Case Studies

Test Rig for Engine Testing

To gain an endorsement from vehicle manufacturers, newly formulated engine oils have to pass several standardised engine tests. Savings in the development costs of new oils can be achieved if an inexpensive laboratory or bench test can be found that mimics the behaviour of the full engine test. Kyle Sutherland-Cash developed an oxidation bench test designed to mimic engine conditions experienced by lubricants.

Background

Shell Global Solutions is a research and development company within the Shell Group. It has a worldwide presence, with over 4,700 employees. It serves the oil industry from ‘well to wheel’ and is involved in the formulation of new oil products and technologies, and in offering technical support to frontline services and directly to customers.

Approach

The apparatus that Kyle worked on is intended to mimic some of the conditions to which motor oil is exposed in a firing internal combustion engine, of the sizes used in road vehicles. Kyle was responsible for the detailed design and testing of a large number of the components and subsystems and of the overall layout and interconnections of the parts of the equipment. He devised, tested and refined systems to achieve the project objectives. He taught himself AutoCAD, in order to make details drawings of parts for manufacture by commercial engineering workshops, then liaised with the workshops during the manufacturing process. He completed the specification of the electronic control system, programmed the controllers and has continued to test and modify the mechanical components of the apparatus.

Results

In constructing a rig that can replicate aspects of engine behaviour that it is not currently possible to match, Kyle has helped to provide Shell with a powerful research tool. The bench test will make it feasible to explore a wide range of formulations and components in a way that would be prohibitively expensive if each had to be tested in an engine.

‘If this rig is successful, this work will have provided Shell with a powerful research tool. It may also help us to reduce the numbers of engine tests we shall need to perform to qualify new products. This will make a substantial impact in an important line of business.’

David Wayne

Senior Scientist, Shell Global Solutions