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cussons TECHNOLOGY
P8750 MULTI-CYLINDER ENGINE TEST BED WITH REMOTE CONTROL, DATA
ACQUISITION & EDDY CURRENT DYNAMOMETER
Automotive
1 Issue 4 [email protected] / www.cussons.co.uk
EXPERIMENTAL CAPABILITY
Measurement of maximum torque and maximum power
allowing of full load power against speed curves to be
plotted
Determination of brake mean effective pressures
Analysis of part load torque, speed characteristics
Air flow rate
Fuel flow rate
Efficiency & fuel consumption characteristics at varying
speed & load
Calculation of brake specific fuel consumption
Analysis of load characteristics at constant speed
Determination of volumetric efficiency
Determination air-to-fuel ratio
Determination of brake thermal efficiencies
INTRODUCTION
An advanced engine test facility designed for automotive
and industrial light duty multi-cylinder engines utilizing an
eddy current dynamometer to provide a load of up to
150kW. The integrated instrumentation and control system is
purpose designed to control, monitor & record all test bed
parameters during engine performance testing. A coolant &
lubricant conditioning module is flexibly mounted to the rear
of the test bed to allow easy engine access. A self-
contained fuel system complete with fuel flow measurement
& an air flow meter also integrated into the test bed
package.
The test bed base is a steel construction with an open front
to allow rapid engine changes utilizing the sub-frame engine
mounting system. Coded quick connect couplings on the
engine test bed ensure simple & correct connection of the
engine. With suitable ancillary equipment, exhaust emissions
analysis and high speed combustion data acquisition
programs can be conducted.
DESCRIPTION
Cussons P8750 Multi-Cylinder Automotive Engine Test Bed has
been developed to provide a facility for the practical
demonstration of internal combustion engine technology. A
comprehensive instrumentation package, data acquisition
and computer control of facilities allows experimental
analysis of engine performance parameters such as power,
torque, speed and efficiency under various operating
conditions, controlled and measured by a dynamometer
and ancillary instrumentation.
Display of all test parameters is via a remote PC screen,
coolant & lubricant temperature is closed loop controlled to
temperatures entered on the PC. A remote control console is
provided to start/stop the engine with 10 turn potentiometers
to control engine load & speed.
Cussons offers two engine options that are sub-frame
mounted to allow rapid engine changes. Coded engine
connections ensure correct connection of services &
instrumentation when the engine is changed.
The test facility is intended for installation within the client’s
acoustic test cell equipped with appropriate services for
power, plant cooling water, ventilation air, exhaust silencing/
dispersion and necessary mechanical lifting aids. Cussons
can, if necessary, advise on the requirements for these
services and can provide a complete facility design and
procurement service at the client’s request. The test stand is
designed for universal engine applications within the range
of the dynamometer selected and can be provided with the
various engines.
cussons TECHNOLOGY
P8750 MULTI-CYLINDER ENGINE TEST BED WITH REMOTE CONTROL, DATA
ACQUISITION & EDDY CURRENT DYNAMOMETER
Automotive
2 Issue 4 [email protected] / www.cussons.co.uk
COOLING PACKAGE
An engine cooling package is installed at the front of the test
stand using plant water/coolant and plant water/oil shell &
tube heat exchangers. Electronically controlled modulating
valves receiving signals from the test bed PC ensure the flow
of plant water through the heat exchangers maintains close
regulation of the engine coolant and lubricating oil
temperatures. The coolant system is a fully sealed header
tank system enabling conventional automotive vehicle
based de-aerated & pressurised operation. A cylinder head
breather line is also connected to the header tank to ensure
correct de-aeration of the cooling system once it is filled with
coolant. Connections to the engine are via quick connect
couplings that are coded to prevent feed & return hoses
being wrongly connected. Drain taps are provided in both
lubricant & coolant circuits to allow the systems to be
drained easily & conveniently. Thermocouples are fitted to
the inlet & outlet of both heat exchangers.
Additional quick connects are provided to allow an engine
sub-frame mounted intercooler to be connected into the
plant water circuit when a turbo diesel engine is fitted.
FUEL SUPPLY
The fuel supply system draws fuel from a small supply tank
housed on the test bed via a filter & fuel select valve. If both
diesel & gasoline engines are supplied with the test bed a
second fuel tank and filter are fitted to the test bed before
the fuel select valve. Fuel flow measurement is via a ‘gear’
type flow-meter located in the fuel system before the vapour
separator to ensure fuel fed back from the engine is not
measured twice. A high pressure electric fuel pump is
incorporated to supply modern fuel injection systems, there is
also a facility for adjusting the delivery pressure to the engine
to suit engine requirements. A shell & tube heat exchanger is
incorporated in the system to cool hot fuel being returned
from the engine in recirculating systems. A vapour separator
with automatic vent is fitted to remove any vapour bubbles
returned from the engine.
AIR FLOW
Air flow measurement is via a laminar flow meter to ensure
accurate air flow measurement of the pulsating air flow
inherent with internal combustion engine inlet tracts. A
differential pressure transducer is provided to allow air flow to
SPECIFICATIONS
DYNAMOMETER
A robust, long operating life eddy current dynamometer
rated for 150 kW power absorption, 500 Nm maximum torque
and up-to 8000 rev/min maximum operating speed. Smooth
operation is ensured by a balanced rotor & shaft mounted in
precision bearings. The reliable twin vented enclosed
energizing coils ensure precise load control under all
operating conditions. The dynamometer is water cooled with
nickel plated cooling passages to prevent corrosion and is
equipped with a safety flow switch to prevent overheating.
A strainer is fitted in the plant water supply line to prevent
water bourn debris entering the dynamometer cooling
system. A strain gauge load cell is fitted for accurate torque
measurement & ‘O’ ring pipe connections are utilized to
reduce torque calibration error due to connections between
the fixed & free parts of the dynamometer. Calibration
equipment for the precision dynamometer load is provided
with the test bed.
A resilient rubber flexible coupling is mounted on the
dynamometer input & another on engine flywheel when
engines are supplied by Cussons. These are tuned to the
inertia of the engine & dynamometer ensuring torsional
vibrations generated during testing do not damage any of
the test bed components. A driveshaft restraining &
guarding arrangement is provided when Cussons supply the
test bed engine(s).
BEDPLATE
The dynamometer is fitted to a specially designed and
fabricated steel bedplate which also incorporates an
adjustable engine mounting arrangement so that a wide
variety of engines can be accommodated. The front
(engine end) of the test bed frame is open so that a pallet
truck can be used to easily & rapidly replace sub-frame
mounted engines. The adjustable engine mounting
arrangement is also used to mount the engine coolant
module so that its location can be adjusted easily to suit
changes in exhaust outlet position. The test bed fame also
carries the self-contained fuel system, air flow meter,
instrumentation/control cubicle and the drive shaft guarding
arrangement. A high capacity d.c. battery for engine
starting is mounted next to the dynamometer, this too has a
quick connect coupling for easier & safer engine changes.
cussons TECHNOLOGY
P8750 MULTI-CYLINDER ENGINE TEST BED WITH REMOTE CONTROL, DATA
ACQUISITION & EDDY CURRENT DYNAMOMETER
Automotive
3 Issue 4 [email protected] / www.cussons.co.uk
be data logged. A thermocouple in the inlet air tract allows
the air flow measurement to be corrected for temperature.
INSTRUMENTATION
The following instrumentation and sensors are supplied:
Pressure transducers - All transducers are connected via
quick couplings that are coded to prevent incorrect
connection.
Fuel pressure (0 to 5 bar gauge)
Engine manifold pressure (-1 to +1.5 bar gauge)
Engine oil pressure (0 to 10 bar gauge)
Barometric pressure (0 to 1200 mbar absolute)
Fuel pressure (0 to 5 bar gauge)
Air flow differential pressure (-10 to 10 mbar
differential)
Fuel flow meter - positive displacement - range 1 to 100
l/hour
Air flow meter –– range 0 to 50 l/sec
Speed sensor - inductive pickup
Load sensor - strain gauge load cell
Temperature inputs - 14 Type K thermocouple inputs :
Ambient air, Air inlet (intercooler outlet), Fuel, Engine coolant
outlet, Engine coolant inlet, Lubricating oil outlet, Lubricating
oil inlet, Exhaust, Dynamometer water outlet, (*) Exhaust gas
inlet to calorimeter, (*) Coolant inlet to calorimeter, (*)
Exhaust gas outlet calorimeter, (*) Coolant outlet from
calorimeter, Spare.
(*) These items for use with Cussons Exhaust Gas Calorimeter
Optional coolant flow-meter range 0-200 l/min (See
selection matrix)
Optional oil flow-meter range 5-50 l/min (See selection
matrix)
CONTROL & INSTRUMENTATION CONSOLE
Comprising a 19" x 12U cubicle mounted on a framework
over the dynamometer, housing signal conditioning and
dynamometer control racks, and a separate operator desk
accommodating a manual control station and PC.
The following measured variables are displayed
electronically and also available as logged signals for data
analysis/post processing purposes:
Engine manifold (boost) pressure
Engine oil pressure
Barometric pressure
Fuel pressure
Air flow
Fuel flow
Engine speed
Engine load
Temperatures - Type K thermocouples
In addition an “hours run” indicator is provided for servicing
purposes.
The following controls are provided on the manual control
station:
Three position key switch for engine ignition & starting.
Remote load (throttle) control - 10 turn potentiometer
Dynamometer speed control - 10 turn potentiometer
Load enable/disable push button
Test bed system reset push button
Emergency stop
This package allows the logged signals from the measured
variables to be downloaded into a spreadsheet template,
which can be customised to suit differing applications. A PC
is included and the data can be stored electronic format or
viewed on the monitor.
DYNAMOMETER CONTROL SYSTEM
Eddy Current Dynamometer Control
This system houses a servo control board and servo driver unit
which together regulate the dynamometer field excitation.
The servo control board provides full PID control. The servo
driver is a current controller that regulates dynamometer
field current, this unit has on board fault detection. The
system is configured to provide closed loop speed control of
the dynamometer and the speed set point is adjusted via a
10 turn potentiometer on the control panel.
SAFETY PROTECTION SYSTEM
Emergency stop switches, loss of plant water & over speed
trips are supplied for safety shutdown.
cussons TECHNOLOGY
P8750 MULTI-CYLINDER ENGINE TEST BED WITH REMOTE CONTROL, DATA
ACQUISITION & EDDY CURRENT DYNAMOMETER
Automotive
4 Issue 4 [email protected] / www.cussons.co.uk
ENGINE OPTIONS The test beds are designed to accept a wide variety of
engines whose power ratings fall within the dynamometer
operating envelope. Where engines are supplied by Cussons
Technology they will be suitably modified and flexibly
mounted on a sub frame which can quickly and easily be
fitted to the test bed.
P8615 Four Cylinder Water Cooled Spark Ignited Engine
Ford ZSG 416, 1600cc four cylinder water cooled gasoline
engine, rated 74kW at 6000 rpm. The engine has twin
overhead camshafts with 4 valves per cylinder, multipoint
sequential fuel injection and control of ignition and fuel
injection via an aftermarket ECU.
P8616 Four Cylinder Water Cooled Compression Ignition
Engine
Ford DV6, 1560cc four cylinder water cooled DI turbo diesel
engine, rated 81kW at 4000rpm. The engine has double
overhead camshafts, 4 valves per cylinder, common rail fuel
injection, electronic throttle & variable geometry turbo
charger with intercooler. Control is via an aftermarket ECU.
NB The engines
specified above
are offered
subject to
availability and
we reserve the
right to supply an
alternative of
similar
specification/
performance.
ENGINE TEST
BED
NUMBERING
& OPTIONAL
EQUIPMENT
cussons TECHNOLOGY
P8750 MULTI-CYLINDER ENGINE TEST BED WITH REMOTE CONTROL, DATA
ACQUISITION & EDDY CURRENT DYNAMOMETER
Automotive
5 Issue 4 [email protected] / www.cussons.co.uk
Head Office
Cussons Technology Limited
102 Great Clowes Street,
Manchester.
M7 1RH England
Tel: + (44)161 833 0036
Fax: + (44)161 834 4688
E-mail: [email protected]
Explore our website!
www.cussons.co.uk
The company may alter specifications as its discretion and without
notice, in line with its policy of continuous development
P8750 Eddy Current Dynamometer ETB
Electrical supply: 220/240V a.c., 10 Amp, 50/60 Hz
single phase.
Water supply: 250 l/min, minimum pressure 2 bar,
max pressure 4 bar, max temp 30o C.
Exhaust connection: 2” BSP.
Ventilation air:- 2.2 m3/sec minimum
INSTALLATION REQUIREMENTS
P8262 Exhaust gas calorimeter
P4660 2 channel indicating electronics for P8615 &
P8616
For emissions analysis equipment options contact -
ACCESSORIES
0
20
40
60
80
100
120
140
160
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
Po
we
r (k
W)
Speed (rev/min)
SE150 Dynamometer Capacity
Sample of Cussons Software for Engine test bed
Sample of Cussons Software - calibration
Sample of Cussons Software - valve control
