Diesel Engine Dynamometer Testing

The AEI facility, which includes ten engine dynamometer test cells, is uniquely designed to provide a research and development environment in support of a breadth of diesel engine and/or vehicle development programs.  Numerous diesel engine testing services are offered, ranging from endurance testing to ratings development for optimum performance and emissions compliance.

AEI’s test cell privacy configuration is structured for protecting proprietary projects and providing a comfortable work environment for customers and AEI support personnel.  Each test cell computer console room is isolated from the other test cells and is equipped with an individual entry door.  Privacy blinds may be closed to prevent others from viewing the engine or other hardware.  These console rooms provide a laboratory-like environment, where customers may view the control screens and see the engine test cell through a window.  A single door provides front entry to the test cell from the control console area.  Large double doors for installing and removing engines are located on the opposite side of the cell from the console area.  This arrangement limits access to visitors, and only allows authorized personnel in all areas where engines are stored, maintained, torn down, inspected etc.

Engine Performance and Durability Test Cells

▪ 10 test cells with 30 to 800 HP

▪ 5 AC Motoring Dynos

▪ 1 DC Motoring Dyno

▪ 4 Eddy Current Dynos (350 to 700 HP)

▪ 150 HP Eddy current dyno (installed as needed for high speed, low inertia requirements)

▪ 24 hour continuous support
▪ Automated data acquisition
▪ Remote data retrieval with customer logins
▪ HEPA filtered combustion air
▪ Cyclic test scripts or steady state operation
▪ Temperature controlled intake air

▪ Variable speed intake and exhaust room ventilation fans

▪ Humidity controlled combustion air to 75 grains of water (optional)

▪ Measurements: pressures, temps, fuel rate, heat rejection, air flow, emissions, smoke, lubricant oil soot etc.

All of the controls and associated electronics for test cell operation were developed at Analytical Engineering, Inc.  The facility controls, including fans, pumps, temperature controls, cooling towers etc., are controlled via a central computer control room. The entire facility computer control systems tie back to this central hub where all data are stored, backed up and maintained by skilled personnel. The entire AEI facilities computer systems are developed in house and utilize Linux real-time operating systems. This, in conjunction with skilled in-house programmers assures complete flexibility, optimum control and the ability to incorporate practically any conceivable experimental requirement.

The operator may access the test cell through a door next to the console. The window is bullet resistant 1 ½ inch thick rubber-reinforced glass and is shaded on an as-needed basis to prevent visual access to the inside of the cell.

Offices are located above the laboratories adjacent the cells providing visibility of the hallway outside the cells, but are so designed to prevent visibility of an engine in the cell. This design provides a comfortable and ergonomic office design without compromising the intellectual property integrity of the test cell. In essence, the AEI facility is designed to provide visitor access to much of the building without concern of that person viewing anything belonging to another client. AEI management and personnel maintain the highest degree of intellectual property protection, both for internal projects and those of our clients.

The test cell facility is constructed with underground plenums that connect each test cell with the central emissions measurement laboratory. Within this lab conventional raw gas analysis is accomplished using NDIR, Chemiluminescent, paramagnetic and flame ionization (FID) analyzers. In addition to these methods and systems for analysis, AEI offers measurement capability well beyond conventional techniques utilizing laboratory grade instrumentation. A 0.25 cm-1 resolution FTIR based gas analysis system provides the ability to simultaneously measure all infrared active gases including NO, NO₂, CO, CO₂, N₂O, NH₃, H₂O, HNO₃, SO, SO₂, HS and many others with excellent precision and detection limits often to below 1 ppm. Additionally, this method can provide hydrocarbon speciation. These capabilities are very important when studying non-regulated emissions and when attempting to elucidate the byproducts or intermediate chemical species for aftertreatment

Test Cell Specifications

The Analytical Engineering, Inc. engine test cells are all roughly equivalent in terms of size and engine testing capacity. Odd numbered test cells have a 16 x 4 foot bedplate and even numbered have 14 x 4 foot bedplates. The bedplates are 4 inch 1018 solid steel construction and are bonded to 60,000 pound steel reinforced concrete inertia blocks. The inertia blocks are isolated from the building through vibration isolation foam seams. The bedplate and inertia block combination are designed for engine / dynamometer combinations up to approximately 3,000 horsepower. Six of the test cells provide rear access through double doors with an opening dimension of 8 feet wide by 9 feet tall, thus accepting practically any conventional engine size.

AEI currently maintains a variety of dynamometers in house.  Six of the test cells have been upfit with extremely high speed motoring dyno controls within the last two years.

Test Cell Ventilation

Each test cell is ventilated with a totally separate, twin air handler system with a bypass. With computer controlled variable speed blowers, air velocity, test cell temperature and inside barometric pressure (delta to outside) can be maintained and carefully controlled. The entering air from outside is filtered through a separate 99.7% efficient superfilter system.

Fuel Storage and Test Cell Fuel Selection

There are currently 6 separate large fuel storage tanks. Each fuel delivery system is computer controlled and is capable of delivering any target pressure as needed. The fuel selection is made on the mechanical side of the test cell with a quick connection to the desired fuel line.  AEI routinely stocks standard #2 on-highway diesel fuel, along with ultra low sulfur fuel that meets future EPA requirements.  Four smaller 500 gallon fuel tanks are available for short-term testing with specialty fuels.  Additionally, the ability to run tests from 55 gallon drums with unique fuel is available.

Process Water

The process water system is also completely computer controlled. This allows for precise control of the bulk storage tank pressure, thus consistent control of the process water temperature over the day. Process water pressure is also computer controlled and delivered to the test cells as needed. All process water is maintained with carefully controlled corrosion inhibitor chemistry and microbiological control. All makeup water to the process water is done with Reverse Osmosis and process bleed is used only to maintain TDS.

Exhaust Systems and Silencing

Supercritical silencing mufflers provide approximately 45 dB attenuation. Each test cell is equipped with 8 inch exhaust with continuously variable damping capability, with the ability to set exhaust restrictions per customer requirements. This system provides exhaust flow for engines up through 2500 horsepower with minimal pressure drop.