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Case Studies

Engine Test Environmental Management System


Huge savings in energy have been made by major engine manufacturer in the UK.
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History and References

FORD ESPAĐA HCS Hot Test Stands

  • Major projects from 1980 until today
  • Introduction of Electronic tags for monitoring and programming production

FORD ESPAĐA Zetec SE Hot Test Stands

  • Several major projects from 1994 until today
  • Control system software and host communications for after test repair loop. Engine repair priority recognition and recycling to defined station

FORD BRAZIL HCS Hot Test Stands

  • 1996 Test Cycle Control System and Software through the UHT module; exchange of engine data via electronic tag; control of speed, temperatures and pressures of fluids; connection with the host system for the passing of data for control of production and quality

SEAT MARTORELL Hot Test Stands

  • Automation of the test cycle of the stands, introduction of running multiple engines types with unique ignition systems
  • 15 Petrol/Diesel test stands for new engine environmental programme

VOLKSWAGEN NAVARRA LANDABEN Hot Test Stands

  • 6 Hot Test Stands in the Engine Plant running multiple engine types with unique ignition systems. Adaptation for Diesel engines with electronic ignition

NISSAN MOTORS IB╔RICA

  • Control System and Instrumentation for the Real Time control of exhaust gas analysis equipment and result management
  • Gearbox test rig

FORD DAGENHAM Common Rail Diesel Hot Test Stands

  • Simultaneous Engineering Consultancy
  • 30 Cells Lynx Engine Hot Test Control System and Software for High Pressure Common Rail diesel engine
  • Engine Laboratory injection control and download workstation
  • 20 Cells Puma Engine Hot Test Control System and Software for High Pressure Common Rail diesel engine
  • Engine Laboratory engine and dynamometer cooling system - 4 cells
  • Engine Laboratory engine fuel system - 10 cells

FORD VALENCIA I4 Hot Test Stands

  • Prototype and 18 Hot Test Cells for I4 Gasoline engine
  • Upgrade for I4 engine with GTDi turbo system and new engine controls
  • Upgrade to SpinTest control systems

ASTON MARTIN Hot Test Stand

  • 1 Universal Test Cell for V12 and V8 High Performance petrol engines. Turnkey facility complete with all support services and engine pallets

JCB POWER SYSTEMS QA and Hot Test Stands

  • 2 Universal Test Cells for industrial diesel engines
  • Turnkey facility complete with all support services and engine pallets
  • Engine BOM, production launch and birth history tracking system
  • Engine control module calibration download station

PERKINS ENGINES STAFFORD

  • Simultaneous engineering exercise for automating rigging and de-rigging of engines
  • Order for upgrading 4 production cells, supplying automating rigging and de-rigging of engines, thus improving production times and operator safety

CONCENTRIC PUMPS LIMITED Pump Test Rigs

  • 2 Universal test machines for production testing of industrial diesel pumps
  • 2 R & D Test Rig for test and development of fuel and oil pumps

CUMMINS ENGINES DAVENTRY

  • Simultaneous engineering exercise for upgrading 6 production hot cells
  • Upgrade of 3 off production cells, replace complete control system with new power distribution, PC and PLC interface with Cummins system, install Profibus, Profisafe and distributed I/O stations, replace transducers, control test cell facilities with PLC, install SCADA Touch screen HMI in control room, new engine control interface, new dynamometer and throttle control interface
  • Test cell ventilation control system with power distribution, Profibus and inverter drive controls
  • Facility services monitoring with distributed I/O
  • Facility oil and fuel reclaim and supply system controls upgrade with distributed I/O and Profibus system monitored with touch screen HMI
  • Oil fill flow monitoring system
  • Test cell safety door entry interlock facility

FORD OTOSAN TURKEY Diesel Engine Hot Test Cell

  • Puma Engine Hot Test Cell for High Pressure Common Rail diesel engine production test

FORD BRIDGEND Jaguar Hot Running Test Stand

  • A complete hot running facility with onboard services for coolant and fuel control
  • A new control system with engine control module interface, test bed services, engine ID barcode scanning and facility services