Dynamic test bench for motocross engines

Simulation of engine components enables early design verification and reduced development time while helping racing teams in getting new knowledge. This article presents a multidiscipline dynamic test bench and a benchmark of two different connecting rods for HONDA CRF250R. The test bench embeds mechanical and control system modeling and simulation including electric starters, ignition timing, power control as well as sensors and actuators enabling closed-loop systems. A non-linear finite element program that combines the traditional separate multi-body simulation and finite element modeling and simulation tasks captures all load cases and dynamic effects in one single run. Model reduction techniques are applied to optimize simulation speed and results accuracy. The virtual test bench captures dynamic engine effects and efficiently provides new knowledge about engine performance and integrity.