Schenck Pegasus Announces a Dynamometer System Capable of Complete Engine Emulation for Powertrain and FEAD Testing
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TROY, Mich.--March 5, 2003--Schenck Pegasus has revolutionized the way vehicle manufacturers test their powertrains and front end accessory devices (FEAD). The Engine Torque Pulsation Simulation (ETPS) Dynamometer system is ultra low in inertia and uses a real time model for engine configuration and combustion. This combination accurately predicts the high frequency torsional pulses that any gasoline or diesel engine produces - even those not in production. This is the first system that uses an adaptive, closed-loop real-time controller to assure predicted torque is actually achieved as an excitation (dynamic input) to the test specimen. Practical problems of shaft connection stiffness, attached inertia and torque measurements have been overcome. Not only does this system reduce the costs associated with maintaining and running a fueled engine, but it also tests accurately and consistently without producing exhaust emissions, or the need for complex real-time hardware-in-the-loop (HIL) simulators, or gathering field recorded data.
To help vehicle manufacturers achieve the ultimate goal of customer satisfaction (durability, driving characteristic, and NVH), transmission and component suppliers must continue to improve upon existing transmissions, as well as develop new powertrains without the aid of an existing engine. Testing technology available to OEMs before the ETPS system was hampering this effort. Until now, the prime mover for test stands was either a fueled engine or an AC motor. Fueled engine prime movers are expensive to maintain considering the costs for fuel, lubrication, heat removal, engine maintenance and repair, as well as maintaining building codes and fire protection. They also deplete precious smoke stack emissions credits for non-emissions related development. Because much of the drivability related testing is done using the actual engine, testing can happen only after the engine is fully developed and installed in the test cell, ultimately lengthening the new vehicle time-to-market. Previous generation AC motor driven test stands simply do not provide dynamics beyond constant torque or speed, or they employed additional rotating servo-hydraulics, which added to the complexity of the overall test stand. The previous AC motor prime mover test stands limited scope to durability and functional testing. Without a close correlation to the real IC engine torque pulses, known driving schedules, and real world vehicle loads, testing accuracy is limited and results do not completely satisfy the needs of design engineers.
The Schenck Pegasus ETPS Dynamometer solution contains three components, a highly transient AC dynamometer (Schenck PT260), an easy to use flexible positioning support base and an open interface real-time controller (sp-ARC). The system uses sophisticated software developed by Schenck Pegasus that incorporates proven algorithms to predict the total torque signature of an IC engine at any operating point. These calculations are performed in real-time allowing any change in input speed (from the road load) or simulated throttle position (from the driver) and are able to duplicate the peak torque distribution in sixteen harmonics of the total engine torque curve. Entire driving cycles can be used to run a powertrain test with complete simulation of driver and the engine maps tuned for emissions. This emulates the IC engine as intended for a vehicle application. An adaptive, closed-loop real-time controller delivers the calculated IC engine torque signature to the transmission for accurate, repeatable and reliable reproduction of torque in a wide range of frequencies.
This new technology provides a cleaner, faster and more flexible way to test powertrains and FEADs. Vehicle manufacturers have already begun to embrace this technology by replacing the prime mover in their powertrain and test stands with an ETPS dynamometer. This means consumers can look forward to vehicles with improved reliability, durability, comfort and overall performance.
Schenck Pegasus, a division of the Durr Group, is a leading global supplier of innovative technologies for development test systems. Schenck Pegasus produces solutions for applications in brake, vehicle, engine, powertrain and wind tunnel balance. Highly regarded industry expertise in solving product development issues is used to accelerate testing programs. Additionally, Dynamic Testing Services, a business unit within the Schenck Pegasus Troy Michigan location, can apply both dynamometer and servo-hydraulic equipment to a variety of component and whole vehicle requirements. For more information, contact Schenck Pegasus Corporation, 2890 John R Road, Troy, Michigan 48083 USA, phone: +1.248.689.9000, fax: +1.248.689.8578, or visit our website at www.schenckpegasus.com
Photo caption: The Schenck Pegasus ETPS Dynamometer system has advanced powertrain and FEAD testing for vehicle manufacturers.
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