How to Build an Engine Test Bed?

Hi, I used to assist some classmates in their work in my university engines lab. It was a quite simple test bed, and we used to test fuel from our brazilian supplier. It was very funny and worked very well. I am also currently responsible for some test stand projects in my company, including jet engines, with different data types to be registered.

This is normally a long time project, specially if you're talking about a customized equipment. Follow the standard project management rules: First of all, define a workscope, and follow it. If your boss try to push you something else during the work, do it after your original workscope is complete (unless it's a simple thing - which normally is not). Then, organize your workscope according your schedule.

About the instruments, go for the consolidated manufacturers. There's a miryad of suppliers that will offer instruments for good prices, but they are normally made for industrial permanent installation processes and, if you need an upgrade, channel number increase or replacement, you may spend more money, or have to rebuild a good part of your equipment. I personally love the data acquisition system from National Instruments (I programmed it with Labview, of course), but I have also another one here from HP programmed in Delphi. VXI signal conditioners. I have purchased a lot of sensors from omega, including thermocouples and pressure transmitters (in the www.omega.com you can find almost everything and with prices, making easy to quote...). Some computer enclosures and racks come from recortec, but there are thousands of suppliers that will sell you standard 19" racks for instrumentation. Vibration accelerometers from Bruel & Kjaer, readers from trig-tek. Dynamometers usually come from Kahn, but we also have one electric load bank to be used with a slave generator that comes from simplex.

What else can I say? If you'd like to, send more details here in the forum, or to my e-mail bhre@brturbo.com.br I really appreciate work with these things.

I would plan on having two rooms, one for the controls and one for the engine test stand. The reason is if the engine fragged, you don't want to be near it. You are going to need a Carbon Monoxide Exhaust System that takes engine exhaust directly outside. You will also need make-up air for engine combustion air. You will need to heat and air condition the room so you can maintain 72 degrees (22 C.) with the engine running giving off heat. You also need to think about being able to deliver 12V DC and a convienence outlet for tools to the engine test stand. You will need an automatic exstiguishing system in case of a fire. There are a whole list of other things like an engine dyno and power for that. You will also need a radiator and coolant system to connect to.

You should be able to monitor everything the engine is doing from the engine tuning software using a laptop. Your throttle controls depend on if is cable or electronic.

I'd also think about having acoustic insulation, of course. And, your fire suppression system must include ways to close the inlet and outlet doors to prevent oxygen from entering the test cell in case of fire, as well as a valve that closes the fuel supply to the engine. Surelly, your fuel reservoir and pump must be remotely located.

Please, Come up with your ideas and let us know what are your doubts, and give us some details of your project. Don't get all the fun only for you!

"I'd also think about having acoustic insulation, of course. And, your fire suppression system must include ways to close the inlet and outlet doors to prevent oxygen from entering the test cell in case of fire, as well as a valve that closes the fuel supply to the engine. Surelly, your fuel reservoir and pump must be remotely located."

Good points. Yes, a Fire Alarm control panel (FACP) would be needed to deactivate magnetic door closers, and power down a Gas Solenoid valve to close. A gas shut off valve could also be operated by a fusible link. (fusible valve)

Hello,

To make an engine test bed you need to have a lot of component.

The best is to ask to company like D2T China or others who are specialist in that field of activity they can provide turn key solution and automation system able to interface all equipement and ECU development tools. It is better to use ready to use prodcut than Tool boxes of the market for acquistion

regards

philippe

An Engine Test Bed is built after collecting the necessary data of the engine and the parameters to be tested.The complexity of test bed design depends on the number of parameters to be tested.But, some of the systems are mandatory are as foll;1.UTILITY SYSTEMS A) Fuel Handling- fuel lines, valves,fittings,storage etc. B) Air Handling- Conditioned air for Engine Intake C) Oil- Lub oil pipings,valves,pump,fittings etc. D) Exhaust Handling

E) Ventilation- Air circulation in chamber

F) Chamber lighting & Fire Protection

2. QUICK RELEASE COUPLINGS ( betwn Engine & Utilities)Design & Selection for the above utility services

3. ENGINE LOADING DESIGN- Dyno/Alternator + Carden Shaft+ Couplings etc.

4. Controller Design

5. Accoustic Enclosure to house all utilities

This is a field where each item is a exhaustive technology and there are very few people who possess the accurate uptodate knowledge.The key is integration of all these technologies.

If you need any specific data you can Email me on rajdesai35@yahoo.com & it would be my pleasure to help you out.

Regards,

Raj Desai

Hi I have worked for a company called AVL as a test bed engineer for many year. These have all the equipment required to run a test bed. Have a look at the web site.

Regards

michael.rainey@yahoo.co.uk