The AEI facility, which includes twenty six engine dynamometer and component development 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 development services are offered, ranging from endurance development to ratings development for optimum performance and emissions compliance. Engineering staff can provide custom engine testing cycles that are written to support cooperative development programs and more rapidly iterate toward a robust working solution.

Featured Capabilities

• 26 engine dynamometer and component development cells
• Emissions Analyzers
• FTIR Analyzers with 5Hz sampling
• Particulate Matter (PM) Measurement – 1065 and tier IV
• Smoke measurements
• Lubricant Oil Soot Measurements
• High Speed Data Acquisition – real time cylinder pressure and heat release up to 96 channels
• Loaded cold start and cold operation
• Dynamic control of intake air and exhaust restrictions/pressures
• Rapid response charge air, coolant, and fuel temperature control
• 24 hour continuous support
• Automated data acquisition
• Remote data retrieval with customer logins
• HEPA filtered, temperature and humidity controlled combustion air
• Automated transient cycles or steady state operation

As engines are being developed with more complex air handling, fuel systems, and integrated aftertreatment exhaust systems, the frequency of required development in the mountains continues to escalate. Engine sociability with smoke during transient operation has also become a large problem with the multi-dimensional air handling systems involving modulated EGR and VG turbocharger. In order to provide useful information about smoke visibility and color, an exhaust stack mounted remote camera can be viewed right at the development cell console.

AEI’s Super Cell is uniquely configured to simulate altitude conditions, with controlled intake air supply sources that are maintained isobarically with the exhaust out pressure. The majority of other facilities’ engine test cells that offer “altitude” capability are only able to maintain exhaust out pressure, and then create a simulated intake supply pressure by increasing intake restriction. Then for transient operation, that intake restriction valve must be modulated to attempt to 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 Capabilites

• Up to 12,000 feet altitude simulation for steady state and transient development
• Altitude is maintained during transient cycle
• Temp to -35ºC at startup
• Driving simulation
• Continuous raw emissions measurement and smoke
• Temperature controlled intake air from 110ºF to below 32ºF
• Temperature controlled CAC out down to 40ºF
• Humidity controlled intake air at 77ºF and 75 gr/lb

Two of the twenty six engine Development cells at AEI are dedicated to Cold Start Engine Development. Development cell temperature can be reduced to -40°. Continuous data acquisition includes: white smoke (unburned hydrocarbons), exhaust smoke opacity, engine speed, and several temperature and pressure channels.

Included Instrumentation

• 16 regular pressure channels (std. list: blowby, boost, coolant, oil)
• 32 temperatures
• Hydrocarbons
• Smoke opacity
• Starter voltage
• Starter current
• Grid heater voltage
• Grid heater current
• Tuning for Hydraulic Load During Start and Idle

• Targeted at engine control strategies and calibration maps for cold operation
• Cold-capable to -35°F
• Engine, fluids, accessories can all be held to desired temperatures
• Motoring dyno: 1-8000 rpm
• In-line torque flange for high-accuracy data
• Subsequent tear-down and component wear analysis available