Client Challenge
A leading commercial vehicle manufacturer faced the challenge of implementing state-of-the-art dynamometer systems to accommodate their new production facilities. The project required not only designing and building a fully integrated dynamometer solution but also ensuring that the system could interface seamlessly with vehicle ECU diagnostics and the corporate database for product validation.
The manufacturer sought a solution capable of measuring absorbed torque and parasitic losses while integrating ABS testing functionality—all within a strict budget of $2.3 million per system.
Our Solution
DSI Innovations undertook the complete design and build of 16 new dynamometers, delivering a robust and scalable solution that addressed all client requirements. The project included:
- PowerFlex Drives Integration: Our team developed a stategy to accurately measure both absorbed torque and parasitic losses, with ABS functionality seamlessly embedded for enhanced testing accuracy.
- Advanced Control Systems: Rockwell 5000-based PLCs were combined with a custom SCADA system to provide a direct interface with vehicle ECUs and the corporate database, ensuring real-time data collection and product validation capabilities.
- Comprehensive Engineering: The solution encompassed mechanical, electrical, and software design, ensuring a finished product optimized for efficiency and performance.
- Project Management Excellence: DSI provided complete project and construction management, overseeing equipment fabrication and installation to ensure timely delivery within budget.
This holistic approach enabled the seamless integration of advanced technology with the client’s existing operational workflows, positioning the manufacturer at the forefront of testing innovation.
The Results
The newly implemented dynamometers exceeded performance expectations, delivering precision measurements and enhancing operational efficiency across the client’s facilities. Key outcomes included:
- Enhanced Data Integration: The custom SCADA system ensured seamless communication between vehicle ECUs and the corporate database, streamlining product validation processes.
- Improved Testing Capabilities: The incorporation of ABS functionality and strategies for measuring parasitic losses significantly increased testing accuracy.
- Timely Project Completion: The comprehensive project management approach ensured that all 16 systems were delivered on schedule and within the $2.3 million per system budget.
The successful execution of this project not only established a new standard for dynamometer systems in the industry but also reinforced DSI Innovations’ reputation for delivering cutting-edge solutions tailored to complex client needs.
