Riassunto analitico
The purpose of this thesis is to investigate the "Coldtest", an innovative method of end-of-line testing for internal combustion engines. The subject of investigation was provided by Automobili Lamborghini, hosting company of the internship.
The supercar's manufacturer is experiencing an upward trend in sales, which has triggered a management problem: to meet this growing demand of vehicles Lamborghini struggles with the available space at its historic Sant'Agata Bolognese facility. Thus require a conversion of the actual production process to the more efficient Model-mix. But as production volume increases, also the powertrain testing process must be adjusted accordingly, ensuring a faster, reliable and more sustainable way of validating their assembly. This is one of the most important and delicate phases of the entire manufacturing process, since not only the quality of the final product depends on it, but above all the performance, the hallmark of every Lamborghini. This thesis aims to meet the factory's request of developing a model capable of understanding whether or not each new ICE is assembled correctly. To achieve the goal, all the tools that the master’s degree in Advanced automotive engineering provides will be exploited, from the analysis of the mechanics to the simulation of the electric drive, relying on software like Matlab, Simulink and Flux. The ultimate goal is to predict the behavior of the future hybrid powertrain in motored condition. For this reason the main thread of this work is the implementation of a physical model which starting from the ICE's characteristics estimates the typical parameters monitored during coldtest. In addition will be included tools to perform post-processing analysis and fault detection.
The paper is divided into four chapters.
In the first is provided an overview of hybrid powertrains, required to understand the technical choiches of new Lamborghini's SSC architecture. Then the focus can move into Lamborghini's Model-mix project and the subsequent EOL test, delving into the Coldtest method and comparing it with the traditional hot-test.
The second chapter begins the theoretical study of coldtest, starting with an analysis of Lamborghini's ICE and arriving at an analytical calculation of its motored torque.
In the third chapter there is the heart of this work, since will be explained the mathematical model developed in Matlab and Simulink platform. At this point is necessary to evaluate the effect on the coldtest of the dual mass flywheel and the electric drive, developing for both dedicated sub-models.
The final chapter will discuss all the model's results, which will be compared with those derived from a test performed on a prototype, searching with experimental results the model's validation.
Additional consideration will be enunciated at the end of the thesis along with possible future developments of this application.
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Abstract
The purpose of this thesis is to investigate the "Coldtest", an innovative method of end-of-line testing for internal combustion engines. The subject of investigation was provided by Automobili Lamborghini, hosting company of the internship.
The supercar's manufacturer is experiencing an upward trend in sales, which has triggered a management problem: to meet this growing demand of vehicles Lamborghini struggles with the available space at its historic Sant'Agata Bolognese facility. Thus require a conversion of the actual production process to the more efficient Model-mix. But as production volume increases, also the powertrain testing process must be adjusted accordingly, ensuring a faster, reliable and more sustainable way of validating their assembly. This is one of the most important and delicate phases of the entire manufacturing process, since not only the quality of the final product depends on it, but above all the performance, the hallmark of every Lamborghini. This thesis aims to meet the factory's request of developing a model capable of understanding whether or not each new ICE is assembled correctly. To achieve the goal, all the tools that the master’s degree in Advanced automotive engineering provides will be exploited, from the analysis of the mechanics to the simulation of the electric drive, relying on software like Matlab, Simulink and Flux. The ultimate goal is to predict the behavior of the future hybrid powertrain in motored condition. For this reason the main thread of this work is the implementation of a physical model which starting from the ICE's characteristics estimates the typical parameters monitored during coldtest. In addition will be included tools to perform post-processing analysis and fault detection.
The paper is divided into four chapters.
In the first is provided an overview of hybrid powertrains, required to understand the technical choiches of new Lamborghini's SSC architecture. Then the focus can move into Lamborghini's Model-mix project and the subsequent EOL test, delving into the Coldtest method and comparing it with the traditional hot-test.
The second chapter begins the theoretical study of coldtest, starting with an analysis of Lamborghini's ICE and arriving at an analytical calculation of its motored torque.
In the third chapter there is the heart of this work, since will be explained the mathematical model developed in Matlab and Simulink platform. At this point is necessary to evaluate the effect on the coldtest of the dual mass flywheel and the electric drive, developing for both dedicated sub-models.
The final chapter will discuss all the model's results, which will be compared with those derived from a test performed on a prototype, searching with experimental results the model's validation.
Additional consideration will be enunciated at the end of the thesis along with possible future developments of this application.
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