DFD90SDG
DIESEL-GASOLINE MULTI ENGINE AUOMOTIVE TEST BED
DFD90-SGD with diesel engine, accessories and PC data acquisition system
GENERAL The Unit consists of two type 4 stroke water-cooled Diesel and Gasoline engine of automotive type. Both engines are alternatively mounted on the hydraulic dynamometer test bed with simple operations by means of vibration dampers and suitable adapters, already mounted on the engines. Further to the gasoline and diesel engine to be mounted for test and running exercises, two additional engines, of the same type of the previous ones, are supplied completely sectioned in order to allow an easy and fast visual detection the of particular components and to help the comprehension of the kinematical motion of all the internal parts. Mounting and dismantling exercises, maintenance and components adjustment are so easier thanks to the direct observation of the internal parts of the machines. The sectioned engine are arranged also with their automotive gearbox with 5 speeds + reverse and with the clutch, while the running engines, in order to allow the connection to the dynamometer, are supplied without gearbox and clutch, but equipped with special adapters for an easy interchangeability on the test bed.
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
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DFD90SDG
DESCRIPTION
The engine-brake unit is mounted by means of vibration damping suspensions on a steel structure stand together with the cooling system. The cooling system is made by means automotive radiators with independent fan, one for each engine. The cooling radiators, already mounted and connected on each engine, are complete with temperature and flow sensors in order to make the engine change easy and without undesired spill of coolant. A small crane with hydraulic piston and pivoted wheels is provided in order to make the engine change easy and safe. Engine lift point are already arranged and engine-brake alignment, further to represent an efficient exercise of mechanical adjustment, is made by means of steel needles positioned opportunely. The engine under test is coupled by means of a flexible coupling to an Hydraulic Dynamometer as a braking system and the torque output is measured by a strain gauge load cell. All rotating parts are protected by steel net guards The engine-dynamometer unit is also suitable to be used to test every engine with power and torque curves inside the dynamometer capacity. Engines under test must be eventually provided with suitable supports for a correct alignment with the dynamometer shaft. Engine feed air pipe is a flexible rubber tube and it is connected to a pulse damper for a correct measurement of the quantity of air sucked up. An efficient exhaust silenced pipe system is provided and exhaust gasses must be discharged outdoor. A rack supporting all the instruments and the fuel tank-consumption meter systems complete the Unit. The connection of the sensors and instruments of the engine under test to the instrument rack is made by means of fast connectors following simple instructions and representing the correct sequence of operation occurring during an automotive engine maintenance activity. All the cables and pipes from the engine-brake assembly to the instrument system are collected in a raceway fixed on top of the control board The Instrument rack is an independent stand in order to avoid vibration effects on the instruments. Two 15 litres fuel tanks, one for diesel and for gasoline, equipped with e fuel consumption meters are fixed on the rear side of the rack. Fuel tank connections to the engines are by means of safe connections without possibility of inversion of the fuel system. 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 and faults diagnosis 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
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DFD90SDG
HYDRAULIC BRAKE
The brake is a sluice gate hydraulic dynamometer and is capable of absorbing a power range up to 100 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.
a 1195
b 726
c 585
d 301
e 716
f 286
g 280
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
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DFD90SDG
ACCURANCIES Torque measurement: +/- 0,5% of max. dynamometer torque Speed measurement: +/- 1,0 rpm (digital) CALIBRATION Periodical calibration of the dynamometer can be easily made by means an included set of weight and a determined length lever harm to be mounted on the oscillating dynamometer case. 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. MOMENT OF INERTIA Including water entrapped and coupling in both sides: 0,00647 Kg/m2.
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
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DFD90SDG
ENGINES
DIESEL (FIAT manufacturer or equivalent) • diesel indirect injection • Water cooled in closed circuit with radiator • cylinders N°4 in line • 4 stroke • total piston displacement cm3. 2400 • max. operating speed Rpm. 4000 • max power 80hp • max torque 200 Nm engine included in the unit in working condition, complete with cooling system, exhaust system, vibration dampers adapters, joint coupling to the brake, instruments connections to the control board. The same engine is also supplied completely sectioned (see photo) complete with clutch, gear box 5 speed + reverse, wheeled stand.
GASOLINE (FIAT manufacturer or equivalent) • gasoline spark ignition camshaft in the crankcase with chain drive • Water cooled in closed circuit with radiator • cylinders N°4 in line • 4 stroke • total piston displacement cm3. 1300 • max. operating speed Rpm. 4800 • continuous power 60hp • max torque 150 Nm engine included in the unit in working condition, complete with cooling system, exhaust system, vibration dampers adapters, joint coupling to the brake, instruments connections to the control board. The same engine is also supplied completely sectioned (see photo) complete with clutch, gear box 5 speed + reverse, wheeled stand.
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
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DFD90SDG
LIST OF EXPERIMENTS PERFORMED With the DFD90-S multiengine test bed, a wide and complete range of experiments and vocational exercises are possible. Detection all the operational parameters occurring in an internal combustion engine and their mutual relationships. engine maintenance exercises adjustment and regulation of the different components and devices included in the most common automotive engines, both diesel and gasoline. The educational solution to provide the engines both sectioned and in order to run, with the necessary testing and instrument system, allow students to easily understand the location and function of each components, the operational sequence of dismantling, adjust and mounting of all the single parts. Subsequently, by means of the test bench and with the instruments provided, it is possible an immediate control of the maintenance activity and a quality check of the mechanical efficiencies. Further than this, it is possible to acquire the necessary skill about the safe starting and running of an engine and learn the principles of operation and the physical phenomena occurring in an internal combustion machine. MEASURABLE QUANTITIES • • • • • • • • • • • • • • •
Engine speed rotation (rpm) Brake torque (Nm) Fuel consumption Air flow rate Ambient air temperature (C°) water inlet temperature upstream circulating pump (C°) outlet temperature downstream circulating pump (C°) Intake header air temperature (C°) Exhaust gas temperature (C°) Relative pressure at intake manifold (mmHg) Relative pressure at exhaust manifold (mmHg) Differential pressure between intake and exhaust (mmHg) cooling water flow rate (l/h) Barometric pressure (mbar) Combustion chamber pressure in form of open and closed diagram (this analysis is included upon request)
The following experiments are only an example of what can be performed with the included instrument system. EXPERIMENT # 1 MEASUREMENT OF THE TORQUE OUTPUT MEASUREMENT OF THE POWER OUTPUT MEDIUM EFFECTIVE PRESSURE a) - Measurement of the torque output b) - Measurement of the power output. c) - Measurement of the medium pressure. EXPERIMENT # 2 FUEL CONSUMPTION MEASUREMENT a) - Fuel consumption b) - Fuel specific consumption EXPERIMENT # 3 COMBUSTION AIR CONSUMPTION MEASUREMENT a) - Combustion Air Consumption b) - Specific air consumption EXPERIMENT # 4 MEASURING OF THE AIR-FUEL RATIO MEASUREMENT OF THE EXCESS IN AIR a) - Measuring of the AIR-FUEL ratio. b) - Measuring of the excess in air. EXPERIMENT # 5 MEASUREMENT OF THE EXHAUST GAS FLOW RATE a) - Measurement of the exhaust gas flow rate. b)Measurementof the exhaust gas specific flow rate. EXPERIMENT # 6 THERMIC BALANCE AND SCATTERED HEAT a) - Quantity of the chemical energy introduced. b) - Effective power. c) - Thermic flow of the exhaust gas. d) - Quantity of heat removed by the refrigerant and by the lubricating oil. e) - Scattered Heat. EXPERIMENT # 7 - PLOTTING OF THE THERMODYNAMIC CYCLE IN OPEN OR CLOSED DIAGRAM by the detection of the combustion chamber pressure with cooled pressure transducer and shaft angular position calculation. (OPTIONAL)
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
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DFD90SDG
DFD90-SGD UNIT ASSEMBLY DRAWINGS N°1 1299 - 1 1299/A Diesel - Gasoline engine - Hydraulic dynamometer (INDICATIVE NOT SCALED) POS. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.
DESCRIPTION ENGINE BASE FRAME DIESEL ENGINE - GASOLINE ENGINE HYDRAULIC DYNAMOMETRIC BRAKE INSTRUMENTS RACK ENGINE AIR FEED DAMPER TANK HANDWHEEL FOR BRAKE REGULATION VENTURIMETER FOR AIR TO ENGINE ENGINE COOLING RADIATOR AIR PIPE TO ENGINE EXHAUST GAS PIPE FUEL MEASURING GLASS BULBS FUEL TAP TO ENGINE ENGINE COOLING WATER FLOW RATE MEASUREMENT UNIT ENGINE MANUAL SPEED GOVERNOR ENGINE SAFETY STOP PUSH BUTTON ENGINE COOLING WATER PUMP DIFFERENTIAL GAGE FOR AIR FLOW TO ENGINE FUEL TAP FROM TANK AMBIENT AIR THERMOCOUPLE THREE-WAY COCK FOR FUEL CONSUMPTION FUEL FROM TANK STOP VALVE TORQUE DETECTION INSTRUMENT DIESEL ENGINE INSTRUMENT PANEL HIGH TEMP. ALARM OF DYNAMOMETER COOLING WATER GASOLINE ENGINE INSTRUMENT PANEL MAINS ON WARNING LIGHT 220 V. MAIN SWITCH 220 V. DYNAMOMETER WATER OUTLET THERMOMETER DYNAMOMETER OUTLET REGULATION VALVE WATER OUTLET FROM BRAKE LOW TENSION ON WARNING LIGHT 12 V. LOW TENSION SWITCH-KEY DYNAMOMETER WATER INLET MANOMETER WATER INLET TO DYNAMOM. BRAKE WATER OUTLET TANK FROM BRAKE PC DATA ACQUISITION SYSTEM (when included) MERCURY U GAGE FOR PRESSURES DETECTION
dimensions and weight (gross - wood case packing): dynamometer and diesel engine assembly: meters 2,2x1,6xH1,7 - Kg.1200 Control board : meters 1,0x2,9xH2,0 - Kg 650 Gasoline engine: 1,5x0,7xH1,3 - Kg 280 Sectioned gasoline engine 1,6x0,6x1,1 – Kg. 200 Sectioned diesel engine 1,6x0,8x1,1 – Kg. 270
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
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DFD90SDG
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
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