SuperFlow AutoDyn Operator'S Manual Download Page 45

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M a n u a l

AutoDyn

Section 5 - Page 8

AutoDyn manual Section 5. PM7, 5/2004

☛

NOTE

The power supply used on the latest models is a standard PC power supply of

the ATX type. The power supply used in older models is a standard PC power

supply of the AT type. Voltage checkpoints for both power supplies are provided

on labels affixed to their case.

Summary of Contents for AutoDyn

Page 1: ...Pub No 190315 Rev 0 March 2019 Operator Manual www PowerTestDyno com Original Instructions Computerized Engine and Vehicle Test Systems...

Page 2: ...division of Power Test Inc All rights reserved No part of this publication may be reproduced transcribed or translated by any means without the prior written permission of SuperFlow N60 W22700 Silver...

Page 3: ...Area Requirements 5 Installation 6 System Operation 7 Handheld Controller 8 Theory of Testing 9 Description of the Configuration File 11 Control Modes 20 Calibration and Maintenance Appendix A Genera...

Page 4: ...AutoDyn Operators Manual Section 1 Page 4 AutoDyn Cover fm...

Page 5: ...1 General Information...

Page 6: ...cautions to prevent damage to these parts Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the cont...

Page 7: ...cts away from any rotating object that can throw debris radially outward 1 3 Room Requirements When working in or building a test cell Follow all local construction codes Install a Carbon Monoxide CO...

Page 8: ...aining carbon such as gasoline kerosene oil propane coal or wood One of the most common sources of exposure in the workplace is the internal combustion engine How does CO harm you Carbon monoxide is h...

Page 9: ...ators with appropriate canisters for short periods under certain circumstances where CO levels are not exceedingly high Educate workers about the sources and conditions that may result in CO poisoning...

Page 10: ...S Y S T E M O V E R V I E W Section 2 Page 1 2 System Overview...

Page 11: ...view 2 1 Purpose 5 2 2 Components 6 2 3 Frame Assembly 6 2 4 Power Absorber Assemblies 7 2 4 1 Single Eddy Current absorber module 7 2 4 2 Dual Eddy Current absorber module 8 2 5 Sensor Box 9 2 6 Spec...

Page 12: ...trucks and similar vehicles within the workshop environment Typical applications include Performance testing Diagnostic testing Education Vehicle certification Research and development Testing on a dy...

Page 13: ...different speed and power characteristics of the dynamometer The rolls have a nominal diameter of 42 106 7 cm and are 28 71 1 cm wide They are spaced 28 71 1 cm apart The inertia of the rolls is meas...

Page 14: ...ge to the CPU for conversion and measurement Because the axle is trunnion mounted all torque reaction forces are measured by the load cell mounted on the differential and there is no need for trunnion...

Page 15: ...e The main advantage of the air cooled eddy current absorber is the ease of installation no external cooling systems are required 2 4 2 Dual Eddy Current absorber module A module containing two identi...

Page 16: ...sorber models measures the torque produced by the vehicle as an analog voltage and converts that voltage to digital information The pressures and thermocouples are also measured as analog voltages and...

Page 17: ...pecifications TheAutoDyn dynamometer uses SuperFlow s New Generation Elec tronics NGE for state of the art data acquisition and control perfor mance Two levels of NGE are used Some older models use th...

Page 18: ...al Converter ADC expandable to hundreds of channels via on board multiplexing Data acquisition rate Base rate 1200 Hz 5 channels at 150Hz 8 channels at 60 Hz 2 groups of 8 128 expansion channels each...

Page 19: ...50 Hz Loop of series connected normally closed switches for external panic buttons Internal loop for panic buttons on SF equipment 4 digital inputs configurable for Normally Open NO Normally Closed NC...

Page 20: ...e 1 kHz 5 channels at 1 kHz 8 channels at 312 Hz 2 groups of 8 128 expansion channels each measured at 1 8 1 128 of the base rate frequency channels at 200 Hz Data filtering User selected 8 filter lev...

Page 21: ...lemented on standard AutoDyn systems EMS Emergency Stop command scanned at 150 Hz Loop of series connected normally closed switches for external panic buttons Internal loop for panic buttons on SF equ...

Page 22: ...ential sensors up to 4 screw in industrial grade transducers 1 8 x 4 male fittings for pressure lines analog input panel 8 channels 4 096VDC 5 VDC 10 VDC excitation voltages 5 VDC and 12 VDC supply v...

Page 23: ...Sect ion 2 PM7 5 2004 system interconnect panel handheld controller serial port air and fuel sensor frequency inputs air humidity and temperature analog inputs optical tachometer input spark clip fre...

Page 24: ...P A C K A G I N G A N D H A N D L I N G Section 3 page 1 Packaging and Handling 3...

Page 25: ...Handling 3 1 Weights 5 3 2 Shipping dimensions 5 3 3 Lifting and handling instructions 5 3 3 1 Main dynamometer frame 5 3 3 2 Absorber module 5 3 4 Packaging of the AutoDyn 6 3 4 1 Order of unpacking...

Page 26: ...Computer package optional 110 lbs 50 kg Accessory box includes sensor box 60 80 lbs 27 36 kg exact weight depends on the model and configuration 3 2 Shipping dimensions Component LxWxH Rollset 91 x51...

Page 27: ...a check sheet when your AutoDyn arrives 1 One dynamometer mounted in a wooden frame The dynamometer is shrink wrapped and secured by metal straps This package includes 1 1 the main dynamometer frame 1...

Page 28: ...l damage 2 Unwrap all the removed parts and inspect them for damage WARNING The cover is heavy and may fall inside the dynamometer Be careful when removing it 3 Remove the screws securing the cover be...

Page 29: ...T E S T A R E A R E Q U I R E M E N T S Section 4 page 1 4 Test Area Requirements...

Page 30: ...issues 7 4 3 1 Safety 7 4 3 2 Environmental 7 4 4 1 Problem statement 8 4 4 2 Air supply 8 4 4 3 Vehicle cooling 9 4 4 4 Exhaust extraction 10 4 4 6 Compressed air supply 11 4 4 7 Electrical power 11...

Page 31: ...om should be at least 12 3 6 m wide 26 8 m long and 8 to10 3 m high The larger the room the more expensive the construction and the more difficult it is to achieve significant ventilation air speeds A...

Page 32: ...systems can be directed away from other nearby buildings to minimize noise impact on your neighbors 4 2 3 Room layout The position of the dynamometer in the room must take into consider ation the type...

Page 33: ...ights and signs to this effect Make sure there is good visibility all around the room This includes good lighting and the installation of wide field mirrors so the operator can see all areas of the ce...

Page 34: ...ssure drop caused by your inlet and outlet ducting Keeping the length and complexity of ducting to a minimum greatly reduces the pressure drop and thus the fan power required Axial fans are most effec...

Page 35: ...ompensate for this deficiency spot cooling fans are recommended Although these fans do not increase the overall airflow through the room they modify the local patterns and speeds of the airflow to acc...

Page 36: ...amount of heat is released through the exhaust system A proper exhaust extraction system is critical for the safety of your employees inside and outside the test room The exhaust system should be abl...

Page 37: ...ate circuit with surge protection and uninterruptible power supply UPS if possible is recommended for the control electronics and computer system Contact your electrician for detailed installation adv...

Page 38: ...oom depending on your climate a secure storage space in the control room for software manuals back up disks and test results also a closed storage space in the test room for sensors cables calibration...

Page 39: ...T E S T A R E A R E Q U I R E M E N T S Section 4 page 13 4 7 Installation drawings Drawings are available for pit installations and for the platform and lift kit available from SuperFlow...

Page 40: ...I N S T A L L A T I O N Section 5 Page 1 5 Installation...

Page 41: ...Wheel Tach Connection 11 5 1 11 Ignition Pick up Connection 11 5 1 12 Air and Fuel Sensor Connection 12 5 1 13 Remote Switch Aux 1 Aux 2 Aux 3 and Control Inputs Connections 12 5 2 Configuration 12 5...

Page 42: ...ny damage 5 1 2 Installation 1 Be sure to think about access to the area and about the maneuvering space required for moving a vehicle onto the dynamometer ramp or lift 2 Position the dynamometer in t...

Page 43: ...hase outlet with a 40A rating 7 Surface mounted dynamometer installations only install the three vehicle restraint bars at the rear of the dynamometer side opposite the dynamometer connection panel 8...

Page 44: ...e bottom of the sensor box must be connected to the control box plug on the dynamometer connection panel 5 1 4 Sensor Box Power Do not connect the sensor box power yet The sensor box power input is se...

Page 45: ...004 NOTE The power supply used on the latest models is a standard PC power supply of the ATX type The power supply used in older models is a standard PC power supply of the AT type Voltage checkpoints...

Page 46: ...n the white power switch The sensor box LCD display and the Handheld Controller should now display information 5 1 6 General check 1 If installed check the tightness of the absorber module to roll mod...

Page 47: ...8 Thermocouple Connections The Sensor Box has inputs for up to 16 type K thermocouples Provided with the system are two open tip thermocouples and two closed tip thermocouples The open tip thermocoupl...

Page 48: ...00A 1936 Sensor Box Connector Panel Be sure to have the power turned OFF before plugging in the connector Insert the connector into the yellow receptacle Apply a small piece of the supplied reflec tiv...

Page 49: ...rd sensor AMP plugs to the connector panel Insert the connector into the red receptacle 5 1 13 Remote Switch Aux 1 Aux 2 Aux 3 and Control Inputs Connections These receptacles black gray lower blue wh...

Page 50: ...you will NOT be able to receive data from the Sensor Box Note that the following instructions are necessarily vague This is because of the variability in computer hardware software in the PC computer...

Page 51: ...3 Configure PC for NetBEUI communications If your computer was supplied or up dated by SuperFlow all of the setup operations described below should already be done If your computer is running Windows...

Page 52: ...nt LAN adapter number A utility has been included as part of the WComNet program to aid in selecting the appropriate LAN adapter This utility is accessed by selecting Configure Lan Adapter from WComNe...

Page 53: ...rench Metric Spanish Metric German Metric Italian Metric Swedish Metric The Units system is applied consistently This means US unit configurations will use all Imperial units and Metric unit configura...

Page 54: ...etailed instructions NOTE Screen display files CDF Specifications files CST and Autotest files TPF are linked to specific configuration files If you have saved a modified configuration file under a ne...

Page 55: ...6 System Operation...

Page 56: ...otect the operator against all these hazards by the design of the dynamometer instrumentation system A proper test cell environment eliminates or reduces the risks associated with dynamometer testing...

Page 57: ...s and could cause bodily injury or material damage Wear ear and eye protection at all times when testing 6 2 2 Handheld stop key To reset the system at any time or to stop a test under way press the s...

Page 58: ...______Visual Inspection of tires ______Tire Pressure _____________________ ______Coolant Level ______Oil Level ______Trans Level ______Visual Inspection of Engine Bay ______Visual Inspection of suspe...

Page 59: ...rn tires are unsafe Tires of different sizes left to right should not be used Correct any such problems before installing the vehicle on the dynamometer Verify the tire pressure and adjust as necessar...

Page 60: ......

Page 61: ...hor points Item 1 These are the power straps that will hold the vehicle in place For high power vehicles the more straps the better Two straps are placed on the drive axle end of the vehicle i e rear...

Page 62: ...cure the rear crossed straps tightly and the front crossed straps a little loose Run the vehicle slowly and adjust the front crossed straps until the vehicle tracks straight Then add the rear power st...

Page 63: ...eld Post test analysis is performed with the WinDyn Stored Data Viewer The Quick Start Section 6 7 1 provides a reference to the test operation Copy this page and place it near the computer for easy v...

Page 64: ...t end the name with a number as WinDyn will tag the name with a sequence number Set the Start At number to 1 This is the sequence number and will automatically increment with each saved test If the St...

Page 65: ...rs Guide for more information on test description notes and data analysis 8 Press F2 or click on Activate to install the new test settings 9 The dyno sensors should be zeroed before the car is rolled...

Page 66: ...process it to provide smoother data with even increments of engine RPM on the data printout See Chapter 3 in the WinDyn Users Guide for more information on ProFilter and how to use it 14 Upon complet...

Page 67: ...iew Plot to display the results in graphical format Use the numeric keys or the mouse to select any of ten available pages Click on the Print Test button printer icon to print the tabular data or sele...

Page 68: ...he dyno see section 6 4 for instructions 9 Select a method for obtaining engine speed See Section 6 8 for instructions 10 Connect any additional sensors to the vehicle Use the Handheld to run the test...

Page 69: ...ative power calculation from the non driven roll added to the positive power calculation from the driven roll and a lower total power readout than what is really there This problem is averted by the u...

Page 70: ...wer derived at that roll positive or negative is ignored in the wheel power calculation The rear load cell will calculate appropriate losses from the front rollset 4 Front roll used rear wheels off re...

Page 71: ...accelerated during the test We measure the rate of acceleration from the roll speed pickup Dyno losses are computed at the factory and are embedded in the system configuration Roll power is derived fr...

Page 72: ...p on the signal wire to get it to work properly Most ignitions with two plugs and one coil fire one plug positive and one plug negative This means there is no way to tell initially which way the clamp...

Page 73: ...wires on an ignition coil Although the pickup implies correct polarity by the red and black lead colors it may work better with the leads reversed Try it A green LED flashing on the device will confir...

Page 74: ...frequency channel 9 in WinDyn 6 9 2 Optical Sensor IFR Optical Tach P N 1200A 0642 1 with cable assembly 1200A 2448 1 This pickup was originally designed by Caterpillar Corporation for use in obtainin...

Page 75: ...l not work with vehicles equipped with an automatic transmission Nor can you obtain an accurate RPM reading if you change transmission gears during the test if you are using the wheel or driveshaft fo...

Page 76: ...a stool jack stand or whatever and you may achieve a stable signal Bear in mind that if the vehicle wheel is severely out of balance that may be causing you signal loss troubles The unit is affected b...

Page 77: ...1 in this channel enables input signals from channel 11 an inductive spark pickup coil pick up or for the direct tach wire connection A zero 0 in this channel will disable channel 11 inputs to the ca...

Page 78: ...H A N D H E L D C O N T R O L L E R Section 7 Page 1 7 Handheld Controller...

Page 79: ...2 4 Stored Data display choices 16 7 2 5 Configuration choices 17 7 2 5 1 Set system filter 17 7 2 5 2 Configuration of Specifications 18 7 2 5 3 Configuration of Calibration 20 7 2 5 4 Configuration...

Page 80: ...of M key on front panel units channel number measured values PRINT Prints a saved test TOGGLE toggles between normal operation and load N key on front panel control command line data entry keys CLEAR...

Page 81: ...u date Status check Color A B C D E Set Time Date screen F G H I J Time Date Setup TIME DATE 0 00 00am Sun Jan 1 0 hours 0 month 1 minutes 00 day 1 seconds 0 year 0 Exit A B C D E System status screen...

Page 82: ...B Proc Nodes CtrlSys Exit A B C D E Pressing Nodes will display connected node information F G H I J System Status 0 00 00 00am Connected Nodes 1 Connected to NameofNode type 1 1 Exit A B C D E Pressi...

Page 83: ...Make sure the system is in a safe mode prior to performing this restart no engine vehicle or other devices running Pressing Node Names will display the list of network node names for your system Scree...

Page 84: ...ing F G H I J Select System type 2 0 Standard system Grav Fuel System 1 Standard system no Grav Fuel 2 SF 820 Chassis Dyno 3 SF 602 Chassis Dyno 4 Motorcycle Dyno CycleDyn 5 Towing Dyno system A B C D...

Page 85: ...942 2060 boardsets torque offsets are normally 10 Pressing Ctrl Setup allows selection of scaling factors for the 2 controllers Both are normally scaled at 100 Upon completion of all configuration set...

Page 86: ...ro Test Data Configure Help Zeroing all sensor channels Boost Blower RollLock DiffLock On Off On Off On Off On Off Starter A B C D E Autozero single channel screen note it is not required to use the S...

Page 87: ...Ch 11 xx Ch 12 xx Ch 13 xx Ch 14 xx Ch 15 xx Enter Channel Number 0 A B C D E Autozero single channel timed message F G H I J Autozeroing channel xx ChName Autozero All Single channels channel Exit A...

Page 88: ...screen computer nodes connected Case 1 no files found in specified WinDyn path F G H I J No Files Found Press any key A B C D E Case 2 files found in specified Windyn path note it is not required to...

Page 89: ...No Valid Test profile found Cannot perform requested function Select Start Manual test test test Exit A B C D E Test Start screen test loaded in system F G H I J Current test TESTNAME Ch 1 0 Ch 2 0 Ch...

Page 90: ...ep xx Increase to full throttle A B C D E Manual Test screen note pressing either A or B softkey will scroll control modes press Done to activate mode Exit to cancel and return to previous screen F G...

Page 91: ...ll scroll through screen 1 9 Records displays total lines of data in test Number displays current line F G H I J First Last Up Down Screen Ch 1 0 Ch 2 0 Ch 3 0 Ch 4 0 Ch 5 0 Ch 6 0 Ch 7 0 Ch 8 0 Ch 9...

Page 92: ...data channels when building a configuration file In that case the filter that will be applied to those data channels will be deter mined by the System filter setting The table below shows the filter c...

Page 93: ...selection of the System filter F G H I J Select required function Filter 5 Channel1 Channel4 Channel7 Channel2 Channel5 Channel8 Channel3 Channel6 Channel9 Set automatic data filter to 5 A B C D E 7 2...

Page 94: ...E3 4 SPCNAME4 5 SPCNAME5 PageUp PageDn Select Exit A B C D E Select Specifications file number screen F G H I J File Selection xxx files found 1 SPCNAME1 2 SPCNAME2 3 SPCNAME3 4 SPCNAME4 5 SPCNAME5 En...

Page 95: ...10 xx Ch 11 xx Ch 12 xx Ch 13 xx Ch 14 xx Ch 15 xx Enter Channel Number 0 A B C D E Edit Specifications channel screen 1 F G H I J Edit specification channel ChName Current value xxxx xx Enter new val...

Page 96: ...h 2 0 Ch 3 0 Ch 4 0 Ch 5 0 Ch 6 0 Ch 7 0 Ch 8 0 Ch 9 0 Reload Save file file Edit Exit A B C D E Reload file will load the calibration file last saved on your computer into the test system Save file w...

Page 97: ...Ch 6 xx Ch 7 xx Ch 8 xx Ch 9 xx Ch 10 xx Ch 11 xx Ch 12 xx Ch 13 xx Ch 14 xx Ch 15 xx Enter Channel Number 0 A B C D E Calibration method selection screen F G H I J Sensor Calibration Calibrating ChNa...

Page 98: ...ChName to xxxxx x Is this correct Yes No A B C D E Calibration screen using Coefficient F G H I J Sensor Calibration Calibrating ChName Enter calibration coefficient xxxx xxx Unit Unit A B C D E Cali...

Page 99: ...rform chan chan to list calibr Exit A B C D E Save calibration screen F G H I J Select required calibration function Ch 1 0 Ch 2 0 Ch 3 0 Ch 4 0 Ch 5 0 Ch 6 0 Ch 7 0 Ch 8 0 Ch 9 0 Changes have been ma...

Page 100: ...channel screen Limit value edit screen End of Note 7 2 5 6 Configuration of the Control System Control screen F G H I J Select Control calibration function Ch 1 Ch 2 Ch 3 0 Ch 4 Ch 5 Ch 6 0 Ch 7 Ch 8...

Page 101: ...tep size xxxx xx Calibrate another mode Yes No A B C D E Step Values screen for Closed Loop mode F G H I J Calibrate Step values Manual Load controller Calibrating Step values for Mode1 COARSE step si...

Page 102: ...D E PID control screen 4 F G H I J Parameters for Load Mode 1 Phase 0 Open Rate 0 Close Rate 0 P Gain 0 000 I Time 0 I Gain 0 000 I Threshold 0 00 D Gain 0 000 D Time 0 Delay 0 Filter Rate 0 Calibrate...

Page 103: ...ns cooling fans or exhaust extraction fans on and off via a digital output 7 3 3 Roll lock control This key turns the roll brakes on or off A speed interlock prevents the roll brakes from engaging if...

Page 104: ...8 Theory Of Testing...

Page 105: ...9 Wheel Torque 9 Corrected Wheel Torque 9 Power Correction Factors 9 Standards 10 SAE 10 STP 11 ECE 11 DIN 11 Aerodynamic Power 11 Test Profile Descriptions 15 Inertia Tests 15 ProInrt tpf 15 Mph_Rpm...

Page 106: ...ation of on road performance Because the weight of the vehicle under test varies considerably this is only possible with variable inertia dynamometers Some variable inertia dynamometers use a series o...

Page 107: ...der wide open throttle WOT conditions This limits applications for this type of dynamometer Any problems which occur at constant speed at partial throttle or during throttle transition will be difficu...

Page 108: ...our testing shows that this is not a problem on any motorcycle under 200hp wheel horsepower or any automobile under 500hp wheel horsepower The knurl of the SuperFlow roll has been selected to provide...

Page 109: ...The most important are Wheel Power and Corrected Wheel Power See the Description of the Configuration File Chapter 9 2 3 for details on the actual calculation formulas used in the system 8 4 1 Wheel...

Page 110: ...tising to represent torque of the vehicle under test 8 4 5 Corrected Wheel Torque Corrected wheel torque is the calculated wheel torque corrected to standard atmospheric conditions using the power cor...

Page 111: ...ed under considerably different test conditions At a single location the correction factor will usually vary less than 5 through the year Power corrections are only valid for Wide Open Throttle WOT te...

Page 112: ...8 F With the advent of European legislation and standards national standards such as the DIN formerly widely used are now less significant 8 6 Aerodynamic Power FAxCd Frontal Area x Coefficient of Dra...

Page 113: ...his FAxCd line can then be used as input for channel 78 Here is an example Assume a Honda CBR1100XX Blackbird has 133 Corrected HP at the rear wheel and rated at 181 mph The intersection of the lines...

Page 114: ...Theory Of Testing Volume 2 9 10 04 Section 8 Page 13 Figure 8 1 Frontal Area Coefficient of Drag US...

Page 115: ...AutoDyn Operators Manual Section 8 Page 14 Theory Of Testing fm Figure 8 2 Frontal Area Coefficient of Drag Metric...

Page 116: ...nrt tpf This is the most commonly used test profile for chassis dynos The Inertia test prompts the operator for an initial test speed in MPH at which the data acquisition system will begin recording d...

Page 117: ...tion is controlled during the entire test by the eddy current absorber This test is similar to the type commonly used on SuperFlow engine dynamometers The engine accelerates at the same rate throughou...

Page 118: ...e only available on eddy current equipped dynamometers The step test uses the eddy current absorber to hold the vehicle at a constant speed for a desired length of time and then samples one data point...

Page 119: ...uare feet to simulate load applied to the vehicle as vehicle speed increases These tests can be used to perform vehicle diagnostic checks under load conditions similar to those experienced on the road...

Page 120: ...entered thus making the rollset feel heavier to the vehicle during the acceleration run At the end of the test the eddy current absorber is engaged to return the vehicle to the starting MPH speed Ano...

Page 121: ...mputer disk drive 8 7 5 5 Eng_Spd tpf The Engine Speed test provides a convenient method for setting up the engine speed pickup on the vehicle you are testing It prompts the operator through several o...

Page 122: ...rameters instead of MPH At the beginning of the test the system compares roll speed to engine speed and calculates a ratio between the two Once that ratio is known the operator is prompted for a stead...

Page 123: ...9 Description of the Configuration File...

Page 124: ...Section 9 Page 3 9 Description of the Configuration File Overview 5 Channel Definitions 5 Measured Channels 5 Specification Channels 11 Calculated Channels 16 Interpolation Tables 29 System Channels 3...

Page 125: ...nput measured data and convert it to a reading In some cases the reading is a direct reflection of the input such volts in to volts out In other cases the input is convert to a different value such as...

Page 126: ...Channel 4 LambVt Channel 4 is used for auxiliary voltages for expansion It may be used for 0 5 vdc sensors on 2242 board sensor boxes or 0 10vdc sensors on 2060 01 board sensor boxes It is currently...

Page 127: ...hannel 8 Freq 2 Channel 8 is used to measure the frequency from auxiliary sensors such as airflow or fuel flow measurement turbines The coefficient for this channel is 1 000 with a maximum input frequ...

Page 128: ...he values displayed The frequency output is combined with the Channel 83 Pulses per Revolution to calculate the engine speed in Channel 125 0 000 5000 0 Hz 0 000 5000 0 Hz Channel 12 OptTac Channel 12...

Page 129: ...ficient of 1 000 and does not require calibration Channels 29 35 0 00 10 00 vdc 0 00 10 00 vdc Channel 36 0 00 20 00 vdc 0 00 20 00 vdc Channels 37 through 49 UNUSED Channels 37 through 49 are not cur...

Page 130: ...70 measure air inlet or exhaust pressure Filtering is set to 5 and zeroing is by command 0 000 3 636 volts 0 000 276 00 InH2O 70 kPa Channel 71 DifSen Channel 71 is used to measure the voltage from t...

Page 131: ...ally needed to be changed manually if they have been entered correctly the first time and stored under the name of the vehicle Channel 77 TotlWt Default Value 4000 00 1409 Channel 77 is for entering t...

Page 132: ...ed in channel 114 to add 10 more power to Channel 112 Numbers created using this factor are for speculation only and should not be used as a standard of any kind Channel 83 Pul Rv Default Value 0 500...

Page 133: ...Value 1 Channel 85 is used to select the engine speed calculation method desired for channel 125 A one 1 in this channel enables input signals from channel 11 an inductive spark pickup coil pick up o...

Page 134: ...front roll any power derived at that roll positive or negative is ignored in the wheel power calculation The rear load cell will calculate appropriate losses from the front rollset 4 Front roll used...

Page 135: ...ng only 2 wheels on an AWD system Channel 91 IntRw Default Value 0 Channel 91 is used in channel 43 to add an approximate rear wheel assembly inertia to the inertia power calculation for the rear whee...

Page 136: ...3 Calculated Channels The calculated channel is one of the most powerful features of the WinDyn software Sensor data specifications interpolation tables another calculation and or any direct constant...

Page 137: ...g to measurement errors This channel and channel 42 are added together to derive total wheel power Channel 39 FwInPw HP 1651 C90 C122 C10 375 kW 1651 0 454 C90 9 91 C122 C10 3600 Used only on AWD Chan...

Page 138: ...used to calculate the measured wheel power delivered to the rear dynamometer roll Channel 37 the eddy current absorber power is added to Channel 43 the inertia power due to acceleration and Channel 44...

Page 139: ...vehicle It uses the rear wheel power channel 42 divided by the total wheel power channel 100 That value is then multiplied by 100 to obtain a percentage value Channels 88 and 89 are used as switches...

Page 140: ...g changes in speed During fast transients some change in the ratio can also be introduced if there are different data filtration rates on the engine tachometer versus the roll speed however this would...

Page 141: ...factors and air density Channel 75 DifTmp C71T136 Channel 75 displays the differential temperature from the thermistor embedded in the rollset differential The voltage from channel 5 is converted usin...

Page 142: ...sorber torque on AWD systems This value is use for Roadload and Aero acceleration tests The channel is defined as a control channel in the AWD system with a minimum value of 0 and a maximum value of 9...

Page 143: ...o calculate wheel power Channel 106 TirLos 2WD and AD 11 Systems HP C77 2 0 010 C10 375 kW C77 2 0 010 9 81 C10 3600 AWD Systems HP C77 2 0 010 C10 375 C88 C89 1 abs kW C77 2 0 010 9 81 C10 3600 C88 C...

Page 144: ...es from the standard horsepower equation constant that uses 33 000 lbs ft min By dividing 33 000 by 5280 and then multiplying by 60 you get 375 This converts to lbs miles hour which works with the MPH...

Page 145: ...2 C82 Channel 114 is used to calculate a comparison rear wheel power for the test vehicle Channel 112 the SAE ECE corrected rear wheel power is multiplied times Channel 82 DJCorF the dyno comparison f...

Page 146: ...0 C74 g l 1 293 C76 101 3 273 273 C74 Channel 119 is used to calculate the air density under the test conditions Air density is measured in pounds per cubic feet grams per liter of air The constant 0...

Page 147: ...m the optical tach pickup channel 9 along with a ratio of the rotating device to the engine s rotation The optical tach could be used on any rotating device on the engine and the ratio should then be...

Page 148: ...1066 8C84 AD 11 only Clb ft C113 5252 113 C123 12 73 C84 CNm C113 9549 C123 323 34 C84 Channel 128 is used to calculate the corrected wheel torque actually applied to the ground derived from the STP c...

Page 149: ...he Interpolation Tables are located in Channels 130 through 139 Interpolation Channel 132 DynLsR 2WD and AWD systems only Channel 132 is an interpolation look up table for the aerodynamic losses on th...

Page 150: ...ct the power number calculated in channel 40 on AWD systems This channel is not used on 2WD or AD 11 systems Metric values are not necessary as the formula in channel 40 converts the loss power to KW...

Page 151: ...36 AirTpT Channel 136 is an interpolation look up table to convert the voltage from the air temperature sensor in Channel 1 and the dipstick temp sensor in channel 5 into actual temperature for Channe...

Page 152: ...escription of the Config File fm Interpolation Channel 137 VaporT Channel 137 is an interpolation look up table to determine the vapor pressure at 100 relative humidity saturation vapor pressure for t...

Page 153: ...be read and displayed in the same manner as data channels and can be used as operators in calculated channels System channels cannot be used for closed loop control Channel 207 SetPt1 Channel 207 is t...

Page 154: ...urrent torque value and compares the current value to the desired value The control system continues to servo the controller up or down depending on whether the current value is higher or lower than t...

Page 155: ...tion calculated and system data channels The display of 9 channels can be grouped onto 9 separate screens for convenience The screen design is defined in the configuration file and can be changed as d...

Page 156: ...Control Mode Digital Encoders PID Control Setup Control Mode Parameters Actuator Phase Controller Phase Open and Close Rate P Gain I Gain P Threshold I Time D Gain D Time Filter Delay Adjusting Contro...

Page 157: ...power can be used as a control mode The System Configuration Editor defines control modes Up to five control modes are available for each controller Up to four controllers are currently supported by t...

Page 158: ...ontrol system corresponds to the value at the throttle actuator not the actual throttle position of the engine If the linkage between the throttle actuator and the throttle valve is not adjusted prope...

Page 159: ...dynamometer load control on in speed mode before you switch the throttle to torque mode If no load is applied by the dynamometer the throttle controller will immediately open the throttle fully in an...

Page 160: ...sole or handheld interface Current hardware limits the number of closed loop control outputs to two controllers Each controller is given a name in the configuration file Typically names such as Load S...

Page 161: ...The actuator phase allowed values 0 or 1 determines the actuator direction of travel as a response to the controller output signal A 1 inverts the signal If the actuator phase is 0 the actuator goes f...

Page 162: ...00 to 0 and the dynamometer load will decrease from full load to zero load Eddy current dynamometer load controllers typically require an actuator phase of 0 SuperFlow Water Brake Load Control The Sup...

Page 163: ...ling engine speed with actuator phase 0 If the controller phase is 1 and measured engine speed increases the controller output will increase and the load will increase maintaining the desired speed If...

Page 164: ...n versus close rate to compensate for a controller that acts differently while opening versus closing unloading versus loading Because nearly all SuperFlow systems have these parameters set to zero th...

Page 165: ...ove the set point Try a minimal value of P Gain Successively double it until step response improves If you notice high frequency 1 10 Hz steady state instability as a result of increasing P Gain use h...

Page 166: ...int where the I Gain will function For example with an I Threshold of 300 rpm and a set point of 1500 rpm the I Gain would be active from 1200 to 1800 rpm the magnitude of the error must be 300 Furthe...

Page 167: ...integrator should work within a fairly narrow time band 11 5 8 D Gain Dterm ErrorCurrent ErrorA_While_Ago Dgain_value Allowed values Any floating point value Suggested Value Range 4 to 20 for engine d...

Page 168: ...o delay its effect Suggested Setup Prior to Adjustment 0 What it Does The D Time parameter is used to control the size of the window over which the derivative is measured Since increasing or decreasin...

Page 169: ...ameters Determine these set points to prevent the engine from reaching excessive speed and to ensure the engine throttle remains above idle It is helpful to create a strip chart display object on a Wi...

Page 170: ...response If the P Gain results in continuous high frequency steady state instability lower it by half again 2 Gradually increase P Gain until instability reappears then lower it by 20 3 Start with a D...

Page 171: ...th the same name as the currently installed configuration file but with a CCP extension The existing file is overwritten without warning To save a CCP file to a different or new file name from the Win...

Page 172: ...20 Service and Calibration...

Page 173: ...hannels 61 70 14 20 3 5 Temperature channels type K thermocouples 15 20 3 6 Air temperature and humidity sensor 16 20 3 7 Optical tachometer 16 20 3 8 Ignition spark pick up 16 20 3 9 Air flow sensor...

Page 174: ...resentative for details Record reference information for your system below Date of delivery Date of installation training by SuperFlow By Date of first use The following table allows you to keep track...

Page 175: ...1200A 2343 Roll to axle bolts every 3 months Remove protective cover and tighten to 425 ft lb 575 Nm stripped or damaged Meritor part Differential cooler hoses every 3 months Inspect for leaks damage...

Page 176: ...r fasteners Tighten to 80 90 ft lb 110 120 Nm stripped or damaged Date Technician Note 1 use Lithium II high temperature water repellent automotive chassis grease Slowly rotate rolls while greasing No...

Page 177: ...cooler hoses Inspect for leaks damage leaking or damaged Differential cooler oil filter Clean filter damaged Differential trunnion bearings 2 pumps with hand grease gun see note 1 Inertia Roll pillow...

Page 178: ...S E R V I C E A N D C A L I B R A T I O N Section 20 page 7 20 2 Maintenance record...

Page 179: ...20 Page 8 AutoDyn manual 1174 Sect20 PM6 5 05 1999 NOTE Roll bearings and absorber bearings which are subject to dusty or high moisture environments should be maintained according to the more stringe...

Page 180: ...ls In harsh environments relubrication should be as often as necessary to maintain a slight grease leakage at the seals Use a lithium base grease or a grease recommended by a reputable grease manufact...

Page 181: ...cent as well The load cell has been pre calibrated at the factory but it is wise to check the calibration periodically SuperFlow recom mends doing this every month To calibrate the load cell perform t...

Page 182: ...ds for the arm to stabilize 5 Enter the correct calibration of 500 lb ft 680 Nm for the current torque on the handheld or from WinDyn From the handheld controller Select Configure I key followed by Ca...

Page 183: ...rrent absorber or the load cell Contact SuperFlow Customer Service for assistance 7 Remove the calibration weights one at a time let the reading stabilize each time and check for linearity Linearity s...

Page 184: ...ncorrected barometric pressure reading in InHg for US units systems or in kPa for metric units systems from a mercury barometer If you have no mercury barometer contact a local airport or weather serv...

Page 185: ...ontroller Select Autozero F then Single Channel C Select the pressure channel to zero Select Exit E 1 2 Using WinDyn Select Calibrate channels from the main menu Select the pressure channel to zero Se...

Page 186: ...simulating the thermocouple sensor signal for a temperature of your choice 2 Remove the thermocouple panel from the box but make sure it is plugged into the NGE sensor system 3 Set switches 1 and 2 t...

Page 187: ...he air flow sensor will be one of three available air turbines produced by SuperFlow These turbines are individually calibrated and linearized at SuperFlow The calibration is tracked by turbine serial...

Page 188: ...udes the output frequency of the turbine for each of several test flow ranges Channel 133 of the DEF Configuration has been reserved for this information Should you wish to use this feature you will h...

Page 189: ...it until the entire procedure is complete about 1 minute The SuperFlow Automated System Update Program window will indicate the current action being performed A status bar will be updated to indicate...

Page 190: ...mize button in the top right hand corner of the display 2 Click on the WComNet button on the task bar at the bottom of the screen 3 Click on Configure System in the WComNet window The display will now...

Page 191: ...g box Make sure you select the new file and not the original prg 12 At least one file with the extension prg should appear Your customer service engineer will inform you of the proper filename Click o...

Page 192: ...on between the PC and the test system WcomNet status should show Connected to AutoDyno 16 Exit WinDyn and WComNet Power off the Sensor Box wait 5 seconds and power it back on 17 Press the System Statu...

Page 193: ...A General Testing Information Appendix...

Page 194: ...raight vaned absorber will not reach 1000 lbs ft 1350N m of torque until approximately 4000 rpm in pressure boost mode and the optional angled vane absorber will not reach 1000 lbs ft of torque until...

Page 195: ...ily as spray flow and works to overcome the momentary lag in the wall flow fuel delivery When the engine is already running at full throttle under rapid acceleration the accelerator pump has no effect...

Page 196: ...some critical information if you do not measure air flow Volumetric efficiency air flow air fuel ratio and brake specific air consumption become critical missing links in your engine test program The...

Page 197: ...level temperature and pressure the air turbine and the flowbench readings will be the same At all other air densities the flowbench flow will differ from the air turbine flow by the square root of air...

Page 198: ...e is approximately one gallon 4 liters of oil per minute for each 1 000 rpm of engine speed As oil passes through the engine the oil temperature will rise 20 to 60 F 11 to 33 C depending on power and...

Page 199: ...ke the shorter the stroke the more power per cubic inch the engine can develop For example an engine with a 3 inch stroke will develop maximum power at approximately 8 000 rpm while an average engine...

Page 200: ...or port injection systems this can then supplies the pressure pump that supplies the injection systems The bypass fuel is returned to the float can Cooling coils may be added to the setup if the retu...

Page 201: ...the cleaning solution and any remaining particles off of the screen using an air hose Hold the nozzle of the hose at a 45 degree angle and blow air from the outside toward the inside of the filter ele...

Page 202: ...surface and radiate heat back to the thermocouple As a result the thermocouple can read up to 150 F 80 C hotter than with a thin walled steel header pipe Conversely pipes which are cooled with an air...

Page 203: ...ding should be more like 28 01 inHg A better solution is to buy your own wall mounted Mercury column barometer Be sure to correct the readings for temperature and gravity as described in the instructi...

Page 204: ...04 Appendix A Page 209 Keep the coil wire when used to less than 18 in length Verify ground paths from spark return to battery a very good filter in itself Do not leave a timing light connected while...

Page 205: ...B Fundamental Concepts to Obtaining Superior Repeatability Appendix...

Page 206: ...nment inside the test cell The engine should draw its air from the shop if possible or use outside shop air Additionally you may add a fan to purge air in the plenum Use some type of exhaust system an...

Page 207: ...uperFlow sells a pressurized cooling tower and an oil cooling heat exchanger Invest in both Fuel system management is also critical Fuel flow and pressure rates should be consistent Fuel temperature m...

Page 208: ...m the changes you made As atmospheric conditions change re establish the correct A F ratio B 4 The Engine The engine must be properly broken in using your established break in procedure The engine s s...

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