X-Series Engine Dynamometer

Transcription

1 X-Series Engine Dynamometer Technical Specifications Metric May 2011

2 B N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)

3 Table of Contents 1.0 Power Test Inc. Company Overview...1 Engine Dynamometers...1 Chassis Dynamometers...1 Hydraulic Test Equipment...2 Data Acquisition and Control Systems X-Series Product Line Overview X-Series X-Series X-Series How it Works...7 How a Water Brake Dynamometer Works...7 Torque Measurement...7 Calculating Power...8 A Typical System X-Series Data X-Series Data X-Series Data Standard Equipment...21 Dynamometer Absorber...21 Trunnion-Mounted Pillow Block Bearings...21 Base Plate...21 Load Cell and Torque Arm...22 Magnetic Speed Pickup...22 Companion Flange...22 Servo Inlet Valve...23 PowerNet WorkStation Optional Equipment...25 Air Starting System...25 Analog Throttle...25 Charge Air Coolers...25 Drive Shaft...26 Drive Shaft Guard...26 Dynamometer Sub Bases...26 Dynamometer System Cooling Towers...27 Engine Adapters...27 Engine Carts...27 Engine Cooling Column...28 Fuel Measurement System...28 Fuel Storage Tanks...28 Room Exhaust Systems...29 Resilient Couplings...29 Torsional Dampeners...29 Water Pressure Regulation...30 Water Recirculation System...30 C

4 D N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)

5 1.0 Power Test Inc. Company Overview Power Test our name says it all! For more than 35 years, we have been providing our customers with the latest technology and systems that define power. As an industry leader in dynamometer and control system design, manufacture and implementation, our products are found in use by manufacturers, rebuilders and distributors around the world. From our headquarters and manufacturing facilities in Sussex, WI, and with sales representatives located worldwide, we continue to build a great reputation based on exceptional products and solid customer service. Image 1.1: Power Test Inc. Corporate Headquarters Engine Dynamometers Power Test Inc. customers can select from three popular dynamometer styles in order to best meet their needs. Our water brake engine dynamometers excel at testing wide ranges of power inputs using a single dynamometer. Typically used on engines removed from the vehicle, we offer many different configurations to match the application. In addition, we also manufacture Eddy Current and AC regenerative models. Chassis Dynamometers Designed for reliable and repeatable in-frame engine testing, our Chassis Dynamometers feature large rollers, heavy-duty construction and state-of-the-art data acquisition & control. Power Test, Inc. manufactures dynamometer systems to handle single-, tandem-, and multi-axle chassis configurations available in water brake, eddy current, AC regenerative and motorized versions. Image 1.2: Power Test 45X-Series Engine Dynamometer Image 1.3: Power Test CF42-Series Chassis Dynamometer 1

6 1.0 Power Test Inc. Company Overview Hydraulic Test Equipment Power Test Inc. manufactures, installs, and services the AIDCO Test Systems line of world-renowned transmission dynamometers and valve body test stands heavily used in mass transit, heavy duty off-highway and military applications. This broad product line encompasses products used to test transmissions, torque converters, and many styles of hydraulic pumps, along with hydraulic motors, cylinders and valves. Data Acquisition and Control Systems Power Test offers outstanding data acquisition and control systems for all of your power train component testing needs. Each of these systems is designed around globally available hardware utilizing our modular software approach. The similarities of these programs, spanning our entire product range, facilitate easy cross training for our customers and technicians and result in simplicity in diagnostics and reporting. Image 1.4: AIDCO Test Systems Model 900 Hydraulic Test Center Image 1.5: PowerNet Data Acquisition & Control Systems 2 N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)

7 2.0 X-Series Product Line Overview The Power Test Inc. line of X-Series water brake dynamometers are designed, engineered and built for testing a wide range of equipment with one robust unit. Available in three sizes to perfectly match the application, each fixed-base dynamometer may be used for continuous-duty power verification, quality assurance, engine development, plus endurance, and certification tests. The X-Series are modeled after each other in design, operation and construction but differ in size, capacities, operating speeds and inertia to meet a customer s demands. The X-Series feature removable bearing and seal housings to facilitate field servicing without the need for specialty tools or to remove the dynamometer. 45X-Series Used for testing on-highway through off-highway and marine diesel engine applications. The 45X-Series water brake dynamometers are available in five configurations in a testing range from 75 to 3,356 at speeds to 4,000 RPM. The 45X-Series may also be used in tandem applications for increased testing capabilities. 35X-Series Used for testing the majority of diesel engines commonly in use today. The 35X-Series water brake engine dynamometers are available in six configurations in a testing range from 37 to 1,566 at speeds up to 4,000 RPM. Image 2.1: Power Test 45X-Series Engine Dynamometer Image 2.2: Power Test 35X-Series Engine Dynamometer 3

8 2.0 X-Series Product Line Overview 50X-Series Used for testing electric motors as well as industrial gasoline and light- to medium- range, higher speed diesel engines. The 50X-Series water brake engine dynamometers feature nonferrous alloy construction for reduced inertia and are available in a testing range from with speeds to 6,000 RPM. Image 2.3: Power Test 50X-Series Engine Dynamometer 4 N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)

9 2.0 X-Series Product Line Overview q w e r t y a s d u i f o Figure 2.1: X-Series Engine Dynamometer (45X06 w/servo inlet manifold shown) q Water Inlet w Absorber Assembly e Specifications Plate r Dynamometer Shaft (floating end) t Gravity Feed Bearing Oiler(s) y Exhaust Gate Valve i Water Exhaust Tube(s) o Dynamometer Base Plate a Load Valve s Pillow Block Assembly d Dynamometer Shaft (fixed end) f Lubrication Line u Water Outlet 5

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11 3.0 How it Works How a Water Brake Dynamometer Works With Power Test water brake dynamometer, water flow proportional to the desired applied load is used to create resistance to the engine or motor. A controlled flow of water through the inlet manifold is directed at the center of the rotor in each absorption section. This water is then expelled towards the outside of the dynamometer body by centrifugal force. As it is directed outward, the water is accelerated into pockets on the stationary stator plates where it is decelerated. The continual acceleration and deceleration causes the applied load to the input device. Through this transfer of energy, the water is heated and discharged. Figure 3.1: Water Flow Torque Measurement A strain gauge load cell is used to measure rotational force. When used in conjunction with a data acquisition system such as PowerNet, the data acquisition system measures the frequency of the signal generated by the load cell. This frequency is then displayed as a unit of measurement such as NM. This load cell is mounted to the dynamometer base plate and connected to a torque arm on the dynamometer absorber through a specially-designed tie rod assembly as shown in Figure 3.2. The load cell is capable of measuring force in either compression or expansion. Figure 3.2: Load Cell & Torque Arm Speed Measurement A magnetic speed pickup as shown in Figure 3.3 is supplied with each X-Series dynamometer system. When used in conjunction with a data acquisition system such as PowerNet, the data acquisition system measures the frequency of a speed input initiated by a 60 tooth gear passing a magnetic pickup. Figure 3.3: Magnetic Speed Pickup 7

12 3.0 How it Works Calculating Power By knowing speed and torque in newton meters, kilowatts of output can be calculated as: = (torque x rpm)/9550 A Typical System Power Test manufactures and supplies a wide variety of engine testing components, ranging from drive shafts and engine adapters to water recirculation systems and data acquisition and automated control. The below illustration provides an example of what is typically found in an engine dynamometer test cell. Dynamometer Drive Shaft Guard Cooling Column Fuel Storage Tank Sub Base Engine Cart Aftercooler Column Fuel Measurement Drive Shaft Data Acquisition/Controls Charge Air Cooler Exhaust Hood Figure 3.4: Engine Dynamometer Test Cell 8 N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)

13 4.0 45X-Series Data 914mm 267mm A 76mm WATER INLET 210mm 45X-SERIES DYNO 1041mm 375mm F 21mm 4 HOLES 483mm 235mm B C 22mm OPTIONAL SUB-BASE 22mm 6 HOLES 257mm 514mm 559mm D 733mm 232mm 489mm 533mm 1111mm 1175mm E Figure 4.1: 45X-Series Dimensions Dimensions (MM) Weight (KG) Inertia (KGM 2 ) Model A B C D E F 45X X X X X Table 4.1: 45X-Series Data 9

14 4.0 45X-Series Data X-Series Power Curve X X Power () X X X Speed (RPM) Graph 4.1: 45X-Series Power Curve RPM Power 45X06 45X07 45X08 45X09 45X10 Torque NM Power Torque NM Power Torque NM Power Torque NM Power Torque NM Table 4.2: 45X-Series Power and Torque 10 N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)

15 4.0 45X-Series Data X-Series imum Parasitic Power X X09 Power () X08 45X07 45X Speed (RPM) Graph 4.2: 45X-Series imum Parasitic Power RPM Parasitic 45X06 45X07 45X08 45X09 45X10 Recmnd Parasitic Recmnd Parasitic Recmnd Parasitic Recmnd Parasitic Table 4.3: 45X-Series imum Parasitic and Recommended Power Recmnd 11

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17 5.0 35X-Series Data 318mm 210mm A 914mm 51mm 35X-SERIES DYNO 1041mm 375mm F 21mm 4 HOLES 483mm 235mm B C 22mm OPTIONAL SUB-BASE 22mm 257mm 514mm 559mm D E 232mm 489mm 533mm 1111mm 1175mm Figure 5.1: 35X-Series Dimensions Dimensions (MM) Weight (KM) Inertia (KGM 2 ) Model A B C D E F 35X X X X X X Table 5.1: 35X-Series Data 13

18 5.0 35X-Series Data X-Series Power Curve X X Power () X Power (HP) 35X X X Speed (RPM) RPM Power 35X01 35X02 35X03 35X04 35X05 35X06 Torque NM Power Graph 5.1: 35X-Series Power Curve Torque NM Power Torque NM Power Torque NM Power Torque NM Power Torque NM Table 5.2: 35X-Series Power and Torque 14 N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)

19 5.0 35X-Series Data X-Series imum Parasitic Power 70 35X X05 Power () X04 35X X X01 RPM Parasitic 35X01 35X02 35X03 35X04 35X05 35X06 Recmnd Parasitic Recmnd Parasitic Speed (RPM) Graph 5.2: 35X-Series imum Parasitic Power Recmnd Parasitic Recmnd Parasitic Recmnd Parasitic Table 5.3: 35X-Series imum Parasitic and Recommended Power Recmnd 15

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21 6.0 50X-Series Data 318mm 210mm A 914mm 51mm 50X-SERIES DYNO 1041mm 375mm F 21mm 235mm 483mm 22mm B C 22mm 257mm 514mm 559mm D E 232mm Figure 6.1: 50X-Series Dimensions 489mm 533mm 1111mm 1175mm Dimensions (MM) Weight (KG) Inertia (KGM 2 ) Model A B C D E F 50X X Table 6.1: 50X-Series Data 17

22 6.0 50X-Series Data X-Series Power Curve X Power () Power (HP) 50X Speed (RPM) Graph 6.1: 50X-Series Power Curve RPM Power 50X01 Torque NM Power 50X02 Torque NM RPM Power 50X01 Torque NM Power 50X02 Torque NM Table 6.2: 50X-Series Power and Torque 18 N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)

23 6.0 50X-Series Data 50 50X-Series imum Parasitic Power X02 30 Power () X Speed (RPM) Graph 6.2: 50X-Series imum Parasitic Power RPM Parasitic 50X01 Recmnd Parasitic 50X02 Recmnd RPM Parasitic 50X01 Recmnd Parasitic 50X02 Recmnd Table 6.3: 50X-Series imum Parasitic and Recommended Power 19

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25 7.0 Standard Equipment Dynamometer Absorber Each X-Series dynamometer features a trunnion-mounted, fixedbase design. These dynamometers provide equal load capability in either direction of rotation. Power Test dynamometers are constructed of multiple absorption sections offering the flexibility to test prime movers of widely varying outputs with the same dynamometer. By closing off selected sections, the absorption characteristics are able to be closely matched to the engine or motor's capability. Trunnion-Mounted Pillow Block Bearings Each X-Series of dynamometers feature trunnion-mounted pillow block bearings. These anti-friction bearings, concentric to the dynamometer shaft, eliminate extraneous torque reactions. Image 7.1: X-Series Dynamometer Absorber Base Plate The dynamometer base plate is a precision ground base that the dynamometer is placed on. It enables precision alignment and provides needed mass during dynamometer operation. Image 7.2: X-Series Pillow Block Assembly Image 7.3: X-Series Dynamometer Base Plate 21

26 7.0 Standard Equipment Load Cell and Torque Arm A strain gauge load cell is used to measure rotational force. When used in conjunction with a data acquisition system such as PowerNet, it measures the frequency of the signal generated by the load cell. The load cell is mounted to the dynamometer base plate and connected to a torque arm on the absorber by a specially designed tie rod assembly. The load can measure either compression or expansion forces. A precision length torque arm coupled to instrument-grade strain-gauge load cell provides accurate torque measurement. Magnetic Speed Pickup Supplied with each X-Series dynamometer, the magnetic speed pickup measures the frequency of a speed input initiated by a 60 tooth gear passing by it. When used in conjunction with a data acquisition system such as PowerNet, the system can use the speed and torque data to determine kilowatts () of output. Image 7.4: X-Series Load Cell and Torque Arm Companion Flange Sturdy companion flanges are available in various configurations to suit the user s engine-to-dynamometer connection needs. Image 7.5: X-Series Magnetic Speed Pickup Image 7.6: X-Series Companion Flange 22 N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)

27 7.0 Standard Equipment Servo Inlet Valve The electric servo drive is used to open and close the water flow to each absorber section when used in conjunction with a servo controller and dynamometer control system such as the PowerNet dynamometer control system. PowerNet WorkStation PowerNet is a two-computer system that incorporates the latest in data acquisition technology. Comprised of the Commander Computer, a modified desktop PC, and the WorkStation, a touch-screen operated unit housed in a rugged industrial enclosure. Both communicate to each other through a standard Ethernet cable that enables rapid data transfer speeds, simplifies wiring, and allows for LAN connections. Remote engine control and data acquisition are taken to a new level with PowerNet. The Commander Computer combines control, data acquisition, test report generation, test pattern management, and data storage into a desktop package placed in the control area. Image 7.7: X-Series Servo Inlet Valve Image 7.8: PowerNet Commander and WorkStation The PowerNet WorkStation is engineered to stand up to the harsh environment of the test cell. Mounted in a sealed enclosure with a 26.4 cm color touch screen, the WorkStation unit accepts all sensor inputs, and controls the load and throttle systems. The WorkStation has front-mounted temperature and pressure input jacks while the pedestal mount allows its display to rotate 350 for viewing at any angle. In addition, Power Test manufactures and supplies a wide variety of engine testing options for the PowerNet data acquisition and control system, including additional sensors for temperatures and pressures, fuel measurement systems, smoke opacity and exhaust gas analyzers, breakout boxes for most popular engines, as well as ECM communications and a variety of application-specific sensors. 23

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29 8.0 Optional Equipment Air Starting System Most Power Test dynamometers can be fitted with an optional Air Starter and Flywheel system. Available in clockwise and counter-clockwise rotations and in two sizes for engines below or above 14.7 L, the air starter eliminates the wiring and battery maintenance associated with a typical engine-mounted starting system. Image 8.1: Air Starting Systems Analog Throttle Power Test's analog "smart" throttle is a high-torque electronic throttle actuator designed for precision speed control and automated testing. It allows for quick adjustments and calibration, and is designed for use with our PowerNet data acquisition & control systems. Image 8.2: Analog Throttle Charge Air Coolers Power Test's water-to-air charge air cooler replaces the vehicle s after-cooler when testing air-to-air, after-cooled engines in a test cell. Internal water temperature is maintained through the use of an electronic temperature controller and an electric valve. Stable to ± 1 C, options include wall-mount or cart styles plus available LED temperature and set-point displays. Image 8.3: Charge Air Coolers 25

30 8.0 Optional Equipment Drive Shaft A sturdy, dynamically balanced, universal joint drive shaft is used to complete the final connection between the Power Test dynamometer and the engine. Shafts are available in a variety of sizes depending on engine type and allow for some misalignment between the engine crankshaft and the dynamometer input flange. A drive shaft guard is required (see below). Image 8.4: Drive Shaft Drive Shaft Guard Required for all engine dynamometer applications, drive shaft guards are designed to protect the test cell area and operator from flying debris should a malfunction occur when testing an engine or electric motor. Constructed of 64 mm thick plate steel to provide some assurance of protection in the event of a drive shaft failure, Power Test drive shaft guards are adjustable for all centerline heights. Image 8.5: Drive Shaft Guard Dynamometer Sub Bases Providing a common mounting platform for the dynamometer, starting system and load sensing strain gauge, dynamometer sub bases are constructed from heavy-gauge steel and eliminate the need for a raised concrete pad. Power Test sub bases can be repositioned within a test cell to allow for expansion and the addition of more dynamometer systems, or for transporting. Image 8.6: Dynamometer Sub Bases 26 N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)

31 8.0 Optional Equipment Dynamometer System Cooling Towers Cooling towers are used to transfer process waste heat from testing to the atmosphere through evaporation. When used in conjunction with a water recirculation system, they process waste heat generated by the dynamometer and provide the return of cool water to the system. Available in a variety of sizes depending on engine or vehicle output load. Rooftop and ground level configurations are available. Image 8.7: Cooling Towers Engine Adapters Available for most popular applications, including engines manufactured by Cummins, Cat, Detroit Diesel, Mercedes, and Volvo, Power Test offers a variety of custom-built flywheel, crankshaft, and bell housing adapters to connect your engine to the dynamometer. Most adapters are in-stock and ready for same-day shipment, plus our in-house fabrication capabilities allow us to provide any type of crank or flywheel adapter desired. Image 8.8: Engine Adapters Engine Carts Designed for quick and accurate positioning of an engine to the dynamometer, Power Test carts feature a Universal Front Support and self-aligning swivel caster that allow for precise, rapid engine placement. From the smallest load to 13,608 KG, and engine lengths to 305 cm, these carts provide a 71 cm, 81 cm or 97 cm centerline height standard. Image 8.9: Engine Carts 27

32 8.0 Optional Equipment Engine Cooling Column A cooling column maintains the desired engine water temperature during testing while it simulates the engine cooling system's operating characteristics. It also allows the engine temperature to be regulated in a confined testing area without a fragile radiator or dangerous fan. Additional benefits include low operating cost, the elimination of excessive cooling system heat from the test cell, and the flexibility to accommodate many engine sizes. The column is adjustable from 71 to 110 C and cart mounted for increased test-cell mobility. Image 8.10: Engine Cooling Column Fuel Measurement System Designed for use with the PowerNet data acquisition & control systems, Power Test's Gravimetric Fuel Measurement System allows reliable collection of engine fuel consumption information during testing. A wall-mounted enclosure houses the components necessary for out-of-frame or in-frame engine test applications, while an integrated heat exchanger maintains fuel temperatures for more consistent results. Image 8.11: Fuel Measurement Fuel Storage Tanks For quick and efficient fueling and re-fueling, Power Test offers portable and fixed fuel storage tanks in a variety of capacities. Storage tanks range from ,780 L and can be equipped with retractable fuel pressure and return lines. A fuel priming system that ensures proper fuel supply at start-up is included. Image 8.12: Fuel Storage Tanks 28 N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)

33 8.0 Optional Equipment Room Exhaust Systems Used to ventilate the cell during testing, room exhaust systems remove heat, fumes and smoke. The two most common types are Hood and Pipe. Hood Systems are often preferred because they do not need to be connected to the engine, as the fan in the hood pulls make-up air into the room and removes both engine and room exhaust. Pipe Systems can be powered by a fan to remove engine exhaust. When using a pipe system, a separate fan-powered room air exhaust system is necessary to pull makeup air into the room and to discharge heat, smoke and fumes. Image 8.13: Room Exhaust Systems Resilient Couplings Resilient couplings are effective at reducing torque spikes and dampening torsional vibrations, and are ideal for use when testing smaller engines on larger dynamometers. The couplings have a spider-type inner hub that mounts to the dynamometer shaft. The outer spider is positioned over the hub with a neoprene resilient block placed between each finger of the 2 spider assemblies. The couplings are capable of absorbing up to 3,390 NM of torque. Image 8.14: Resilient Couplings Torsional Dampeners Compatible for use with all Power Test engine adapters, the engine-mounted torsional dampener minimizes the effects of torsional vibration, helping protect components of the engine, dynamometer, and drive shaft. If a failure should occur, the unit s self-supporting rubber in-shear helps minimize any damage. The Torsional Dampener mounts between the engine crankshaft adaptor or flywheel and the drive shaft. Image 8.15: Torsional Dampeners 29

34 8.0 Optional Equipment Water Pressure Regulation A Water Pressure Regulation System regulates a testing facility s water pressure to dampen the potentially damaging effects of water hammer. The Power Test system features an adjustable water regulator valve; dynamometer sub-base and wall-mounted versions are available. Image 8.16: Pressure Regulation Water Recirculation System Dynamometer performance can be greatly improved by using a water recirculation system to ensure proper water pressure, volume, and temperature. A controlled water supply also offers the benefits of reduced dynamometer maintenance costs while conserving water can help reduce operating costs. A water recirculation system should be strongly considered if there is a limited supply capacity or excessive cost at the local water system (city or private), or if the local sewer system does not permit water discharge temperatures of 77 C or more. Image 8.17: Water Recirculation 30 N60 W22700 Silver Spring Drive Sussex, WI phone: (262) fax: (262)