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Charge Air Cooler Thermal Cycle Machine

This machine is a two station Charge air cooler thermal cycle machine used to administer thermal shock cycles to heat transfer devices. The machine cycles very hot air through one of the units under test while cool air is being circulated in the other. During this time blowers independently draw air across the face of the test articles to control the thermal drop from inlet to outlet. After a certain stabilization time, the hot and cold channels are swapped automatically so that the test parts see the opposite condition. Pressure and air flow data is being monitored and stored during the entire operation. Since this machine is mainly intended for stand alone use, it is capable of emailing or paging an operator in the even of a failure or shutdown condition. The fixture was designed so that a range of different size charge air coolers could be accommodated.

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Charge Air Cooler Pressure Cycle Machine

This machine is a two station charge air cooler pressure cycle machine for fatigue testing at high temperature. The fixture was designed to accommodate a variety of shapes and sizes of Charge air cooler devices. Air pressure to each component is controlled to a programmable target and then released. The machine monitors the fill and decay rate as well as checking for leaks on a programmable interval. Airflow across the face of the coolers are also independently controlled to a programmable target to achieve the desired temperature drop across the test parts. All cycle information is stored to a data file and can be recalled at a later date. As this test is mainly unattended for long periods of time, the machine can e-mail or page an operator in the event of a failure or shut down condition.

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Turbo Charger Production Functional Tester

This machine is a production turbo charger functional tester. The machine is designed with two pallets at the front that allow one turbo to be loaded and unloaded while the other is being tested. The pallet is automatically drawn into the machine where it is automatically clamped up and the turbo intake and exhaust ports on the compressor and turbine are automatically engaged. The oil supply ports and electrical connector is also automatically engaged. A barcode scanner automatically reads the turbo as it is presented and ties this number to test results that are also stored on the machine for later retrieval.

The turbo is tested for leakage in both the turbine and compressor housings as well as performance hysteresis, actuator response time and actuator oil consumption. High volume compressed air is used to spin the turbine while the pressure drop is controlled to a target. Mass airflow is measured on both the compressor and turbine side of the test part as well as air pressure, oil flow and oil pressure. The vane actuator RMS current is also measured.

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Engine Timing advance valve performance machine

This machine performs an automated functional test at the end on an assembly line for a high production hydraulic proportional valve.

The machine drives the valve with a specially designed piece of hardware, sweeping the product through its control range and back. Pressure drop is maintained at 58 PSI within 1/2 PSI while the flow, RMS current and pressure is monitored. The curves are collected and post processed to yield, valve hysteresis, max flow, leakage, and null position among other measurements. The machine also has a blow-out fixture that is automatically loaded to clear the test part of any test oil before packaging.

Machine completely stores valve curves and test results for later retrieval and evaluation. Test cycle is approximately 30 seconds per head. There are two heads per machine and a system consists of two machines mirrored back to back. One system yields a tested part every 8 seconds. Modular design lends to easy integration in to assembly lines.

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Automated EGR Valve functional end of line tester

This four station machine is automatically loaded by robot on an assembly line and performs an end of line test on an EGR (Exhaust Gas Recirculation) valve. Performance tests include mass airflow, hysteresis and step response and leakage. The vacuum drop across the part is controlled by the test machine at all times. The part is driven with MCM designed and built electronics.

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Automated In-line production pressure transducer calibrator

This machine calibrates automotive engine pressure transducers in high production volumes. The transducers are subjected to an ambient environment, high temperature environment and several different pressures up to 40,000 PSI. The transducer data is processed and calibration information is generated. The new coefficients are then flashed to each processor controlled transducer. This machine is truly a hydraulic feat.

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