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How to determine a continuous torque or power for an automobile engine

02/11/2022 9:43 PM

Automobile manufacturers typically specify the engines that they install in their cars by maximum horsepower and the corresponding rpm, and maximum torque and its corresponding rpm.

A quick look at my own car's specs tells me that at maximum horsepower the engine would have a life measured in minutes. I have even hesitated to rev the engine up to the rpm corresponding to maximum torque, even without putting it under load.

The question: for people selecting a production engine for use other than in an automobile (industrial use, marine propulsion, aircraft propulsion) where it will have to provide power for a long period of time - how do they come up with that "continuous service" value? The closest I have been able to get to it so far is that aircraft piston engines seem to be rated at the maximum torque value, but presumably they are designed to operate continuously at that value, and I suspect that car engines are not.

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#1

Re: How to determine a continuous torque or power for an automobile engine

02/11/2022 11:17 PM

The main problem with engines as I see it is heat and motion, so lower speed is key and proper cooling as failsafe as possible, and proper lubrication, is to me key to longevity....Marine engines are a good example, and 18 wheelers another, and farm tractors, generators, all examples of diesel engines with high torque at low RPM...

Actually it comes down to piston speed....

https://en.wikipedia.org/wiki/Mean_piston_speed

"Continuous power rating is used in applications where supplying power is at a constant 100% load for an unlimited number of hours each year. Continuous power rated units are most widely used in applications where the power grid is unreachable. Such applications include mining, agriculture or military operations."

"The continuous power (COP) rating is used when the generator set must supply a constant load for an unlimited number of hours annually. These applications, such as remote power stations, typically use multiple generator sets to power this constant load, which is also known as a “baseload power station.” The baseload is the minimum amount of power that a utility must make available to meet its customers’ demand for power.

Most manufacturers follow the ratings detailed in ISO-8528-1. However, some have slight exceptions to these ratings, which help them meet their customers’ requirements, performance capabilities or maintenance schedules."

https://www.generatorsource.com/Standby_vs-_Prime_vs-_Continuous_Generator_Power.aspx

Engine speed Ne [rpm] is characterized by four main points:

Nmin – is the minimum stable engine speed at full load
NTmax – is the engine speed at maximum engine torque
NPmax – is the engine speed at maximum engine power; also called rated engine speed
Nmax – is the maximum stable engine speed

The full load engine torque curve Te [Nm] is characterized by four points:

T0 – engine torque at minimum engine speed
Tmax – maximum engine torque (peak torque or rated torque)
TP – engine torque at maximum engine power
TM – engine torque at maximum engine speed

The full load engine power curve Pe [HP] is characterized by four points:

P0 – engine power at minimum engine speed
Pmax – maximum engine power (peak power or rated power)
PT – engine power at maximum engine torque
PM – engine power at maximum engine speed

https://x-engineer.org/power-vs-torque/

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#3
In reply to #1

Re: How to determine a continuous torque or power for an automobile engine

02/12/2022 12:29 AM

Super. Just what I was looking for.

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#2

Re: How to determine a continuous torque or power for an automobile engine

02/11/2022 11:25 PM

The word for today is "dynamometer."

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#4
In reply to #2

Re: How to determine a continuous torque or power for an automobile engine

02/12/2022 12:31 AM

Well, yes, but I don't seem to have one of those, and they are not cheap.

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#5
In reply to #4

Re: How to determine a continuous torque or power for an automobile engine

02/12/2022 12:55 PM

Smartphones have sensors for acceleration, location, speed, elevation, etc. Given tire sizes and gear ratios, an app can compute RPM. Horsepower can be computed by torque x rpm.

I haven't tried this one, but it's something to look at. There are probably others out there also.

https://play.google.com/store/apps/details?id=brandoncharliekaylie_industries.com.g_meterapp&hl=en_US&gl=US

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#10
In reply to #5

Re: How to determine a continuous torque or power for an automobile engine

02/13/2022 8:10 PM

Computing isn't the problem. The problem is determining where, on an engine's performance map, you can safely operate it for long periods.

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#6

Re: How to determine a continuous torque or power for an automobile engine

02/12/2022 10:59 PM

Do some digging into current mfgr testing procedures. I think you'll find that your fears are unfounded. The torture and duration of that torture is far worse than any reasonable, or even unreasonable, person is likely to inflict on an engine.

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#16
In reply to #6

Re: How to determine a continuous torque or power for an automobile engine

02/16/2022 4:01 AM

Will do.

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#7

Re: How to determine a continuous torque or power for an automobile engine

02/13/2022 12:30 AM

A few comments about spark-ignited engine life:

  1. Over the years, I have been involved with gasoline (and natural gas /LPG) spark ignited engines designed for passenger cars or pickup trucks that last for many 100's of hours above the the redline rpm (say 6000+ rpm) on engine dynamometers when doing OEM-specific durability tests. Valve recession is often a limiting factor for these engines at high speeds.
  2. An old engineering rule of thumb, says that valve recession (wear) rate goes as the rpm to the third power. That means that valves wear out 27 times faster at 6000 rpm versus 2000 rpm. (6000/2000)^3 = (3)^3 = 27.
  3. And yes thermal affects are also crucial - especially with respect to oil oxidation and potential piston rings problems (coking). So good cooling is critical too.
  4. In practical oil field applications (like pumping heavy oil out of wells in Northern Alberta), slightly modified spark ignition automotive engines are used that will run almost continuously (24/7) at approximately 1500 to 2000 rpm. I have seen very good engines with decent maintenance that actually exceed 30,000 hours (3.4 years) of life. Extra large oil pans (25 quarts or so) were used to allow extended oil change intervals of 2500 hours (~ 3.5 months).

I hope that gives some extra perspective.

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#9
In reply to #7

Re: How to determine a continuous torque or power for an automobile engine

02/13/2022 10:11 AM

Stellite valves practically eliminated valve wear,and I think Plymouth was the first to use them.

I wonder what the limiting factors are now?

I would think clean oil,clean air,and proper oil temperature,around 160F,and the number of thermal cycles.Cold starts do a lot of harm in gasoline/diesel engines.

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#11
In reply to #7

Re: How to determine a continuous torque or power for an automobile engine

02/13/2022 8:15 PM

It does help.

I had assumed that bearings would be the problem - that an engine with more main crankshaft bearings would last longer at higher load. I hadn't thought about the valves.

The rule about rpm cubed will be useful.

The long life of engines running 1500 to 2000 rpm makes sense, as that is the speed at which they usually operate in automobiles, except for overtaking and hill climbing.

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#8

Re: How to determine a continuous torque or power for an automobile engine

02/13/2022 10:03 AM

There are always some outliers in every field,and I know of one in particular:A 1959 VW beetle.A friend drove one over 2000 miles every weekend for many years.The odometer had tripped over several times,and it still ran great,no smoke,using only a quart of oil every 3000 miles.I asked him how often he changed the oil.He said "Never changed it.Just added a quart when it gets low."

How often do you have the valves adjusted "Never had them adjusted,he replied."

It sounded incredible to me because VW beetles do not have an oil filter,just a strainer,and the valves need adjusting every 3000 miles,and#3 exhaust valve is the weak link in the motor because it gets hotter than the others because the oil cooler blocks some of the air flow to number3 cylinder.

I decided to look up the serial number,and discovered it was an industrial engine,made for a generator that had been transplanted into the car before he got it.36 hp rated,but he could keep up with I 95 traffic from Florida to Virginia and back,but he confessed to drafting big trucks to keep up at 70 mph.

He said he could practically let off the gas and let the draft pull him along.when he got close enough.

I told him he liked to live dangerously,but he said that he could stop a lot faster than the truck,and if he saw brake lights on the truck,he hovered over his brake pedal with his left foot.

The body finally rusted out to the point that it was un drive-able,and he junked it.

I would like to have been able to tear that motor down and find out what was so special about it.

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#14
In reply to #8

Re: How to determine a continuous torque or power for an automobile engine

02/16/2022 3:57 AM

My suspicion is that the valves and valve seats were harder (see an earlier reply to my question) and the engine had more (or better) main crankshaft bearings. Better baffling would help the "hot" cylinder head (VW baffling was pretty primitive).

And then, if it was an industrial engine, running a slightly rich mixture would reduce the thermal load and reduce detonation.

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#15
In reply to #8

Re: How to determine a continuous torque or power for an automobile engine

02/16/2022 3:59 AM

My suspicion is that the valves and valve seats were harder (see an earlier reply to my question) and the engine had more (or better) main crankshaft bearings. Better baffling would help the "hot" cylinder head (VW baffling was pretty primitive).

And then, if it was an industrial engine, running a slightly rich mixture would reduce the thermal load and reduce detonation.

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#12

Re: How to determine a continuous torque or power for an automobile engine

02/15/2022 11:12 AM

<...to rev the engine up to the rpm corresponding to maximum torque...>

Torque is the property presented to the prime mover by the load. With no load attached, the prime mover is not overcoming any torque, and therefore not developing any shaft power.

[Output shaft power] = [torque overcome] x [shaft speed]. It is quite possible, and indeed usual, for the peak torque capability and the peak output power to be at different shaft speeds.

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#13
In reply to #12

Re: How to determine a continuous torque or power for an automobile engine

02/16/2022 3:53 AM

Correct. I was just referring to the alarming noises made when the engine approached, at no load, the rpm at which maximum torque was developed at full throttle.

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#17
In reply to #13

Re: How to determine a continuous torque or power for an automobile engine

02/17/2022 11:15 AM

Loose bearings? They would be quieter under load.

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#18

Re: How to determine a continuous torque or power for an automobile engine

06/26/2022 12:16 AM

Of course they are not. Won't brake right away, but continous stressing is not what they're designed for. And another thing, actually reving with no load is a bit worse mechanically than reving under moderate load. Now thermally it's another story. Depends on the design and engine condition. On the other hand keeping revs low is good most of the time for gas millage, but does stress parts like catalytic onverters, engine mounts and other things on less than perfect designed engines, increases carbon deposition all around from EGRs, can increase fuel dilution caused wear etc. And if I need max 60HP all the time why on earth I would buy 300? (LOL) S.M.

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