Super Cell Altitude Testing

Super Cell simulates all of the conditions encountered on a mountain road in Colorado, with one major exception.  Repeatable test cycles can be easily achieved in the test cell, while every test driving down the road is subject to changes in traffic, weather, and driver variability.  Super cell enables development engineers to more quickly develop a robust product that meets both customer requirements for drivability, while simultaneously meeting regulatory requirements for exhaust emissions. 

As engines have become much more complex with sophisticated air handling, fuel systems, and integrated exhaust aftertreatment systems, the required testing frequency for vehicles in the mountains continues to escalate.  Engine sociability issues with smoke during transient operation has also become a larger problem with the multi-dimensional air handling systems involving modulated EGR and VG turbochargers.  The engine exhaust stack can be viewed at the test cell console via a remote camera.  This provides useful information about the smoke visibility and color.

Super cell is uniquely configured to simulate altitude conditions, with controlled intake air supply sources that are maintained isobarically with the exhaust out pressure.  This offers the capability to do actual transient drivability cycles at altitude.  The majority of other facility’s engine test cells that offer altitude capability maintain only the exhaust out pressure, and create simulated intake supply pressure by increasing intake restriction.  Then for transient operation, that intake restriction valve must be modulated to try and achieve a certain pressure level.  AEI's isobarically controlled intake and exhaust systems eliminates the need for feed-forward control of the intake restriction, therefore, providing a better altitude environment for transient development requirements. 

Super cell also addresses the need to demonstrate emissions compliance capability with AECD control strategies.  Emissions levels can be measured under conditions involving altitude, cold start, and below normal coolant, oil, and air operating temperatures.

AEI Super Cell Testing Summary:
▪ Up to 15,000 feet altitude simulation for transient and steady state operation
▪ Maintain steady altitude throughout transient cycle
▪ Engine Cold soak down to -35ºC
▪ Driving simulation with motoring dyno
▪ Continuous raw emissions measurements
▪ EPA heavy duty FTP cycle simulation
▪ Sustained cold operation
▪ Independent engine coolant control down to 100°F
▪ Independent intake manifold temperature control down to 40°F
▪ Readily available fuel types: ULSD, JP8, #1 diesel, climatized diesel. Test cell is capable of running specialty fuels from drums.
▪ 800 HP motoring dynamometer
▪ Temperature and humidity controlled intake air
▪ Particulate matter (PM) measurement available using AEI's real time laser instrument.