Mobile dynamometer for power measurement of industrial engines
We had a request for a mobile PTO dynamometer for benchmarking Agricultural, Construction and Industrial engines.
MadsTech Engineering made the solution!
We had a request for a mobile PTO dynamometer for benchmarking Agricultural, Construction and Industrial engines.
MadsTech Engineering made the solution!
Project - Mobile dynamometer for testing agricultural, construction and industrial engines:
1: Mobile trailer mounted system
2: Brake-system dyno design
3: Full curve auto-measurement up to 1000hp
4: Full customizable control system
5: High longterm engine load performance
6: Maximal total mass 2000kg
7: Minimal maintenance
8: Changeable input shafts
Best option - Eddy Current retarder system design.
Eddy Current brake modules creates drag by changing direction of the magnetic poles inside the steel-flywheels when rotating, by the electrical coils.
This creates friction which will heat up the flywheels. As the flywheels are getting hotter, the magnetism is getting lower, and maximum possible brake-torque will reduce.
Each brake module have a capacity of maximum 4700Nm and support up to 4000rpm.
Electrical power usage for full braking capacity include cooling is 12kW.
To maximize the braking torque and brake-duration, an optimal cooling system is important.
The video is showing the internals of the mobile trailer where two retarders are braking at full capacity which equals 750kW of heat generated.
The color is describing the temperature of the air, where red is hottest.
To increase the heat dissipation, a forced induction of air is ensured by 2 big ventilators flowing 13.000m3 of air per hour, mounted in the front of the trailer.
The most important part of removing heat is to make the airflow as turbulent as possible.
Design is optimized live, by changing the placement of the ventilators, and the flow output size and location. The result in cooling capacity is immediately displayed, which ensures absolutely best cooling performance.
Notice that this design creates a circulating flow of air all around the retarders at the bottom of the trailer.
Differences as temperature in and out of the system is considered, and also local air velocity and turbulence specially near loadcells, which are critical for ensuring stable dyno measurements.
The shafts are high loaded by the torque generated between the engine and the retarders. The Stress and Safety factors are simulated to ensure longterm durability, without breakdown.
In total the retarders have a brake capacity of 9400Nm, which the input shaft will be loaded by.
The color of the simulation is describing the internal material stress.
The input shaft is made by heat-treated Cromax 280X steel which is heat and corrosion resistant.
Under full load the highest loaded axle will still archive a safety factor of 2.5, which will ensure lifelong durability, also when material fatigue is taken into consideration.
The frame is designed with priority of keeping the mass low, and the strength high.
The video is simulating two different load scenarios.
1: Emergency braking of the towing vehicle. The mass of the retarders are nearly 1000kg in total. The frame must be able to resist any kind permanent deformation that will appear of normal use according to the machinery regulation.
This simulation ensures that there will be no permanent deformation after an vehicle emergency brake down. In other words, a real-life safety factor of almost 6 is archieved if towing vehicle is making an emergency brake down.
2: Retarders braking down by full torque. This will put a force of almost 20.000N directly on the loadcell mounts.
This simulation verifies that the dynamometer can be used again and again without having any deformation of the loaded parts of the frame.
The control system is designed to control two Eddy Current retarders.
The control system ensures a stable measurement under full PID control, which ensures stable automatic measurements, no matter if a 50hp engine, or an 600hp engine is being measured.
The dyno system includes environmental factors in consideration for accurate power measurement, no matter outside air temp, humidity or pressure.
Simulation of field driving, manually controlling engine steady-state setpoints, and auto measurement of the engine is possible.
MadsTech products are in full conformity with EU Regulation.
All machines are equipped with CE marking
Before releasing any product on the market, the information package is verified. This ensures maximum safety for end customers. This means that our machine fulfill RISK analysis, Instruction manual and spare catalogs, Machine safety warnings, and a lot more according to EU regulations!
This PTO dyno is in full conformity with:
2006/42/EU
2023/1230/EU
2014/35/EU
ISO 12100
ISO 3600
EN 60204
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