ENGINE aNd TRaNSMISSION TEST SYSTEMS YOUR

Transcription

ENGINE aNd TRaNSMISSION TEST
SYSTEMS
YOUR PaRTNER FOR
RELIaBLE SOLUTIONS
1
June 2012
www.pcs.com.tr
TEST SYSTEMS
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TEST SYSTEMS
Our Services
Projects and Contracting
Design and Production
Construction
Assistant Services
Mechanical
Instrumentation
Electricity
Data Acquisition
June, 2012
Software, Research-Development
Assembly
Testing and Commissioning
Supervision
Training
Periodic Maintenance
Technical Support
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TEST SYSTEMS
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TEST SYSTEMS
Introduction
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PCS has expertise on engineering, design, installation, commissioning and software
development for engine, motor, hybrid engines and transmission test stands.
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PCS supplies tailor made solutions according to customer’s requirements by using carefully
chosen and high quality hardware products of global companies and by using PCS products.
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Engines, motors and transmissions are tested by applying load with suitable dynamometers
which can one be of hydraulic, Eddy-Current (EC) , Alternating Current (AC) types.
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Engineering of the test system includes designing and manufacturing of supplementary
units and their automation working in conjunction with the test bench.
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PCS is the leader company of the local market and has know-how & experience which will
fulfill customers’ requests.
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
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Activities / Sectors
Gasoline and Diesel Engine Test Benches
Compressor Test Benches
Electric and Hybrid Motor Test Benches
Steering Box Testing System
Transmission and Gear Box Test Systems
Brake Testing
Chassis Dynamometer Systems
Test System Design and Installation
Automotive
R&D Laboratories
Universities and Technical Schools
Railways
June, 2012
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Defence
Industrial Vehicles
Marine
Agricultural Machines
TEST SYSTEMS
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TEST SYSTEMS
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Dynamometers
Hydraulic (Water Brake)
Eddy Current (water cooled)
Eddy Current (air cooled)
AC Regenerative (active dynamometer)
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Dynamometers
PHD-140 Hydraulic Dynamometer
 Model
: PHD-140
 Max. Power
: 50 Hp
 Max. Torque
: 250 Nm
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: 7000 Rpm
Max. Speed
 Cooling Water : 0,75 m3/h
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Dynamometers
 Model
: PHD-190
 Max. Power
: 160 Hp
 Max. Torque
: 750 Nm
 Max. Speed
: 7500 Rpm
 Cooling Water : 2,4 m3/h
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Dynamometers
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Model
: PHD-220
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Max. Power
: 300 Hp
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Max. Torque
: 1600 Nm
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Max. Speed
: 6000 Rpm
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Cooling Water : 4,5 m3/h
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Dynamometers
 Model
: PHD-260
 Max. Power
: 450 Hp
 Max. Torque
: 2000 Nm
 Max. Speed
: 5000 Rpm
 Cooling Water
: 6,75 m3/h
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Dynamometers
 Model
: PHD-290
 Max. Power
: 800 Hp
 Max. Torque
: 4000 Nm
 Max. Speed
: 4000 Rpm
 Cooling Water
: 12,0 m3/h
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Dynamometers
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Model
: PHD-320
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Max. Power
: 1200 Hp
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Max. Torque
: 5500 Nm
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Max. Speed
: 3500 Rpm
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Cooling Water
: 18,0 m3/h
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Signal Converters
• Load Cell
 Speed
 Torque
 Power
 Temperature
 Pressure
 Flow
 Humidity
 Position
 Vibration
 Blow-By
 Angle
 Noise
 Frequency
 Fuel consumption
• Rezistive Bridge
• Resistance
• Potentiometer
• Thermocouple
• Resistive Thermoelement
• Frequency
• Pulse
• AC / DC Voltage - Current
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Temperature Sensors : PT100 & Thermocouples
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High accuracy measurements,
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Rugged,
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Durable against vibration,
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Fast response,
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Fast and easy plugging with high quality Lemo
connector,
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Stainless steel,
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Special design for the application
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
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Throttle Control Unit
DC Servo control,
Variable speed adjustment,
Adjustable Min. , Max. Position,
Safe operation with 24V DC supply,
Positioning capability,
Fault detection,
Continious control by Planetary gear
 Profibus,
 Can-Bus
 Digital control
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
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Operator Control Desk
Ergonomic Design
Durable Metal construction
Top made of laminated wood
Alarm and warning lamps
Emergency button
Mains disconnector
Functional control buttons and
switches
Slots for PC and 19” UPS
Cooling fan
Air filters
Ergonomic seat
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Control Panel
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Ergonomic Design
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Aluminum structure
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Turns around 270 degrees
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Control section moves up and
down 90 degrees
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Emergency button
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Control buttons and switches
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Touch screen monitor
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Profibus communication
By using the butons and touch screen monitor,operator can control the system locally and view the status
of the system by lamps and and the monitor.
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
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Blow-By Measurement
Minimum effect on motor performance,
Low pressure drop,
High stability,
High accuracy even at low flow rates,
Continious measurement,
40:1 Min. Max. turndown ratio,
Measurement range : 0,24 – 1019 m3/hr.
Operating temperature : -18 - +93 ˚C
High repetition capability,
No maintenance,
Compact design includes air filter and flow regulator.
June, 2012
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TEST SYSTEMS
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Fuel Consumption Measurement
Coriolis Mass Principle
High accuracy
No calibration and maintenance required
Easy and fast installation
By-Pass feature
Stainless steel construction
Profibus communication option
Mass and volumetric measurement
Fuel filter
For gasoline and diesel engines
0.1 to 125 kg/h., 0...165l/h(at 0,75g/cm3)
Optional features
Flame capture filter
Bubble elimination
Fuel conditioning
June, 2012
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Ex Approval : EEx ia IIC T3-T6
Uncertanity : (DIN 1319)is 0.12%
Operating Temp : -40......+115 deg.C
Accuracy
: % 0.1 of full scale
Density
: 0…2.9 g/cm3
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TEST SYSTEMS
Can-Bus Gauges
• Can-Bus (J1939)
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Rpm
Speed
Pressure
Temperature
Current
Voltage
Tank level
June, 2012
• Can-Bus (Can-open)
• 0-5V../12V../24V DC Voltage
• Frequency
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TEST SYSTEMS
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TEST SYSTEMS
Electromechanical Design and Modelling
Mechanic and Electromechanic designs are made and modelled using CAD software. Design verification,
simulation and analysis are implemented before manufacturing. These are made using SolidWorks
professional software.
June, 2012
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TEST SYSTEMS
Quick Coupling
Basic Features
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Stainless steel couplings for
hydraulic and pneumatic connections
diameter range from 1/8” to 3”
no leakage during connection and
disconnection
Hydraulic connections operates up to
40 bar
Pneumatic connections operates up
to 16 bar
Operates with pneumatic piston
Precise coupling with guide bearings
Pneumatic lock mechanism avoids
high pressure disturbances
Coupling for the connecting hydraulic, pneumatic and electrical supplies. Operates with pneumatic
mechanism. Consists of male and female connectors mounted on two parallel plates.
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Operator Control Desk
Drive and MCC cabinets
June, 2012
Test Bench Components
Data acqusition and Signal conditioning
Pressure transmitter boxes
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Local control and monitoring panel
Servo Positioners for
Shift selector and steering control
TEST SYSTEMS
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TEST SYSTEMS
Illumination and air conditioning
Test Carts
Locking and guiding mechanisms
Torque measurement
Test rooms
Test cart accessories
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Supplementary Units:
Oil, water, fuel and air conditioning units
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Gasoline and Diesel Engine Testing
Hydraulic (Water) Dynamometer, Power = 800 Hp,Torque = 2500 Nm,Speed = 4500 Rpm
Data acqusition, fully automatic test cycle, dynamometer control, throttle control, fuel consumption
measurement & fuel conditioning, blow-by measurement, turbocharger air cooler
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Hydraulic (Water) Dynamometer, Power 160 Hp, Torque = 750 Nm, Speed = 6000 Rpm
Data acqusition, fully automatic test cycle, dynamometer control, throttle control, fuel consumption
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Hydraulic (Water) Dynamometer, Power =800 Hp,Torque = 2500 Nm,Speed = 4500 Rpm
Hydraulic
(Water)
Dynamometer,
Power
=800
Hp,Torque = 2500
Nm,Speed
4500 Rpm
Data
acqusition,
fully
automatic test
cycle,
dynamometer
control,
throttle= control,
fuel
Data
acqusition,
fully
automatic
test
cycle,
dynamometer
control,
throttle
control,
fuel
consumption
consumption measurement & fuel conditioning, blow-by measurement, turbocharger air
cooler
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Diesel Engine Testing
Tested Engines
AVDS 1790 General Dynamics / MB 833 MTU / MB 837 MTU / MB 838 MTU
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Gasoline and Diesel Engine Tesing
MAN-D2866F, CUMMINS-CM850, CUMMINS-CM260 CB E2, MERCEDES-OM447 HLA
CAN-BUS J1939 and CAN OPEN Communication
Hydraulic (Water) Dynamometer, Power = 450 Hp, Torque = 2000 Nm, Speed = 5000 Rpm
Data acqusition, fully automatic test cycle, dynamometer control, throttle control, fuel consumption measurement & fuel
conditioning, blow-by measurement, turbocharger air cooler
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Gasoline and Diesel Engine Test Systems
Hydraulic (water) Dynamometer, Power = 450 Hp, Torque = 2000 Nm, Speed = 5000 Rpm
Measuring parameters on theTest bench; torque, power and speed measurement, engine oil temperature, engine oil
pressure, engine cooling water inlet temperature, engine cooling water outlet temperature, exhaust temperature,
dynamometer water outlet temperature, dynamometer water inlet pressure. 10 step test data (torque-speed-power) can
be printout end of the test.
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Hybrid Vehicle Electric Motor Testing
Hybrid vehicle electric motor test stand at TUBITAK
4 Quadrant AC Regenerative Dynamometer, Power = 89 Kw, Torque = 710 Nm, Speed = 2800 Rpm
Data acqusition, dynamometer drive and control, high speed & high Precision 4 phase (3AC,DC) power analyser, dynamic
torque transducer, high accuracy 500kHz AC-DC current sensors, harmonic measurement up to 99th harmonic,
industrial PC, fast data transfer via GPIB, up to 3600 test steps, fully automatic test cycle, Can open communication
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Railway Engine Testing
Non-proprietary
Locomotive Engine testing at TULOMSAS
Hydraulic (Water) Dynamometer; Power=4000 Hp,Torque=30000 Nm,Speed=2500 Rpm
Modernization of the Test Bench: Installation of new computer and PLC controlled test control unit and data acqusition,
adaptation of torque measurement and mechanical controls to digital control system
renewing of the MCC cabinets, fuel measurement, temperature and pressure sensors.
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Transmission Testing
Allison TX100 Transmission Test Bench
Functional specifications, design and installation of the test bench
civil works, air conditioning, illumination, AC actuation and AC dynamometer units, oil conditioning
unit, quick coupling mechanisims for coupling of hydraulic, pneumatic & electrical
connections, transmission carriage carts & locking mechanisims, data acqusition and control
units, software, shift selector and steer control units, instrumentation, torque measurement,
training
Non-proprietary
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Allison X200 Transmission Test Bench
civil works, air conditioning, illumination, AC actuation and AC dynamometer units, oil conditioning unit, quick coupling
mechanisms for coupling of hydraulic, pneumatic & electrical connections, transmission carriage carts & locking
mechanisms, data acquisition and control units, software, shift selector and steering control units, instrumentation,
torque measurement, training
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
FOR TRANSMISSIONS;
TX100, TX200, CD850-5, CD850-6A, CD500,
XTG1410, XTG1411
Cross Drive Transmission Test Bench with Actuating AC Motor and AC Dynamometer
Inline and cross drive transmissions are actuated by AC motor and load is applied by AC regenerative dynamometers.
Electrical energy produced by the dynamometers feeds the mains supply. This gained energy is around %80.
Transmission carriage carts, electronic units and software are designed for flexibility which is used for testing various
transmissions on a single test rig. The tailor made testing softwares are developed by PCS engineers.
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Cross Drive Transmission Test Bench with Actuating DC Motor and Eddy-Current Dynamometer
FOR TRANSMISSIONS;
TX100, TX200, CD850-5, CD850-6A, CD850-T5 CD500, CLBT754, 4 HP 250
DC actuation and Eddy -Current dynamometer units, cooling water and oil conditioning control,
controlling quick coupling mechanisims for coupling of hydraulic, pneumatic & electrical
connections, transmission carriage carts & locking mechanisims, data acqusition and
control units, software, shift selector and steer control units, instrumentation, torque
measurement, training
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Power-Pack Testing
Power-Pack Test Bench
FOR POWER-PACKS
TX100, TX200, CD850-5, CD850-6A, CD850-T5 CD500, CLBT754, 4 HP 250
cooling water and oil conditioning control, controlling quick coupling mechanisims for coupling
of hydraulic, pneumatic & electrical connections, transmission carriage carts & locking
mechanisims, data acqusition and control units, software, shift selector and steer control
units, instrumentation, training
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
General Transmission Test bench
Complete facility design and manufacturing electrical infrastructure,Cooling
water and oil conditioning automation, Transmission stands and fittings.
Electrical systems, Data acquisition and control systems, Control
consoles and control panels, robotics gear shifter and servo systems,
Test system software, Instrumentation and measurement systems,
Dynamic torque measurement and contol, Documentation and training
FOR TRANSMISSIONS (AUTOMATIC AND MANUEL)
ZF5S-42, ZFS6-65, ZFS6-85, ZF6S-850,ZF6S-890, ZF9S-75, ZF9S-109, ZF16S-130, ZF16S-151, ZF16S-151L,
EATON 4106, EATON 8209, MT 75, STC 1546N, STC 1547N, TRC 102980, TRC 103150, TRC 103160,
5928R, 5928N, ALISSON CLBT 754, ALISSON HD4560, ALISSON HD4560PR, GM4L80, G240-16,
MERCEDES G3/50-5/8.5, G155-9/15.9+NA 4/120.1C, UG100-8/9.57-0.74 GPA, UG3/40-8/13.01 GPA,
UG3/65-8/13.01 GPA
June, 2012
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TEST SYSTEMS
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TEST SYSTEMS
Gear Box Testing
Gear Box Test System
DESIGNED FOR PERFORMENCE, FATIQUE,
EFFICIENCY ANALYSIS AND BACKLASH
MEASUREMENT OF GEARBOXES
.
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Measure all defined parameters
Create automatic test scenarios
Backlash measurement and graphical display
Both motors can be operated individually
Measure dynamometer’s power, current and voltage
Selectable sample rates
Display the measured parameters on time graphic
June, 2012
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TEST SYSTEMS
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TEST SİSTEM
Turbine Engine Test
Helicopter Engine Test Bench
FOR ENGİNES
General Electic T700 –GE701A
General Electic T700 –GE401 / 401C
General Electic T700 –GE701C / 701D
Rolls Royce 250-C20B/F/J
Rolls Royce 250-C20R4
Rolls Royce 250-C30 serisi
Honeywell T53-L13B/703
Two different dynamometer: 8500 rpm ve 24000 rpm
2500 KW
Complete facility design and manufacturing
mechanical and electrical infrastructure,
Cooling water and oil conditioning automation,
Electrical systems, Data acquisition and control
systems, Servo systems, Test system software,
Instrumentation
and
measurement
systems,
Documentation and training
2013
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TEST SİSTEMİ
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TEST SYSTEMS
Our Suppliers
Our suppliers
SIEMENS
ABB
HBM
Instrumentation and
control
Instrumentation and
control
Data acqusition hardware-software,
test & measurement electronics,
Torque, force, pressure and
strain transducers
BORGHI & SAVERI
Eddy-Current
Dynamometer
NATIONAL INSTRUMENT
Data acqusition and Labview software
June, 2012
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TEST SYSTEMS
41
TEST SYSTEMS
References
Military Factories
Description
Date
Gendarmerie Maintenance Factory–ANKARA
Engine Test Systems (3 sets 160HP)
Before 1995
1015 MND Maintenance Factory-İZMİR
Engine Test System (1 set 450HP)
Before 1995
1014 MND Repair Factory-ANKARA
Engine Test System (1 set 160HP,1 set 450 HP)
Before 1995
Military Factory–CYPRUS
Before 1995
MND Air Supply Center-ESKİŞEHİR
Before 1995
Military Factory-CAIRO-EGYPT
Before 1995
Before 1995
500 MND Maintenance Factory-AFYON
1996
600 MND Maintenance Factory-BOR-NİĞDE
1996
1013 MND Maintenance Factory-İSTANBUL
1996
Admiralty Black Trees Maintenance Factory-GÖLCÜK
1996
1500 MND Maintenance Factory-ANKARA
1997
1012 MND Maintenance Factory-BALIKESİR
Engine Test System (3sets 450HP,2sets160HP,1set 650HP)
2001
Engine Test System Modernization (3 sets 160HP)
1997
Military Tank Factory-BAKÜ-AZERBAIJAN
1997
1009 MND Maintenance Factory-KAYSERİ
1998
Miitary Factory-MACEDONIA
2001
Automatic Test System (1 set 160HP,1 set 800HP)
2004
June, 2012
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TEST SYSTEMS
42
TEST SYSTEMS
References
Military Factories
Description
Date
1010 MND Tank and Pallet Factory-ARİFİYE
Automatic Test System (5 sets 450HP)
Engine Test System Modernization (2 sets 450 HP,2 sets 160HP)2003
MND 6. Maintenance Center-BALIKESİR
Automatic Test System (1 set 160HP)
2005
MND Petty Officer Vocational High School-BALIKESİR
Automatic Test System (1 set 160HP)
2003
6.Maintenance Center Command-BALIKESİR
Maintenance and repair of engine test benches(1set 650HP,2sets 450HP)2007
2.Maintenance Center Command-KAYSERİ
Transmission Automatic Test System (2 Sets)
June, 2012
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TEST SYSTEMS
2003
2009
43
TEST SYSTEMS
References
Universities
Description
Date
Anadolu University-ESKİŞEHİR
Before 1995
Faculty of Engineering-ADAPAZARI
Before 1995
Trakya University-Vocational High School-ÇORLU
2003
ITU Marine Faculty-TUZLA-İSTANBUL
Engine Test System Modernization (1 set 160HP)
2003
Gazi University Department of Motor-ANKARA
2005
Erciyes University Faculty of Engineering-KAYSERİ
2006
Dicle University Faculty of Engineering-DİYARBAKIR
2006
METU Space and Aviation of Engineering-ANKARA
2007
June, 2012
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TEST SYSTEMS
44
TEST SYSTEMS
References
Other Customers
Description
Date
Tümosan Motor Factory-KONYA
Engine Test System (2 sets 160HP )
Before 1995
Taksan A.C.-ANKARA
Engine Test System (9 sets 450HP)
Before 1995
ESHOT-İZMİR
Engine Test System (1 set 450 HP)
Before 1995
State Water Works-ANKARA
Before 1995
TCC Ege Lignite.Opr.Maintanance Center-SOMALIA
Before 1995
Borghi&Saveri srl Bologna-ITALY
Engine Test System (1 set 160HP,1 set 450HP)
Before 1995
Sugar Company -CAIRO-EGYPT
Engine Test System
Before 1995
Oil Company - CAIRO-EGYPT
Engine Test System
Before 1995
Helwan Diesel Engine Co-EGYPT
Engine Test System
1996
Tractor Factory Turkey-ANKARA
1997
Ramzey Ltd.Cpy-İSTANBUL
Engine Test System (1 set 50 HP)
1997
En-ka Trade and Marketing A.C.-İSTANBUL
1997
Anatolia Industrial Engine Factory-İSTANBUL
1998
GM Tractor Factory -KARACHI-PAKISTAN
2001
Al-Ghazi Tractor Factory -KARACHI-PAKISTAN
2000
Al-Ghazi Tractor Factory-MULTAN-PAKISTAN
2000
State Railways Ray Factory-ANKARA
Engine Test System Modernization(1 set 6000HP)
2003
ESHOT-İZMİR
Engine Test System Modernization(1 set 450HP)
2008
June, 2012
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TEST SYSTEMS
45
TEST SYSTEMS
References
Other Customers
Description
Date
TCC Ege Lignite.Opr.Maintanance Center-SOMALIA
Engine Test System Modernization(1 set 450HP )
2004
Al-Ghazi Tractor Factory-MULTAN-PAKISTAN
2005
Dewan Group-KARACHI-PAKISTAN
Engine Test System (2 sets 160 HP)
2006
National Education Ministry-ANKARA
2006
June, 2012
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TEST SYSTEMS
46

ENGINE aNd TRaNSMISSION TEST SYSTEMS YOUR

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