Automating End-of-Line Gen Set Test Cells and Delivery System

We had the opportunity to present a case example of an end-of-line automated production test system for generator sets using propane, natural gas, diesel and gasoline. Two primary goals for our client were no human interaction during the test for increased safety and eliminating testing variability. The system includes a total of seven independent test enclosures with integrated controls and data acquisition systems, an automated delivery conveyor system, and a centralized prep area.

Challenges of the project included the number of product families of various size and layout, requiring a multitude of configurations; product size ranging from 5 kW to 35 kW; single and multiple phase power output; multiple test specifications and protocols; and limitations on footprint in an existing facility.

Working in partnership with the client team, ACS developed the concepts and designed the test enclosures and all related components of the system. Units were built and FAT (Factory Acceptance Test) was conducted at our facility. We managed onsite installation, commissioning, training and turnover.

More About the Project

About the presenters:

Matt Jorgensen – Principal; Director, Facility Engineering and Site Management
With over 17 year’s experience at ACS, Matt has extensive experience in the engine and vehicle industry and knowledge of R&D and production testing gained from working with OEMs, tier suppliers, and third-party research facilities around the world. Matt received his B.S. in Mechanical Engineering from the University of Wisconsin-Madison.

Tom Reiter – Senior Instrumentation and Controls Engineer
Tom’s role is to manage the design, procurement, manufacture, integration, and commissioning of automated control systems and equipment. Tom has been at ACS over 14 years, with project experience in R&D diesel engine testing and facilities, production testing, test stands and equipment, and safety instrumented systems. Prior to ACS, Tom worked as a controls engineer for a machine and test stand builder and an automated door OEM. Tom has a B.S. in Electrical Engineering Technology from the Milwaukee School of Engineering.