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! !! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! Sierra CP Engineering Ltd. UK: +44 (0) 1684 584 850 / USA: +1 (0) 517 669 0514 India: +91 8600 148 055 / China: +86 10 6059 3951 www.sierra-cp.com / info@sierra-cp.
We Specialize in Flexibility Thirty!years!of!successfully!meeting!tough! customer!challenges!has!taught!us!at!Sierra!CP! Engineering!that!the!concept!of!“one!solution!fits! all”!just!doesn’t!work!in!the!auto!test!industry.!!!!!!! As!a!result,!we!have!positioned!our!company!to! embrace!the!critical!role!that!flexibility!plays!at! every!stage!of!design!and!development.!And!it!all! starts!with!creating!an!open!atmosphere!for!client! interaction!that!breeds!innovation.
!!!!!! Contents! !!!!! INTRODUCTION TO SIERRA CP TECHNOLOGY ..................................................................................... 6! Engine!Testing!Overview..............................................................................................................7! Vehicle!Testing!Overview.............................................................................................................8! Powertrain!and!E!Motor!Testing!Overview.................................................
INTRODUCTION TO SIERRA CP TECHNOLOGY! ! The!CADET!control!system!has!been!installed!in!test! facilities!worldwide,!providing!full!control!and!data! logging!capability!to!the!engine!and!vehicle!testing! market.!Both!hardware!and!software!has!been! designed!and!developed!specifically!for!engine!and! vehicle!testing,!it!is!all!manufactured,!written!and! tested!inLhouse.!! ! CADET!V14!is!a!constantly!evolving!software!package! which!is!designed!specifically!to!meet!the!needs!of! engine!and!vehicle!testing.
ENGINE TESTING OVERVIEW ! Sierra!CP!can!supply!and!interface!to!a!wide!range!of!dynamometers!for!steady!state,!transient,! highly!dynamic!testing!and!vehicle!simulation,!including!AC,!DC,!Eddy!Current!and!Hydraulic.
VEHICLE TESTING OVERVIEW ! Sierra!CP!can!supply!for!chassis!dynamometers!for!passenger!cars,!motorcycle,!SUV,!MPV,!LDV,! MDV,!HDV!and!off!road!vehicles.
POWERTRAIN AND E MOTOR TESTING OVERVIEW ! ! ! Sierra!CP!can!supply!powertrain!test!solutions!from!single!gearbox,!engine!and!transmission!units!to! full!4x4!as!installed!in!vehicle!test!solutions.
IN CELL SUPPORT PRODUCTS OVERVIEW ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Sierra!CP!supply!peripheral!support!items!for!inLcell!use!including:! ! • Fuel!measurement!and!conditioning! • Engine!coolant,!lubrication,!intercooler!fluid!temperature!control! • Combustion!air!handling!for!temperature,!humidity!and!pressure!control! • Extensive!data!acquisition! • Vehicle!cooling!fans! • Robot!driver! • Tyre!burst!detectors! • Vehicle!retention! • Extensive!interfaces!for!third!party!equipment! • Emissions!samplin
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! CADET V14 Control, Automation and Datalogging for Automotive Test Issue 4.
More!detailed!CADET!hardware!and!software!documentation!is!available!on!request.!Please!contact! Sierra!CP!for!further!details.!!! ! INTRODUCTION ! CADET!is!Sierra!CPs!in!house!designed! hardware!and!software,!specifically!designed! for!the!automotive!testing!industry.!The! CADET!software!has!been!extensively! developed!over!the!last!20+!years,!to!include! the!latest!features!demanded!by!the! automotive!test!community.!The!latest!release! of!CADET!software!is!currently!V14.4a.
SPECIFICATION ! The!maximum!capability!of!the!current!build!of!CADET!(V14.4)!is!detailed!in!the!table!below:! ! Description! Maximum!Channel!Count,!V14.
Application!Protocols! ASAPE3) ASAP)CCP)DAQ)functions) J1939)DTC)functions) OBD)II) AK)protocols) MATLAB) Sierra)CP)Cell)Services) ) ) Horiba)Mexa)6000)Series) Horiba)Mexa)7000)Series) Horiba)Mexa)9000)Series) Horiba)EXSA)1500) AVL)AMA)i60) AVL)SESAM)i60)FT) Fischer)Rosemount)NGA)2000) Signal)Instruments)series)3) Signal)Instruments)series)4) Sierra)CP)Emissions)bench)controller) ) ) Horiba)9000)series) Horiba)7000)series) Signal)Instruments) Fischer)Rosemount) Pierburg)PSE)2000)ser
APPLICATIONS ! • • • • • • • • • • • • • Engine!test! o Petrol/Gasoline! o Diesel! o LPG!and!other!specialist!fuels! o E!Motor!and!Hybrid! Vehicle!test! o 2WD!up!to!8WD! o Tracked!systems! o Independent!rollers! o Hub!mounted!systems! Powertrain!testing! Vehicle!robots! Fuel!systems! Emissions!control!and!testing! Test!cell!and!facilities!control! Combustion!air!handling! Component!testing! Specialist!rigs!(injectors,!pump!test! etc)! Production!test! Hot!test! Cold!test! ! Please!contact!Sierra!CP!with
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! CADET Edge Dynamometer and Engine Controller Issue 4.
INTRODUCTION ! The!CADET!Edge!is!part!of!the!CADET! range!of!control!systems!(see!separate! datasheet),!designed!specifically!for! dynamometer!control!and!engine! throttle!actuation.!The!CADET!system!can! actuate!eddy!current,!hydraulic,!AC!or!DC! dynamometers!and!will!be!supplied!with! the!appropriate!power!modules.!! ! Control!of!the!dynamometer!and!throttle! is!either!automatic!or!manual.!When!in! automatic!mode!the!throttle!and! dynamometer!setpoints!follow!a!preL programmed!test!cycle.
BENEFITS AND FEATURES ! • • • • • • • • • • Integrates!with!any!dynamometer,!new!or!existing! Mechanical!or!electrical!throttle!actuation! Compact!4U!module!with!integrated!industrial!PC! Manual!or!automatic!control!modes! Integrated!software!independent!safety!shutdowns! Easy!to!use!CADET!control!software! 21!point!form!based!calibration!system!with!various!‘best!fit’!options! PID!tuning!! Datalogging!options!–!up!to!12!channels! Trace!feature!allows!power!curve!generation!or!multiple!channels!to!be!viewe
OPTIONS ! The!dynamometer!controller!will!be!supplied!with!a!control!enclosure,!inLcell!box,!keyboard!and! mouse.!The!dynamometer!controller!can!be!specified!by!selecting!one!option!from!each!of!the!rows! below.!Customer!specific!options!may!also!be!available,!please!contact!Sierra!CP.
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! CADET V14 Compact Starter Control, Automation and Datalogging System Issue 4.
INTRODUCTION ! CADETLCompact!offers!an!easily!expandable!solution!to!meet!the!needs!of!educational! establishments,!smaller!companies!or!those!who!require!accurate!dynamometer,!engine!and! coolant!control!but!with!limited!monitoring!channels.!CADET!Compact!uses!the!same!control!and! data!logging!system!and!base!structure!as!the!Full!CADET!V14!systems!but!with!a!reduced!channel! count!and!associated!cost.
SYSTEM DESCRIPTION ! Cabinet! ! The!CADETLCompact!12U!(600mm!x!600mm)!cabinet!houses!the!two! Sierra!CP!i/o!racks!and!also!the!rack!mounted!system!controller!PC.! The!cabinet!includes!all!the!termination!for!the!control,!safety!and! dataLlogging!subLsystems!such!as!the!Engine!Protection!Panel.!Any! wiring!associated!with!inLcell!equipment!is!terminated!into!modules! within!the!cabinet!that!provide!a!multiLway!connection!for!onward! connection!using!the!supplied!looms.
Dynamometer!Control!and!Engine!Electrics!Box! ! This!inLcell!box!contains!the!power!modules!for!the! Throttle!Actuator!and!eddy!current!or!hydraulic! dynamometer.!There!are!four!relay!switched!low!voltage! terminals,!which!switch!from!a!common!power!source! connection!such!as!an!inLcell!power!supply!or!battery.! These!can!be!switched!on!or!off!with!the!associated!Digital! Outputs!during!tests.!They!are!typically!linked!to!ECU,! Fuel,!Glowplugs!and!Ignition.
OPTIONS ! The!CADET!compact!system!is!of!a!standard!build,!meaning!that!design!costs!can!be!kept!to!a! minimum.!On!order!placement!the!customer!should!let!Sierra!CP!know!the!type,!make!and!model! of!dynamometer!being!controlled,!and!select!a!suitable!transducer!panel!(as!detailed!previously).! The!customer!should!also!detail!the!loom!lengths!required!for!installation.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! TLS – Test Laboratory System Emissions Calculation, Reporting and Test Scheduling Issue 4.
! Please!note:!a!more!detailed!specification!document!on!the!TLS!system!is!available!on!request,! please!contact!Sierra!CP!for!further!details.! ! INTRODUCTION ! TLS!is!a!software!solution!developed!specifically!to!support!testing!of!Engines,!Vehicles!&! Components.!It!integrates!seamlessly!with!the!Sierra!CP!Engineering!CADET!Automation!System!to! provide!a!complete!solution!for!configuring!&!running!tests,!pre!&!post!test!data!entry,!emissions! calculations!and!report!generation.
! Multiple!Test!Cell!Operation! Testing!activities!may!be!distributed!across!multiple!test!cells!at!the!test!Process!level.!Each!test!cell! within!the!scope!of!TLS!has!a!local!TLS!Cell!Manager!client!which!communicates!with!the!TLS! Repository!server!and!the!test!cell!Automation!System.! ! Project!Model! Related!test!activities!and!data!are!grouped!within!a!Project!model.!A!single!Project!may!cover!one! or!more!Units!Under!Test!(UUT)!and!provide!multiLphase!Tests!on!each!one.
TEMPLATE BASED DATASET CONFIGURATIONS ! TLS!uses!configurable!Templates!to!create!dataset!Cards!which!meet!specific!organisational! requirements.!Templates!and!dataset!Cards!are!stored!in!the!TLS!Repository!server!and!are! accessible!to!all!connected!clients.! ! The!TLS!Lab!Manager!client!is!used!to!configure!Templates!and!create/edit!dataset!Cards.
! Life!Cycle!mode! Data!type! Precision! ! ! ! Defines!whether!the!data!is!optional,!mandatory!(i.e.!must!be!present!to! continue),!or!read!only!(visible!but!not!editable)!at!each!point!of!the!life!cycle.! Type!of!data,!for!example:!integer,!decimal,!boolean,!text,!date!etc.
REPORT GENERATION ! Reports!are!produced!in!EXCEL!workbook!format!and!a!PDF!copy!is!automatically!created!for!online! viewing!within!the!TLS!Lab!Manger!and!Cell!Manager!clients.!TLS!generates!reports!by!copying!a! preLprepared!layout!and!populating!it!with!data.!The!finished!report!is!then!stored!on!the!TLS! Repository!in!a!folder!hierarchy!specified!using!macros.! ! Layout!Templates! Report!layouts!are!created!using!the!EXCEL.!Multiple!worksheets,!embedded!macros!and! formatting!options!may!be!used.
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IN CELL EQUIPMENT ! Our!philosophy!of!flexibility!and!simplicity!of!design!helps!provide!the!foundation!for!our!range!of! modular,!ancillary!inLcell!products!to!meet!the!diverse!and!demanding!requirement!of!modern!test! facilities.!Our!inLcell!support!solutions!are!designed!as!part!of!our!turnLkey!engine!and!vehicle!test! cell!automation!and!are!also!available!as!standLalone!solutions!suitable!for!use!with!non!CP!host! test!systems.
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! Dynamometers AC, Eddy Current or Hydraulic Dynamometers Issue 4.
INTRODUCTION ! Sierra!CP!offers!a!large!range!of!various!dynamometers!which!are!suitable!for!a!wide!range!of!petrol! and!diesel!engines!and!other!rotating!test!requirements.!Sierra!CP!can!supply!motoring!and! absorbing!AC!Dynamometers!and!inverter!drives!up!to!1,000!kW!and!8,000!Nm.!Eddy!Current! Dynamometers!with!a!performance!ranging!from!5!to!3,000!kW!and!torques!up!to!20,000!Nm!can! be!offered.!Hydraulic!machines!are!also!available!to!meet!most!requirements!with!powers!in!excess! of!20MW!available.
Each!dynamometer!is!matched!to!a!3Lphase!AC!four!quadrant!regenerative!drive.!The!drive! incorporates!filters!for!high!and!low!order!harmonics!to!prevent!cross!talk!with!adjacent! equipment.!The!range!of!drives!is!physically!compact!without!sacrificing!outright!performance.
High!Torque!Dynamometers! ! ! ! ! ! ! 145kW! 249kW! 325kW! 423kW! ! Base! Max! Base! Max! Base! Max! Base! Max! Speed!rpm! 1,200! 3,150! 1,200! 3,400! 1,200! 3,500! 1,400! 4,000! Absorbing!Torque!Nm!! 1,170! 305! 1,960! 480! 2,600! 650! 2,850! 770! Absorbing!Power!kW! 145! 249! 325! 423! Free!Accl’n!rpm/sec! 10,541!up!to!Base! 10,173!up!to!Base! 9,441!up!to!Base! 9,652!up!to!Base! Rotor!Inertia!kg/m ! 1.06! 1.84! 2.63! 2.
EDDY CURRENT DYNAMOMETERS ! A!selection!of!eddy!current!dynamometers!that!Sierra!CP!can!supply!are!listed!below:! ! Max!Speed! (rpm)! 15,000! Inertia!(kg.m2)! 5! Max.!Torque! (Nm)!at!(rpm)! 17!at!2,800! 20! 40! 120!at!1,600! 150!at!2,500! 15,000! 15,000! 0.02! 0.02! 75! 450!at!1,800! 13,000! 0.05! 110! 190! 450!at!2,300! 800!at!2,300! 13,000! 12,000! 0.05! 0.15! 290! 2,000!at!1,400! 9,000! 0.6! 400! 440! 1,600!at!2,200! 800!at!4,500! 9,000! 12,000! 0.3! 0.
HYDRAULIC DYNAMOMETERS ! Sierra!CP!are!able!to!supply!a!range!a!hydraulic!dynamometers!suitable!for!most!testing! applications!up!to!20MW.!For!further!details!please!contact!Sierra!CP!with!your!specific! requirements.!ReLconditioned!dynamometers!are!also!available.
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! Valve Manifold and Cooling Post Engine Circuit Temperature Control Issue 4.
INTRODUCTION ! The!Sierra!CP!valve!manifold!assembly!is!designed!to!provide! temperature!control!of!engine!coolant,!engine!oil!and!turbo! /intercooler!(or!other!cooling!circuits)!in!engine!test!applications,! from!a!single!bed!water!feed!and!return.!The!compact!module! supports!the!rapid!control!of!coolant!flow!through!the!three! independent!bed!water!circuits.!These!circuits!are!usually! connected!to!suitably!sized!heat!exchangers,!which!in!turn!are! connected!to!the!engine!circuits.
BENEFITS AND FEATURES ! ! • • • • • • Only!two!connections!required!for!feed!and!return!water! Compact!unit!reduces!clutter!in!the!cell! Proportioning!valves!aid!accurate!flow!control! Adjustable!for!a!wide!range!of!engine!sizes! Can!be!expanded!to!offer!additional!cooling!channels!(such!as!dynamometer!cooling)! Cooling!post!can!be!mounted!on!castors!to!be!moved!around!the!cell!as!required! APPLICATIONS ! ! • • • Engine!test!work,!where!air!cooling!of!radiator!is!not!appropriate!!! Emissions!work!to!
OPTIONS ! As!standard!the!valve!manifold!is!supplied!with!1off!1!½”! circuit!for!coolant!conditioning!and!2off!¾”!circuits!for!oil! and!intercooling.!On!request!Sierra!CP!can!provide!2off! or!3off!1!½”!circuits!instead,!or!provide!valve!manifolds! with!4+!circuits.!Please!contact!Sierra!CP!with!your! specific!requirements.!! ! The!Sierra!CP!cooling!post!is!usually!built!with!a!header! tank!style!heat!exchanger!for!coolant!conditioning!and!a! lower!mounted!oil!coolant!heat!exchanger.
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! Mechanical Throttle Actuator AT12 and OM22 Issue 4.
INTRODUCTION ! The!AT12!is!an!enclosed!DC!motor!driven!fast!acting! Mechanical!Throttle!Actuator!which!can!be!used!with! Sierra!CPs!or!3rd!party!control!systems.!The!actuator! provides!performance!suitable!for!‘pull!cable!type’! throttle!applications!ranging!from!small!two!stroke! engines!up!to!heavy!duty!diesels!and!racing!engines.!! A!lever/rod!actuation!version!of!the!AT12!is!also! available!for!pedal!or!alternative!actuation! requirements.
BENEFITS AND FEATURES ! • • • • • • ! Fast!Acting! Compact!Unit! Operates!in!any!Plane! Easily!Adaptable!to!Various!Throttle!Systems! Safety!shutdown!system!(24VDC!active!signal)! Closed!loop!positional!control!with!setpoints!provided!by!CADET!or!3rd!party!control!system! OPTIONS ! As!standard!the!throttle!actuation!system!will!be!supplied!with!the!following:! ! • AT12!mechanical!throttle!actuator! • OM22!power!module,!built!into!a!wall!mountable!enclosure!(can!also!be!supplied!loose)! • 1.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! Exhaust Back Pressure and Air Valves Exhaust and Inlet Air Pressure Simulation Issue 4.
INTRODUCTION ! The!Exhaust!Back!Pressure!Valves!and!Air! Valves!are!fast!acting!ALL!Stainless!Steel! Butterfly!Valves!ranging!from!2”!–!8”! diameter,!controlled!by!an!AV12!electronic! actuator.!The!valves!are!used!for!adjusting! and!simulating!the!effective!pressure!drop! of!the!test!bed!inlet!and!exhaust!system.! The!vales!are!supplied!with!OM22!Closed! loop!control!modules,!which!adjust!the! position!of!the!valve!in!response!to!a!0L 20mA!control!signal.
SPECIFICATION ! The!specification!for!the!various!sizes!of!valves! and!electrical!requirements!are!detailed!below.
SYSTEM DESCRIPTION ! The!valves!are!actuated!by!the!AV12!actuator,!which! consists!of!a!permanent!magnet!DC!motor,!which!is! driven!through!a!worm!reduction!gearbox.!Actuator! position!feedback!is!provided!by!an!internally!mounted! servo!potentiometer!within!the!AV12,!which!is!directly! coupled!to!the!output!shaft.! ! The!unit!is!very!easy!to!install!in!existing!ductwork!due!to! its!compact!size.
OPTIONS ! There!are!a!number!of!different!valve!arrangements!available!to!the!customer;!these!are!detailed!in! the!table!below.!One!variant!should!be!selected!from!each!row:! ! Valve!and! Actuator! ! A14!–!4”!Exhaust!Valve! A15!–!5”!Exhaust!Valve! A16!–!6”!Exhaust!Valve! A18!–!8”!Exhaust!Valve! ! ! A24!–!4”!Air!Valve! A25!–!5”!Air!Valve! A26!–!6”!Air!Valve! A28!–!8”!Air!Valve! ! A12!L2”!Cable!Driven!Valve!with! AT12!Actuator!and!1.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! AirTrak Intake and Combustion Air Measurement Issue 4.
INTRODUCTION ! Sierra!CP’s!AirTrak!628S!Thermal!Mass!Flow!Meter!was!originally! designed!to!work!specifically!with!our!BG3!Particulate!Partial!Flow! Sampling!System!as!an!extremely!fast,!accurate,!and!repeatable!engine! air!intake!mass!flow!meter.!The!instrument!has!proven!to!be!an! excellent!solution!in!all!engine!testing!applications.
SYSTEM DESCRIPTION ! • • • • • • • • • • • • • ! Gases:!Air! Gas!Pressure:!120!psig!(8!barg)!maximum!design!pressure! Gas!Temperature:!14°!to!176°F!(L10°!to!80°C)! Ambient!Temperature:!32°!to!120°F!(0°!to!50°C)! Power!Requirements:!18!to!30!VDC!(regulated),!625!mA!maximum! Output!Signal! o Linear!0–5!VDC,!1000!ohms!minimum!load!resistance!or!! o Linear!4–20!mA!proportional!to!mass!flow!rate,!700!ohms!maximum!resistance! power!supply!dependent!UserLselectable.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ExhaustTrak Direct Exhaust Mass Flow Meter Issue 4.
INTRODUCTION !! With!our!roots!in!flow!measurement,!Sierra!has!entered!the!market!with!an!innovative!flow!meter,! named!ExhaustTrak,!to!handle!this!tough!application.!ExhaustTrak!is!directed!toward!satisfying! customer!requirements!for!a!rugged,!accurate!and!fast!solution!for!direct!exhaust!mass!flow! measurement,!and!is!specifically!designed!for!transient!cycle!flow!rate!measurement.
system!response,!created!by!sample!line!length!and/or!individual!analyzer!response!times,!relative! to!an!engine!operating!event!such!as!an!acceleration!or!load!acceptance.!!This!approach!may!be! further!complicated!by!required!changes!in!engine!exhaust!mass!flow!rate!due,!for!example,!to!an! engine!power!rating!change.!Further,!modifications!of!the!exhaust!system!consist!which!may!affect! intake!or!exhaust!stack!volumes,!or!a!change!in!after!treatment!device!status,!may!be!particularly! problematic.
mechanism!that!can!be!either!manually!or!automatically!activated!to!address!any!buildLup! concerns.! ! GENERAL SPECIFICATIONS !! • • • • • • • !! Accuracy!<1.5%!reading! Pneumatic!signal!delay!due!to!porous!rings!is!less!than!10!milliseconds! Permanent!pressure!loss!is!less!than!10%!of!deltaLP! ExhaustTrak!is!customLsized!by!exhaust!pipe!diameter!and!engine!back!pressure! requirements.
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FUEL SYSTEMS ! Sierra!CP!has!a!complete!range!of!measurement!and!conditioning!solutions!for!fuel!and!other! liquids!and!gasses!associated!with!engine!and!vehicle!testing.!With!over!40!years!of!experience!in! fluid!flow!measurement,!Sierra!CP!brings!tremendous!expertise!and!passion!to!this!sector.
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! FuelTrak 1000 & 3000 Gravimetric Fuel Measurement Issue 4.
INTRODUCTION ! The!FuelTrakL1000!and!3000!Gravimetric!Fuel! Measuring!Systems!are!compact,!high!precision! instruments!for!measuring!specific!fuel! consumption!of!diesel!and!petrol/gasoline!engines.! The!FuelTrakL1000’s!and!3000’s!wetted!parts!are!all! stainless!steel!and!Viton,!enabling!standard! reference!and!ethanol!based!fuels!to!be!used.! ! The!FuelTrak!range!is! controlled!and! monitored!either!by! a!CADET!V14!host,!or! the!CADET!V14!Fuel! Controller,!which!is!detailed!in!a!separate!datasheet.
BENEFITS AND FEATURES ! ! • • • • Holding!tank!deLgasses!spill!back!fuel! Self!calibrating!with!integrated!mass!calibration!capability! When!run!in!hardware!mode!acts!as!a!header!tank! Small!size,!wall!or!post!mountable! APPLICATIONS ! ! • • • • Specific!Fuel!Consumption!Measurements! Special!Fuels!Research!and!Development! Fuel!Additives!and!Resultant!Effects! Emissions!Certification!Work! SYSTEM DESCRIPTION ! The!FuelTrakL1000!and!3000!systems!are!controlled!and!monitored!by!CADET!V14,!this!record
OPTIONS ! The!table!below!shows!the!various!configurations!and!options!available!with!the!FuelTrak! gravimetric!flow!meters.!One!option!from!each!row!should!be!selected!(multiples!can!be!selected! from!‘Additional!Equipment’).!Images!are!for!reference!only.
! • • • • Fuel!fill!solenoid!valve!(for!installation!on!the!incoming!fuel!supply)!with!1!metre!loom!to!the! control!module! 1!metre!signal!loom!between!FuelTrak!Module!and!Control!Module! 5!metre!power!loom!between!Control!Module!and!110/230VAC!single!phase!power!supply! (3!phase!required!with!FCUL3000)! 10!metre!loom!between!Control!Module!and!Automation!System! ! Nonstandard!loom!lengths!are!available.!Please!make!Sierra!CP!aware!of!this!on!order!placement.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! FuelTrak Transient 100 & 300 Continuous Fuel Consumption Measurement Issue 4.
INTRODUCTION ! The!Transient!FuelTrak!fuel!consumption!meter!is!a!technical!development!of!the!Sierra!CP!FuelTrak! 1000!gravimetric!fuel!measurement!system.!The!FuelTrak!Transient!enables!continuous!and! dynamic!fuel!flow!measurement!as!well!as!offering!fuel!density!measurement.! ! The!meter!utilises!two!measuring!techniques!to!determine! and!confirm!the!fuel!consumption!of!the!engine;!gravimetric! and!coriolis.
BENEFITS AND FEATURES ! • • • • • • • ! • • High!accuracy!measurement! Continuous!fuel!measurement!capability! Two!measuring!techniques!allows!cross!referencing!for!calibration! Fuel!density!measurement! Bubble!separation!on!return!line!type!fuel!systems! Stainless!Steel!wetted!parts!for!reference!and!special!fuels! Integrated!fuel!temperature!conditioning!heat!exchangers!(Supply,!feed!to!engine!and! spillback!from!engine).
OPTIONS ! The!table!below!shows!the!various!configurations!and!options!available!with!the!FuelTrak!transient! flow!meters.!One!option!from!each!row!should!be!selected!(multiples!can!be!selected!from! ‘Additional!Equipment’).!Images!are!for!reference!only.
! *FCUL1000!is!suitable!for!the!FuelTrak!100.!FuelTrak!300!can!function!with!either!FCUL1000!or!FCUL 3000,!depending!on!the!temperatures!and!maximum!fuel!supply!and!spillback!rates!required.! Please!contact!Sierra!CP!with!your!specification!for!further!details.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! Fuel Conditioning Units 1000 & 3000 Fuel Temperature Control Issue 4.
INTRODUCTION ! The!Sierra!CP!Fuel!Conditioning!Unit!is!designed!to! enhance!the!features!of!the!FuelTrakL1000,!3000,! Transient!FuelTrak!or!other!3rd!party!Fuel! Measurement!Systems.!The!FCU!provides!computer! controlled!fuel!supply!temperatures,!to!either! combat!extreme!ambient!conditions,!high!fuel! return!line!temperatures!or!to!match!specific!test! requirements.
SYSTEM DESCRIPTION ! The!Control!Enclosure!marshals!the!mains!switching!and!i/o!associated!with!the!control!of!the! Process!Enclosure.!The!Process!Enclosure!requires!one!set!of!Feed!and!Return!lines!for!the!process! fluid!circuit!and!one!for!the!Chilled!Water!Circuit,!therefore!minimising!the!inLcell!pipework.!The! temperature!in!the!header!tank!is!maintained!or!adjusted!by!directing!the!conditioning!loop!intake! to!one!of!two!circuits.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! Fuel Pressure Regulation Issue 4.
INTRODUCTION ! The!Sierra!CP!Fuel!Pressure!Regulation!Unit!has!been! designed!to!allow!a!range!of!settable!fuel!delivery! pressures!to!be!achieved.!The!pressure!setpoint!inputted! by!the!customer!(either!directly!entered!into!CADET,!or! sent!to!the!fuel!controller)!is!controlled!by!an!electro! pneumatically!actuated!regulator!valve!and!an!pressure! transducer!to!provide!pressure!feedback.!A!PRT!probe!is! also!integrated!to!provide!fuel!temperature!feedback.
SYSTEM DESCRIPTION ! The!regulator!consists!of!a!constant!flow!automotive!fuel!pump.!The!fuel!flows!from!the!pump!to! the!manifold!block!which!is!used!to!mount!the!pressure!and!temperature!sensors.!The!constant! flow!rate!from!the!pump!is!typically!greater!than!the!engine!consumption.!This!over!supply!of!fuel! results!in!an!increase!in!pressure!seen!at!the!regulator.!When!the!resultant!pressure!is!achieved!the! excess!fuel!is!byLpassed!through!the!regulator!to!the!fuel!meter!return!line.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! Fuel Dosing Rig Precision Fuel Additive Control and Consumption Measurement Issue 4.
INTRODUCTION ! The!SierraLCP!fuel!dosing!rig!is!designed!to!supply!a!continuous,!precise,!controllable!dose!of! additive/additives!to!fuel!for!delivery!to!an!engine!or!vehicle!under!test.!The!system!is!designed!to! provide!a!continuous!supply!of!dosed!fuel,!with!high!precision!fuel!consumption!measurement.!The! dosing!rig!measures!a!batch!of!fuel!to!the!required!dosing!ratio.
SYSTEM DESCRIPTION ! The!fuel!dosing!system!is!based!on!two!of!Sierra!CPs!high!precision!FuelTrakL1000!gravimetric!fuel! measurement!meters.!The!dosing!rig!is!connected!to!the!customer’s!standard!fuel!supply!system.! Prior!to!testing!a!stainless!steel!storage!vessel!is!filled!with!either!a!highly!dosed!fuel!mixture!(of! known!dosed!ratio)!or!the!pure!additive/additives!mixture,!dependant!on!the!final!additive! concentration!required.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! Independent Fuel Controller Issue 4.
INTRODUCTION ! The!Sierra!CP!Independent!AKLFuel! Controller!has!been!designed!in!response! to!the!requirement!to!use!models!from! Sierra!CP’s!comprehensive!range!of!Fuel! Measurement!and!Conditioning!system! with!non!Sierra!CP!host!controllers.!This! controls!Sierra!CP!fuel!equipment!and! relays!data!to!3rd!party!host!controllers!via! an!Ethernet!TCP/iP!connection.!The!fuel! controller!has!been!packaged!into!a!4U!19”! unit!which!can!be!rack!or!desk!mounted.
SYSTEM DESCRIPTION ! The!Fuel!Controller!is!based!on!the!Sierra!CP!CADET!control!hardware!with!an!integrated!small! format!industrial!PC,!based!on!the!latest!specification!of!the!standard!CADET!system!controller,!! running!a!‘component’!version!of!CADET!V14!software.!This!controls!all!aspects!of!the!Fuel!Meters! and!Conditioners!to!the!same!high!performance!standards!of!a!full!CADET!system,!but!allows! interfacing!to!alternative!test!system!hosts!using!an!AK!protocol!over!Ethernet!TCP/iP.
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TEST CELL SERVICES ! Driven!by!increasingly!stringent!legislation!around!the!world,!particularly!in!the!area!of!emissions! validation!and!development,!there!is!a!need!to!minimize!test!variability!by!reducing,!controlling!or! eliminating!all!external!influences!that!effect!the!accuracy!and!repeatability!of!test!results.
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! !! Combustion Air Handling Unit (CAHU) Temperature, Pressure and Humidity Issue 4.
INTRODUCTION ! The!Combustion!Air!Handling!Unit!(CAHU)! conditions!the!available!ambient!air!supply!and! generates!output!air!of!controllable!pressure,! temperature!and!humidity!levels!(humidity! control!optional).!Humidity!is!controlled!by!the! introduction!of!steam,!either!from!an!internal! generator!or!a!customer!steam!supply.
SPECIFICATION ! Below!are!the!specifications!for!the!standard!CAHU!units.!Please!note!that!custom!CAHUs!are! possible!with!expanded!delivery!conditions,!flow!rates,!accuracies!and!physical!layouts.!Please! contact!Sierra!CP!with!your!specification!for!further!details.!Details!on!Sierra!CPs!high!performance! ‘Motorsport’!specification!CAHU!can!be!found!in!a!separate!datasheet,!available!on!request.
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 100! Standard!CAHU! Delivery!Range! Minimum!Achievable!Humidity! Level!With!1°C!Chilled!Loop! Maximum!Ambient! Enthalpy!90kJ/kg! STANDARD DELIVERY RANGE
BENEFITS AND FEATURES ! • • Control!of!Pressure,!Temperature!and!Humidity!levels! o Only!conditions!air!for!the!engine! Simulate!alternative!air!conditions,!such!as:! o Race!Circuits! o Foreign!Countries!Ambients! Fast!condition!response!for!transient!work! o All!potential!air!is!conditioned!ready!for!use! Self!contained!unit! Send!SetLpoints!from!an!Existing!Test!Controller! Two!sided!access!for!ease!of!installation,!operation!and!servicing! Four!sizes!as!standard,!1000,!1500,!2500!and!3500!kg/Hour,! o P
SYSTEM DESCRIPTION ! The!most!accurate!method!of!conditioning!the!air!to!the!required!level!is!to!control!the!reLheating! and!reLhumidification!of!the!ambient!air!to!achieve!the!necessary!output.!In!order!to!do!this,!the! ambient!air!is!passed!through!the!primary!coil!and!is!cooled!to!a!base!temperature!and!humidity! level.!This!initial!cooling!of!the!air!causes!a!large! proportion!of!the!water!content!to!condense!out.!! The!result!is!cold!relatively!dry!air!that!can!then!be! conditioned!by!the!CAHU.
OPTIONS ! Sierra!CP!can!offer!custom!designed!CAHUs!to!meet!specific!customer!requirements!such!as:! • Expanded!temperature!and!humidity!ranges! • Altitude!simulation!with!low!pressure!ranges! • Weatherproofed!units!for!external!installation! • Enhanced!transient!stability!for!motorsport!applications! • Custom!intake/extract!port!locations! ! Sierra!CP!can!offer!various!combustion!air!handling!units,!such!as!Temperature!or!Temperature!and! Humidity!versions.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Ventilation Systems Test Cell Conditioning Issue 4.
INTRODUCTION ! Sierra!CP!offer!bespoke!cell!ventilation!solutions!for!automotive!test!cells.!Ventilation!systems!can! be!designed!to!fit!around!design!constraints!of!existing!test!cells,!or!can!be!designed!as!part!of! complete!turnkey!test!cell!installations.!Sierra!CP!ventilation!systems!generally!provide!test!cell! temperature!and!pressure!regulation.
SYSTEM DESCRIPTION ! Sierra!CP!can!supply!recirculation! ductwork!as!well!as!traditional!intake! and!extract!ventilation!systems.!On!a! colder!day!this!can!reduce!the!amount! of!duty!required!from!the!heater! elements,!as!ambient!air!can!be!mixed! with!reLcirculated!air!(warmed!by!the! engine)!to!allow!a!stable!cell! temperature!to!be!maintained.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Test Cell and Facility Services Products and Services for Turnkey Installations Issue 4.
INTRODUCTION ! Sierra!CP!are!able!to!supply!and!install!the!cell!support!services!required!for!test!cell!installations;! either!as!separate!items,!upgrades!or!as!part!of!a!turnkey!project.!This!includes!bed!and!chilled! water!circuits,!ventilation!systems!(see!separate!datasheet),!exhaust!extracts!systems,!compressed! air,!steam!generation!and!fire!suppression!systems.!Sierra!CP!can!also!design!and!construct!test! cells!in!either!blockwork!or!prefabricated!panels.
CHILLER UNITS ! Sierra!CP!are!able!to!provide!a!range!of!chilled!plant!equipment,!ranging!from!3kW!(rated!for!the! Sierra!CP!FCUL1000)!to!100kW+!(rated!for!the!larger!CAHU!and!vent)!to!2,000kW!(multiple!cell! facilities)!heat!extraction.!The!chiller!units!are!typically!used!to!provide!a!chilled!loop!(generally!1ᴼC)! required!for!CAHU,!FCU!and!ambient!air!cooling!in!ventilation!systems.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! Transient Single Cylinder Test Systems Issue 4.
INTRODUCTION ! Sierra!CP!have!developed!a!complete!range!of!test!cell!equipment!specially!tailored!towards!single! cylinder!engine!research!and!development.!Sierra!CP!offer!a!range!of!standard!transient!AC! dynamometers!with!regenerative!drive!to!allow!transient!motoring!and!absorbing!of!a!single! cylinder!engine.!The!engine!and!dynamometer!are!generally!mounted!to!a!common!test!frame.! ! Sierra!CP!offer!a!range!of!complimentary!sub!systems!to!enhance!the!testing!of!single!cylinder! engines.
AC DYNAMOMETER AND INVERTER DRIVES ! Sierra!CP!offer!AC!Dynamometers!and!regenerative!drives!are!suitable!for!motoring!and!Absorption! of!the!engine.!When!in!Absorption!mode!the!drive!!!regenerates!the!electrical!power!back!into!the! main!electrical!supply.!This!is!deemed!the!most!efficient!method!of!absorbing!the!energy!from!the! engine!as!heating!does!not!occur.
CADET CONTROL AND DATALOGGING SYSTEMS ! Sierra!CP!single!cylinder!test!beds!are!usually!supplied!with!a!full!CADET!V14!control,!automation! and!datalogging!system.!CADET!V14!has!been!developed!to!create!a!single!source!integrated,! flexible!solution!for!engine!test,!research!and!development.!When!used!in!conjunction!with!other! products!from!the!Sierra!CP!range!it!provides!an!excellent!basis!for!the!specific!needs!of!single! cylinder!engine!testing!and!research.
CADET!Integrated!Safety!Features! ! Many!safety!features!are!built!into!the!CADET!hardware!and!the!software!to!protect!the!test!bed,! dynamometer!and!the!engine!under!test.!The!system!does!not!simply!use!a!3rd!party!datalogging! system!with!computer!monitored!protection,!Sierra!CP!offer!dedicated!protection!for!key!channels! and!systems!on!the!test!bed,!with!8!computer!independent!shutdown!channels.! ! Each!CADET!channel!(physical!or!calculated)!can!be!set!with!its!own!Low!/!High!Alarm!and! Shutdown!levels.
switched!12V/24V!DC!terminals,!which!switch!from!a!common!power!source!connection!such!as!an! inLcell!power!supply!or!battery.!These!can!be!switched!on!or!off!with!the!associated!Digital!Output! during!tests.!They!are!typically!linked!to!ECU,!Fuel,!Glowplugs!and!Ignition.!These!modules!can! either!be!supplied!in!an!engine!electrics!box,!or!integrated!into!the!datalogging!transducer!layout.
OIL AND COOLANT CONDITIONING ! Typically!single!cylinder!engines!do!not!have!oil!or!coolant!conditioning!and!circulating!abilities!as! standard,!thus!Sierra!CP!have!developed!an!oil!and!coolant!conditioning!unit.! ! The!cooling!system!allows!the!temperature!of!both!coolant!and!oil!to!be!conditioned!by!either! heating!or!cooling!the!circulating!fluids.!Oil!pressure!control!on!the!circuits!supply!lines!can!be! included!as!an!option.!This!is!achieved!by!having!a!bleed!valve!installed!in!the!supply!pipework.
Standard!Supply,!for!the!conditioning!units! ! • Heaters! • Heat!exchanger!for!cooling!modes! • Control!box! • Flexible!hoses!to!connect!to!the!engine!circuits! • Circulating!pumps! • Sump,!aeration!tanks! • Level,!pressure!and!temperature!monitoring! • 3way!control!valve!for!cooling!circuits! Typical!Cooling!system!specifications! ! Oil! Max!Oil!Flow!Rate! Typical!Oil!Supply!Pressure! ! 5!l/min! 4!bar!gauge! Suggested!Oil!Delivery!Temperature! Maximum!Heat!Rejection!in!Oil! 80!L!100°C! 5kW!(Δ28°C!at!Max
HIGH PRESSURE BOOST RIG ! Sierra!CP!are!able!to!provide!a!boost!rig!that!will!allow!dynamic!control!of!pressure!and!steady!state! control!of!temperature!of!the!engine!supply!air,!to!simulate!turbo!charger!conditions.!High!pressure! air!is!provided!by!a!compressor!unit!(usually!supplied!by!the!customer).!The!boost!rig!conditions!the! temperature!of!this!air!by!passing!it!though!a!fluid/air!heat!exchanger,!whereby!the!fluid!circuit!has! been!suitably!conditioned.
Standard!Delivery!Specification! ! Delivery!Pressure! Pressure!Control!Accuracy!(Assuming! consumption!remains!constant)! 1.2!–!5!bar!Absolute!(Dependant!on!Compressor)! Maximum!Flow!Rate! Maximum!Temperature! 700!kg/hr*! 60°C! Minimum!Temperature! Compressor!Supply!Temperature!(Standard!Unit)! 6°C!(Unit!with!Cooler!and!1°C!Chilled!Loop)! Steady!State!Temperature!Accuracy!! ±1°C! ±0.
OPTIONS ! Sierra!CP!are!also!able!to!adapt!standard!equipment!to!meet!any!specific!requirements.!Please! contact!Sierra!CP!for!further!details.!Sierra!CP!offer!a!wide!range!of!test!cell!equipment!and!services! which!will!complement!the!single!cylinder!test!equipment.!Further!information!can!be!found!in!the! specific!datasheets!which!are!available!on!request.!! ! Ventilation!Systems! Sierra!CP!can!supply!bespoke!ventilation!systems!for!existing!and!new!test!cells.
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VEHICLE TESTING SYSTEMS ! Since!the!midL1990's,!Sierra!CP!have!been!a!global!supplier!of!chassis!dynamometer!solutions!for!a! wide!variety!of!Vehicle!Test!applications.!We!can!provide!chassis!dynamometers!to!suit!most! customer!test!cell!specifications.!Sierra!CP!are!able!to!offer!custom!designed!dynamometers!to!suit! vehicles!from!motorbikes!to!trucks!and!tracked!vehicles!including!combination!test!sets!that! accommodate!a!wide!range!of!vehicle!types!in!a!single!installation.
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Chassis Dynamometers Issue 4.
INTRODUCTION ! Sierra!CP!design!and!manufacture!custom! dynamometers!for!vehicles!ranging!from! motorbikes!and!heavy!duty!equipment!to! tracked!vehicles.!As!a!global!provider!of! custom!systems!flexible!enough!to!meet!a! range!of!test!specifications!and!budgets,! we!can!provide!chassis!dynamometers!to! match!most!customer!test!cell! installations.!In!addition!to!custom!designs,! a!range!of!‘Standard’!pre!designed!roller! sets!are!available!in!a!range!of!sizes!please! contact!Sierra!CP!for!further!details.
SYSTEM DESCRIPTION ! Pre!Designed!Roller!Sets! ! Sierra!CP!have!a!range!of!pre! designed!roller!sets!which!can!be! easily!integrated!into!a!test!cell.!48! inch!roller!independent!or!twin!roller! systems!are!available,!suitable!for! emissions!or!climatic!testing.!Multiple! axles!can!be!combined!with!wheel! base!adjustment!to!allow!vehicles! with!more!than!one!driven!axle!to!be! tested.!All!control!is!via!a!standard! CADET!V14!cabinet!which!will!be! configured!for!a!number!of!operation! modes.
! Sierra!CP!are!used!to!providing!custom!solutions!to! fit!existing!site!requirements,!such!as!existing!pit! dimensions!or!building!restrictions.!Complete! turnkey!installation!can!be!offered!as!necessary.! ! All!chassis!dynamometers!are!controlled!by!CADET! V14!CDS,!which!offers!precision!and!flexible!control! of!your!chassis!dynamometer.! ! For!further!information!please!contact!Sierra!with! your!testing!requirements.
OPTIONS ! Sierra!CP!offers!a!range!of!integrated!System!components!and!products!to!support!the!complete!operation! of!a!Chassis!dynamometer!Facility.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! Motorcycle Chassis Dynamometer Issue 4.
INTRODUCTION ! Sierra!CP!have!developed!a!range!of!Modular! Chassis!Dynamometers,!controlled!by!CADET!V14! CDS!software,!which!have!been!designed!and! developed!to!provide!a!cost!effective!solutions!for! the!testing!of!motorcycles!&!scooters!on!the!single! roll!set!and!threeLwheeler,!Quad!bike!and!sub! compact!city!type!vehicles!on!the!twin!roller! version.!For!Specific!High!performance!motorcycles! alternative!dynamometer!options!are!available.
SYSTEM DESCRIPTION ! Rollers! ! The!roller/s!are!manufactured!as!a!steel!fabrication!and!are! capable!of!supporting!the!axle!loads!detailed.!The!roller! mass!is!designed!to!provide!the!base!inertia!of!the! dynamometer;!after!stress!relieving!it!is!machined!and! balanced.! ! A!pneumatically!actuated!brake!is!incorporated!into!the! system!and!acts!upon!the!stiffening!webbing!of!the!roller.! This!is!designed!for!use!as!a!parking!brake!only.
! CADET!V14!Chassis!Dynamometer!Control!System! ! The!CADET!system!will!be!supplied!with!the!following!major!assemblies:! ! • Control!Cabinet!25U,!19”!cabinet!housing!the!control!hardware!and!system!controller! • Operator!Interface!Monitors!and!Winged!Keyboard,!providing!a!display!of!all!data!and! manual!control! • InSCell!Equipment!providing!the!system!interfaces!with!the!chassis!dynamometer!and! vehicle! ! Software! ! Typically!the!following!software!will!be!installed!on!the! system!controller.
OPTIONS ! Sierra!CP!offers!a!range!of!integrated!System!components!and!products!to!support!the!complete! operation!of!a!Chassis!dynamometer!Facility.! ! • TLS!–!facility!management!&!emissions! reporting!software! • Drivers!Aid!! • Robot!Driver! • Hand!Grip!Throttle!Actuator! • Auto!Fuelling!/!Measurement!system! • Headwind!fans!to!simulate!air!speeds! ! Further!details!can!be!found!in!the!relevant! datasheets,!or!are!available!on!request.
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! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! Vehicle Robot Vehicle Automation for Emissions and Endurance Issue 4.
INTRODUCTION ! The!Sierra!CP!Vehicle!Robot!is!designed!for! standLalone!or!integrated!actuation!of!a!vehicle! under!test!on!a!chassis!dynamometer.!The! robot!consists!of!a!pedal!module,!gear!shift! module!and!control!module.!! ! The!pedal!module!consists!of!up!to!three!DC! rotary!pedal!actuators!which!can!be!easily! installed!in!the!foot!well!of!a!vehicle!under!test.! Clamps!are!supplied!to!attach!to!the!pedals,! with!a!variable!length!strut!connecting!between! the!actuator!and!clamp.
SPECIFICATION ! Robot!Specification! Operating!Temperature! Units! °C! Value! L10!to!+50*! Maximum!Shift!Force!(Clutch!Protected)! N! 60!with!350!mm!arms!(Shorter!arms! are!available!for!increased!force)! Maximum!Gear!Travel! mm! 250!(in!X!or!Y)! Typical!Gear!Shift!Time! ms! Gear!Module!Weight! kg! 440! 19!(can!also!be!split!into!9kg!and! 10kg!modules)! Gear!Actuation!Module! Pedal!Actuation!Module! Maximum!Pedal!Force! Maximum!Pedal!Travel! N! mm! 250! 250! Typical!Shift!Time! ms! Modul
SYSTEM DESCRIPTION ! The!Vehicle!Robot!is!made!up!of!the!following!! subLassemblies:! • • • • • Torso!shift!module.!!XLaxis!gear!shift!position! Torso!select!module.!!YLaxis!gear!select!position! Pedal!Box! o Throttle! o Clutch!–!optional! o Brake!–!optional! Ignition!actuation!module!–!optional! 12U!19”!Control!Cabinet! o Electronic!Control!Unit.
Torso!Module! ! The!Torso!module!is!split!into!two!sections!that!are! locked!together!in!use.!!These!contain!the!Shift! (leftLright!XLaxis)!and!the!Select!(frontLback!YLaxis)! modules.!!One!person!may!split!the!torso!to!enable! lighter!installation!of!the!robot.! ! The!Torso!gear!selector!module!has!been!designed! around!the!general!envelope!of!a!human!driver!to! allow!it!to!be!used!in!the!majority!of!vehicles.
The!throttle!is!automatically!mapped!to!determine!the!required!throttle!positions!during!the!gear! changes.!!This!is!achieved!under!the!control!of!the!software!with!the!engine!running.!!A!signal!is! required!which!represents!the!engine!RPM.!Both!the!clutch,!and!the!brake!biteLpoints!are!taught!to! the!system!by!the!press!of!a!single!key!as!it!is!determined!manually.
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EMISSIONS PARTICULATE MEASUREMENT EQUIPMENT ! Our!mission!is!to!be!your!engine!particulate!emissions!specialist.!We!give!our!customers!throughout! the!world!a!complete!engine!PM!emissions!sampling!solution!using!our!flagship!BG3!as!the!hub!of! this!effort.!! ! Our!goal!is!to!develop!worldLclass!Particulate!Flow!Dilution!(PFD)!systems!that!provide!the!highest! quality!sample!data,!greatly!increase!testing!efficiency,!drastically!reduce!costs,!and!improve!testL cell!safety.
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! BG3 Partial Flow Dilution Particulate Sampling System Issue 4.
INTRODUCTION ! In!use!since!2004,!BG3!Partial!Flow!Dilution!(PFD)!technology!effectively!performs!engine!research! and!development!to!accurately!sample!exhaust!PM!(Particulate!Matter)!emissions!over!both!steady! state!and!transient!test!cycles.!On!January!7,!2011,!PFD!was!signed!into!law!and!is!now!included!in! the!United!States!Federal!Register!as!a!legally!recognized!alternative!method!to!CVS!in!40!CFR!part! 1065!for!engine!certification.
BG3!United!States!EPA!Approval!(January!2011)! ! BG3!PFD!technology!has!been!in!use!since!2004!effectively!performing!engine!research!and! development!to!accurately!sample!exhaust!particulate!matter!emissions!over!both!steady!state!and! transient!test!cycles.!On!January!7,!2011,!PFD!was!signed!into!law!and!is!now!included!in!the!United! States!Federal!Register!as!a!legally!recognized!alternative!method!to!CVS!in!40!CFR!part!1065!for! engine!certification.
! • • Dilution!Air!Supply:!90!PSI,!3.5!CFM!(6.
BG3!is!an!integrated!product!that!incorporates!two!flow!devices!supplying!and!extracting!gas!used! in!the!dilution!tunnel!design.!The!mass!flow!of!raw!exhaust!sampled!at!the!probe!is!the!difference! between!the!flow!rates!of!the!dilution!and!total!mass!flow!meters.!This!sample!flow!is!calculated!as! the!difference!between!the!total!and!dilute!flow.
Tracker!Screen:!The!engineer!will!find!the!calibration!of!the!system!very!manageable!and!efficient.! The!fully!automated!calibration!routine!can!be!performed!at!any!time.
! • • ! Step!3:!Collect!the!Sample.!Press!the!standby!button,!the!BG3!automatically!collects!the! sample.! Step!4:!Sample!Complete.!Remove!filter!pairs!for!PM!mass!measurement.!A!filter!weight! calculation!sheet!is!available!for!the!engineer’s!convenience.
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! ! ! Innovate to Differentiate. SootTrak Laser Based Real Time Emissions Particulate Sampling Issue 4.
INTRODUCTION ! Sierra!CP’s!SootTrak™!laser!measures!realLtime!diesel!engine!soot!particle!mass!emissions!and! performs!characterization!of!average!soot!agglomerate!size,!number!and!surface!area.!SootTrak! provides!researchers!and!engine!developers!the!accurate!information!they!require!about!particle! transport.
• • • • • • ! ! Correlation!to!Gravimetric!Filter!Measurements!L!A!fundamental!model!(patent!pending)!is! used!to!relate!the!fast!and!sensitive!optical!scattering!measurements!of!SootTrak!to! equivalent!mass!concentration!measurements!at!EPALdefined!partial!dilution!conditions! provided!by!the!BG3.!Concentration!measurements!agree!with!gravimetric!filter!results!(see! Correlation!Testing!section).
SYSTEM DESCRIPTION ! While!there!are!other!scattering!techniques,!the! SootTrak!method!is!unique!in!calculating!soot! concentration!from!first!principles!(patent!pending),! without!the!need!for!gravimetric!calibration.!SootTrak! operates!at!near!ambient!pressure!to!prevent! evaporation!of!volatile!and!semiLvolatile!particles,!and! it!requires!no!consumables.
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Innovate to Differentiate. ! ! ! ! ! ! ! ! ! ! ! ! ! ! BG3 Particulate Sampling Support Equipment Issue 4.
INTRODUCTION ! Sierra!CP!manufactures!a!complete!offering!of!gravimetric!particulate!filter!sampling!and!postL processing!solutions!to!complement!our!BG3!Partial!Flow!Dilution!technology.!Our!filter!processing! solutions!assure!that!this!critical!final!step!of!weighing!the!filter!is!done!with!precise!accuracy.!It!is! said!that!50%!of!data!variability!is!explained!by!poor!post!sample!filter!processing.!Our!goal!is!to! drastically!reduce!the!effect!of!poor!post!filter!processing!procedures.
FILTER WEIGH CHAMBERS ! After!a!high!quality!gravimetric!sample!is!made!by! BG3,!it!is!extremely!important!to!assure!high!quality! postLprocessing!procedures.!Up!to!50%!of!any!error! in!data!can!be!attributed!to!these!extremely! important!procedures.!Our!filter!postLprocessing! weigh!chamber!is!a!compact,!complete,!readyLtoL run!package!that!allows!sample!filter!media!to!be! accurately!weighed!per!regulatory!requirements.
AUTOMATIC FILTER CHANGER ! Our!Automatic!Filter!Changer!is!a!plugLandLplay!cartridgeLstyle!device!that!allows!the!engineer!to! complete!several!tests!in!succession.!It!works!seamlessly!with!BG3!Partial!Flow!Dilution!technology! to!fully!automate!particulate!collection!to!greatly!improve!testing!efficiency!and!more!importantly,! testing!safety.!The!system!can!hold!up!to!22!single!filter!cartridges!(dependent!on!filter!size,!47mm,! 70mm,!or!90mm).
CONSTANT VOLUME SAMPLER UPGRADE ! The!Constant!Volume!Sampler!(CVS)!systems!have!been!an!accepted!method!for!measuring!both! gaseous!and!particulates!for!engine!manufacturers!for!many!years.!Over!that!time,!specifications! for!the!CVS!systems!have!changed!significantly.! ! Sierra!CP!Engineering!Automotive!Test!Group!has!identified!the!need!to!upgrade!older!CVS!systems! to!meet!the!current!specifications!and!requirements!for!both!chassis!and!engine!dynamometer! testing.
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! ! ! ! ! GLOBAL LOCATIONS ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! www.sierraScp.
