Borghi & Saveri has designed and built an innovative, fully custom test bench for OTK Kart Group, a worldwide leader in karting.
Developed in collaboration with Alma Automotive, the project addresses the need for faster, more precise, and highly reliable tools to support the development of racing engines.
The Heart of the Test Bench: the FA-75 Dynamometer
The test cell is equipped with the new Borghi & Saveri FA-75 active dynamometer, designed to accurately replicate on-track laps using telemetry data. This dynamic test bench offers greater precision and faster response compared to passive benches:
- Active Bench: the dynamic test bench can actively brake or drive the engine, following configurable power curves that replicate on-track performance. During acceleration phases, the bench applies controlled braking while measuring engine output; during deceleration, it slows the engine according to a programmable profile. This ensures complete repeatability of tests and fully comparable data, with each test starting from the same initial conditions.
- Advanced Automation and Control: thanks to integrated sensors and systems, every parameter can be precisely monitored, and data remain consistent even under changing environmental conditions, a key strength of Borghi & Saveri test cells.
- Torque is measured using a high-precision torque sensor.
- Cooling is managed by dedicated fluid conditioning units, directly controlled by the bench automation system. Thanks to precise closed-loop control, water temperature is maintained within ±1°C of the target value.
- Tailor-Made Flexibility: the test cell can be quickly adapted to a wide range of engine configurations, from KZ (geared engines) to OK and Mini (single-speed engines), with the ability to connect to either direct-drive or chain transmissions.
- Lap Replicability: every lap recorded on track can be reproduced multiple times on the test bench, making it ideal for durability and component stress testing.
- Engine Protection: the system can quickly detect engine seizure and stop the test before any damage occurs, much faster than even a professional driver could react on track.
Repeatable Testing
By combining the dynamic test cell with Borghi & Saveri’s automation system, engine comparisons can be carried out with extremely high precision, virtually eliminating variables unrelated to the powertrain.
The highly stable testing conditions ensure reliable results, as confirmed by OTK technicians: for example, precise control of water temperature and careful management of test cycles effectively remove the influence of external factors. This accuracy is reflected in the close correlation between exhaust gas temperatures on the bench and on track, as well as in timing comparisons between different engines.
The result is a tool that simplifies engineers’ work and makes test bench evaluations more reliable and effective, reinforcing Borghi & Saveri as a reference point for tailor-made motorsport solutions.
Advanced analysis with OBI-M2
The test cell is also equipped with Alma Automotive’s OBI-M2 combustion analysis system, derived from Formula 1 technology. In the version dedicated to two-stroke engines, it delivers an even higher level of detail for the pursuit of maximum performance.
The combustion analysis system enables the development and optimization of engine calibration both on the test bench and on-board the vehicle, thanks to in-depth information and its extremely compact dimensions. OBI-M2 also acts as a monitoring tool, detecting any deviation from user-defined limit values and recording raw data with a complete pre- and post-event history.
The value of Borghi & Saveri
This project exemplifies our approach: designing and building fully custom test benches to the highest quality standards, with meticulous attention to detail, always tailored to meet our clients’ specific needs.
As a long-standing supplier in the karting world, Borghi & Saveri strengthens its position as a leader in applied innovation, and the partnership with a top international brand like OTK Kart Group is a clear testament to this.
By bringing to karting the same technologies used in our MotoGP-dedicated test benches, we have raised the standards of precision, safety, and repeatability.