End of Line Gen-Set Production Testing
Project Features: Genset, Test, Automation, EOL, Data Acquisition, DAQ, Equipment Design, Production, Fabrication, PLC

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
- Designed with swappable components for wide product application:
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.