X-Series Engine Dynamometer - Power Test Europepowertesteurope.com/attachments/article/52/X-Series Technical...dynamometer and control system design, manufacture and ... ferrous alloy

May 2011

X-Series Engine DynamometerTechnical Specifications

Metric

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N60 W22700 Silver Spring Drive ▪ Sussex, WI 53089 phone: (262) 252-4301 ▪ fax: (262) 246-0436

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1.0 Power Test Inc. Company Overview ...........................................................................1Engine Dynamometers ...................................................................................................1Chassis Dynamometers ..................................................................................................1Hydraulic Test Equipment ...............................................................................................2Data Acquisition and Control Systems ............................................................................2

2.0 X-Series Product Line Overview .................................................................................345X-Series ......................................................................................................................335X-Series ......................................................................................................................350X-Series ......................................................................................................................4

3.0 How it Works .................................................................................................................7How a Water Brake Dynamometer Works ......................................................................7Torque Measurement ......................................................................................................7Calculating Power ...........................................................................................................8A Typical System ............................................................................................................8

4.0 45X-Series Data .............................................................................................................95.0 35X-Series Data ...........................................................................................................136.0 50X-Series Data ...........................................................................................................177.0 Standard Equipment ...................................................................................................21

Dynamometer Absorber ...............................................................................................21Trunnion-Mounted Pillow Block Bearings ...................................................................21Base Plate ....................................................................................................................21Load Cell and Torque Arm ...........................................................................................22Magnetic Speed Pickup ..............................................................................................22Companion Flange ......................................................................................................22Servo Inlet Valve ..........................................................................................................23PowerNet WorkStation ...............................................................................................23

8.0 Optional Equipment .....................................................................................................25Air Starting System .......................................................................................................25Analog Throttle .............................................................................................................25Charge Air Coolers .......................................................................................................25Drive Shaft ....................................................................................................................26Drive Shaft Guard .........................................................................................................26Dynamometer Sub Bases .............................................................................................26Dynamometer System Cooling Towers .........................................................................27Engine Adapters ...........................................................................................................27Engine Carts .................................................................................................................27Engine Cooling Column ................................................................................................28Fuel Measurement System ...........................................................................................28Fuel Storage Tanks .......................................................................................................28Room Exhaust Systems ...............................................................................................29Resilient Couplings .......................................................................................................29Torsional Dampeners ....................................................................................................29Water Pressure Regulation ...........................................................................................30Water Recirculation System ..........................................................................................30

Table of Contents

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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.

Engine DynamometersPower 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 DynamometersDesigned 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.

1.0 Power Test Inc. Company Overview

Image 1.1: Power Test Inc. Corporate Headquarters

Image 1.2: Power Test 45X-Series Engine Dynamometer

Image 1.3: Power Test CF42-Series Chassis Dynamometer

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1.0 Power Test Inc. Company OverviewHydraulic Test EquipmentPower 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 SystemsPower 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

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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-SeriesUsed 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 KW to 3,356 KW at speeds to 4,000 RPM. The 45X-Series may also be used in tandem applications for increased testing capabilities.

35X-SeriesUsed 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 KW to 1,566 KW at speeds up to 4,000 RPM.

2.0 X-Series Product Line Overview

Image 2.1: Power Test45X-Series Engine Dynamometer


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2.0 X-Series Product Line Overview50X-SeriesUsed 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 non-ferrous alloy construction for reduced inertia and are available in a testing range from 15-746 KW with speeds to 6,000 RPM.


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q Water Inlet w Absorber Assembly e Specifications Plate

r Dynamometer Shaft (floating end)

t Gravity Feed Bearing Oiler(s)

y Exhaust Gate Valve

u Water Outlet

i Water Exhaust Tube(s)

o Dynamometer Base Plate

a Load Valve

s Pillow Block Assembly

d Dynamometer Shaft (fixed end)

f Lubrication Line

q

a

Figure 2.1: X-Series Engine Dynamometer(45X06 w/servo inlet manifold shown)

w

r

y

u

i

o

d

t

f

s

e

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How a Water Brake Dynamometer WorksWith 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.

Torque MeasurementA 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.

Speed MeasurementA 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.

3.0 How it Works

Figure 3.1: Water Flow

Figure 3.2: Load Cell & Torque Arm

Figure 3.3: Magnetic Speed Pickup

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Calculating PowerBy knowing speed and torque in newton meters, kilowatts of output can be calculated as:

KW = (torque x rpm)/9550

A Typical SystemPower 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.

3.0 How it Works

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

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4.0 45X-Series Data

F

D

E

BC

A

232mm733mm

267mm

210mm

76mm WATER INLET

45X-SERIES DYNO

235mm

OPTIONALSUB-BASE

22mm6 HOLES

21mm4 HOLES

489mm 533mm1111mm1175mm

514mm559mm

257mm

914mm

1041mm375mm

483mm

22mm

Figure 4.1: 45X-Series Dimensions

Dimensions (MM) Weight (KG) Inertia (KGM2)Model A B C D E F45X06 1321 851 895 1226 1346 76 1220 8.24

45X07 1397 927 972 1302 1422 76 1343 9.60

45X08 1473 1003 1048 1378 1499 76 1465 10.96

45X09 1549 1080 1124 1454 1575 76 1588 12.33

45X10 1626 1156 1200 1530 1651 76 1710 13.69

Table 4.1: 45X-Series Data

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4.0 45X-Series Data

45X06 45X07 45X08 45X09 45X10RPM Power

KWTorque

NMPower

KWTorque

NMPower

KWTorque

NMPower

KWTorque

NMPower

KWTorque

NM800 573 6836 668 7975 764 9114 859 10254 955 11393

850 685 7690 799 8972 913 10254 1027 11535 1141 12817

925 854 8813 996 10281 1139 11750 1281 13219 1423 14688

1000 1011 9651 1180 11260 1348 12868 1517 14477 1685 16086

1100 1241 10766 1448 12561 1654 14355 1861 16150 2068 17944

1200 1482 11792 1730 13757 1977 15722 2224 17688 2471 19653

1300 1740 12778 2030 14907 2320 17037 2610 19167 2770 20337

1400 1913 13046 2232 15220 2551 17395 2870 19569 2983 20337

1500 1974 12561 2303 14654 2632 16748 2961 18841 3196 20337

1600 1996 11909 2329 13894 2662 15879 2994 17864 3327 19849

1700 2005 11259 2345 13165 2680 15046 3015 16926 3350 18807

1800 2014 10681 2350 12461 2686 14241 3021 16021 3357 17802

1900 2014 10119 2350 11805 2686 13492 3021 15178 3357 16865

2000 2014 9613 2350 11215 2686 12817 3021 14419 3357 16021

2200 2014 8739 2350 10195 2686 11652 3021 13108 3357 14565

2400 2014 8011 2350 9346 2686 10681 3021 12016 3357 13351

2500 2014 7690 2350 8972 2686 10254 3021 11535 3357 12817

3000 2014 6409 2350 7477 2686 8545 3021 9613 3357 10681

3600 2014 5340 2350 6231 2686 7121 3021 8011 3357 8901

4000 2014 4806 2350 5606 2686 6409 3021 7210 3357 8011

Table 4.2: 45X-Series Power and Torque

Graph 4.1: 45X-Series Power Curve

0

500

1000

1500

2000

2500

3000

3500

4000

800 1200 1600 2000 2400 2800 3200 3600 4000

Pow

er (K

W)

Speed (RPM)

45X-Series Power Curve

45X06 - 2014 KW

45X07 - 2350 KW

45X08 - 2686 KW

45X09 - 3021 KW

45X10 - 3357 KW

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4.0 45X-Series Data

45X06 45X07 45X08 45X09 45X10RPM Min

Parasitic KW

Min Recmnd

KW

Min Parasitic

KW

Min Recmnd

KW

Min Parasitic

KW

Min Recmnd

KW

Min Parasitic

KW

Min Recmnd

KW

Min Parasitic

KW

Min Recmnd

KW

800 4 9 5 10 6 12 7 13 7 14

850 5 9 5 11 6 13 7 14 8 16

925 5 11 6 12 7 14 8 16 9 18

1000 6 12 7 14 8 16 9 18 10 20

1100 7 14 8 16 9 19 10 21 12 23

1200 8 16 9 19 11 21 12 24 13 27

1300 9 18 11 22 12 25 14 28 15 31

1400 11 21 12 25 14 28 16 32 18 35

1500 12 24 14 28 16 32 18 36 20 40

1600 14 27 16 32 18 36 20 41 23 45

1700 15 30 18 35 20 40 23 45 25 51

1800 17 34 20 39 23 45 25 51 28 56

1900 19 38 22 44 25 50 28 56 31 63

2000 21 42 24 49 28 55 31 62 35 69

2200 25 50 29 59 33 67 38 75 42 84

2400 30 60 35 70 40 80 45 90 50 99

2500 32 65 38 76 43 86 49 97 54 108

3000 47 94 55 109 62 125 70 140 78 156

3600 68 136 79 158 90 181 102 203 113 226

4000 83 168 96 195 111 223 126 253 138 282

Table 4.3: 45X-Series Minimum Parasitic and Recommended Power

Graph 4.2: 45X-Series Minimum Parasitic Power

0

20

40

60

80

100

120

140

160

800 1200 1600 2000 2400 2800 3200 3600 4000

Pow

er (K

W)

Speed (RPM)

45X-Series Minimum Parasitic Power

45X06

45X07

45X08

45X09

45X10

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4.0 45X-Series Data


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5.0 35X-Series Data

318mm210mm

51mm

F

A

BC

22mm

35X-SERIES DYNO

914mm

375mm1041mm

257mm514mm559mm

489mm 533mm1111mm1175mm

483mm

D

E

235mm

22mm

OPTIONALSUB-BASE

21mm4 HOLES

232mm


Dimensions (MM) Weight (KM) Inertia (KGM2)Model A B C D E F35X01 1003 533 578 908 1029 51 653 1.41

35X02 1080 610 654 984 1105 51 776 2.77

35X03 1156 686 730 1060 1181 51 898 4.13

35X04 1232 762 806 1137 1257 76 1025 5.5

35X05 1308 838 883 1213 1334 76 1152 6.86

35X06 1384 914 959 1289 1410 76 1275 8.22


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5.0 35X-Series Data

35X01 35X02 35X03 35X04 35X05 35X06

RPM Power KW

Torque NM

Power KW

Torque NM

Power KW

Torque NM

Power KW

Torque NM

Power KW

Torque NM

Power KW

Torque NM

800 75 890 149 1780 224 2670 298 3560 373 4450 447 5341

850 89 997 177 1994 266 2991 355 3988 444 4985 532 5981

925 111 1142 221 2285 332 3427 443 4570 553 5712 664 6854

1000 131 1251 262 2502 393 3753 524 5004 655 6256 786 7507

1100 161 1396 322 2791 482 4187 643 5583 804 6978 965 8374

1200 192 1529 384 3057 576 4586 768 6114 960 7643 1153 9172

1300 225 1656 451 3313 676 4969 902 6626 1127 8282 1353 9938

1400 248 1691 496 3382 744 5074 992 6765 1240 8456 1488 10147

1500 256 1628 512 3257 767 4885 1023 6513 1279 8141 1535 9770

1600 258 1542 517 3084 775 4626 1034 6168 1292 7710 1550 9253

1700 260 1458 519 2915 779 4373 1038 5831 1298 7288 1557 8746

1800 260 1381 520 2761 781 4142 1041 5523 1301 6903 1561 8284

1900 261 1312 522 2623 783 3935 1044 5247 1305 6559 1566 7870

2000 261 1246 522 2492 783 3738 1044 4985 1305 6231 1566 7477

2100 261 1187 522 2374 783 3560 1044 4747 1305 5934 1566 7121

2200 261 1133 522 2266 783 3399 1044 4531 1305 5664 1566 6797

2300 261 1084 522 2167 783 3251 1044 4334 1305 5418 1566 6502

2400 261 1038 522 2077 783 3115 1044 4154 1305 5192 1566 6231

2500 261 997 522 1994 783 2991 1044 3988 1305 4985 1566 5981

3000 261 831 522 1662 783 2492 1044 3323 1305 4154 1566 4985

3500 261 712 522 1424 783 2136 1044 2848 1305 3560 1566 4272

4000 261 623 522 1246 783 1869 1044 2492 1305 3115 1566 3738



0

500

1000

1500

2000

800 1200 1600 2000 2400 2800 3200 3600 4000

Pow

er (K

W)

Speed (RPM)


35X01 - 261 KW

35X02 - 522 KW

35X03 - 783KW

35X04 - 1044 KW

35X05 - 1305 KW

671

1341

2012

2682

Pow

er (H

P)

35X06 - 1566 KW

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5.0 35X-Series Data

35X01 35X02 35X03 35X04 35X05 35X06RPM Min

Parasitic KW

Min Recmnd

KW

Min Parasitic

KW

Min Recmnd

KW

Min Parasitic

KW

Min Recmnd

KW

Min Parasitic

KW

Min Recmnd

KW

Min Parasitic

KW

Min Recmnd

KW

Min Parasitic

KW

Min Recmnd

KW

800 1 1 1 3 2 4 3 6 4 7 4 9

850 1 2 2 3 2 5 3 6 4 8 5 9

925 1 2 2 4 3 5 4 7 4 9 5 11

1000 1 2 2 4 3 6 4 8 5 10 6 12

1100 1 2 2 5 3 7 5 9 6 12 7 14

1200 1 3 3 5 4 8 5 11 7 13 8 16

1300 2 3 3 6 5 9 6 12 8 15 9 18

1400 2 4 4 7 5 11 7 14 9 18 11 21

1500 2 4 4 8 6 12 8 16 10 20 12 24

1600 2 5 5 9 7 14 9 18 11 23 14 27

1700 3 5 5 10 8 15 10 20 13 25 15 30

1800 3 6 6 11 8 17 11 23 14 28 17 34

1900 3 6 6 13 9 19 13 25 16 31 19 38

2000 3 7 7 14 10 21 14 28 17 35 21 42

2100 4 8 8 15 11 23 15 31 19 38 23 46

2200 4 8 8 17 13 25 17 33 21 42 25 50

2300 5 9 9 18 14 27 18 37 23 46 27 55

2400 5 10 10 20 15 30 20 40 25 50 30 60

2500 5 11 11 22 16 32 22 43 27 54 32 65

3000 8 16 16 31 23 47 31 62 39 78 47 94

3500 11 23 23 45 34 68 45 90 56 113 68 136

4000 14 28 28 56 42 84 56 112 70 140 84 168


0

10

20

30

40

50

60

70

80

90

800 1200 1600 2000 2400 2800 3200 3600 4000

Pow

er (K

W)

Speed (RPM)


35X01

35X03

35X02

35X04

35X05

35X06


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5.0 35X-Series Data


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A

BC

F

D

E

318mm210mm

51mm

21mm

50X-SERIES DYNO

235mm

22mm

232mm

22mm

914mm

375mm1041mm

483mm

257mm514mm559mm

489mm 533mm1111mm1175mm


Dimensions (MM) Weight (KG) Inertia (KGM2)Model A B C D E F50X01 1003 533 578 908 1029 51 630 0.55

50X02 1080 610 654 984 1105 51 730 1.06


6.0 50X-Series Data

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6.0 50X-Series Data


0

250

500

750

1000

800 1800 2800 3800 4800 5800

Pow

er (K

W)

Speed (RPM)


50X01 - 373 KW

50X02 - 746 KW

670

1005

1341

Pow

er (H

P)

50X01 - 373 KW

50X02 - 746 KW

Pow

er (H

P)

335

50X01 50X02

RPM Power KW

Torque NM

Power KW

Torque NM

800 106 1264 212 2528

850 127 1424 254 2848

925 158 1632 316 3264

1000 187 1787 374 3575

1100 230 1994 459 3988

1200 274 2184 549 4367

1300 322 2366 644 4733

1400 354 2416 708 4832

1500 365 2326 731 4652

1600 371 2212 741 4424

1700 373 2094 746 4189

1800 373 1978 746 3956

1900 373 1874 746 3748

50X01 50X02

RPM Power KW

Torque NM

Power KW

Torque NM

2000 373 1780 746 3560

2100 373 1695 746 3391

2200 373 1618 746 3237

2300 373 1548 746 3096

2400 373 1483 746 2967

2500 373 1424 746 2848

3000 373 1187 746 2374

3500 373 1017 746 2035

4000 373 890 746 1780

4500 373 791 746 1582

5000 373 712 746 1424

5500 373 647 746 1295

6000 373 593 746 1187


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6.0 50X-Series Data

0

5

10

15

20

25

30

35

40

45

50

800 1800 2800 3800 4800 5800

Pow

er (K

W)

Speed (RPM)


50X02

50X01


50X01 50X02

RPM Min Parasitic

KW

Min Recmnd

KW

Min Parasitic

KW

Min Recmnd

KW

800 0 0 0 0

850 0 0 0 0

925 0 0 0 1

1000 0 0 0 1

1100 0 1 1 1

1200 0 1 1 1

1300 0 1 1 2

1400 1 1 1 2

1500 1 1 1 3

1600 1 2 2 4

1700 1 2 2 4

1800 1 3 3 5

1900 2 3 3 6

50X01 50X02

RPM Min Parasitic

KW

Min Recmnd

KW

Min Parasitic

KW

Min Recmnd

KW

2000 2 4 4 8

2100 2 5 5 9

2200 3 6 6 11

2300 3 7 7 13

2400 4 8 8 16

2500 4 9 9 18

3000 7 14 14 29

3500 10 20 20 40

4000 13 25 25 51

4500 15 31 31 61

5000 18 36 36 72

5500 21 42 42 83

6000 24 47 47 94


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6.0 50X-Series Data


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Dynamometer Absorber Each X-Series dynamometer features a trunnion-mounted, fixed-base 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.

Base PlateThe 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.

7.0 Standard Equipment

Image 7.1: X-SeriesDynamometer Absorber

Image 7.3: X-SeriesDynamometer Base Plate

Image 7.2: X-Series Pillow Block Assembly

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7.0 Standard EquipmentLoad 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 (KW) of output.

Companion Flange Sturdy companion flanges are available in various configurations to suit the user’s engine-to-dynamometer connection needs.

Image 7.4: X-SeriesLoad Cell and Torque Arm

Image 7.5: X-SeriesMagnetic Speed Pickup

Image 7.6: X-SeriesCompanion Flange

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7.0 Standard EquipmentServo 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.

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.

Image 7.7: X-SeriesServo Inlet Valve

Image 7.8: PowerNetCommander and WorkStation

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7.0 Standard Equipment


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Air Starting SystemMost 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.

Analog ThrottlePower 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.

Charge Air CoolersPower 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.

8.0 Optional Equipment

Image 8.1: Air Starting Systems

Image 8.2: Analog Throttle

Image 8.3: Charge Air Coolers

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8.0 Optional EquipmentDrive ShaftA 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).

Drive Shaft GuardRequired 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.

Dynamometer Sub BasesProviding 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

Image 8.4: Drive Shaft

Image 8.5: Drive Shaft Guard

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8.0 Optional EquipmentDynamometer System Cooling TowersCooling 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.

Engine AdaptersAvailable 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.

Engine CartsDesigned 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 8.7: Cooling Towers

Image 8.8: Engine Adapters

Image 8.9: Engine Carts

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8.0 Optional EquipmentEngine Cooling ColumnA 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.

Fuel Measurement SystemDesigned 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.

Fuel Storage TanksFor 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 37.8 - 3,780 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 8.10: Engine Cooling Column

Image 8.11: Fuel Measurement

Image 8.12: Fuel Storage Tanks

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8.0 Optional EquipmentRoom Exhaust SystemsUsed 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 make-up air into the room and to discharge heat, smoke and fumes.

Resilient CouplingsResilient 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.

Torsional DampenersCompatible 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 8.13: Room Exhaust Systems

Image 8.14: Resilient Couplings

Image 8.15: Torsional Dampeners

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8.0 Optional EquipmentWater Pressure RegulationA 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.

Water Recirculation SystemDynamometer 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 8.16: Pressure Regulation

Image 8.17: Water Recirculation

Documents

X-Series Engine Dynamometer - Power Test Europepowertesteurope.com/attachments/article/52/X-Series Technical...dynamometer and control system design, manufacture and ... ferrous alloy