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EDL TEST FACILITIES KOTHRUD

EDL Test Facilities – Kothrud

The Engine Development Lab (EDL) at ARAI at Kothrud provide world-class infrastructure and expertise to support automotive and powertrain innovation

  • 10 nos of performance engine test cell Accredited to ISO/IEC 17025:2017
    • 5 Steady-State Eddy Current Dynamometers (up to 800 kW)
    • 5 Transient Engine Dynamometers (up to 460 kW)
  • 3 Durability Test cells
  • 1 Vehicle Development Test Cell with 150 kW 2WD Chassis Dynamometer

STEADY STATE TEST FACILITY FOR HEAVY-DUTY IC ENGINES – 800KW

This facility supports testing of engines up to 800 kW output, 5650 Nm torque, and speeds of up to 4000 rpm. It is equipped with advanced instrumentation, including:

  • Emission Measurement System with FTIR for ammonia slip
  • Particulate Measurement System (PM)
  • Airflow measurement system
  • Fuel metering with conditioning
  • Coolant and Intake air conditioning system
  • Smoke meter and opacimeter
  • High-speed data acquisition with pressure and temperature sensors

APPLICATIONS INCLUDE:

  • Advanced combustion development for conventional and alternate fuels
  • Testing of non-automotive engines (CEV, tractors, gensets, earth-moving and mining equipment)
  • Retrofit Emission Control Device (RECD) development and certification for high-power applications
  • Fuel efficiency and thermal management optimization

TRANSIENT ENGINE TEST FACILITY – 460 KW

Our advanced transient test facility is designed for high-performance engine evaluation and calibration and it supports testing of engines up to 460 kW, 2680 Nm torque, and speeds of up to 5010 rpm. It is equipped with advanced instrumentation, including

  • Two-line raw emission analyser system
  • FTIR for ammonia slip measurement
  • Particulate measurement system
  • PN 23 – Particle number measurement system
  • Airflow measurement system
  • Fuel mass flow measurement system
  • Fuel, Coolant and Intake air conditioning systems
  • Smoke meter and Opacimeter
  • High-speed data acquisition system for Crank angle, SOI, EOI, DOI, Combustion pressure, Intake manifold pressure etc. measurement with Post-processing
  • Wide range of temperature sensors and pressure transducers

APPLICATIONS INCLUDE:

  • Evaluation, Calibration and testing of engines for automotive application as per BS-IV, BS-VI norms
  • Evaluation, Calibration and testing of engines for tractor application as per Bharat (Trem) Stage IV norms
  • Evaluation, Calibration and testing of engines for CEV application as per BS-IV, BS-V norms
  • Evaluation, Calibration and testing of engines for genset application as per CPCB-IV+ norms
  • Calibration and optimization for engines operating on Diesel, Gasoline, CNG, Biodiesel, Ethanol ED95, and Methanol

ENGINE DURABILITY TEST FACILITY

Our Engine Durability Test Facility is designed for comprehensive reliability and performance validation.

CAPACITY:

  • Up to 350 kW, with three dedicated test cells
  • Testing range: 150 kW to 350 kW

KEY FEATURES:

  • Three-shift operation with highly skilled manpower
  • Over 100,000 hours of durability testing experience

APPLICATIONS:

  • Complete engine durability testing for automotive and non-automotive engines
  • Component validation
  • Fuel and oil evaluation
  • Type testing as per IS 10000 standards
  • Mild thermal shock and end-of-line testing
  • After-treatment performance evaluation
  • Deterioration factor (DF) identification

INSTRUMENTATION & EQUIPMENT:

  • Fuel meter (0–100 kg/hr) with temperature control (15°C to 60°C)
  • Water conditioning system (up to 300 kW) with temperature control (25°C to 120°C)
  • 8 pressure sensors and 24 temperature sensors
  • Smoke meter
  • Blow-by meter (up to 300 LPM)
  • ECU interface supporting 300 parameters

GENSET ENGINE EMISSION CERTIFICATION

1) Type Approval (TA) & Conformity of Production (CoP) testing for Genset engine up to 800kW gross mechanical power and Portable Generator sets (upto19KW & 800cc engine displacement) as per CPCB norms.

  • Testing of Genset engine operating on Diesel fuel
  • Testing of Genset engine operating on Gasoline fuel
  • Testing of Genset engine operating on Alternate Fuel- Ethanol, CNG, LPG, HCNG, Duel-Fuel etc.
  • Testing of Portable Generator sets operating on Gasoline fuel, Alternate Fuel

2) Facility

  • Test facilities are Accredited as per – NABL- ISO / IEC 17025: 2017
  • Test facility having 11 performance & emission test cells
  • Testing of Genset engine at NTP condition with close loop intake & exhaust system
  • Measurement of Genset engine gross mechanical Power on engine dynamometer
  • Measurement of Gaseous & Particulate emission- CO, HC, NOx, Smoke, PM, NH3
  • Testing Portable Generator Sets (upto 19KW) by using resistive load bank
  • Testing of Genset engine as per D2 5-mode steady state discrete mode test cycle
  • Testing of Genset engine as per D2 5-mode RMC test cycle
  • Testing of Portable Generator sets as per D1 3-mode test cycle
  • Testing of Genest engine for off-cycle emission-NTE
  • Testing of Genset engine for NOx control diagnostic-NCD
  • Testing of Genset engine for Particulate control diagnostic-PCD
  • Testing of Genset engine for Infrequent Regeneration Adjustment Factor-IRAF determination
  • Testing of Genset engine for Deterioration Factor-DF determination
  • Running-in of Genset engine as per requirement

FLOW CALIBRATION

ARAI has developed a state-of-the-art Fluid Flow Calibration Facility for precise calibration of a wide range of flow measurement instruments, including volumetric air flow meters, blow-by meters, and mass air flow (MAF) meters.

This facility is accredited by NABL in accordance with ISO/IEC 17025:2017 under the Fluid Flow discipline. ARAI offers reliable and repeatable calibration services to support the needs of the automotive industry.

BLOW BY / FLOW METER CALIBRATION

Range CMC (±)
>10 LPM to 30 LPM ±1.50% of Reading
>30 LPM to 100 LPM ±1.05% of Reading
>100 LPM to 200 LPM ±1.02% of Reading

MASS AIR FLOW METER CALIBRATION

Range CMC (±)
>20 kg/hr to 200kg/hr ±1.20% of Reading
>200 kg/gr to 2000 k/hr ±0.75% of Reading

ENGINE COLD STARTABILITY TESTING

ARAI offers cold start ability testing up to –40°C, simulating real winter conditions for engines, batteries, and accessories.

  • In-house cold start test rig captures key parameters—engine speed, battery behaviour, temperatures, pressures, smoke, and HC—using high-speed data acquisition.
  • Test data is analysed with AVL Concerto, ensuring accurate evaluation and detailed technical reports.
  • Supports diesel and gasoline engines, enabling OEMs to validate cold-start performance with high acquisition frequency.

VEHICLE DEVELOPMENT TEST CELL 150KW 2WD CHASSIS DYNAMOMETER

  • Facility is compliant for ISO 17025
  • Exhaust gas sampling system [Constant Volume sampling-CVS]
  • CVS Flow: 4 to 30 m3/min with gasoline/diesel separation in GDi Tunnel
  • Venturi Sizes 4, 6, 8 & 12; Flow Rates from 4 to 30 m3/min in steps of 2 m3/min
  • Heated Bag Double Cabinet for 12 Bags (35 ᵒ C)
  • CO, CO2, THC, CH4, NO2 & NO, NOx concentration along with 5-Gas Analyser (CO%, THC(C6), CO2, NOx, O2, Lambda, RPM, Oil Temp., etc.) for TYPE II emission measurement
  • Particle number Counting
  • PM measurement for GDi and Diesel Vehicles
  • Emission measurement equipment – Dilute bench
  • FTIR for measurement of Non-regulation emissions (~ 25 Nos of Parameters)
  • Compliant to handle regulated fuel: Gasoline, Diesel, Ethanol, Methanol, Blends of Ethanol/Methanol with gasoline, CNG, HCNG (18%) etc.