS DYNAMOMETER TESTING 11GEARBOX/TRANSMISSION TESTING 12SUBSYSTEM TESTS 13STANDARD TESTING FOR LUBRICANTS 15OTHER SERVICES 16

YOUR CONTYOUR CONTACTSACTSSales department: +33 (0)1 30 13 07 53

D2T is a strategic subsidiary of IFP Energies nouvelles

Skill setActivities on D2T sites or on-site sub-contracting

AA WIDE RANGE OF SKILLSWIDE RANGE OF SKILLS

Prototyping/instrumentation technicianMechanical and electro-technical technician

Engine test bed technician (energy and mechanical fine-tuning)

Chassis dynamometer test technicianTest bed implementation technician

(software, integration, settings)Test systems maintenance technicianSupport technician

(automation, technical support, training)

Gasoline and diesel calibration technician

Test driver: track and road circuit

Engine assessor

Test bed operations engineerTest bed implementation engineer

Gasoline and diesel calibration engineerReliability engineerArchitectural development engineer

(engines, gearboxes, subsystems)Simulation-calculation engineerEngine control engineer

Project management engineerQuality engineer

Fuel and lubricants specialists

LEVELS

Level 1: 1 to 2 years of experienceLevel 2: 3 to 7 years of experienceLevel 3: more than 7 years of experience

65% of our technicians and engineers have morethan 4 years of experience,25% have more than 6 years of experience.

Steady state engine test bedEddy current dynamometers and AC dynamometers

TECHNICALTECHNICAL CHARACTERISTICSCHARACTERISTICSAutomation, measurement acquisition and engine controlAutomation using MORPHEE, Automapping Number of channels configured according to the requirements of each testECU communications: INCA, ATI Vision, Diag-RA, etc.

Fuels: petrol, diesel, biofuels, LPG, CNGTemperature- and hygrometry-controlled combustion air

Loading machineEC or AC dynamometers(brake or drive mode) Maximum speed: 6,000 to 10,000 rpmMaximum power: 130 to 500 kWMaximum torque: 400 to 2,800 Nm

Data sorting and post-processingData sorted using Excel, Diadem or Concerto according to D2T or customer standards

Possible additional equipment Additional air flow meterCombustion analysisChilled water generator for cold testsAccessory loadParticle meterSmoke meter, opacimeter, blow by meter5-gas + EGR analysis rack with possible double rackComplete vehicle exhaust lineRichness probes

AAVVAILABLE TESTSAILABLE TESTSEndurance/Reliability- Endurance cycles- Thermal shocks- Development and execution of fouling cycles

Characterization of engine architectures- Strip method measurement of friction losses when the engine is driven

with and without combustion- Function characterization (lubrication circuit, de-oiling, cooling circuit,

injectors, super-cooled EGR or not, particulate filter, SCR, distribution, turbo, etc.)

- Vibratory characterization of the powertrain in tests- Measurement of instantaneous speeds and characterization

of acyclisms- Characterization of the lubrication circuit (aeration and permeability)- Thermal balance

Calibration of engine control functions

Dynamic engine test bedAC dynamometers

TECHNICALTECHNICAL CHARACTERISTICSCHARACTERISTICSAutomation, measurement acquisition and engine controlBed tests:- Controlled by MORPHEE 2 and Automapping- Road law simulation by Simudyn 2

Number of channels configured to meet the requirements of each test(pressure, TCK, PT100, analogue input, digital input)Communication with ECUs by ASAM-MCD 3: INCA, ATI Vision, Diag-RA, etc.

Fuels: petrol, diesel, biofuels, LPG, CNGTemperature- and hygrometry-controlled combustion air

Loading machine Type: asynchronous machineMaximum speed, according to power: 7,500 to 10,000 rpmMaximum power: 250 to 530 kWMaximum torque in brake or drive mode: 480 to 3,000 NmAcceleration greater than: 10,000 rpm/s

Data sorting and post-processingData sorted using Excel, Diadem or Concerto according to D2T or customer standards

Possible additional equipment Additional air flow meterCombustion analysisChilled water generator for cold testsAccessory loads (vacuum pump, A/C, alternator with charge variation)Particle meterSmoke meter, opacimeter, blow by meter5-gas + EGR analysis rack with possible double rackComplete vehicle exhaust lineRichness probes

AAVVAILABLE TESTSAILABLE TESTSEndurance/Reliability- Drive simulation in a cycle defined by the customer using vehicle and

road cycle data (speed and selected gear according to the time)- Tests of components that are sensitive to transients

(turbos, particulate filters, etc.)

Characterization of engine architectures- Strip method measurement of friction losses when the engine is

driven with and without combustion in steady state or transient thermal conditions.

- Function characterization under dynamic conditions (turbo response time and pumping, lubrication circuit under severe transient conditions, etc.)

Dynamic calibration of engine control functions- Fine-tuning of footlift strategies (injector reset, maintenance of

the turbo speed, etc.)- Simulation of standard cycles (NEDC, etc.) for depollution fine-tuning.- Simulation of peripheral components of the engine (gearbox) or hybrid

operation (by integrating Simulink models)

Chassis dynamometer48" single-roller dynamometer

TECHNICALTECHNICAL CHARACTERISTICSCHARACTERISTICSAutomation, measurement acquisition and engine controlTest controlled by MORPHEE (automatic rotation possible 24x7)Number of channels configured according to the requirements ofeach test (100 Hz/channel)ECU communications: INCA, DDT 2000

Loading machineSingle-roller 48''Power 190 kWPermissible weight 3,000 kg/axleSimulated inertia 567 to 2,325 kgMaximum load 5,000 NMaximum speed 220 KphMax. height of tested vehicle 2.45 m

VentilationSurface 0.45 m2Speed up to 160 Kph

(variable slaved to the speed of the roller)

Data sorting and post-processingData sorted using Excel or Concerto according to D2T or customer standards

Possible additional equipment:PLC: intended to execute perfectly repeatable cycles by controllinga vehicle on a roller dynamometer using the pedals and gear leverFuel flow meter: used to precisely measure the impact of a systemor strategy on consumption during a standard or endurance cycleCombustion analysis: possibility of using instruments to monitorchanges in cylinder pressure during the testsOpacimeter: used to measure exhaust fumes5-gas analysis rack: measurement of raw exhaust gasesLambda probes: measurement of richness at the exhaust

AAVVAILABLE TESTSAILABLE TESTSEndurance/Reliability- Development and execution of endurance cycles (catalyzer

ageing, particulate filter durability, resistance of the clutch, vehicle/engine/subsystem validation)

- Cylinder head/injector fouling cycles

Thermal- Alternator validation tests in hot atmospheres and in different

road cycles

Functional diagnostic- Validation of engine control functions (EOBD) in specific cycles(NMVEG, Artemis, etc.)

Chassis dynamometer4x4, hybrid, climatic & emission chassis dynamometer (-7°C)

Chassis dynamometer4x4, hybrid, climatic & emission chassis dynamometer (-7°C)

TECHNICALTECHNICAL CHARACTERISTICSCHARACTERISTICSTest cellRegulation of ambient conditions (22°C/50% hygrometry and -7°C)Maximum vehicle height 3,000 mm

Roller2 x single-rollers 48''Front- and rear-wheel drive and 4x4 (hybrid) modesMax. power 2 x 300 kWMax. load 6,600 NMax. speed 250 KphSimulated inertia: up to 4,000 kg, depending on the modeRoad load simulation, speed, effort regulation modeAdjustable wheelbase: 2,000 to 4,200 mm

Radiator grill ventilationThree ventilation surfaces: 0.55 to 0.7 m²Max. speed 140 Kph

Gas analysisDilution: 2 tunnelsDilution flow adjustable from 1 to 15 m3/minPossibility of 4-phase samplingSpecific bags for clean tests

Analysis racksOne bay for diluted, continuous and bag analyses (THC, CH4, NO, NOx, CO, CO2, O2)Two rack for continuous raw analyses (THC, CH4, NO, NOx, CO, CO2)One EGR line

Particles4-phase filter sampling on the two tunnelsFilter scales (range 2 g, precision 0.1 μg) in the regulated enclosureBoth tunnels are pre-equipped for particle metering

Vehicle maceration roomTemperature-controlled macerationStorage for 8 vehicles (7 passenger cars + 1 LCV)

SupervisionTest bed controlled by MORPHEE 2Measurement channel acquisition configured to meet the customer's needsECU communications: INCA, DDT 2000Operations guide

AAVVAILABLE TESTSAILABLE TESTSAnti-pollution tests- Anti-pollution tests according to standard cycles

Stabilized tests- Anti-pollution tests according to standard cycles

Performance tests- Characterization of vehicle performance

Cold start chamberVehicle or engine test cell

TECHNICALTECHNICAL CHARACTERISTICSCHARACTERISTICSEngine pedal position controlled by MORPHEECylinder pressures (by time and angle) recorded by OSIRISThe number of channels (pressure, T°C) can be extended and configu-red to meet the requirements of each testECU communications: INCA

Loading machineNo-load accelerations onlyAn adjacent chassis dynamometer is used to perform the cleaning/conditioning cycles

ChamberTest temperature of between -30°C to +25°C (the enclosure is heated when T° test >T° ambient)Dimensions (length x width x height): 5.4 m x 2.25 m x 2.2 mCan accommodate several vehicles at the same timeEvacuation of exhaust gases

Data sorting and post-processingData sorted using Excel or Concerto according to D2T or customer standardsAnalysis of driver impressions when starting

AAVVAILABLE TESTSAILABLE TESTSAll types of low-temperature tests on static vehicles- Low-temperature fluid tests- Cabin thermal tests- Validation of cold starts (the DV6 C D2T campaign was conducted

using only this system)- Characterization of the impact of biofuels and their properties

on the quality of cold starts

Possibility of conducting engine tests on a carriage- Off-load oil pressure tests- Oil buoyancy tests when empty- Off-load cold start tests

Heater unit test bedCooling radiator & motor driven fan

TECHNICALTECHNICAL CHARACTERISTICSCHARACTERISTICSCapacity (in terms of coolant) 4,000 litersHeating power 190 kWFan power 45 kWMax. dimensions of the air/liquid exchanger 1,200 x 1,500 mm

OPERAOPERATING PRINCIPLETING PRINCIPLEA radiator is positioned in a wind tunnel in a manner that is repre-sentative of the planned application.The flows of air and coolant, the inlet and outlet temperatures andthe pressures on either side of the radiator are measured at diffe-rent temperatures and variable air flows.

The characteristic parameters of the radiator are determined on thebasis of this data.

DESCRIPTIONDESCRIPTIONThis bed is used to generate the characteristic data of automotiveradiators, while taking account of the various installation and vehicleenvironment restrictions, in order to determine their efficiency.It can also be used to measure the thermal exchange properties ofliquids or cooling systems.

This equipment is regularly used to characterize radiators andexchangers for the automotive industry.

MEASUREMENTSMEASUREMENTSCoolant inlet temperature 0 to 100°CCoolant outlet temperature 0 to 100°CAir inlet temperature (ambient) 0 to 100°CDifferential pressure in the radiator -1,500 to +1,500 PaOverpressure on the radiator 0 to 10,000 PaAir flow 0 to 18,000 l/hCoolant flow 0 to 8,000 l/h

TEST DIAGRAMTEST DIAGRAM

AAVVAILABLE TESTSAILABLE TESTS- Radiator thermal performances - Radiator or motor driven fan

calibration or performance grid

Gearbox/Transmission test bedHigh torque electric test bed - single or dual shaft

TECHNICALTECHNICAL CHARACTERISTICSCHARACTERISTICSElectric motortype 1: 110 kW - 350 Nmtype 2: 130 kW - 450 Nm - 10,000 rpmtype 3: 250 kW - 450 Nm - 10,000 rpmTorque meters T10F HBMMultipliersEC dynamometer 400 kW

Additional equipmentGear shift robot by gear lever or cableClutch actuator or automatic gearbox control

AAVVAILABLE TESTSAILABLE TESTS- Tooth, roller bearing and gear shift durability tests- Efficiency measurements- Vibratory characterization of the gearbox under test conditions

Dyno 1 Mult 3,13

Mult 3,13

Mult 3,13

Dyno 2

Dyno 3

GearboxElectricmotor

Gear boxcooling

Oil temp. regulation with blowing on carter

Bearing

Torquemeter

Subsystems test bedsSubsystems, components, accessoiries

SHIFTING TEST BED - MANUALSHIFTING TEST BED - MANUAL GEARBOXGEARBOX- Synchronization tests- Lubricants tests- Selector fork tests- Mechanism tests

TRIBOLOGICALTRIBOLOGICAL LUBRICANTSLUBRICANTS- FZG machines- 4 ball- 4 ball wear- VKA KRL- Timken E.P. and wear- Falex lubricant tester

HEAD TEST BEDHEAD TEST BED- Materials validation- Components tests

DIESELDIESEL INJECTION TEST BEDINJECTION TEST BED- Durability tests- Wave of pressure measurements

GASOLINE INJECTION TEST BEDGASOLINE INJECTION TEST BED- Cycled pressure and temperature- Corrosion tests

EFFICIENCYEFFICIENCY TEST BEDTEST BED- Miscellaneous transmissions tests- Engine friction losses tests

THERMOSTTHERMOSTAATS TEST BEDTS TEST BED- Thermostats tests

Subsystems test bedsSubsytems and transmissions

SYNCHRONISER TESTING MACHINE SAE II TYPESYNCHRONISER TESTING MACHINE SAE II TYPEMANUALMANUAL GEARBOX FRICTIONGEARBOX FRICTIONElectric motor 15 kWSynchroniser applied force 100 to 1,200 NGradient load force up to 20,000 N/sSpeed (dynamic) 0 to 2,970 rpm Temperature -10°C to +70 °C Synchroniser diameter 50 to 80 mm Lubricant 0.3 litre depending upon synchroniser Inertia 0.047 to 0.35 kg.m²

TESTING MACHINE SAE II TYPETESTING MACHINE SAE II TYPEAUTAUTOMAOMATIC & MANUALTIC & MANUAL GEARBOX FRICTIONGEARBOX FRICTIONDRDRYY & WET CLUTCHES& WET CLUTCHESElectric motor 22 kWDynamic speed max 6,000 rpmElectric motor 1 kWBreakaway torque 0.7 to 4.7 t/mn Contact pressure 0 - 900 kPaTorque 0 - 500 NmTemperature 20 to 180°CClutch plate diameter 100 to 190 mm Lubricant 0.3 to 1 liter no flowFlow up to 7 liters / min with oil flowInertia 0.13 to 0.29 kg.m²

Test bed control settingTest bed controlled by MORPHEE or Labview(rotation all around the clock)Number of channels configured according to the requirements of each test (100 Hz / channel)

Data sorting and post-processingData sorted using Excel or Concerto according to D2T or customer standards

AAVVAILABLE TESTSAILABLE TESTS- Durability cycles- Product quality control for lubricants, additives or materials- Braking drag- Screening tests

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