HYBRID ENGINE TEST STANDTEST MANUAL

MODEL: STEAMER 1.0TEAM STEAM

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Contents

1 Required Materials ................................................................................................................................ 2

2 Safety .................................................................................................................................................... 2

2.1 Safety Checks .............................................................................................................................. 2

2.2 DOs and DON’Ts ........................................................................................................................ 2

2.3 Recommended Safety Equipment: .............................................................................................. 3

3 System Testing ...................................................................................................................................... 3

3.1 Test Stand Preparation ................................................................................................................. 3

3.2 System Validation ....................................................................................................................... 4

3.2.1 General Operation ................................................................................................................... 4

3.2.2 Operation with Resistive Load ................................................................................................ 6

3.2.3 Emergency Stop Testing ......................................................................................................... 7

3.2.4 6-Stroke Operation / Water Injection ..................................................................................... 8

3.2.5 Mechanical Considerations ..................................................................................................... 9

4 Witness Sign-Offs ............................................................................................................................... 12

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1 Required Materials The following materials are required to carry out system testing on the Steamer 1.0.

• Steamer 1.0 test stand

• Steamer 1.0 load cell – Filled to brim with fresh tap water. Temperature less than 30C

• Extension cord to reach 110 VAC mains power (14 gauge minimum)

• 1 liter clean water (tap water is fine)

• 1 liter standard grade fuel – 87 octane

• Computer with LabVIEW runtime environment. See Operations Manual for system

requirements

• Well-ventilated work area designed for engine testing. If such an area does not exist,

outdoors works fine.

• USB cable to connect computer to test stand (3 ft. minimum)

2 Safety Safety precautions should always be taken when working with or around the Steamer 1.0. Note the

location of the emergency stop in the event of a malfunction.

2.1 Safety Checks

• Prior to operation check for obvious leaks or blockages in the air, fuel, or water lines.

• Prior to operation check for any obviously loose bolts.

• Prior to operation ensure wires are secure and not close to rotating or hot components.

• Prior to operation verify that the choke solenoid and all servos move freely.

2.2 DOs and DON’Ts

• Use in a well-ventilated environment. Do not inhale fumes.

• Do not stand in front of test stand during operation.

• Do not touch anything inside the test stand during operation.

• Do not store fuel on the test stand.

• Do not leave excess fuel in graduated cylinder for extended periods of time.

• Apply E-Stop and disconnect power when working within the test-stand.

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2.3 Recommended Safety Equipment:

• Safety glasses

• Ear plugs

• Nitrile gloves for fuel handling.

3 System Testing System testing is to be performed after system modifications to anything that directly impacts the

functionality of the test stand. If a section of the system testing fails, the Discrete Testing section

may be used to troubleshoot the problem.

3.1 Test Stand Preparation

The test stand needs to be set up as described below to ensure proper

testing.

a) Depress the red emergency stop (E-Stop) button

b) Plug in test stand power or extension cord to a wall outlet (120 VAC)

c) Fill fuel (100 mL) and water tanks (100 mL). The fuel tank is the

graduated cylinder sitting on top of the test stand. The water tank is filled

through the small white tube protruding from the top of the test stand.

d) Connect computer to test stand’s USB module

e) Set up load cell

a. Connect the load cell to the load port on the test stand as shown below

H2O Input H2O Output

Switches

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b. Turn all switches on the control board to the OFF position

c. Remove the lid and fill the resistive load container with water and press the lid back on.

3.2 System Validation

Each specification is tested to ensure that the test stand meets the engineering specification.

3.2.1 General Operation

The system is first tested to validate the general functionality of the test stand.

a) Reset the E-Stop button by lifting upward on the knob until it clicks. The test stand is now

powered.

b) Follow the procedure found in the Operations Manual under Section 7: Graphical User Interface

to start up The LabVIEW program and to connect to the test stand.

c) Leaving GUI settings at default values click “Log Data”. When prompted, select a location to

save data and click OK.

d) Click “Start Engine”. The engine should turn over for about 1 second before the engine kicks in

and begins idling.

Design Spec: SXX - Engine must be able to start remotely through computer interface.

Expected Result: Engine starts and begins to idle after command given.

Actual Result:

PASS/FAIL: Initials:

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e) Allow engine to run for about 5 minutes (depending on ambient conditions) to allow

thermocouple measurements to stabilize. After this period, observe the three temperature readouts

(Tamb, Tblock, Texh).

a. Tamb is expected to show the ambient temperature of the test stand in degrees Celsius.

This thermocouple should be between ambient and 20C greater than ambient

temperature. The thermocouple is located in the air intake of the engine.

Design Spec: S7 - Measure air input temperature up to 100°C to within 10%.

Expected Result: LabVIEW readout shows the temperature of the air intake. Thermocouple must physically remain in air intake and not fall out.

Actual Result:

PASS/FAIL: Initials:

b. Tblock is expected to show the temperature of the engine block. The temperature should

be between 100 C and 200 C. The thermocouple is inserted in a deep hole in the engine

block and rigidly attached.

Design Spec: S15 - Measure cylinder temperature up to 500°C to within 10%.

Expected Result: LabView readout shows the temperature of engine block. Thermocouple must physically remain connected inside engine block.

Actual Result:

PASS/FAIL: Initials:

c. Texh is expected to show the exhaust temperature. The temperature should be between

800C and 1100C. The thermocouple is inserted through a hole in the exhaust pipe to

measure exhaust air temperature.

Design Spec: S2 - Measure exhaust temperature up to 1200°C to within 10%.

Expected Result: LabView readout shows the temperature of engine block. Thermocouple must remain physically connected inside engine block.

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Actual Result:

PASS/FAIL: Initials:

f) Change engine speed on GUI to 75%. The engine should speed up to between <<>> and <<>>

RPM as shown on the GUI readout.

g) Change engine speed down to 25%. The engine should slow down to between <<>> and <<>>

RPM. The engine may stall at this slower speed, this is OK. If the engine stalls stop data logging

and, restart the engine per the above procedure (Section 1.2.1.c) and continue from this step.

h) Change engine speed back up to 50%

3.2.2 Operation with load cell

WARNING: This procedure must be completed in less than 30 minutes and may not be repeated if

load cell is warm. For extended operation, follow the procedure in the Operations Manual to

connect the load cell to circulating water.

a) Start the engine (if not already running).

b) Set engine speed to 50%.

c) Enable the load cell on the GUI by clicking the “Load Enable” switch.

d) On the load cell, toggle the 1500 W switch to the ON position as shown below.

e) Observe the power output graph on the GUI. Power output should increase to between <<500

W>> and <<3 kW>> depending on engine speed and specific configuration.

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Design Spec: S1 - Measure engine shaft output power. S10 - View test data in GUI. Expected Result: LabVIEW displays power output within the bounds of 500 W and 3 KW.

Actual Result:

PASS/FAIL: Initials:

f) Turn on the other two loads, and then observe the power output graph. Power output should

increase to between <<>> and <<>>.

g) On the GUI, click the “Start Engine” button to OFF.

h) Using explorer, navigate to the directory where the test data was saved (selected by operator) and

verify that the file contains data.

Design Spec: S9 - Test data must be digitally stored.

Expected Result: Open the file selected to store test data, verify that the file contains data.

Actual Result:

PASS/FAIL: Initials:

3.2.3 Emergency Stop Testing

This test is designed to validate the emergency stop function of the test stand. This test supports the

“Safety” requirement.

a) Start the engine (if not already running).

b) Set engine speed to 100%, and turn load cell ON.

c) Press the E-Stop button on top of the test stand.

d) After the test stand comes to a full and complete stop, reset the E-Stop button by lifting up on the

button.

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e) Confirm that the system comes back up after LabVIEW automatically re-connects with the USB

devices.

Design Spec: SXX - Test stand must utilize a hard wired emergency stop function.

Expected Result: After E-stop pressed, engine shuts off. When E-stop reset, test stand recovers after automatic re-connecting to computer.

Actual Result:

PASS/FAIL: Initials:

3.2.4 6-Stroke Operation / Water Injection

This test is designed to demonstrate the proper operation of the six-stroke function of the test stand.

a) Stop the engine if currently running by clicking the “start engine” switch to OFF.

b) Remove the water injector from the air intake bracket by pushing the injector head to the right

then removing from the bracket (simulating water injection). Point the injector head in a safe

direction, into a clean bucket for example.

c) Start the engine.

d) Set engine speed to 50%

e) On the GUI, change the “Stroke Mode” from “four” to “six” by clicking the switch.

f) Water should begin to spray out of the injector head in bursts at an approximate frequency of 20

Hz (depending on engine speed). There should be an audible chattering, but may be drowned out

by sound of engine.

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Design Spec: S11 - Test stand must control water injection.

Expected Result: When Stroke Mode set to six and engine is running, water injector sprays water.

Actual Result:

PASS/FAIL: Initials:

3.2.5 Mechanical Considerations

These tests are used to demonstrate that the test stand meets the mechanical specifications outlined

in the Engineering Specification and meets the mechanical Design Specification

a) The fuel tank is a 1000mL graduated cylinder. Verify that the tank is greater than 500mL.

Design Spec: S13 - Test stand must be able to hold at least 500 mL of water.

Expected Result: Graduated cylinder reads 1,000 mL which is greater than 500 mL.

Actual Result:

PASS/FAIL: Initials:

b) The water tank is a pipe with approximate dimensions of 10cm inside diameter and 30 cm long.

The water tank volume is approximately 3 liters which is greater than 500mL. Measure and

calculate to confirm.

Design Spec: S12 - Test stand must be able to hold at least 500 mL of water.

Expected Result: Volume of pipe is greater than 500mL.

Actual Result:

PASS/FAIL: Initials:

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c) Test stand weighs approximately 150 lbs. The structure is strong enough to withstand another 150

lb. static load. Test by standing on the base of the test stand as shown below

Design Spec: S14 - Test stand can securely support twice its weight.

Expected Result: When a person statically applies his weight to the structure of the test stand, the structure does not fail.

Actual Result:

PASS/FAIL: Initials:

d) Test stand is operated with mechanical interface to Kohler CH5 engine.

Design Spec: S19 - Test stand must provide mechanical interface for Kohler CH5 engine.

Expected Result: Test stand operates while mechanically interfaced with Kohler CH5 engine.

Actual Result:

PASS/FAIL: Initials:

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e) Push the test stand through a standard sized doorway to demonstrate that it can be moved to an

appropriate testing area. The test doorway is the path to go from the MSD work area on the 4th

floor of the RIT engineering building to the balcony.

Design Spec: S16 - Loaded test stand must not be heavy. Must be able to be moved by no more than 2 people.

S17 - Test stand width must be less than door width. S18 - Test stand height must be less than door height. Expected Result: Test stand can be easily pushed through doorway by one person.

Actual Result:

PASS/FAIL: Initials:

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4 Witness Sign-Offs After the completion of the above test, the engineers present shall sign below to confirm that the tests

have taken place and that the results were as stated.

Design Engineer __________________________________________

Design Engineer Signature __________________________________

Design Engineer Initials ____________________________________

Test Engineer ____________________________________________

Test Engineer Signature ____________________________________

Test Engineer Initials ______________________________________

Witness ________________________________________________

Witness Signature ________________________________________

Witness Initials __________________________________________