Instrumentation&Engine System

Focus Applied TechnologiesInstrumentation & Engine Systems

Revision 1 28-June-2013

Dynamometers, Measurement and Control Systems

Focus Applied Technologies Instrumentation & Engine Systems 2013

Focus Applied TechnologiesDynamometer Systems: Baby Chassis

DynamometerModel BCD

Focus Applied Technologies Instrumentation Systems 2013

This low-cost Dynamometer is based on a synchronous generator which is modified to give high torque loads over a wide speed range, all the way down to 0 rpm. It is carefully suspended in bearing assemblies. Torque is measured by a precision load cell and shaft speed by a speed sensor. The power is dumped in a resistive load (air heaters), which may be located away from the test cell, eliminating heat and the need for pluming, and reducing installation costs. An Idler roller prevents vehicle run away, allowing the vehicle to be restrained either by a rider, or a single hold-down strap to the front wheel or over the seat.

Features

10 kW Mechanical power ratings Suitable for motorcycle up to 200cc Up to 90 kph, 120Nm at wheel Precision Torque and Speed Measurement Simple Air Heater dump load Advanced Dynamometer Controller Includes Analog Input Channels for Logging Free computer software for Graphic Display 1 Year Warranty Included 240VAC, 70kg, 50 x 90 x 30cm

Focus Applied TechnologiesDynamometer Systems: Benchtop Dyno

Model BD1-MU4KW

A complete dynamometer system with a selection of power sources, Couplers and loaddevices.


Our Bench Top dynamometers feature heavy duty frame, integrated torque and speed measurements, and a universal dynamometer controller for control, display and recording of information via a computer interface. Our generator type dynamometer does not require water circulation, and the electrical dump load may be mounted remotely. Various power sources and coupling options are available.

This is an ideal choice for universities and poly-techs as it comes with a variety of laboratory exercises and sample data.

Power Sources Include:3kW Gasoline Engine2.5kW Diesel Engine DC Electric MotorAC Electric Motor

Couplers Include:Universal Joint Shaft Horizontal Inertial Shaft (Various Inertial Disks Available)

Load devices Include:4kW Generator DynoElectric Motor/Generator User Defined Dyno


VARIOUS SYSTEM CONFIGURATIONS


The following are photos and diagrams are examples of various configurations.

Typical installation with 3kW gasoline Internal Combustion Engine, Horizontal Inertial shaft (no inertia disk loaded) and 4kW generator type dyno:

Typical installation with 3kW Electric Brushless DC Motor, Horizontal Inertial shaft 4kW generator type dyno:




Electrical Motor dyno with Universal joint shaft and 4kW generator type dyno:

Electric Motor Universal Joint Shaft Dynamometer

Torque Table Torque Load Cell Speed Pickup

3kW gasoline Internal Combustion Engine, Universal joint shaft and 4kW generator type dyno:




600W Separately Excited DC Electric Motor with Inertial Load disk and User Dyno(powder type dynamometer):


POWER SOURCES


3kW Gasoline EngineOur systems feature a MitsubishiG131 Gasoline utility engine. This engine has an internal speed governor and air cooling fan.Maximum Speed: 4000rpmMaximum Torque: 8NmMaximum Power: 3kW

2.5kW Diesel EngineOur standard diesel engine is a Yanmar L48N with internal governor and air cooling. Maximum Speed: 3600rpmMaximum Torque: 10.5NmMaximum Power: 3.5Kw

AC/DC Electric MotorA variety of AC and DC motors are available with our systems. For more information on these systems please contact us directly.

User Defined Power SourceSystems can also be provided without a power source for testing of your own motor or engine. We can provide systems with either a Universal joint or Horizontal Shaft coupler which can be turned to the diameter of your drive shaft.

SOURCE-LOAD COUPLINGUniversal Joint ShaftThis allows height mismatches between the power source and load. The U-jointcan be drilled to fit most common shaft diameters and includes a key-way and locking screw. Maximum speed: 4000rpmMaximum Torque: 20Nm

Horizontal Inertial ShaftThe horizontal shaft requires couplers at the source and load ends. Two heavy duty bearings are included on the shaft and the center section is free for mounting inertial disks to simulate heavy inertial loads. The Inertial loads are fastened to the shaft using a taper lock allowing for quick installation and removal with out requiring re-balancing. Maximum Speed: 4000rpmMaximum Torque: 20NmInertial Disks: 0.1 to 2Nm


LOAD DEVICES


4kW Generator DynoOur systems feature a synchronous generator as the dynamometer. The units are rated at 2 to 3kW electrically and 4kW mechanically. Maximum Speed: 4000rpmMaximum Torque: 20NmMaximum Power (mech): 4kW

Electric Motor/GeneratorA variety of AC and DC motors are available with our systems. For more information on these systems please contact us directly.

User Defined DynoSystems can also be provided without a dynamometer for testing of your own dynamometer or motor. We can provide systems with either a Universal joint or Horizontal Shaft coupler which can be turned to the diameter of your drive shaft.

DYNAMOMETER OVERALL DESCRIPTION

Dynamometer

The dynamometer is a generator-type eddy current dynamometer. Power from the engine or motor rotates the rotor of the generator. The rotor field is controlled by the dynamometer current. More current gives a stronger rotor magnetic field, inducing more power in the stator coils. Power from the stator coils is sent to a dump load located distant from the dynamometer. The torque measurement table is suspended, and torque is read by a load cell. Bearing friction can be calibrated out, resulting in a highly accurate, low cost robust dynamometer.

Torque Measurement

Torque is measured via the tensional force on the torque table. This can be mounted either under the power source (eg. Engine or motor) or under the load device (eg. dynamometer or generator). When measuring the torque at the dynamometer end, shaft friction must be calibrated to correctly determine the torque at the power source.



Speed Measurement

A 30-tooth speed wheel shaft is attached to the main shaft at the load, horizontal shaft or on the dynamometer as required. An inductive type variable reluctance speed pickup senses the passing teeth as the shaft spins, and generates pulses which are read by the dynamometer controller.

Dynamometer Controller

This dynamometer controller allows the user to control the dynamometer in two different modes: Manual mode or Speed mode. Which of these modes to use depends on the specifics of your testing. For simple loading of an engine (ie. adding or reducing the load) the easiest mode is the Manual Control mode. For constant speed operation (Torque will vary) use the Speed Control mode.

Computer Communications

A computer can be connected to the dynamometer controller for logging data from the Dynamometer Controller, Fuel Scale and Data Acquisition systems via Serial Ports. If serial ports are unavailable then a USB-Serial Port converter may be used. Serial port communications are via RS232: 9600 baud, No parity, 1 Stop bit. The cable should be a straight through cable connecting pins 2, 3, and 5 at both ends. The controller automatically sends data out in the format Speed , Torque [CR] at approximately 4Hz. During power on the controller sends out a Power Onmessage with the firmware code. Data can be logged from various serial communications programs including Hyperterminal. Controls tuning is possible via the serial port as well. Sending an h (for help) to the controller over the serial com lines causes the controller to respond with a menu. Various items from the menu can be modified to change the PID control parameters (ie. typing P020 [ENTER] changes the proportional gain to 20.



Data Acquisition System

Some systems feature an integrated USB Data Acquisition System (DAQ). This system is a stand alone system for reading signals from various sensors commonly used in engine testing such as Thermocouples, Pressure Sensors and etc. Several channels are left open for the addition of user defined sensors. All of these sensors can be read by the computer data logging software for display and recording. Pressure sensors are also used in a high-speed mode where the pressure is recorded and displayed allowing the change in pressure to be viewed through out an individual engine cycle.

Fuel Scale

This digital gravimetric fuel scale weight fuel as it is consumed by the engine under test. The data is fed to the computer via serial (RS-232) communications link, allowing seamless integration with our dynamometer and DAQ systems. The weight of fuel is measured as a function of time allowing direct measurements of fuel consumption, and calculation of Break Specific Fuel Consumption (BSFC), and Fuel Mass Flow rate, for calculation of actual Air Fuel Ration (AFR) when combined with an air flow sensor.

Dump Load

Power extracted from the generator dynamometer is sent al electricity to the dump load where is heats air. The dump load is a high quality industrial heater, and is operating at relatively high temperatures (in excess of 100C) and voltages (up to 400VAC). This heater should be rigidly mounted to a wall high up out of the reach of people and out of the way of any equipment. This system should be inspected before operation of the dynamometer and maintained if required.



DIMENSIONS _____LxWxH: 1200 x 490 x 400 mmWeight: Approximately 65kg (without engine)

POWER IN _____Voltage: 220 VAC +/- 10%Frequency: 50HzCurrent Draw: 4A max

CONTROLLER OUTPUT ________________Resistance: 10 ohms minimumPower: 300W maximumVoltage: 50V nominalCurrent: 5A maximum

DYNAMOMETER POWER _____Mechanical Power: 5,000W maximumVoltage output: 400V maximumCurrent: 10A maximum

INPUTS _____Speed Input: Variable Reluctance type input

1 to 60 pulse per revolution10V pk-pk maximum60 to 10,000 rpm (typical)

Strain: 200 to 500 ohm4-wire Wheatstone bridge 5 or 10V excitation

SERIAL COMMUNICATIONS _____Baud, Bits, Parity, Stop: 9600, 8, N, 1

ENVIRONMENT _____Temperature: 10 to 40C Operational

0 to 50C Non-OperationalHumidity: 5 to 90% Non-condensingShock/Vibe:



EXTERNAL WIRING DIAGRAM

5A BreakerPush to reset

FAN

5

I0

Serial Com AC Mains

DYNO

Dump Load: WARNING! High Voltage - High Temp!

Keep out of reach!

Speed Pickup

Load Cell

Torque Amplifier

Dyn

o+

Dyn

o

+12

VG

nd

Torq

ue

Gn

dSp

eed

Power Switch

The Controller unit is powered from a clean AC line power source.

The Dynamometer coils are connected to the Dyno Coil Output of the controller with power cables. The resistive load is non-polar, and the signal is up to 400V AC.

The speed pickup is connected to the appropriate inputs via a shielded co-axial cable. This signal is non-polar and should be approximately 2 to 30V AC depending on the speed and proximity of the sensor to the speed target wheel.

The load cell amplifier is connected to the appropriate connections (+12V, GND, or Torque (ie. the signal))

Serial port communications are via RS232: 9600 baud, No parity, 1 Stop bit. The cable should be a straight through cable connecting pins 2, 3, and 5 at both ends. The data from the controller will be decimal coded ACSII number for the speed and torque separated by a comma, and terminated by a linefeed/carriage return. The controller will send data 4 times a second.



FUNCTIONAL BLOCK DIAGRAM

The Dynamometer and Dynamometer Controller together with the engine form a complete system. The Dyno controller reads the speed and torque from the dynamometer and controls the load according to its mode and set point. Power extracted from the engine is dissipated as heat in the dump load.

Data from the dynamometer controller may be displayed and logged on a computer. The data is transferred via serial port connection.

Systems with a fuel scale can record and display the weight of fuel during engine operation. As fuel is consumed the weight of the fuel supply tank reduces, allowing calculation of fuel consumption. Data is transferred to the computer via serial port connection.

Additional data may be acquired from the engine with a Data Acquisition (DAQ) system. Generally several channels of temperature, pressure and etc. are logged and displayed on the computer. Data is transferred from the DAQ via USB.

Computer

Fuel Scale

Fuel

Data Acquisition

Dyno Controller

Power Supply

Dynamometer Engine

Dump Load

Focus Applied TechnologiesDynamometer Systems: Desktop Dyno

Model DD1-1KW


Bench mounted small engine dynamometer with Universal joint and Electric Motor.

Options Include:F Fuel ScaleD Data Acquisition SystemZ Emissions AnalyzerE EngineM Electric Motor

Typical Maximum Specifications

RPM: 6000Power: 1kW

Focus Applied TechnologiesDynamometer Systems: Desktop Dyno

Model DD1-1KW


Product overviewOur current manual Small EngineDynamometer (shown to the right) consists ofan aluminum load plate (black disk) connectedto the engine under test. The Magnet Plate (grey disk, Magnets shown at lower left) is placed in proximity to the load disk. As the engine spins eddy currents are induced in theload plate, slowing the engine. The torque is measured by the rotational deflection of the magnet plate which is carefully suspended in bearing assemblies. Load is controlled by the proximity of the magnet plate to the load plate.This technique has been proven successful on a wide variety of small engines, down to 35cc. Our commercial model will replace the magnetplate with an automatically controlled electromagnet assembly combined with anelectronic load cell for fully automatic operation.

Features (Commercial Version) 0.02 to 2.0 kW power ratings Easy coupling to engine Excellent vibration immunity No load bank required 1 Year Warranty Included

Compatible with: Focus Dyno Controller Focus DAQ System Focus Digital Fuel Scale System

Focus Applied TechnologiesDynamometer Systems: Motorcycle Chassis DynamometerModel MCD-lPMD10KW

Loaded inertial dynamometer for small motorcycles, with Pneumatic wheel clamp.

Options Include:

F Fuel ScaleD Data Acquisition SystemZ Emissions AnalyzerM Motored Roller

Typical Maximum Specifications

Speed: 100kphPower: 20kW


Focus Applied TechnologiesDynamometer Systems: Motorcycle Chassis DynamometerModel MCD-lPMD10KW


This Focus Applied Technologies chassis dynamometer system consists of a chassis dynamometer incorporating the main roller, an inertial roller, an motor/load unit, front and rear pneumatic wheel clamps, a pneumatic control console, associated power supplies and controllers, and a computer with data acquisition system.

It is designed for performance testing of 2-wheeled vehicles where a single operator can mount the vehicle, perform the required testing on both front and rear wheels, and remove the vehicle within a few minutes. A ramp is provided for easy vehicle mounting and dismounting.

System overview

FEATURES Dynamometer Inertial Load Traction Motor/Load Device Data Acquisition System Dump Load 1 Year Warranty Included


Focus Applied TechnologiesDynamometer Systems: Low Cost Eddy DynoModel DLC-FDM10KW

Floor mounted small dynamometer with controller, Fuel Scale and Data Acquisition System

Options Include:U Universal JointI Inertial LoadF Fuel ScaleD Data Acquisition SystemG Generator LoadA Alternator LoadZ Emissions Analyzer

Typical Maximum Specifications RPM : 6000 POWER : 20KW

Focus Applied TechnologiesDynamometer Systems: Low Cost Eddy DynoModel DLC-FDM10KW


Product overviewThis low-cost Eddy Current Dynamometer is based on a synchronous generator which is modified to give high torque loads over a wide speed range, all the way down to 0 rpm. It is carefully suspended in bearing assemblies. Torque is measured by a precision load cell and shaft speed by a speed encoder.

External Wiring Diagram

Focus Applied TechnologiesDynamometer Systems: Automotive Engine DynoModel ED1-DH75KW


Directly coupled Hydraulic pump dynamometer for use with automotive engine

Typical Maximum SpecificationsRPM: 6000Power: 75kW

Focus Applied TechnologiesDynamometer Systems: Portable ChassisDyno

Model PCD2-C4KW


Portable Chassis dynamometer with Controller.

Options Include:I Inertial LoadF Fuel ScaleD Data Acquisition SystemZ Emissions Analyzer

Typical Maximum SpecificationsRPM: 6000Power: 5kWWeight: 20kg

Focus Applied TechnologiesEngine System : Fuel Injection System(EFI)

4-Stroke LPG/CNG Port Fuel Injection system for Motorcycles

Focus Applied Technologies Engine Systems 2013

A follow on to the 2-stroke GXI system our Gaseous Port Injection (GPI) system is currently undergoing final field trials in Malaysia before our Philippians Launch in late 2012. This system is an update of the previous 4-stroke system originally introduced in 2009 for fleet delivery motorcycle owners. It features our latest ECU design with 12 x 12 fuel maps, and a 12 point spark advance curve. Results show very robust starting and performance, and greatly reduced operating costs. The LPG version will be offered in the Philippians market, while CNG will be available in Malaysia, Indonesia and India.

4-Stroke Kit

Tank Ecu Wire Harness Pressure Regulator Temperature Sensor Injector

Focus Applied TechnologiesEngine System : Fuel Injection System(EFI)

2-Stroke LPG Transfer Port Fuel Injection

Focus Applied Technologies Engine Systems 2013

After two years of laboratory testing our patented Gaseous Xfer port Injection (GXI) fuel injection system is soon to be available for commercial sales. The system uses Liquid Petroleum Gas (LPG) or Compressed Natural Gas (CNG) as the fuel, and an Electronic Control Unit (ECU) to control fueling amount and timing for injection into the combustion chamber through the transfer-port of 2-stroke engines. As the fuel is pressurized, this results in a low-cost system, which reduces emissions by 80% and can save up to 40% of the fuel. In many markets LPG or CNG is less expensive than gasoline, thus reducing operating cost even further. With optional spark timing control the unit can deliver power greater than the original gasoline system.

2-Stroke Kit

12V Batteries Vreg ECU Wire Harness Throttle Tank 2T Pump CPS Injector Temperature Sensor Magnet Pressure Regulator Cylinder

Focus Applied TechnologiesInstrumentation : Dynamometer ControllerModel DC3APT


The DC3APT is a stand-alone unit featuring internal load cell amp, high-current power supply, and remote throttle control and is ideal for replacement or upgrade of existing dynamometer systems and OEM applications. Bump-less mode switching is made possible by an encoder load point input

FEATURES

Direct (Manual) Control Mode Speed Control Mode (PID) Torque Control Mode (PID) Road Load (N) Mode (PID) Internal High-Current Power Supply Internal Load Cell Amplifier Free Software for Logging/Display Large LCD Display

Focus Applied TechnologiesInstrumentation : Combustion VisualizationModel CV1205C-GIF


This Focus Applied Technologies combustion visualization system consists of anengine head and open engine cylinder where the combustion happens.Observation of the air-flow and combustion can be done through the cylinder.The controller controls the fuel injection, spark as well as the supply air-flow. Itconsists of a box with internal power supply, control board, transistor driver for 1injector and 1 fan, and contains a DC CDI unit.

The unit has an alphanumeric LCD displaying of operation parameters, 5 knobs for parameters adjustment and a button for manual mode operations as well as setting mode selection. The controller operate from 220-240VAC.

FEATURES Injector Spark Fan 1 Year Warranty Included

Combustion Visualization Controller with Gaseous Fuel Injection, Spark and supply air flow control

Focus Applied TechnologiesInstrumentation : Digital Fuel Scale

This digital gravimetric fuel scale weight fuel as it is consumed by the engine under test. The data is fed to the computer via serial (RS-232) communications link, allowing seamless integration with our dynamometer and DAQ systems.

The weight of fuel is measured as a function of time allowing direct measurements of fuel consumption, and calculation of Break Specific Fuel Consumption (BSFC), and Fuel Mass Flow rate, for calculation of actual Air Fuel Ration (AFR) when combined with an air flow sensor.

Features 0.1 to 0.1 precision available 3.0 to 6.0 kg maximum fuel weight RS 232 Serial Communications Compatible with Focus DynoMonitor Compatible with all types of fuel



ECU Scanner

O2 ShifterVehicle Data Logger

Focus Applied TechnologiesInstrumentation : Other Products

For further information on this or other products please contact us via the following:

Web site: www.FocusAppliedTechnologies.comEmail: [email protected]

Post: FOCUS APPLIED TECHNOLOGIES SDN. BHD. NO. 34 JALAN JAWI INDAH SUNGAI JAWI 14200 PENANG, MALAYSIA

Office (+60 4)582 2466

PIC: Dr.Horizon Gitano (CTO)[email protected]

Nurul Shafina ( Admin & Finance Executive)[email protected]

Focus Applied Technologies Instrumentation & Engine Systems 2013

Focus Applied TechnologiesContact Information

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