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Over the last decades, the use of computers has become an integral part of the engine development process. Computer-based tools are increasingly used in the design process, and especially the layout of the various subsystems is conducted by means of simulation models. Computer-aided engineering plays a central role e.g. in the design of the combustion process as well as with regards to work performed in the area of engine mechanics, where CFD, FEM, and MBS are applied. As a parallel trend, it can be observed that various engine performance characteristics such as e.g. the specific power output and the power-to-weight ratio have undergone an enormous increase, a trend which to some extent counteracts the increase in safety against malfunction and failure. As yet, due to the constant need for further optimization, mechanical testing and verification processes have not become redundant, and it is assumed that they will remain indispensable for the foreseeable future.

During the past years, there has been an increasing tendency to seriously question and break up old and ingrained structures in combustion engine testing. The reason for this is the continuously increasing number of engine and vehicle variants and a variety of applications resulting from it, which significantly push up development costs and times when carrying out the classical testing patterns. The following article by FEV Motorentechnik GmbH introduces a comprehensive test methodology for purposeful endurance testing of modern drive units (in particular from the fields of passenger cars and commercial vehicles). The procedure and the testing philosophy are explained in detail, illustrated by a concrete development example.

The requirements for diesel and gasoline engines are continuously increasing with respect to emissions, fuel consumption and durability. Besides the engine development process the quality of the production engine itself has to be ensured. This paper discusses alternative philosophies and approaches in terms of the quality management process. Based on a detailed analysis of the required equipment advanced solutions are presented. Modular containerized test cells are described being equipped exactly to the current testing task ready to use in low infrastructure. The testing capacity of the facility can be adjusted to the actual production volume by simply removing or adding modular test cells. Thus, at every facility the testing tasks can be executed successfully and the investment can be kept low.