End of Line Gen-Set Production Testing

Project Features: Genset, Test, Automation, EOL, Data Acquisition, DAQ, Equipment Design, Production, Fabrication, PLC

end line gen set production testing, systems integration services, integrated equipment, integrated test facility

The client wanted to automate and relocate their end-of-line production test system for generator sets that use propane, natural gas, diesel and gasoline. The goal was a total time of three minutes to align with production rates. The process had to be a fully automated test and transportation system, to increase the overall efficiency. 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.

Project Scope

Conveyor System:

  • Multiple product line inputs with random product mix
  • Individual sections for fine product control
  • 100% automated system

Test Pallets:

  • One design – accepts all gen-set families and variations
  • Quick connections
    • Designed with swappable components for wide product application:
      • Fluid
      • Controls
      • Power

Test Enclosures:

  • 1 hour fire rated and 100 PSF blast rating
  • No hearing protection required in vicinity – below 85 DBA emitted
  • Multiple fuel types supported
    • Including flammable fuels, propane and natural gas
  • Fully Automated
    • Product entrance/exit
    • Fluid and electrical connections via match plate with test pallet
    • Test sequence configuration
    • Product tuning and adjustments
    • Safety Instrumented System monitoring

Project Challenges:

  • Multiple Gen-Set Families varying sizes and layouts
    • 5kW – 35kW
    • 11 product families with a multitude of configurations
    • Single & multiple phase power output
  • Multiple Test Specification & Protocols
  • Overall Footprint Limitation

With experience in engine and gen-set testing, data acquisition and PLC programming, ACS delivered a turnkey solution with extensive testing capabilities that met the performance criteria for this long-time customer.