Michigan-based Sakor Technologies has designed a dynamometer testing system consisting of a 42kW AccuDyne AC motoring dynamometer and a DynoLAB test automation controller.
The new system, which was developed for a major OEM for testing starter/alternators for hybrid/electric vehicle (H/EV) applications, communicates with the customer’s ECU via CANbus technology.
It is capable of operating at speeds as high as 18,000rpm and as low as 0rpm, providing full torque in a stall condition. Furthermore, the dynamometer can run in motoring or loading modes at maximum rated torque/power in either direction at any time and can switch between these modes instantaneously. As a result, the test system can expose starter/alternators to all conditions they may potentially undergo in actual vehicle use.
The system can also test the maximum power, speed and generator capacity of starter/alternators. It enables operators to run road load cycles to simulate real-world conditions, including starting the engine, dynamic braking, power assist and battery charging modes.
Two battery simulators function as regenerative DC power supplies. One can supply power at up to 120V and 400A, while the other unit can supply up to 40V and 1,200A. As a result, the system can test the full range of customer components while keeping costs relatively low.
“This system is a uniquely configured solution to our customer’s very specific needs,” said Randal Beattie, president of Sakor. “Whereas this OEM may have needed to purchase two to three different off-the-shelf machines to perform this testing, the Sakor system is capable of meeting a broad range of test requirements in a single machine. The cost of operation of the test cell is also greatly reduced because the system is capable of power recapture and therefore uses much less electrical energy over the testing cycle.”
