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Eddy Current Dynamometer Test System

Eddy Current Dynamometer


Test System

© Piper Test & Measurement Ltd.


THE BARN
BILSINGTON
ASHFORD
KENT TN25 7JT
ENGLAND
TELEPHONE 01233 720130
FACSIMILE 01233 720140
EMAIL: info@piperdynamometers.com

CONTENTS

GENERAL LAYOUT............................................................................................................................. 1

SCOPE OF SUPPLY............................................................................................................................ 2
PEC 25 - 25 BHP - DRY GAP EDDY CURRENT DYNAMOMETER............................................................2
PEC 200 – 200BHP - DRY GAP EDDY CURRENT DYNAMOMETER........................................................2
P15CLC - PIPER/SAJ ENGINE & DYNAMOMETER CONTROLLER...........................................................3
PETA - HIGH SPEED ENGINE THROTTLE ACTUATOR.............................................................................3
PVFF – 25 VOLUMETRIC FUEL CONSUMPTION UNIT............................................................................4
PVFF – 200 VOLUMETRIC FUEL CONSUMPTION UNIT (FOR PEC 200)..................................................4
PHT - HEADER TANK FOR FUEL.......................................................................................................... 4
MAIN DYNAMOMETER MOUNTING FRAME............................................................................................... 4
ADJUSTABLE HORIZONTAL ENGINE MOUNTING FRAME............................................................................4
DRIVE SHAFT GUARD AND SUPPORTS................................................................................................... 4
LAYOUTS............................................................................................................................................. 5
LAYOUT DIMENSIONS.......................................................................................................................... 5
WATER & ELECTRICAL LAYOUT............................................................................................................ 6
SYSTEM - 3D VIEW............................................................................................................................. 7
SYSTEM - ENGINE END VIEW.............................................................................................................. 7
SYSTEM - DYNAMOMETER END VIEW................................................................................................... 8
SYSTEM – PLAN VIEW......................................................................................................................... 8
POWER & TORQUE CAPABILITY CURVES.......................................................................................9
PEC 25 POWER CAPABILITY............................................................................................................... 9
PEC 25 TORQUE CAPABILITY............................................................................................................ 10
PEC 200 POWER CAPABILITY........................................................................................................... 11
PEC 200 TORQUE CAPABILITY.......................................................................................................... 12
PEC TECHNICAL DESCRIPTION...................................................................................................... 13
INTRODUCTION................................................................................................................................. 13
OPTIONS.......................................................................................................................................... 13
STANDARD FEATURES....................................................................................................................... 13
TECHNICAL DATA.............................................................................................................................. 14
DESCRIPTION OF STANDARD FEATURES.............................................................................................14
CONSTRUCTION................................................................................................................................ 14
TRUNNION BEARINGS........................................................................................................................ 14
SHAFT AND ROTOR........................................................................................................................... 15
COOLING PASSAGES......................................................................................................................... 15
WATER CONNECTIONS...................................................................................................................... 15
CONTROL......................................................................................................................................... 15
PEC Dimensional Details................................................................................................................ 16
Visit our web site at www.piperdynamometers.com
The Barn, Bilsington, Ashford, Kent, UK. TN25 7JT
Tel: 01233 720130 Fax: 01233 720140 Email: info@piperdynamometers.com

(Registered in England and Wales, Company No: 2668838 Registered Office: Ropers Yard, Canterbury, CT2 7EX)
Eddy Current Dynamometer Test System

© Piper Test & Measurement Ltd.


Eddy Current Dynamometer Test System

General Layout

© Piper Test & Measurement Ltd. 1


Eddy Current Dynamometer Test System

SCOPE OF SUPPLY

PEC 25 - 25 BHP - Dry Gap Eddy Current Dynamometer


(Item 2 on drawing KU002)

The PEC – 25 dynamometer is capable of absorbing & measuring 20kW (25 BHP) – 80 Nm
(58 lb/ft) in accordance with its Power and Torque characteristic curves attached.

The dynamometer is fitted with a high accuracy precision strain gauge load-cell, with a
measuring accuracy better than ±0.25 % of the dynamometer maximum torque capacity.

The dynamometer will be fitted with 60 toothed wheel & non-contact type magnetic pulse
pick-up sensor for measurement of speed.

The following in-built features are provided with the dynamometer as a standard,

 Inlet water pressure switch to ensure adequate dynamometer water pressure supply.
This activates a trip condition to prevent the dynamometer from dry running.
 Loss plate temperature is monitored (sensor for both loss plates are provided on
dynamometer & an indicator is fitted in the control panel) & trip condition is achieved
against high temperature crossing the set limit.
 Two half couplings
 Grease lubricated shaft bearings.
 Water inlet filter with Magnetic Separator.
 Calibration arm, counter balance bar with rider weight and weight pan. (no weights)
 Unless otherwise specified, the dynamometer torque measuring system will be
calibrated in Nm as a standard.
 Suitable drive shaft with universal joint at both ends. Minimum compressed length: 258
mm. Telescopic adjustment length: 42 mm. Selection to be finalized.

PEC 200 – 200BHP - Dry Gap Eddy Current Dynamometer.


(Item 3 on drawing KU002)

The dynamometer is capable of absorbing & measuring 150 kW (200 BHP) – 500 Nm
(365lb/ft) in accordance with its Power and Torque characteristic curves attached.

The dynamometer is fitted with a high accuracy precision strain gauge load-cell, with a
measuring accuracy better than ±0.25 % of the dynamometer maximum torque capacity.

The dynamometer will be fitted with 60 toothed wheel & non-contact type magnetic pulse
pick-up sensor for measurement of speed.

The following in-built features are provided with the dynamometer as a standard,

 Inlet water pressure switch to ensure adequate dynamometer water pressure supply.
This activates a trip condition to prevent the dynamometer from dry running.
 Loss plate temperature is monitored (sensor for both loss plates are provided on
dynamometer & an indicator is fitted in the control panel) & trip condition is achieved
against high temperature crossing the set limit.
 Two half couplings.
 Grease lubricated shaft bearings.
 Water inlet filter with Magnetic Separator.
 Calibration arm, counter balance bar with rider weight and weight pan. (no weights)
 Unless otherwise specified, the dynamometer torque measuring system will be
calibrated in Nm as a standard.
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Eddy Current Dynamometer Test System
 Suitable drive shaft with universal joint at both ends. Minimum compressed length: 724
mm. Telescopic adjustment length: 60 mm. Selection to be finalized.

P15CLC - Piper/SAJ Engine & Dynamometer Controller


(Item 9 on drawing KU002)
Includes the following features:
i. Multi – mode close loop controller:
a. Constant Speed, Constant Torque, Position & Power law.
ii. Analogue & Digital Speed & Torque indicator unit,
Measurement Accuracy: -
a. Analogue speed & torque: + / - 1.5% of FSD
b. Digital Speed: +/- 1.0 rpm
c. Digital torque: +/- 0.25% of FSD
iii. Mode selection unit, Modular rack (Type TC/MS)
iv. Throttle Controller, Multi mode Close loop.
v. Cabinet, 1828 mm. H x 650 mm D x 19” Rack width.

PETA - High Speed Engine Throttle Actuator


(Item 8 on drawing KU002)

Features:
- High transient torque to overcome linkage friction.
- High resolution for accurate control.
- Stroke adjustment within wide limits.

The actuator is designed to provide remote control


of an engine throttle and works in conjunction with
its electronic controller. The actuator comprises a
printed armature geared motor (Yasakawa, Japan
make), driving an output shaft carrying an operating
lever, through a torque-limiting clutch for safety
purpose. A precision potentiometer is driven by a
toothed belt from the output shaft and is provided
for position indication & feedback. A fabricated
enclosure is provided for housing complete
assembly of actuator & supported by a fabricated
pedestal with height adjustment. Removable covers
are provided for enclosure from side and top, for easy access for maintenance and setting
of stroke. The connection between the actuator and engine control lever is by means of a
link with rod end bearings.

The Actuator is provided with inbuilt safeguards such as:


- Thermal Cut-out, to prevent motor overload.
- Torque limiting clutches as well as mechanical limit stops.
- Pneumatically operated fail-safe arrangement, to retain the’ 0’ position in case of
power.

Specifications:
- Stroke (mechanical adjustment): minimum 25 mm to max. 140 mm.
- Max. pull at 25 mm stroke: Continuous 55 Kg & transient (1 second) 150 Kg.
- Resolution: 0.1 degree.
- Response: 0.5 second for full travel & 0.25 second as an optional feature for special
application.

© Piper Test & Measurement Ltd. 3


Eddy Current Dynamometer Test System

PVFF – 25 Volumetric Fuel Consumption Unit


(Item 10 on drawing KU002)

Glass tube assembly (25+50 cc) is housed in a fabricated


enclosure with top and bottom supports. Photo sensors are fitted
on glass tube, to regulate specific volume of fuel required during
testing. The unit is provided with solenoid valve (flame proof) for
filling the fuel into the glass tube. This unit could be mounted on
wall as per convenience.

Digital timer (with suitable interface to connect with PC based


system) is provided for indication time in seconds for the selected
volume of fuel. Least count of timer is 0.1 seconds.

PVFF – 200 Volumetric Fuel Consumption Unit (for PEC 200)


(Item 11 on drawing KU002)

As above but with glass tube assembly of 50 + 100 cc


All other specifications are the same as PVFF-25.

PHT - Header Tank for Fuel


(Item 5 on drawing KU002)

One self standing support for the mounting of two 20lts tanks for the storage of diesel and
petrol. Both tanks are fitted with air & vent mechanism and level indicator for alarm
purposes.

Main dynamometer mounting frame


(Item 1 on drawing KU002)

This frame will be fabricated as two individual frames, one for each dynamometer but joined
by link bracket to form a single structure. The reason for joining them is to enable to pre-
assembly of water and electrical systems.

Adjustable horizontal engine mounting frame


(Item 2 on drawing KU002)
Brackets for mounting individual engines on mounting frame to be arranged by user.

Drive shaft guard and supports


(Item 7 on drawing KU002)

© Piper Test & Measurement Ltd. 4


Eddy Current Dynamometer Test System

Layouts

Layout Dimensions

© Piper Test & Measurement Ltd. 5


Eddy Current Dynamometer Test System

Water & Electrical Layout

© Piper Test & Measurement Ltd. 6


Eddy Current Dynamometer Test System

System - 3D View

System - Engine End View

© Piper Test & Measurement Ltd. 7


Eddy Current Dynamometer Test System

System - Dynamometer End View

System – Plan View

© Piper Test & Measurement Ltd. 8


Eddy Current Dynamometer Test System

Power & Torque Capability Curves

PEC 25 Power Capability

© Piper Test & Measurement Ltd. 9


Eddy Current Dynamometer Test System

PEC 25 Torque Capability

© Piper Test & Measurement Ltd. 10


Eddy Current Dynamometer Test System

PEC 200 Power Capability

© Piper Test & Measurement Ltd. 11


Eddy Current Dynamometer Test System
PEC 200 Torque Capability

© Piper Test & Measurement Ltd. 12


Eddy Current Dynamometer Test System

PEC Technical Description

Introduction
The PEC Range of Dynamometers provide a range of Eddy-Current machines designed for
testing engines from 20 kW to 400 kW capacity.
The strain gauge load cell provides high accuracy torque measurement for exacting test and
development applications. The rugged design of the power absorbing system ensures a
long operating life, even in the most demanding production and endurance testing
environments. This long life is further enhanced by the electroless nickel plating of critical
components in contact with cooling water.

Options
 Calibration equipment (SI or Imperial)
 Driveshaft and guards
 Under frames
 Engine start systems (DC, AC or Pneumatic)
 High speed version

Standard Features
 Twin silicon rubber encapsulated energising coils, with central ventilation to ensure
reliability in extreme conditions.
 Carcase mounted in deep groove ball bearings.
 High accuracy strain gauge load cell for torque measurement.
 Electroless nickel plating of cooling passages to ensure corrosion free operation.
 ‘O’ Ring pipe connections to minimise torque calibration errors from variations in
water supply pressure.
 Water flow failure warning fitted as standard.
 Balanced high rigidity shaft assembly on precision bearings to ensure smooth
operation. The rotor is designed for low inertia.
 Precise control possible, even at low loads and rapid changes in demands.
 Bi-directional operation.

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Eddy Current Dynamometer Test System
Technical Data

Description of Standard Features

Construction
These are fully encapsulated two piece coils, used in place of the more common and
cheaper single coil arrangement.
This configuration ensures optimum distribution of flux throughout the working area for
maximum low speed torque, and at the same time allows the free flow of air from the centre
of the machine, through the critical air gap between rotor and stator, and out of radical
ventilation slots.
These features ensure both rapid response, and reliability under the loading conditions,
which can be the cause of local overheating in single coil machines.

Trunnion Bearings
Deep groove ball bearings provide the most precise method of carcase mounting and are
virtually free from friction. They are also extremely rigid and free from resonance problems
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Eddy Current Dynamometer Test System
which can occur on the flexible type of mounting systems. The bearing selection ensures
extended life.

Shaft and Rotor


The Rotor is manufactures from a high magnetic permeability material for maximum
performance, and is designed for minimum inertia. Precision grade bearings are used to
ensure accurate shaft location and high safe operating speeds.

Cooling Passages
The cooling passages and “loss plate” are critical areas in any Eddy-current dynamometer,
as thermal loading is high, and cyclic loading can cause corresponding temperature
changes. Associated loss plate distortion may cause catastrophic contact between plate and
rotor, or loss of coolant. Extensive design and development has therefore been carried out
by us for system of loss plate mounting, which allows controlled radical expansion without
water leakage and prevents loss plate distortion, the water passages have been optimised
to ensure consistent cooling, and these are electroless nickel plated to ensure that corrosion
doe not detract from performance.

Water Connections
Water connection is by means of O ring sealed articulated pipes, leading to flanges suitable
for connection to the customers water supply. These ensure water connection and supply
pressure variations have minimum effect on machine accuracy. An integral flow detector
monitors flow rate, and ensures that a warning signal is given if water flow should drop
below safe levels.

Control
The level of power absorbed is controlled by varying the excitation current at the coil. When
used in conjunction with feed back signals for torque from the load cell and speed from the
pulse pick-up and toothed wheel, closed loop control is provided.
We offer both manual and automated control systems, data acquisition and alarm
annunciation.

© Piper Test & Measurement Ltd. 15


Eddy Current Dynamometer Test System

PEC Dimensional Details

© Piper Test & Measurement Ltd. 16