TABLE OF CONTENTS
CHAPTER CONTENTS
DECLARATION DEDICATION
ACKNOWLEDGEMENT ABSTRACT
ABSTRAK TABLE OF CONTENT
LIST OF FIGURES LIST OF TABLES
NOMENCLATURE
CHAPTER I INTRODUCTION
1.1 Problem Statement
1.2 Objective
1.3 Scope
1.4 Chapter Summary
CHAPTER II LITERATURE REVIEW
2.1 Engine Dynamometer Test Cell
2.2 Dynamometer
2.3 Engine Dynamometer Concept
2.4 Type of Dynamometer
2.5 Control Console and Data Acquisition
System PAGE
ii iii
iv v
vi vii
x xii
xiv
1 1
2 2
2
5 5
9 10
11 16
CHAPTER CONTENTS
2.6 Ventilation and Air Conditioning System
2.7 Engine Cooling System
2.8 Adequate Fire and Safety Precautions
System 2.9
Electrical System 2.10
Fuel Storage and Supply System 2.11
Engine Exhaust System
CHAPTER III METHODOLOGY
3.1 Introduction
3.2 Research on FKM, UTeM Engine Test
Cell 3.3
Research on PROTON Engine Test Cell 3.4
Testing Capabilities 3.5
FKM, UTeM Test Cell - Engine Testing Requirement
3.6 PROTON Test Cell - Engine Testing
Requirement
CHAPTER IV RESULTS AND DISCUSSION
4.1 Comparative Analysis
4.2 Identify Problem
CHAPTER V CONCLUSION AND RECOMMENDATIONS
5.1 Conclusion
5.2 Recommendations
5.3 Recommended Operating Procedure
PAGE
21 24
28
32 34
38
39 39
40
48 71
74
78
85 85
90
92 92
93 96
CHAPTER CONTENTS
REFERENCES BIBLOGRAPHY
APPENDICES PAGE
LIST OF FIGURES
NO. TITLES
2.1 An Open Thermodynamic System
2.2 Test Cell With Regenerative Electrical
Dynamometer 2.3
Output Diagram of Cell Thermal Analysis Software
2.4 Engine Test Cell
2.5 Eddy Current Dynamometer Layout
2.6 Hydraulic Dyno Schematic
2.7 Open Cooling Water System
2.8 Service Module Circuit
2.9 Typical Fuel Day Tank System
2.10 Engine Fuel Pressure Control System
2.11 Lubricating Oil Cooling Unit and
Conditioning Unit 3.1
Methodology Flowchart 3.2
Mustang Dynamometer MD-DEG 150 3.3
Manual Controller
3.4 Engine Cooling System
3.5 Dynamometer Cooling System
3.6 PROTON Engine Dynamometer
Complete System
PAGE
5 6
7
8 10
12 25
27 34
36 37
40 41
44 45
46 48
NO. TITLES
3.7 Froude-Consine Eddy Current
Dynamometer 3.8
TEXCEL V6 Control and Data Acquisition System
3.9 PROTON Ventilation System Illustration
Design 3.10
Low Level Inlet and High Level Outlet Ducted System
3.11 PROTON Cooling System
3.12 PROTON Electrical System
3.13 PROTON Fuel System
3.14 PROTON Fire Alarm and Safety System
3.15 Sample Engine Testing Result
5.1 Heat Exchanger Diagram
5.2 Transducer Box and Signal Conditioning
Card
PAGE
50
53
62
62
64 65
67 69
83 93
94
LIST OF TABLES
NO. TITLES
2.1 Engine Control and Dynamometer Control
Sequences 2.2
Instrumentation and Transducer Required For Measurement
2.3 Ventilation Ducts Layouts
2.4 Characteristic of Major Fire Suppression
System 2.5
Electrical Power Supply Specification 2.6
Test Cell Exhaust Layout 3.1
UTeM Dynamometer Technical Data 3.2
UTeM Dynamometer Specification
3.3 Features and Characteristics of
Dynamometers 3.4
Froude-Consine Eddy Current Dynamometer Specification Data
3.5 AG 150 Froude-Consine Eddy Current
Dynamometer Technical Data 3.6
AG 250 Froude-Consine Eddy Current Dynamometer Technical Data
3.7 Standard Signal Conditioning Packages
3.8 Ventilation System Requirements
PAGE
17
19
23 31
33 38
41 43
49
50
51
52
61 63
NO. TITLES
3.9 Minimum Dyno Water Pressure
3.10 PROTON Water Pressure Set Up
3.11 Electrical System Requirements
3.12 Testing Capabilities Table
3.13 Parameter Monitored at PROTON
4.1 Test Cell System Comparison
4.2 Comparative Analysis Summary
5.1 Standard Size of Transducer Box
PAGE
64 65
66 72
79 86
89 94
NOMENCLATURE
A.C =
Alternate Current AG
= Air Gap
AHU =
Air Handling Unit BIPO
= Break In and Pass Off
CO
2
= Carbon Dioxide
D.C =
Direct Current DGEC
= Dry Gap Eddy Current
DTC =
Digital Throttle Control ECU
= Electronic Control Unit
F =
Force, N FCU
= Fuel Controller Unit
FKM =
Fakulti Kejuruteraan Mekanikal FMS
= Fuel Measurement System
IGBT =
Insulated Gate Bipolar Transistor LVDT
= Linear Variable Displacement Transducer
MUT =
Machine under Test MD
= Mustang Dynamometer
NVH =
Noise, Vibration, Harshness
P =
Power, kW PID
= Proportional, Integral, Derivative
PLC =
Programmable Logic Controller PROTON
= Perusahaan Otomobil Nasional Sdn Bhd
PRT =
Platinum Resistance Thermometers R
= Distance, m
S =
Shaft speed, rpm SAE
= Society of Automotive Engineering
T =
Torque, Nm TDC
= Top Dead Centre
UTeM =
Universiti Teknikal Malaysia Melaka VAC
= Volt Alternate Current
WOT =
Wide Open Throttle
CHAPTER I
INTRODUCTION
1.1 Problem Statement
