Dynamometer Control System

OVERVIEW

The Michigan division of a large automotive powertrain components manufacturer needed a dynamometer control system that incorporated three different operator configurable control loops for torque converter research and development. They also wanted 32 channels of data acquisition at a 200 Hz sampling rate as well as the ability to regulate torque, flow and temperature characteristics of torque converters attached to the dynamometer.When it came to the hydraulic system, the customer requested a smooth operation of the valves at contamination levels as high as 40 microns.

SOLUTION

Develop an intuitive and multifunctional control dynamometer test system including motors, drives, control data acquisition package and control software for the project. This solution formed by Galco's engineering department, integrates with the valves, dynamometer bases, feedback transducers, and hydraulic package provided by a third party. The transducers provide pressure, flow, RPM, temperature, and current feedback to the system. Completing the project installation are two 125 HP 1750/5000 RPM liquid cooled motors along with two model ACS600 vector drives from ABB. Each drive is configured for common buss operation. Galco's solution uses Dataq® data acquisition and analysis software in conjunction with HMI and IEC 1131 control software and allows the customer to conduct research and development on torque converters for approximately 1/10 the cost of the previous version.

SOLUTION

The test operator can configure four valves with either an automatic or manual setpoint. They also have the ability to configure each valve to regulate the torque, flow, or temperature associated with the test article.