DFD90-S
MARINE / INDUSTRIAL / AUTOMOTIVE ENGINE TEST UNIT
DFD90-S Marine diesel engine/hydraulic dynamometer
GENERAL The Unit consists of A 4 stroke, 4-6 cylinders, water cooled engine coupled by means of a flexible coupling to a Dynamometer as a braking system. A rack supporting all the instruments and the fuel tank-consumption meter system complete the Unit. All the instruments cables from the engine-brake assembly are collected in a raceway fixed on the top of the instrument rack. The engine-brake system is mounted by means of vibration damping suspensions on a steel structure stand together with the cooling system. Engine cooling is provided by a radiator mounted on the rear side of the engine and it is cooled by an engine driven fan. If the engine mounted is of marine type, cooling is provided by the direct suction of the water (simulating the salt water feeding) from a tank at the sides of the engine main frame, and is must be fed with a suitable water source (eventually a cooling tower can be connected). In the marine arrangement, water cooling circulation is provided by an engine driven pump and the outlet is drained in a suitable tank for re-cooling or for final drainage. In accordance to the engine mounted, the unit can be equipped with a salt water/fresh water heat exchanger. On the cooling water circuit are provided the necessary temperature taps and flowmeter. The rack supporting all the instruments is an independent stand in order to avoid vibration effects on the digital instruments. If the PC based Video Training System is included, in an insulated sector of the instrument rack, are mounted the analogue to digital electronic boards connected to the DAQ board for the PC data acquisition system. A 15 litres fuel tank equipped with e fuel consumption meter is fixed on the rear side of the rack. All rotating parts are protected by steel net guards. The Unit simply rests on the floor, no masonry is requested for installation. A simple connection to water line and electricity and the Unit is in order to work. An instruction-maintenance book allowing the conduction of every experiments is supplied. I - 16153 P.D. da Bissone 36r. GENOA - ITALY - Tel.: +39 010 6501969 Fax: +39 010 6501969 e-mail: patrone@ giacomopatrone.com http://www.giacomopatrone.com
DFD90-S
AVAILABLE ENGINES All the engines are four stroke, four or six cylinders in line, of a max power output comprised from 40hp up to 400hp. ENGINES • Marine Diesel four cylinder in line naturally aspirated direct or indirect injection • Marine Diesel four cylinder in line turbocharged direct or indirect injection. • Industrial/automotive Diesel four cylinder in line naturally aspirated direct or indirect injection • Industrial/automotive Diesel four cylinder in line turbocharged direct or indirect injection. • Marine six cylinders in line naturally aspirated or turbocharged indirect injection • Industrial six cylinders in line naturally aspirated or turbocharged indirect injection • Marine four cylinders in line gasoline coil ignition • Automotive four cylinders in line gasoline with carburettor. • Automotive four cylinders in line gasoline electronic injection. • More types of engines upon request are available DYNAMOMETERS HYDRAULIC The brake is a sluice gate hydraulic dynamometer and is available of a power range from 80 hp up to 450 hp at a maximum speed of 7500 rpm.
CONSTRUCTION The rotor and stator are precision castings of special developed alloy for good resistance to erosion, corrosion and cavitation. The rotor is mounted on the dynamometer shaft with keys, maintaining a high degree of shaft dynamic balance. The couplings are fitted using the same method. The shaft runs in deep groove ball-bearings which are grease lubricated. The shaft assembly power absorption elements, bearings and seals are all housed in a cast iron casing. Water leakage from the vortex chamber is restricted by multiple-rope glands. DYNAMOMETER CONTROL The power absorbed by the dynamometer is controlled by varying the quantity of water circulating in the vortex of the rotor and stator elements. This is achieved by a moving sluice gate in the dynamometer casing. TORQUE MEASUREMENTS Torque is measured by a high accuracy strain gauge load cell mounted between the trunnion bearings, supported casing and bedplate. SPEED MEASUREMENT The dynamometer shaft speed is measured by a pulse pick-up mounted adjacent to a 60 toothed wheel on the dynamometer coupling. TECHNICAL DATA ACCURANCIES Torque measurement: +/- 0,5% of dynamometer torque Speed measurement: +/- 1,0 rpm (digital)
max.
WATER SUPPLY Ideal water condition: • Max. water outlet temp: 60°C • PH : 7,4 to 8,4 • Filtration: 185 micron • Suspended particles not to exceed 1000 parts per million • The volume of water required for cooling is dependent on the temperature of the water supply and varies from 18,5litres/Kw/hour at 16°C inlet temp. To 39,1litres/Kw/hour at 38°C inlet temp. • Supply of water pressure is dictated by power and torque to be absorbed and at max. dynamometer capacity should be up to 2,8 bar.
I - 16153 P.D. da Bissone 36r. GENOA - ITALY - Tel.: +39 010 6501969 Fax: +39 010 6501969 e-mail: patrone@ giacomopatrone.com http://www.giacomopatrone.com
DFD90-S
EDDY CURRENT 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.
ENERGISING COILS 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 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 radial ventilation slots. These features ensure both rapid response, and reliability under the severest loading conditions, which can be the cause of local overheating in single coil machines. TRUNNION BEARINGS Deep grove ball bearings provide the most precise method carcase mounting and are virtually free from friction. They are also extremely rigid and free from resonance problems which can occur on
the flexible type of mounting systems. The bearing selection ensures extended life. SHAFT AND ROTOR The rotor is manufactured 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 radial 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 does 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 that 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 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 or automated control systems, data acquisition and alarm annunciation. TECHNICAL FEATURES • Max power: from 16kW up to 400kW • Max torque: from 70 up to 2000 Nm • Max speed: 9000 rpm • Accuracy: torque +/- 0,25% - speed +/- 1% • Water minimum supply (dipending on the power absorption) : 11-280 l/min at 1-2,5 bar • Max water outlet temp: 60C° • Energising coil: Volt 75 - 125 - 5A
I - 16153 P.D. da Bissone 36r. GENOA - ITALY - Tel.: +39 010 6501969 Fax: +39 010 6501969 e-mail: patrone@ giacomopatrone.com http://www.giacomopatrone.com
DFD90-S
DFD90-Sindustrial diesel engine/electric brake
AC GENERATOR BRAKE The dfd90-S is also available with a AC generator 380V three phases as braking system. Energy generated is dissipated by means of suitable load resistances. Generator cooling is made by means of independent electric driven centrifugal fan. Power output available is from 30 up to 100 kW INSTRUMENTS In order to allow a better use of this Unit as a didactic aid, all the instruments are not a simply multiway indicator with a selector switch but every temperature or parameter has a proper indicator on the main control boards in order to allow the instant a simultaneous acquisition of every parameters.
I - 16153 P.D. da Bissone 36r. GENOA - ITALY - Tel.: +39 010 6501969 Fax: +39 010 6501969 e-mail: patrone@ giacomopatrone.com http://www.giacomopatrone.com
DFD90-S
MEASURABLE PARAMETERS
MAIN EXPERIMENTS AND CAPABILITIES
The following parameters can be measured in accordance to the instruments included in the different system available: • Engine speed rotation (rpm) • Brake torque (Nm) • Instantaneous Fuel consumption (l/h) • Air consumption • Fuel calibrated bulbs emptying time (sec.) • Ambient air temperature (C°) • Cooling water temperature upstream circulating pump (C°) • Cooling water temperature downstream circulating pump (C°) • Cooling water flow rate (l/h) • Intake header air temperature (C°) • Exhaust gas temperature at discharge manifold (C°) • Relative pressure at intake manifold (mmHg) (optional - available only for diesel turbocharger) • Relative pressure at exhaust manifold upstream turbine (mmHg) (optional - available only for diesel turbocharger) • Differential pressure between intake and exhaust (mmHg) • Differential pressure upstream and downstream turbine (mmHg) (optional available only for diesel turbocharger) • Differential pressure downstream and upstream compressor (mmHg) (optional available only for diesel turbocharger) • Barometric pressure (mbar) • Oil pressure
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Plotting of the characteristic diagram of maximum output 1/1, 2/3 and 1/3 of normal output, being normal output 85% of the max. Plotting of fuel consumption vs/ rpm. Plotting of air consumption vs/ rpm Plotting of specific fuel consumption, fuel flow rate vs/rpm. For any aforementioned condition. Plotting of the engine efficiency for any of the aforementioned condition. Plotting of the cooling water temperatures. Plotting of exhaust temperatures. Turbine and compressor efficiencies Thermodynamic balance. Plotting of oil pressure. Plotting of the engine cycle in the form of open or closed diagram (*OPTIONAL)
We reserve the right to modify/improve the unit without any previous notice.
INDICATED AND OPEN CYCLE DETECTION (*OPTIONAL) Special hardware is supplied for the detection of the pre-chamber pressure and the visualisation of the engine cycle. • Inductance pressure transducer up to 250Bar independently water cooled. • Steel adapter for transducer mounting • Encoder All the signals from the pressure transducer and the encoder are processed by the DAQ board and by means of a special software it is possible the real time data processing and cycle plotting.(see the Video Training technical data sheet)
I - 16153 P.D. da Bissone 36r. GENOA - ITALY - Tel.: +39 010 6501969 Fax: +39 010 6501969 e-mail: patrone@ giacomopatrone.com http://www.giacomopatrone.com