October 29, 2015 – Twinsburg, Ohio, USA – Mustang Advanced Engineering (MAE) today announced the company has released a new product that merges on-road and chassis dynamometer emissions testing
Mustang Awarded Contract To Supply Complete Turnkey Test Stand For The U.S. Army’s Vehicle Innovative Powertrain Experimental Research (VIPER) Facility
Mustang Advanced Engineering (MAE) today announced that the company has been awarded a contract to supply and install a new test stand capable of conducting experiments on a wide array of Army transmissions, gearboxes, and other powertrain systems. The contract calls for MAE to deliver a turn-key solution which includes interfacing with existing and/or new facility utilities. The test stand will be capable of testing the following powertrain configurations:
- Helicopter main transmission, single/dual inputs (1,000 HP each)
- Helicopter tailrotor drivetrain 1,000 HP class
- Helicopter tailrotor drivetrain 250 HP class
- Ground vehicle driveline 600 HP class
- Ground vehicle driveline 250 HP class
The test stand will be configured with five AC variable speed dyne motors, and configured in a common bus arrangement to allow the electrical power to be re-circulated within the system. This drive configuration offers significant power savings over the life of the test stand and provides a true next-generation “green” test stand.
The test stand includes a hydraulic blade simulation system to dynamically impart forces and moments to the helicopter main transmissions which will simulate the blade forces. This is a state of the art, 6 degrees of freedom design concept. In addition, the turnkey systems will be supplied with all fixturing, test article mounting systems, torque disc calibration systems, MAE’s TRANSdyne Control Software and a comprehensive data acquisition package.
“Mustang is extremely pleased to have been awarded this advanced and very versatile test stand,” said David Ganzhorn, V.P. Sales. “Our decades of experience with sophisticated transmission test stands, and our recent successes with similar advanced military test stands was key to winning this project and we look forward to starting work on this advanced system.”
Mustang Awarded Contract To Supply Complete Turnkey End-of-Line Test System for RWTH-Aachen University’s Electric & Hybrid Vehicle Production Line
Mustang Advanced Engineering (MAE) today announced that the company has been awarded a contract to supply and install a new test stand capable of conducting end-of-line tests on electric and hybrid vehicles produced at RWTH Aachen University’s new production facility in Aachen, Germany.
The test stand consists of an advanced dynamometer developed specifically for electric and hybrid vehicle testing, a computerized wheel alignment system, and a headlight tester tightly integrated into an automated package.
The engineers at MAE designed the dynamometer to leverage the precision of 4 independently controlled AC motors, each coupled to its own set of rollers, to control the load to each wheel independently. This setup allows test engineers to exert unprecedented control over testing conditions. The design consists of several custom modifications to MAE’s standard AC-4000 product, which comes standard with 4 independently
controlled AC motors, and an integrated ABS Brake Tester. The AC-4000 also utilizes automatic vehicle restraints for increased testing throughput and efficiency while ensuring the test vehicle remains safely in position on the tester.
The integrated wheel alignment system utilizes patented robotics technology and has been proven as the most accurate system in the industry while the headlight tester is equipped with a CCD camera and integral software to measure headlight aim and intensity.
David Ganzhorn, V.P. Sales, worked closely with RWTH Aachen’s engineers in developing the specific testing requirements. “MAE takes great pride in working with colleges worldwide to further drive vehicle technology.”
Mustang Advanced Engineering (MAE) today announced that the company has been awarded a contract to supply an 8 x 8 mobile tow dynamometer system to Hubei Sanjiang Space Wanshan Special Vehicle Co., LTD.
The mobile tow dynamometer consists multiple PAU’s, controls, software, generator, etc. to provide a turn key system for Wanshan Specialty Vehicle’s research and development application. Wanshan Specialty Vehicles is a Chinese manufacturer of extremely large, highly specialized vehicles from 4 to 64 wheels. The engineers at MAE designed the tow dynamometer to 300 KN of drawbar force at 5 kph, with a maximum speed of 75 kph. The unit is equipped with MAE’s automated adjustable hitch which provides a hitch height of 200 – 1,000 mm.
David Ganzhorn, V.P. Sales, worked closely with Wanshan Specialty Vehicle in developing the specific testing requirements. “MAE’s reputation as the leading supplier of choice in the tow dynamometer market led to this exciting project award.”
January 26, 2012 – Mustang Advanced Engineering delivers an end-of-line tester to The TORO Company for their line of Greensmowers. The unit is replacing The TORO Company’s existing outdated unit.
The custom dynamometer designed for The TORO Company uses two 6.5”-diameter rubber-coated rolls that provide a special grip for the lawnmowers. Two strain-gauge load cells accurately measure the precise reaction torque from the dynamometer’s two 150-hp motors, with easy calibration to ensure continuous accuracy.
Adjustable motor bases and telescoping drive shafts give the unit flexibility for the variations in size between Greensmower machines. Loading and unloading mowers is as simple as decoupling the drive shafts and removing the mower from the test stand.
The end-of-line tester was designed to allow continuous, real-time monitoring of the mower’s speed and temperature. Throughout the test sequence, other values that are tested include:
- Oil Pressure
- Engine Coolant Temperature
- Engine RPM
- Engine Oil Temperature
- Vehicle Power Output
With the end-of-line testing dynamometer, Mustang also delivered a custom EOL software package specifically designed for both electric and gasoline models. The software comes with a touch screen interface with clear, easy-to-read controls and pass/fail results.
The software has robust customization options so that The TORO Company’s rigourous PASS/FAIL criteria can easily be tweaked and adjusted in the future. Specific test sequences have been written for each unique lawn mower, which are easily selectable at the beginning of the test. Designed for high throughput, the software is simple and clear, making it easy to run test after test, and assuring that every Greensmower that leaves The TORO Company’s facility is working perfectly.
“This comprehensive End-of-Line tester for TORO is another great example of the custom solutions we design and build for our customers” said Dean Ganzhorn, Mustang President and CEO. “This particular project was exciting because of the unique form factors of the mowers and the very thorough testing procedures that TORO puts their equipment through. We’re proud to have supplied TORO with this tester.”
December 5, 2011 – Mustang Advanced Engineering delivers an Inertia Test Stand for brake testing. The test stand utilizes a 40 HP AC Motor with corresponding variable frequency drive operating to a maximum speed of 3,000 rpm. The test stand provides base inertia of 77 lb ft2 with eight (8) selectable 29 lb ft2 inertia weights and eight (8) selectable 37.5 lb ft2 inertia weights.
The test stand’s prime mover is an electric motor that is rated for multi-directional and reliable variable speed control. A 480 VAC motor is used to reduce the current requirements of the system. The motor is capable of providing continuous constant torque from the base speed down to and including zero speed.
The inertia weight system for EATON is similar in size and scope to existing MAE inertia weight systems. The inertia weight system consists of a structurally stiff base frame which will attach EATON’s bed plate. The frame has an integrated gantry crane to assist in changing weight configurations.
The software provided will allow EATON the fl exibility to confi gure the system’s data collection. The software will collect all data including start and stop times. The system includes data acquisition channels to icollect all required data including speed, torque, pressure, and various digital inputs including E-stops and cover counterlocks.
“Mustang is extremely proud to have been chosen by EATON Corporation for this project,” said Dean Ganzhorn, Mustang President and CEO. “Mustang’s experience with this type of application was key to us winning this project and to our ability to deliver this system to EATON. Mustang anticipates a bright future with EATON and we look forward to working together on potentially many more projects.”
December 2011 – Twinsburg, Ohio – Mustang Advanced Engineering recently delivered an HSU test stand designed to simulate transmission input speeds and loads and vehicle output loads to the X1100-3B. The testing stand has the ability to control both the HSU’s input speed and output loads, allowing the operator to apply loads to the HSU as though it is in the vehicle. Cooling/Heating of the HSU will be accomplished with in tank heaters and thermostatically controlled oil to water heat exchangers located in the test tank and oil reservoir systems.
The HSU Test Stand will consist of 8 primary components:
• Input Drive Unit Assembly
• Power Absorption Unit Assembly
• HSU Container Assembly
• Test Stand Base Frame
• Oil Lubrication System
• Test Stand Tooling – Adapters, Fixtures and other hardware
• Roll Over Stand
• Test Stand Instrumentation
The X1100-3B HSU test stand power unit consists of a variable frequency AC motor drive and a variable speed AC electric motor prime mover. The test stand’s prime mover is an electric motor that is rated for multi-directional and reliable variable speed control. The prime mover is continuously rated at 1,455 HP with a base speed of 2,500 rpm and maximum speed of 3,990 rpm.
The test stand’s output PAU is a bi-directional water cooled eddy-current PAU. The PAU is capable of up to 4,000 lb-ft of dynamic load torque with a maximum speed of 3,330 rpm. The PAU has an infi nitely variable control range from no-load to full-load which is controlled via a manual controller on the control panel. The eddy-current power absorption unit is water cooled and will use less than 150 gpm of cooling water at 85°F.
“Mustang is proud to deliver this complex and extremely important test stand to Anniston Army Depot” said Dean Ganzhorn, Mustang President and CEO. “These HSUs are important to the success of the military and Mustang prides itself on delivering a quality and efficient test stand.”
MAE Delivers Turnkey Heavy-Duty Cross-Drive Transmission Dynamometer for X200-4A Transmission Test Cell to Anniston Army Depot
November 2011 – Twinsburg, Ohio – Mustang Advanced Engineering recently delivered a heavy-duty transmission dynamometer for testing of the X200-4A transmission for the Anniston Army Depot. The state-of-the-art test cell was designed by MAE to efficiently accomodate the transmission test stands, while meeting all required codes for mechanical and electrical hook-ups as put forth by the State of Alabama.
The system can perform a multitude of tests, including:
- Check shift points (automatic transmissions)
- Full throttle upshift test
- Downshift inhibitor test
- Check for abnormal noise and vibration
- Check transmission control system
- Closed throttle downshift test
- Leak check shaft seals and clutches
- Check main, clutch, and converter pressures
- Determine mechanical binding
The X200-4A transmission test stand power package consists of an AC motor drive and electric prime mover, rated for 325 HP (continuous), with a base speed of 2,620 rpm and maximum speed of nearly 4,000 rpm. The motor possesses low inertia to more accurately simulate the inertia values seen by the transmission when connected to an engine. This lower inertia value provides better up/down shift simulation due to the motor’s inertia value being in the range of a typical engine’s inertia value.
The test stand’s power absorption units are bi-directional eddy-current PAUs which provide high performance loading torque. The PAU’s are capable of up to 2,000 lb-ft of dynamic load torque with a maximum speed of 4,000 rpm. Air actuated caliper brakes are incorporated into the load units for stall testing.
Among the facilities of Golisano Institute for Sustainability (GIS) is a dedicated laboratory for internal combustion research that is fully equipped with MAE systems. The Engine Dynamometer Laboratory is staffed and equipped for investigation of engine performance and emissions resulting from use of biofuels formulated in a variety of blends.
April 2011 – Twinsburg, Ohio – Mustang Advanced Engineering recently delivered a heavy duty, electric motor, tandem axle chassis dynamometer system with a variable wheelbase system for testing Class 4 to Class 8 truck and buses to The Ohio State University Research Foundation’s Center For Automotive Research.
MAE delivers modular electric vehicle test lab equipped with a new MAE 48″ roll AWD chassis dynamometer to Southern California-Edison.
Mustang Advanced Engineering (MAE) is currently set to deliver a turnkey, modular, outdoor test lab for Hybrid and Electric Vehicle testing to Southern California – Edison. The MAE designed and built test built test facility will be equipped with a new, state-of-the-art 48″ roll AWD chassis dynamometer with twin 250-hp AC motor and a variable wheelbase.
The two axle system features two sets of chrome-plated 48″ rollers that can be operated independent of one another. Tests that the system can perform include, but are not limited to hybrid calibration, dynamic performance test, fuel economy performance test, ABS braking performance test, emissions performance test, creeper gear performance test, constant speed, constant force, constant torque, constant power, controlled acceleration and vehicle simulation road load testing.
The 48-inch roll AWD chassis dynamometer is being installed this winter and includes the AWD dynamometer and a complete outdoor modular test facility; both designed by Mustang. A variety of testing is planned including electric and hybrid electric vehicle testing. The dynamometer offers two (2) 250-hp AC motors, one for each roll axis. The test chamber is modular and includes sound abatement, lighting, electric and HVAC. The projuect is being turn-keyed by Mustang AE.
Southern California-Edison (SCE) is committed to the deployment of cost-effective and energy efficient electro-drive transportation technologies to meet EPAct requirements. SCE’s fleet of approximately 2,400 light-duty vehicles, includes 260 Toyota RAV4 EVs, and approximately 40 neighborhood electric vehicles (e.g., GEMs and Th!nks), that operate at more than 40 different field locations throughout SCE’s 50,000 square-mile service territory. The EV fleet currently averages about 110,000 miles per month. Since 1987, the EV fleet has traveled over 14.5 million miles, and is the largest working EV fleet in North America.
SCE operates a state-of-the-art, ISO 9001:2000 registered, EV Technical Center (EVTC) in Pomona, California, that performs testing and evaluation of all electro-drive transportation technologies. The EVTC started evaluating EVs and batteries in 1993. Today its operations include the testing and evaluation of advanced energy storage devices, hydrogen fuel-cells for mobile and stationary applications, hybrid electric vehicles, fuel cell vehicles, and plug-in hybrid electric vehicles. The EVTC’s projects have included clients and partners such as the US Department of Energy, the National Laboratories, aero-space agencies, auto and battery manufacturers, the Electric Power Research Institute, and California state agencies.
MAE teams up with the Kettering University Green Mobility Lab to deliver three specialized tester stands for Electric Vehicle Systems Simulation.
Mustang Advanced Engineering recently delivered three specialized test stands to Kettering University to support the university’s Green Mobility Lab located in Flint, Michigan.
MAE delivers unique 4×4 chassis dynamometer to Lawrence Technological University Automotive Engineering Institute for advanced R&D of next generation vehicles.
Mustang Advanced Engineering recently delivered a unique 4×4 vehicle chassis dynamometer to Lawrence Technological University’s Automotive Engineering Institute. The dynamometer features individual wheel torque electronic controls of one, two, three, or all four drive wheels and speed capability of up to 100 mph. Four individual power absorbers provide 175-hp per wheel load capability for continuous operation and up to 350-hp intermittently. Wheelbase adjustment from 89 to 175 inches allows the dynamometer to test a wide range of AWD vehicles.
MAE delivers a newly designed 48″ Electric AC Heavy-Duty Chassis Dynamometer to the University of California – Riveside, College of Engineering – Center of Environmental Research and Technology
The science of measuring emissions from mobile and other sources has evolved significantly over the past several years. The most important changes in the nature of emissions measurement science has been a shift to examining emissions from diesel sources and to understanding emissions under in-use driving conditions.
MAE delivers 8×8 independent wheel AC motor chassis dynamometer & Multi-Function Performance to BIT.
MAE recently completed the design and manufacture of one of the world’s largest Heavy-Duty AC Motor Chassis Dynamometers and Multi-Performance Testers for The Beijing Institute of Technology. The massive dynamometer is designed to carry out testing for medium-duty and heavy-duty vehicles with drive axles ranging from one to four, including 8×8, 8×6, 8×4, 6×6, 6×4, 6×2 and 4×4. (more…)
MAE delivers Multi-Function EOL dynamometer & ABS Brake Tester to Superior Controls for testing Military MRAP 4×4 and 6×6 vehicles.
Mustang Advanced Engineering recently delivered a turn-key End-of-Line multi-function test system to Superior Controls for the testing of the US Military’s Mine Resistant Ambush Protected (MRAP) 4×4 and 6×6 vehicles as they come off the production line. (more…)
MAE delivers custom engineered dynamometer for testing moving armor target vehicles to Meggitt Defense Systems Caswell.
Mustang Advanced Engineering recently delivered a custom dynamometer to Meggitt Defense Systems Caswell for the testing of three different-sized Moving Armor Target (MAT) Vehicles ranging in size from 600 lbs to 3,200 lbs, each having a different wheel configurations and track widths and a series of electromagnetic trip sensors. (more…)
MAE recently delivered a sophisticated Mobile Laboratory Tow Dynamometer for use in validating tractors to the Nebraska Tractor Test Drawbar Test. Previously MAE delivered the PTO test stand, which is used to perform the PTO portion of the Nebraska Tractor Test to the same customer. The Mobile Lab Tow Dynamometer consists of a modified extended cab class-8 over-the-road truck with a modified powertrain and adjustable front tongue assembly. The system is supplied with a tractor fuel measurement system to measure the pulling tractors fuel usage during testing. A weather Station is located in the dynamometer system to measure ambient temperature, relative humidity and barometric pressure, while a portable data pod located in the test tractor’s cab captures the tractor’s engine rpm, engine pressures & temperature. The system is also easily expanded to communicate with the tractor’s ECM. (more…)