Chassis Dynamometer Test Cell Upgrade for Class 8 Vehicle Testing

Enhancing Precision and Data Integration in Class 8 Vehicle Testing

ACS executed a comprehensive design-build expansion for a major manufacturer to modernize its class 8 vehicle testing capabilities. To replace an obsolete chassis dynamometer, ACS renovated the facility’s infrastructure, installed a custom truck dynamometer test cell, and introduced high-precision air flow and axle cooling systems. Additionally, custom PLC software integration was implemented to directly align U.S. test data with European headquarters for repeatable, controlled testing worldwide. This upgrade supports rigorous class 8 vehicle testing and integrates procedures tailored for class 8 truck engines on a modern truck chassis dyno.

The Challenge

Our client, a major international vehicle and equipment manufacturer, was using an obsolete chassis dynamometer test cell combined with over-the-road testing for its class 8 vehicle testing program. This combination did not give the company sufficient control over test conditions or testing repeatability. The primary issue was an outdated infrastructure and limited testing range, as the air simulation and chassis dynamometer test systems limited the air temperature and speed ranges, requiring a modernized building and utility infrastructure. Additionally, the existing axle cooling system offered no control over cooling rates or fluid temperatures, driving the need for a system to precisely regulate the oil temperature inside the differential. Finally, test data from the U.S. facility was not aligned with the software program used at European headquarters, requiring extensive post-processing; the client needed U.S. test data aligned for direct integration and seamless data sharing across facilities. These limitations affected evaluations of class 8 truck engines and constrained the effectiveness of the chassis dynamometer test process.

The Solution

The ACS solution involved a comprehensive design-build expansion of the existing testing facility to house the new customized chassis truck dynamometer test cell and provide the condition control the manufacturer wanted. As part of the facility overhaul, we gutted and reconstructed the space to accommodate a new air circuit while entirely revamping the mechanical and electrical systems to deliver the power and control needed for evolving test requirements. For the air flow and control systems, our engineers designed an adjustable nozzle to blow air in front of the truck and built a mixing flow conditioner inside the temperature-controlled air circuit, achieving the narrow range of temperature and velocity uniformity the client required. To improve axle cooling, we replaced the obsolete setup with a custom-designed oil cooling system that facilitated lower axle oil temperatures and tighter control than previously achievable. In addition, our software engineers built the PLC software and hardware with two-way integration into the manufacturer’s test automation software, matching their European facility and providing centralized control over industrial facilities to meet set test conditions. This approach ensured a consistent chassis dynamometer test methodology across sites and supported advanced assessments of class 8 truck engines using a truck chassis dyno.

The Outcome

ACS renovated the existing building and its utilities to accommodate the customized chassis dynamometer test system. With a new air handling unit and custom air flow nozzle, the company increased its test air temperature range while providing temperature uniformity. The enhanced truck dynamometer test cell, combined with improved controls, now sustains stable conditions for repeatable chassis dynamometer test cycles.

The upgrades notably improved testing capabilities, offering the company enhanced control, reliable repeatability, and improved accuracy in test results. Consequently, the client now possesses an improved ability to conduct rigorous and dependable testing for their heavy-duty truck development programs using a modern truck chassis dyno and correlated procedures for class 8 vehicle testing. The facility can execute precise evaluations of class 8 truck engines and maintain cross-site data integrity for class 8 vehicle testing programs.

Key Features

• Revamped the testing facility, introducing a custom-built chassis truck dynamometer test cell, upgrading mechanical and electrical systems, and replacing the air circuit to support consistent chassis dynamometer test practices
• Expanded class 8 vehicle testing parameters with a significantly increased air speed range and an extended temperature range, enabling robust validation of class 8 truck engines
• Attained precise air speed and temperature including a custom-fabricated nozzle, meeting rigorous uniformity standards for heightened testing accuracy on the truck chassis dyno
• Designed a PLC system compatible with the test software used in the client’s main lab facilities for cross-site data alignment and repeatable truck dynamometer workflows

ACS Services

• Designed and built new mechanical and electrical systems
• Renovated existing space for a new test lab and added office space
• Procured and commissioned the new chassis dynamometer test systems to strengthen class 8 vehicle testing capabilities
• Designed and built an axle cooling system, articulated engine exhaust, custom fabricated air flow nozzle, and Air Handling Unit (AHU)
• Conducted Site Acceptance Testing (SAT) and correlated truck dynamometer procedures for global consistency, ensuring repeatable chassis dynamometer test results across facilities