MD-ED400-20

MD-ED400-20 Engine Dynamometer –for testing Heavy-duty Diesel Engines

The MD-ED400-20 was designed to test diesel engines after overhaul or to validate performance upgrades following installation. The system has an exceptionally low cost of ownership and is virtually maintenance free. The unit only requires readily available 230VAC single phase power and no water is required for cooling the system. Eddy current brakes are very repeatable and infinitely variable. The unit includes two exceptionally large eddy current frictionless brakes mounted on a robust steel frame. The brakes are trunnion mounted with spherical ball bearings that support the brakes on both ends. Individual torque sensors are mounted to each brake to measure torque. A speed sensor measures RPM. Each brake is capable of absorbing 1,500-lb-ft of torque and 900-hp when cold. Continued use will reduce capacity over time and thus fans are mounted to the dynamometer to temper heat loads. A complete control and data acquisition system lets you design a wide range of tests or select from a host of pre-configured tests. The software is user friendly and Windows based. Colorful screens let you view data in real time via user-configurable charts and gauges. Optional accessories that are available include an electromechanical throttle actuator, diesel fuel consumption system, a heavy duty engine docking cart, data acquisition systems, sensors, forced air cooling, smoke meter, blowby meter, engine water jacket cooling system, charge-air cooling system, engine flywheel adaptors, torsionally compliant drive-shafts and breakout boxes for ECM controlled engines. Each MD-ED400-20 is made to order per the customer’s requirements.

Fuel Consumption Unit for Diesel Fuel ​

Mustang offers a standard fuel measurement system with a small 5-gallon tank, volumetric metering meters and cooling. The unit comes mounted to a pedestal and includes inlet as well as return circuits. The system measures instantaneous fuel consumption as well as a running total of fuel burned during a test procedure. Various size flow meters can be fitted to accommodate different flow rates. The standard unit can accommodate up to 1,000-hp diesel engines and large sizes can be ordered. Accuracy is better than +/- 1%.

Engine Docking Cart with Receiver ​

Mustang offers a robust engine cart with engine supports. These carts come with heavy duty casters, engine mounting feet with adjustments, large pull handle, SAE bellhousing support, guide pins for docking with receiver and a receiver which mounts at the base of the dynamometer. These carts can be acquired in multiple sets to allow for engines to be dressed in preparation for testing while another engine is being tested. The HD carts are larger than the gas engine cart to handle larger diesel power plants. Carts measure approx. 40-inches by 60-inches and accommodate most on-highway and stationary diesel engines. Weight capacity is 5,000-lbs.

Electromechanical Throttle Actuator ​

Mustang’s HD Throttle Actuator is designed to cope larger engines with heavier throttle return spring tension. The mechanism is designed to allow the user to open and close the engine’s throttle from the dynamometer console. This units mount to a stand this secured to the dynamometer frame or to the floor. The throttle can be controlled based on a target % opening (0-100%) or to a target RPM.

Charge Air Cooler ​

Charge air cooling systems are housed in a convenient roll around cabinet and are intended as a substitute for the charge air cooler when it is missing from the engine. These units include a thermostat to control for the inlet temperature going into the engine. A valve controls the amount of water flowing into the heat exchanger. Various sizes are available based on the air flow and delta T required of the application.

Starting Systems

In some cases engines that need to be tested may not include an electronic starter. If this is a possibility for your application Mustang offers electric starting packages that mount to the dynamometer itself and this allows the user to crank the engine connected to the dynamometer via a cardan shaft. These are large commercially available starters that mount to the dynamometer and include proper gear-sets to achieve the required crank torque. In some cases Mustang will use an air starter instead of an electronic started depending on the torque that is required.

Blowby Meter

Blow-By Metering provides an indication of piston-ring leakage under actual operating conditions by measuring the flow out of the crankcase vent or sump vent. The frequency output connects to our dynamometer input channel to record the blow-by flow rate alongside rpm, hp, temperature, etc. This measurement helps find efficiency problems with ring flutter, ring end gap, cylinder wall distortion, ring clearance and ring tension.

Data Acquisition

Mustang’s engine dynamometers are available with multi-channel data acquisition systems to collect various temperatures, flows and pressures from the engines being tested. For users with limited needs Mustang offers the perfect solution with our 14-channel Jbox units which include nine (9) analog inputs, three (3) frequency inputs and two (2) temperature inputs. This unique system also includes a built-in weather station. This solution is very compact and economical. If needed more than one Jbox can be used and stacked to achieve the required solution. We also offer 32 channel solutions as well as 64 channel solutions which come housed in a NEMA enclosure and with a sturdy steel stanchion. These units mount to the floor or wall and individual sensor connections are wired to the exterior of the enclosure.