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Safety Warnings

SuperFlow Technologies Group 1-3

1.1 Safety Warnings

WARNING: To ensure safe operation, this equipment must only be operated according to
the instructions in the

SuperFlow AutoDyn Operator’s Manual

. It is also essential that this

equipment is installed, maintained, and operated according to local safety requirements.

Any person instructed to carry out installation, maintenance or repair of the equipment must read

and understand the

AutoDyn Operator Manual

and in particular the technical safety instructions.

Any users of this equipment must operate only the controls of the equipment. Only qualified

personnel should remove exterior panels and service equipment.

1.1.1 Dangers Due to Non-observance of Safety

Instructions

• Carbon monoxide poisoning
• Hearing damage due to high noise levels
• Electrical shock
• Exposure to rotating parts

1.2 General Safety Procedures

CAUTION:

Electronic controls contain static-sensitive parts. Observe the following precautions 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 control).

•

Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around Printed Circuit Boards
(PCBs).

•

Do not touch the components or conductors on a PCB with your hands or with conductive
devices.

CAUTION:

To prevent damage to a control system that uses an alternator or battery-charging

device, make sure the charging device is turned off before disconnecting the battery from the
system.

Always follow basic safety precautions when using this product to reduce risk of injury and/or

damage to equipment.

• Only authorized personnel trained in the operation of the dynamometer should have access

to the equipment.

• Read and understand all instructions in the user guides.
• Use only the proper electrical sources as prescribed in the installation guide. Ensure circuit

breakers are easily accessible and have the proper rating.

• Observe all warnings and instructions marked on the product.
• Ensure proper ventilation of exhaust gases from the vicinity of the dynamometer

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Содержание AutoDyn

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

Страница 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...

Страница 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...

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

Страница 5: ...1 General Information...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 55: ...6 System Operation...

Страница 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...

Страница 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...

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

Страница 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...

Страница 60: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 104: ...8 Theory Of Testing...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 172: ...20 Service and Calibration...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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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