Client Challenge
A major commercial vehicle manufacturer needed to modernize and refurbish four aging dynamometer systems that were no longer meeting the demands of modern production and testing standards. These systems lacked the capability to accurately measure absorbed torque and parasitic losses while incorporating ABS functionality.
Additionally, the client required seamless integration with vehicle ECU diagnostics and their corporate database for real-time product validation. With budgets starting at $850,000 per rebuild, the challenge was to provide high-quality, cost-effective upgrades while minimizing downtime during refurbishment.
Our Solution
DSI Innovations delivered customized rebuilds and refurbishments for four dynamometer systems, transforming them into advanced, high-performance testing solutions. Key elements of the project included:
- PowerFlex Drive Integration: Our team developed a new strategy to measure absorbed torque and parasitic losses while embedding ABS functionality to enhance testing precision.
- Advanced Controls: Rockwell 5000-based PLCs were paired with a custom SCADA system, enabling direct integration with vehicle ECUs and the corporate database for real-time data collection and validation.
- Comprehensive Upgrades: The project encompassed mechanical, electrical, and software redesigns, ensuring that each system was rebuilt to deliver optimal performance and reliability.
- Project Management Excellence: From equipment refurbishment to reinstallation, DSI provided full project and construction management, ensuring minimal disruption to ongoing operations and timely delivery.
DSI’s tailored approach ensured that each rebuild aligned with the manufacturer’s specific operational requirements and long-term goals.
The Results
The refurbished dynamometer systems provided the client with significant performance improvements while staying well within budget. Notable achievements included:
- Enhanced Testing Accuracy: The inclusion of ABS functionality and advanced torque measurement capabilities elevated the testing process to meet modern standards.
- Seamless Integration: The custom SCADA system enabled real-time communication with vehicle ECUs and the corporate database, streamlining product validation workflows.
- Cost-Effective Modernization: By refurbishing existing systems, the client achieved state-of-the-art functionality at a fraction of the cost of new installations.
These upgrades allowed the client to extend the lifecycle of their existing equipment, ensuring reliable, efficient operations for years to come while establishing a new benchmark for dynamometer refurbishment in the industry.
