Mustang Advanced Engineering News

Welcome to the news section of Mustang Advanced Engineering. In this section you will gain an inside look at what's going on at MAE. We will post featured articles regarding recent projects, company updates, industry trends and more. Please bookmark this page so that you can stay up to date on all events and information regarding the industry leader in testing technology and systems - Mustang Advanced Engineering

Mustang Advanced Engineering Delivers AC Chassis Dynamometer to California Air Resouces Board (CARB) for Motorcycle & ATV Emissions Certification

June 1, 2010 -- Download PDF

MAE recently delivered an AC Motor Chassis Dynamometer System for motorcycle and ATV emissions certification to California Air Resources Board (CARB). The Motorcycle/ATV Chassis Dynamometer is intended to be used to perform emissions certification testing while performing a variety of drive cycles for motorcycles having a loaded vehicle mass between 80 - 550 kg.

The dynamometer is an AC motor (absorbing/motoring) dynamometer capable of producing a load at 65 km/hr as described in CFR 40 part 86, section 529.78. The dynamometer is capable of producing loads to meet the ECE R40, ECE R47 and the CNS (Taiwan) test procedures as well as customized mode up to the performance specifications outlined.

Mustang has a long history as a supplier of choice to CARB, having supplied CARB with numerous chassis dynamometer systems in the past for emissions certification purposes.

MAE has multiple generations of knowledge and experience in the specialized area of AC Motor Chassis Dynamometers. Our experience dates back to 1975 and our applications range from small, high-speed motorcycle test systems to extremely large, high-torque heavy-duty vehicle test systems. When it comes to advanced dynamometer technology, precise and repeatable road load simulation, accurate speed and/or force control and sophisticated data acquisition packages, the engineers at Mustang Advanced Engineering are hard to match.

Mustang Advanced Engineering is awarded contract to supply a state-of-the-art AWD 48" electric motor in the middle chassis Dynamometer system to The University of Alabama's Center for Advanced Vehicle Technologies (CAVT)

April 29, 2010 -- Download PDF

Mustang Advanced Engineering today announced that it has been awarded a contract to supply a new, state-of-the-art dynamometer systems to The University of Alabama's Center for Advanced Vehicle Technologies (CAVT). Under the terms of the agreements, Mustang will supply a complete AWD 48" Electric AC Motor in the Middle Chassis Dynamometer System.

The AWD 48" Electric Motor in the Middle Chassis Dynamometer will be used to perform EPA certified testing according to Federal Test Procedure US06 as well as fuel systems performance testing, emissions systems research and road simulation of AWD and 2WD vehicles. This EPA compliant system features dual axle 48" roll sets, each containing an integrated 315-hp AC electric motor and regenerative motor drive systems. The dynamometer is capable of testing AWD wheelbases ranging from 85" to 150" and is rated for vehicles with axle weights up to 6,000 lb., making it a very versatile dynamometer and allowing CAVT to test vehicles ranging from The Smart Car to HMMWV military vehicles.

"Mustang Advanced Engineering is excited to be working with such a prestigious institution as The University of Alabama and the folks at The Center for Advanced Vehicle Technologies. We have a strong commitment at Mustang to work together with Universities and other similar research organizations to provide them with the advanced engine and vehicle test systems at a price that creates value for them and gives them the technology they need to complete in today's global marketplace", said Dave Ganzhorn, Mustang Vice President of Sales.

The Center for Advanced Vehicle Technologies (CAVT) is a University of Alabama Research Center dedicated to the advancement of vehicle technology. Based on unique, interdisciplinary research and education programs, it strives to provide the vehicular industry with novel ideas, scientific consultation, as well as new generations of engineers and scientists formed in the latest technologies in this field. Located in Tuscaloosa, Alabama, on the campus of the University of Alabama, it is at the heart of the automotive industry emergence in the United States Southeast region.

Mustang Advanced Engineering is a leading provider of comprehensive testing solutions for the development and testing of engines, powertrain systems and complete vehicles. Since its founding in 1975, Mustang has been a trusted source of expertise in measurement and testing technologies for the global industrial market. World-class product offerings, custom design support and technical assistance, backed by a dedicated factory customer service team have positioned MAE among the global leaders in providing advanced testing solutions.

Mustang Advanced Engineering delivers a newly designed 48" Electric AC Heavy-Duty Truck Chassis Dynamometer to The University of California - Riverside

March 25, 2010 -- Download PDF

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.

The Bourns College of Engineering – Center for Environmental Research and Technology (CE-CERT) at The University of California Riverside has recently installed a heavy-duty tandem axle truck chassis dynamometer in the facility's research area. Designed and manufactured by Mustang Advanced Engineering, the development of this chassis dynamometer design was based on targeting vehicles in the medium to heavy-duty diesel vehicle range. Heavy-duty applications that can be tested at the facility include on-highway trucks, buses, waste haulers, yard tractors, and more - under test conditions representative of their specific in-use operations. The facility couples the new heavy-duty chassis dynamometer from Mustang Advanced Engineering with CE-CERT's Mobile Emissions Laboratory (MEL), to perform precise vehicle simulation and in-operation emissions measurements.

The first research conducted on the new facility will be a comparison of federally mandated diesel fuel formulas versus the stricter formulation required in California. The program calls for 10 heavy-duty trucks to be tested with several different fuels.

The new dynamometer will simulate on-road driving conditions for any big rig using its 48" precision rollers with dual, direct connected, 300 horsepower motors attached to each roll set. The dynamometer applies the appropriate loading to a vehicle to simulate factors such as the friction of the roadway and wind resistance that it would experience under typical driving conditions. An additional large inertia weight was incorporated into the dynamometer to increase the base mechanical inertia and enable the dynamometer to provide precise on-road simulation for a wide range of vehicle weights. The driver accelerates and decelerates according to a driving trace which specifies the speed and time over a wide range of vehicle simulation cycles. As the on-road driving conditions are being simulated on the dynamometer, emissions measurements will be collected with CE-CERT's Mobile Emissions Laboratory (MEL).

"This adds new capabilities in California that are only available at a limited number of facilities around the country," said Tom Durbin, who with J. Wayne Miller, are the principle investigators for the project. At both the state and federal levels, scientific requirements for emissions testing are trending away from steady state engine testing in favor of transient conditions found in typical driving, Durbin explained. "This addition will significantly expand our laboratory and measurement capabilities and help us continue our role as leading experts in the field of emissions research," said CE-CERT Director Matthew Barth.

CE-CERT’s new heavy-duty chassis dynamometer will allow the testing of a variety of heavy vehicles under loaded and transient in-use conditions with corresponding emissions measurements. The dynamometer configuration is capable of meeting the inertia simulation range requirements of 10,000 to 80,000 lb for each of the cycles listed below. This includes acceleration rates up-to 6 mph/sec, as found in the UDDS Section D Drive Schedule and deceleration rates of up to 7 mph/sec as required for the WHM Refuse Drive Schedule. The dynamometer can also provide a load in excess of 600 HP @ 70 mph. The dynamometer also has the ability to continuously handle 200 Hp @ 15 mph for applications such as yard tractors.

The Dynamometer system is designed to meet the Heavy Duty Drive Schedules for diesel trucks in the weight range of 10,000 to 80,000 lb with acceleration rates for the following cycles:

• CARB HHDDT Cruise Mode Drive Schedule
• UDDS (Urban Dynamometer Drive Schedule)
• CARB 50 mph HHDDT Cruise Cycle
• HHDDT Transient Mode Drive Schedule
• WHM Refuse Drive Schedule
• Bus cycles such as, the CBD, OC Bus cycle, NY bus cycle
• In-use cycles for applications such as yard tractors

"As part of our strategic plan, Mustang has developed a cost effective series of diesel, petroleum and hybrid certification grade dynamometer systems to address the needs of the global emissions and R&D market. There is a clear and present demand for a full performance cost effective dynamometer systems that offer all of the capabilities and confidence of a certification system at a price point that makes it no longer cost-prohibitive for organization to perform critical emissions studies, hybrid system calibration development, performance evaluation and other cutting edge research technologies. Researchers are in need of dynamometer systems to develop the next generation technologies which mimic the capabilities of the certification requirements, but at a fraction of the cost of a true certification system. That is what we are developing with this series of dynamometers and universities are lining up for them", said Executive Vice President, Donald Ganzhorn.

Mustang Advanced Engineering Awarded Anniston Army Depot (ANAD) Powertrain Transmission Addition Facility (PTAF) Project

February 16, 2010

Twinsburg, OH - Mustang Advanced Engineering, a division of Mustang Dynamometer, today announced that it received an award from Walbridge for supply of up to four new military test stands, relocation of seven existing test stands, and ten ‘turn-key’ modular, soundproof enclosures for the Anniston Army Depot (ANAD) Powertrain Transmission Addition Facility (PTAF) project.

The PTAF project includes a new 109,824 ft² building to house a transmission rebuilding facility complete with administrative area, a transmission disassembly area, a parts cleaning area, a machine shop area, a packaging/shipping area, assembly area, painting areas, parts storage area, and a transmission dynamometer test area. The transmission dynamometer test area will house up to 11 dynamometer systems, including four new dynamometer systems and seven relocated dynamometer systems. All dynamometer systems are to be housed in Mustang supplied external, modular, soundproof enclosures attached to the main facility.

These ‘turn-key’ systems will provide the Government with state-of-the-art, high throughput test stands to efficiently process the various test articles processed by ANAD. The total value of the award with options and provisions will approach $8,000,000.

The test stands provide final testing for the following assemblies:

• X200-4A crossdrive transmission dynamometer for the M113 family of tracked vehicles
• X1100 hydraulic steer unit dynamometer for the M1 tank family
• M9ACE steer unit dynamometer for the M9 armored combat earthmovers
• Inline transmission dynamometer for the Stryker family of armored vehicles and the M9 armored combat earthmovers

The relocated test stands provide final testing for:
• X1100 crossdrive transmissions for the M1 tank family
• X200-4A hydraulic steer units for the M113 family of tracked vehicles
• MD3066P transmissions for the Stryker family of armored vehicles
• XT-1410 crossdrive transmission for the M88 family of recovery and repair tracked vehicles
• XTG-411 transmissions for the M108/M109/M110 family of self-propelled howitzers
• CD-850 crossdrive transmission for the M60 tank family

"Mustang is extremely proud to work with Walbridge and the U.S. Army Corps of Engineers on the PTAF project" said Dean Ganzhorn, Mustang President and CEO. "Mustang’s experience with military test stands, especially containerized systems, was key to being awarded this project."

MAE is located in Twinsburg, Ohio where it has been based since 1986. MAE is a leading supplier of automotive, military, industrial and aerospace testing equipment worldwide.

Mustang Advanced Engineering awarded contract to supply a Heavy Duty Electric Motor Chassis Dynamometer to The Ohio State University Research Foundation's Center For Automotive Research

February 5, 2010 -- Download PDF

Mustang Advanced Engineering today announced that it has been awarded a contract to supply a heavy duty, electric motor, tandem axle chassis dynamometer system with a variable wheelbase option for testing Class 4 to Class 8 truck and buses to The Ohio State University Research Foundation’s Center For Automotive Research.

The heavy duty chassis dynamometer will consist of a dual axle roll set. Each axle roll set comprises a quanitity of 2 48" rollers coupled to a 1,000-hp electric motor.. While one of the 48" axle roll sets is fixed in place, a second, movable 48" axle roll set will give the system the ability to test varying vehicle wheelbases. The wheelbase movement system will use linear bearings to allow the moveable roll set to adjust to different wheelbase requirements. Since the test stand will be used for tandem and AWD vehicles, the dynamometer system will provide a minimum wheelbase testing capability of 45" and maximum wheelbase of 472 ½". The wheelbase system will have a static locking brake to hold the movable axle in location and an electric gear motor connected to a power drive carriage with wheelbase distance tranducer and display to precisely move the axle wheel base.

The primary use for the dynamometer is intended for hybrid electric vehicle testing and calibration. This application requires low speed (<70 mph/113kph), high wheel force testing (24,000lb/105,000N). This testing will be conducted to validate vehicle performance, efficiencies, and power electronics calibration on both on-road and off-road vehicles. The dynamometer will allow vehicles to accelerate with 8.3 mph/s acceleration rates or greater depending on inertia simulation range and dynamometer speed. Additionally the dynamometer will achieve inertia simulation in the range of 8,000 to 60,000 lb.

The system will be able to carry out performance testing of heavy duty wheel type vehicles with multiple drive axles including: 4 x 4, 4 x 2, 6 x 4, and 6 x 2.

As configured, the system can perform many different types of tests such as:

• Dynamic performance testing
• Electric or fuel economy performance testing
• Hybrid regenerative performance testing
• Vehicle simulation testing
• Lug down testing
• Scripted cycle testing from infield data
• Scripted cycle testing from imported engineering file

"As part of our strategic plan, Mustang has developed a cost effective series of diesel, petroleum and hybrid certification grade dynamometer systems to address the needs of the global emissions and R&D market. There is a clear and present demand for full performance cost effective dynamometer systems that offer all of the capabilities and confidence of a certification system at a price point that makes it no longer costprohibitive for organizations to perform critical emissions studies, hybrid system calibration development, performance evaluation and other cutting edge research technologies. Researchers are in need of dynamometer systems to develop the next generation technologies which mimic the capabilities of the certification dyne requirements, but at a fraction of the cost of a true certification system. That is why we have developed this series of dynamometers and universities, OEM, tiers and suppliers are lining up for them", said Executive Vice President, Donald Ganzhorn.

"This project provides yet another example of why Mustang is the supplier of choice for custom test stands to the R&D and university communities. Mustang’s size and speed, flexibility and experience with virtually every type of dynamometer technology put us in a great position to win this bid and our ability to integrate some existing hardware in order to meet Ohio State's budget requirements for this project was key to the award of this contract", said President and CEO, Dean Ganzhorn.

MAE Develops 8x8 Independent Wheel Truck Chassis Dynamometer

November 25, 2009

MAE recently completed development of the most sophisticated heavy duty truck chassis dynamometer on the market. Yes, MAE has built 7 axle chassis dynamometers, and yes MAE has built AWD independent wheel end chassis dynamometers. Now the bar is raised. This titan of a chassis dynamometer consists of 8 independent motors attached to each roll located under each wheel assembly. The 8 independent chrome plated 48” diameters rollers can be cross coupled or independently operated. Each wheel can be independently operated in any of the available control modes or can be configured to follow the feedback or command of any other roll. The ultra-flexible system allows development of (2x4, 4x4, 6x6, 8x8) traction control, stability systems, braking systems, performance, durability, emissions, powertrain calibration, and hybrid integration system monitoring. This type of pre-designed laboratory grade system, with minor design modifications, can be installed in many other testing environments such as wind tunnels, climatic chambers, NVH, EMC/RFI, high altitude and other specialty chambers and/or environments and greatly expands the testing possibilities for R&D.

The 4-Axle 8x8 chassis dynamometer is configured with larger capacity motors on the rear four rolls and normal capacity motors on the front 4- rollers per current customer request. The combined peak full load capacity of the motors is 1,200 kW (1,600 Hp) with a combined wheel force of 260,000N (58,450 Lbs.). The system is capable of operating at speed up to 130 km/hr (81 mph). The 4-Axle chassis dynamometer is equipped with one fixed roll set and three independently adjustable roll sets to accommodate a wide range of axle wheelbases from 1,350mm to 12,000mm (53.2" to 472") with a wheelbase adjustment accuracies of +/-2mm (0.08"). The system is also supplied with a large, fast-responding motoring/regenerative variable speed cooling fan system which replicates wind speeds up to 130 km/hr (81 mph).

The state of the art system is complimented with many other features such as fuel measurement and conditioning system, weather station, ECM Interfaces and data collection systems, engine rpm monitoring systems, vehicle weight scale, comprehensive data acquisition system and Mustang’s PAC/PLC controller. An expanded version of Mustangs Multi-Track Chassis Dyne Control System is also supplied. The Multi-Track control system allows for independent control of each independent roll motor as well as the vehicle cooling fan and operator test display trace. The Multi-Track is configured to communicate with the Allen Bradley MicroLogix's PLC controlling the complete system with dual control room monitors, remote drivers trace monitor and remote hand pendent system.

Delivery and commissioning of the system is scheduled for this coming March in Beijing, China. To learn more about how MAE can help solve your most demanding testing challenges contact one of our sales engineers.

MAE Wins High Speed Regenerative AC Dynamometer Bid

April 10, 2009

MAE is awarded the coveted 465 HP, 12,000 rpm High Speed Regenerative AC Dynamometer Project for the new Ground System Power & Energy Laboratory(GSPEL) at TARDEC (Tank and Automotive Research, Development and Engineering Centers) in Warren Michigan. Being Awarded this project further advances Mustang Advanced Engineers capabilities in supplying high speed AC powertrain test systems. The high speed test stand consists of a liquid cooled 465 Hp Variable Speed AC Dyne Motors capable of sustained speeds of 12,000 rpm and torques of 2,450 Lb-ft of torque. This highly engineered dynamometer is one of the highest torque to inertia AC dynamometers ever built. The dynamometer will consist of a dual stator design on a common rotor shaft design. The system is capable of inertia simulation over a large range of inertia down to 0.3Kg-m2. The dyne motor and control system is designed for 4-Quadrant bi-direction Motoring or Loading capability. Mustang is using our “Advanced Green Initiative” high efficiency regenerative system to convert the absorbed power in to electricity and put it back on the power line. The test stand will be used for various advanced design and development applications with functionalities including:

• Inertia Simulation
• Torque Estimator
• Speed Control
• Torque Control

Connected to the dyne’s output shaft is a, low inertia, high precision 0.03% accuracy class, torque disc to measure the torque applied by the dyne to the test article. Mustang is supplying a Liquid and air Cooling System for the dyne.

MAE Receives Award of NASA Transmission Test Stands

April 3, 2009

This project further establishes MAE's Advanced Engineering capabilities. The high speed test stand consists of two liquid cooled 200 Hp Variable Speed AC Dyne Motors capable of sustained speeds of 15,000 rpm. The equipment and control system is designed for 4-Quadrant bi-direction Motoring or Loading capability. Mustang is using our “Advanced Green Initiative" high efficiency AC power recirculation power structure to operate the Dyne motors. The test stand will be used for various advanced design and development applications including:

• Space: NASA's Rover Vehicle Drive System used in Non-Earth based space vehicle applications.
• Aero: The Test Stand will be used to test variable speed rotorcraft transmission applications.
• Land: Testing various new concept manned and unmanned transmission and powertrain systems

Connected to each dyne's output shaft is a, low inertia, high precision, torque disc to measure the Test Article's Torque. Mustang is supplying a Cooling System for the dynes and the test article. The Test Article oil cooling system consists of a high and low pressure system capable of cooling the oil to user adjustable set-points. The Flexible and User Configurable control Software is based on our industry leading Transmission & Powertrain Dyne Software package allowing the operator various speed, torque, power, polynomial loading, script building, data playback and manual control of the system. The control system is interfaced with Mustang's Non-propriety PLC based control and data acquisition system.

MAE Releases Optimized PAC/PLC Data Acquisition System

March 25, 2009

MAE releases our New Optimized PAC / PLC Based High Speed Control and Data Acquisition System. (Programmable Automation Controllers-PAC, Programmable Logic Controllers-PLC). Mustang has teamed up with Allen Bradley to produce this industrialized control and data acquisition system. This non proprietary hardware control system uses off the shelf Allen Bradley PAC / PLC components in an optimized configuration to control and acquire data from various Test Stands and Production Activities. Mustang and Allen Bradley have a 30-year history of joint project applications and teaming. The PAC / PLC Based Control and Data Acquisition System was developed to meet our customer’s demands for:

• Easily Available Non-Proprietary Hardware
• Robust Construction with 99.9% Up-time
• Customer needs a Self Sustaining Platform
• Configurable with Scalability
• Used in a Wide Range of Environmental Conditions
• International Support and Parts Availability
• Cost Conscious Solution

Mustang listened to our customers request and developed a cross platform control and data acquisition system which operates on the following hardware platforms:

• MicroLogix: PLC platform, cost effective
• CompactLogix: PLC platform , cost effective with high performance capabilities
• ControlLogix: PLA platform for Ultra High Performance and High Channel Density.

Virtually all of Mustangs PC based Control Systems can Interface to the new PAC / PLC Control and data Acquisition system via high speed digital Interface to transfer data from the PAC / PLC to the Operator PC. A watch dog verifies both entities are operating correctly. The Operator PC stores the PAC / PLC data and sequences the control commands to the PAC / PLC. Compatible Mustang PC Control, Automation and Data Acquisition Systems:

• EDTcell – Engine Test Cell Test Cell Automation and Data Acquisition Software
• T&PDTCell – Transmission & Powertrain Test Cell Automation and Data Acquisition Software
• PowerDyne – Chassis Dynamometer Test Cell Automation and Data Acquisition Software
• TowDyne – Tow Dyne Control and Data Acquisition Software
• MotorDyne – Motor Dynamometer Control and Data Acquisition Software.
• TestCell™ - Test Cell Automation and Data Acquisition software
• MAPS²- Manufacturing Advanced Production Sequencing System Software
• Inspection-Maintenance – Safety & Emissions Single and Multiple Position Software

Mustand Advanced Engineering Launches New Website

March 18, 2009

Welcome to the new online home of Mustang Advanced Engineering. As you can see we've been quite busy. The website is currently not completed, but it is being updated on a daily, even hourly basis. We are working on building a complete and comprehensive library of many of our over 50,000 test system projects. If you cannot find what you are looking for on our site right now, please contact one of our Sales Engineers for a custom quote. There is a good chance that we have already completed a project that is similar in scope to your testing needs.

You may want to bookmark our homepage so that you can stay up to date on the current news and industry trends, as well as keep an eye on our growing library of project summaries.

Mustang Advanced Engineering Delivers Multi-Function End-of-Line Dynamometer & ABS Brake Tester to Superior Controls For Testing Military MRAP 4x4 and 6x6 Vehicles.

July 9, 2007 -- Download PDF

Mustang Advanced Engineering recently delivered a turn-key End-of-Line multi-fuction test system to Superior Controls for the testing of the US Military's Mine Resistant Ambush Protected (MRAP) 4x4 and 6x6 vehicles as they come off the production line.

David Ganzhorn, MAE's Vice President of Sales, stated "Mustang's previous experience and proven success in supplying similar EOL systems to a number of other heavy-duty truck manufacturers around the world was a key factor in being chosen as the supplier of choice for this project."

This comprehensive EOL testing system is the first of several systems to be supplied for the US Military, as they will be replacing most of their light and medium duty armored vehicles with the new generation of MRAP in order to better protect the US troops worldwide. The new EOL system performs an entire series of EOL functionality tests including vehicle performance tests, driving coarse test, exhaust brake testing, retarder testing, functional and visual test, ECU test and DTC evaluations via the dynamometer portion of the multi-function tester. The brake portion of the multi-function tester performs a complete interactive function braking system test of the foundation brakes and the ABS braking system. The comprehensive series of vehicle functional testing is designed to be performed with the vehicle remaining in a single position on the multi-function tester. The system is designed to perform an aggressive parking brake test.

Mustang worked with Superior Controls, Force Protection and the US Military to develop a comprehensive test system that identifies the majority of production assembly issues that would be found during "on-road" test driving of new vehicles.

"Superior Controls and the US Military are very pleased with the low maintenance of the test stand and its ability to perform the comprehensive ABS and Performance Testing on a vehicle in a single-position test stand." stated Donald Ganzhorn, Mustang's Executive Vice President and Cheif Engineer.

In addition to the comprehensive testing of the vehicle performance and ABS Braking System, the new system included a custom configuration of Mustang's Production Line Software, Data Acquistion and Control System that will allow the US Military to standarize all its testing with standard reports and testing procedures. More importantly, the new control systel directly communicates with the vehicle ECM to verify the vehicle's status.

Mustang Advanced Engineering Delivers Custom Engineered Dynamometer For Testing Moving Armor Target Vehicles to Meggitt Defense Systems Caswell

July 10, 2006 -- Download PDF

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.

The dynamometer supplied by MAE was designed to enable MDS Caswell to perform road-load simulated acceleration testing as well as to apply simulated loads for constant velocity testing. The dynamometer was custom engineered to enable it to test three different moving target vehicles including, Moving Armor Target (MAT) model DP62, Elevated (MAT) model DP63, and the Moving Infantry Target (MIT) model DP28.

In addition to providing the engineering support for the design of the custom chassis dynamometer's track, roller and vehicle restrain systems, Mustang's needed to design a system to remotely trip various electromagnetic sensors located on the different MAT vehicles. To accomplish this and meet MDS Caswell's requirements for this functionality, the engineers at MAE incorporated a series of air cylinders to enable the sensors to be tripped as required.

"For this project Mustang had to think out of the box a bit and be creative to come up with a system that was capable of handling such unique vehicles and testing requirements. Our engineers did a great job of handling all of the unique challenges this project threw at them and provided a design and system that exceeded our customers expectations." stated Vice President of Sales, David Ganzhorn.

MAE upgrades CalsonicKansei Thermal Climatic & Solar Wind Tunnel with a state-of-the-art AWD 48" AC Motor Chassis Dynamometer with Fully Regenerative Drive Technology.

April 15, 2006 -- Download PDF

In April, 2006 Mustang Advanced Engineering completed an upgrade for CalsonicKansei of their existing Thermal Climatic & Solar Wind Tunnel Test Cell, replacing an existing 48" 2WD Eddy Current chassis dynamometer with a state-of-the-art AWD 48" AC Motor Chassis Dynamometer with Fully Regenerative Drive Technology.

This project was performed on site at CalsonicKansei's lab in their metro Detroit, Michigan location. The upgrade to an AWD chassis dynamometer was required by CalsonicKansei due to the changing vehicle population and the increasing shift towards AWD vehicles. Both CalsonicKansei and their customers were requesting a new, state-of-the-art, AWD chassis dynamometer for the test cell. Chief among the concern and the overriding issue for CalsonicKansei for this project was down time. The test cell was operating 24 hour a day, 7 days a week and the dyne schedule was booked up for months in advance. Therefore, maintaining the project time line was of utmost importance to the success of this project.

The general scope of the project was for MAE to remove the existing chassis dynamometer, modify the current pit construction to accommodate the new dyne, install the required utilities for the new dyne, run conduit to the control room, and supply a new AWD 48" AC chassis dynamometer with vehicle restraint system, vehicle throttle control and new dyne control system.

With the project time line as the central focus, MAE's project mangers worked closely with CalsonicKansei project managers and developed a detailed schedule and project gant chart. Precise coordination of project tasks and schedules was critical to the success of this project. Facility and utilities modifications where planned to be performed during the dynamometer design and manufacturing phase in order to allow both companies to strictly focus on the test cells modifications well in advance of the dyne installation and to help minimize the test cells down time. The project schedule was set to allow for a one month shutdown of the test facility.

Projects to be completed during this one month time frame included:

• Removing the Existing Dyne
• Saw Cutting the Floor and Excavating a Pit
• Forming the Pit
• Pouring the Pit
• Installing the Pit Ventilation
• Manufacturing the Dynamometer
• Installing and wiring the Dynamometer
• Top Plate Assembly
• Calibrating the Dynamometer and sub-assemblies
• Start-up and test-out the Dynamometer System
• Training

Thanks in large part to the close cooperation and coordination between the CalsonicKansei and MAE's project managers, the down time of the test cell was minimized to the planned one month time frame without the need for any contingent down time. The cell was up and running with full operation of the dynamometer system on time. The project was considered by all involved to have been a complete success for being completed on time and under budget.

The ultimate result of this project is that CalsonicKansei's Thermal Climatic & Solar Wind Tunnel now possess the industry's most advanced AWD AC Motor Chassis Dynamometer with fully regenerative drive technology. The new system adds significant testing capabilities and has broadened the horizons of their operations, giving CalsonicKansei the ability to test a much wider range of vehicles using the most advanced vehicle testing technologies. The regenerative drives, by returning electrical power back to the system, minimize electrical usage and have reduced operational costs of the system. The MAE system has been running flawlessly since installation in April 2006.

Mustang Delivers Track & Wheeled Multi-Function and Validation Test System For Caterpillar's Multi-Terrain Loader & Skid Steer Loaders

June 20, 2003 -- Download PDF

Mustang Dynamometer delivered an End Of production Line (EOL) Multi-Function and Validation Testing System located in Caterpillar's Sanford, S.C. Multi-Terrain Loader(MTL) & Skid Steer Loader (SSL) Production Facility.

For this project Mustang supplied the test equipment, vehicle interface data acquisition system, Manufacturing Automation Production & Performance Software (MAP2S), engineering for test development, including system design, installation assistance, start-up and training. Caterpillar was so impressed with the system that after the first quarter of operation Caterpillar asked Mustang to up-grade the software on other existing test stands to be compatible with MAE's software system.

The Multi-function test stand is required to test both wheeled vehicles and track vehicles. The systems configuration allows independent operation of the left and right wheels/tracks. This independent loading allows the test stand to stall one side of the vehicle's wheel/track while the other side rotates at full speed. The system also allows for double stall testing where by the vehicles wheel/tracks are stalled along with the vehicle's hydraulic actuated bucket. This double stall testing puts tremendous stress on the vehicle's hydraulic system testing for pressures and leaks.

The mechanical test stand components are unique to allow for dual testing of both wheeled and track driven vehicles. A highly engineered road surface simulation interface was developed to independent left & right load the vehicle's powertrain. Two large capacity electrically controlled power absorber systems are independently connected to the left & right road surface simulators to allow separate left and right load control. The system is designed to completely proof check the final assembly of CAT's SSL and MTL machines.

Integrated within the test stand is an automated vehicle restraint and pull-down system to ensure proper road surface simulation interface and load distribution on the track vehicles. This is important to keep the track loading constant and uniform across the track to dyne's road surface interface. The MAP2S software and data acquisition supplied with the system collects real-time data of the test stand and aligns it with the engine performance, hydraulic pump pressure performance, engine coolant pack capacity, hydrostat pressure performance, operator controls, then transmits the results to CAT's line control computer via a Real-Time Data Importer.

"The testing criteria, process flow, and data storage is in accordance with CAT's highly integrated quality control systems" said Donald Ganzhorn, Executive Vice President and Chief Engineer for Mustang Dynamometer. He added, "In addition, the innovative design of this system will provide Caterpillar with the flexibility to test a wide range of both current and future track & wheel driven machines."

Dean Ganzhorn, Mustang's President and CEO stated, "Mustang's extensive high throughput production testing experience was key to winning the contract and being able to provide this legendary American company with a state of the art test system."