Test Stand SpecificationTest Stand Specification

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Test System Services Provided Test System Services Provided

by Southwest Research Instituteby Southwest Research Institute

� Functional Specification

� Detailed Design

� System Fabrication

� Verification Testing

� Installation

� Documentation

� Training

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Comprehensive Multidisciplinary Comprehensive Multidisciplinary

SpecificationSpecification

� Mechanical

� Facility

� Instrumentation

� Data Acquisition

� Emission Analyzer

� Costs

– Functional Requirement

– Component Discussion

– Accuracies and Operating Parameter

– Review Three Manufacturers’ Products

– Recommend Specific Supplier

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Functional SpecificationFunctional Specification

� Detail Specification Defining

– Components

– Systems

– Interconnects

– Wiring Diagrams

– Facility Modifications

– Instrumentation

– Data Acquisition Hardware

– Software

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Project TeamProject Team

� Multidisciplinary Approach

– Mechanical

– Electrical Electronics

– Computer Software

– Computer Hardware

� Experienced Project Team in Place

� Many Similar Past Projects

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Natural Gas FacilityNatural Gas Facility

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Modular/HighModular/High--PerformancePerformance

Test CellTest Cell

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Layout of Typical Engine TestLayout of Typical Engine Test

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Production Engine Test CellProduction Engine Test Cell

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Test Cell Floor PlanTest Cell Floor Plan

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Internal Access to Internal Access to

Instrumentation RackInstrumentation Rack

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Test Cell InstrumentationTest Cell Instrumentation

� Torque

� Speed

� Pressure

� Temperature

� Position

� Fluid Flow

� Gaseous Flow

� Specialized Requirements

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COMPUTERCOMPUTER--BASED DATA ACQUISITION BASED DATA ACQUISITION

AND CONTROL (DAC) SYSTEM AND CONTROL (DAC) SYSTEM

DEVELOPMENTDEVELOPMENT

� Test System Flexibility Provided Through Menu

Based Operator Interface

� Complete Range of Data Acquisition Rates

Supported

– Steady State 0-1 Hz

– Transient 0-10 Hz

– Dynamic 10-1,000 Hz

– High Speed 1,000 Hz - 1 MHz

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DoubleDouble--BayBay

Instrumentation RackInstrumentation Rack

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Test CellTest Cell

Instrumentation Rack LayoutInstrumentation Rack Layout

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Overhead Instrumentation BoxOverhead Instrumentation Box

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Transmission EfficiencyTransmission Efficiency

Test StandsTest Stands

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Wheel Bearing Test StandWheel Bearing Test Stand

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Clutch Pack Test StandClutch Pack Test Stand

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Hydraulic Pump Test StandHydraulic Pump Test Stand

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Powertrain Test StandPowertrain Test Stand

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Chassis DynamometerChassis Dynamometer

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Tractor PTO Test StandTractor PTO Test Stand

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Electric Dynamometer Test StandElectric Dynamometer Test Stand

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Air Actuated Disc Brake Air Actuated Disc Brake

DynamometerDynamometer

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Variable Thrust Load Test StandVariable Thrust Load Test Stand

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80,00080,000 ftft--lb Low Speed lb Low Speed

DynamometerDynamometer

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Integral High Speed Gearbox Integral High Speed Gearbox

DynamometerDynamometer

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Tractor Test StandTractor Test Stand

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Tractor Test StandTractor Test Stand

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Project ApproachProject Approach

� On-Site Investigation

� System Specification

� Design, Detail, and Documentation

� Prototype System Build

– At SwRI

– By SwRI

� System Check-Out and Demonstration

� Demonstration and Approval

– At SwRI

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Project ApproachProject Approach

� Fabrication By SwRI and Shipment

� Installation

– SwRI Engineering & Technicians

– Local General Contractor

� System Check-Out and Approval

� Training Classes by SwRI

� Responsibility Transfer

� Warrantee Period

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Tractor Test Facility ProjectTractor Test Facility Project

� Multidisciplinary Project

– Mechanical

– Electrical

– Electronic

– Computer Scientist

– Software

� 13 Man-Year Program/18 Calendar Months

– Completed On-Time to 10 Weeks Ahead of

Schedule

� 4 Test Cell Configurations

– PTO, Axle, Chassis

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Tractor Test Facility ProjectTractor Test Facility Project

� 11 Dynamometers

� 4 Instrumentation Racks

� 1 Mainframe Computer

� 12 Load Cells

� 15 Optical Endcoders

� 120 Pressure Transducers

� 210 Thermocouples

� 580 Ft of 4’ EMT Tubing

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Tractor Test Facility ProjectTractor Test Facility Project

� 18,000 Ft of Thermocouple/Multi-Conductor

Cable

� 5,000 Ft of Black Pipe, Copper Tubing, and

Rubber Hose

� 140,000 lb of Fabricated Steel

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Tractor Test Facility ProjectTractor Test Facility Project

� 50,000 Lines of Software Written

� 1,272 Purchase Orders Executed

� 7 Tractor Trailers Fitted with Equipment

� 1,500 Miles Installation Site

From San Antonio, TX

� 10 Volumes of Documentation and Manuals

� 60 Hours of Video Tape Classroom Instruction

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Tractor Test CellTractor Test Cell