Benchmarking in IPCO involves deconstructing competitors’ products to find strengths and weaknesses to design new products or to upgrade current ones.
IPCO has design teams with core knowledge in engines, drivelines, transmissions, ranging from passenger cars to commercial, marine propulsion systems, and associated markets such as renewable power generation. Our design proficiency is supported by wide-ranging CAD and CAE softwares.
Simulation has become a key enabling factor in the development of highly competitive and advanced powertrain systems. CAE methods play a vital role in defining new powertrain concepts from hybrid to pure electric vehicles.
CAE activities include stress analysis and fatigue life prediction of components, three-dimensional and one-dimensional simulation of gas exchange and cooling systems, vibration tests, and dynamic behavior studies.
Engine functional tests
Investigation of engine systems and component functionality is the main scope of functional tests. With functional tests we can gather more information on the behavior of cooling, lubrication, crankcase ventilation, friction, and inclination systems and also some main components such as valve and piston.
Engine durability tests
Investigation of engine component durability under severe mechanical and thermal loading is the main scope of durability tests. Some durability tests are designed based on accelerated tests, which mostly are fast and severe compared to real conditions. More data from the field thus assists the validation engineer in designing and implementing more precise durability cycles. During durability tests, different failures may occur, which should be investigated.
Root cause analysis
After reporting a failure, it is necessary to inform all relevant people involved in the team and in the creation of the product. This is performed in IPCO using a psychological model, MBTI, to find the root cause(s) of the failure. Our experts in the validation department, in cooperation with other colleagues, help customers analyze the root causes. It is possible to establish this methodology on a consumer site.
Professional validation services
Design validation plan (DVP) as a “know-how” document of IPCO, focuses on the durability and reliability of a product. This plan includes several items, such as component tests on the rig (the “rig test”), functional tests, durability tests, and vehicle field tests. DVP documents should also satisfy reliability aspects. IPCO experts in the validation department support consumers in this area to define their own validation plan from development until production.
Weak point analysis
Weak point analysis is a professional task, preferably performed by the original designer. In most cases, it is difficult to connect with the designer. Based on experience and knowledge, some person can do this job. IPCO, as powertrain pioneer in Iran, believes that supporting one's own customers in assessing components before and rating them after running, is important. Component rating and relevant root cause analysis is an experience that could be offered to customers. This consultancy consists in design and material shortcut review, assembly, and working boundary condition aspects of the validation team.
Stricter regulations and standards for reduction of fuel consumption and emissions, rising fuel prices and increased pressure on better engines and vehicles performance, in addition to lowering the cost of maintenance, highlights the importance of the calibration process in engines. The calibration process in engines is performed in an engine laboratory equipped with the most advanced equipment. Some of the tests associated with ECU mapping and calibration of gasoline engines are as follows: Calibration of ECU load detection strategy, calibration of base mapping, torque structure calibration tables, and knock calibration.
IPCO engine research center, in collaboration with international academic centers, has established a modern combustion laboratory, at which to conduct fundamental research on combustion and injection spray phenomena. In this laboratory, spray and combustion characteristics of different fuels are inspected using high-speed photography. In addition, the operation of ignition systems is examined using high-voltage probe and high sensitive current sensor.