The Challenge
A leading manufacturer sought to automate and relocate their end of line production test systems for generator sets (gensets) running on various fuel types, including propane, natural gas, diesel, and gasoline. The goal was to reduce the production test systems total test time to three minutes, aligning with their production rates. They required a fully automated test and transport system to enhance overall efficiency. The system needed to accommodate multiple genset families while ensuring seamless integration into their existing production line.
The solution would involve automating the entire testing process and managing different product configurations in a single setup. It had to meet strict safety requirements, handle diverse fuel types, and ensure the process was fully automated from product entry to exit. Additionally, the system needed to include a robust transportation mechanism to efficiently move products through the testing process for their generator test stand. This was a critical component of the desired end of line systems.
The Solution
ACS designed and implemented fully automated end of line systems for production testing that met the client’s stringent time and safety requirements. The production test systems included seven independent test enclosures equipped with integrated controls and data acquisition systems. Each enclosure was built with fire-rated and blast-rated specifications, ensuring safety, while also supporting multiple fuel types, including flammable options like propane and natural gas. The automated conveyor system streamlined product delivery and managed a random product mix from multiple lines, offering fine control for each product type within each generator test stand.
Key to the system’s flexibility was the use of standardized test pallets designed to handle all genset families. These pallets featured quick connections for fluid, control, and power systems, allowing the client to easily switch between various genset configurations. The pallet design also included swappable components to further expand its versatility within the generator test stand framework. This modularity was a key aspect of the new end of line systems.
The fully automated system included match-plate connections for fluid and electrical interfaces, ensuring seamless transitions during testing. The test process itself was configured to allow for product-specific adjustments and tuning, all while adhering to the client’s strict timeline of three minutes per test cycle. The system also included a Safety Instrumented System (SIS) to monitor critical safety factors throughout the process.
The project was further complicated by the need to accommodate 11 different product families, with generators ranging from 5kW to 35kW, all with varied layouts and configurations. ACS addressed these challenges by integrating multiple test specifications and protocols into a single automated system while managing the space constraints within the facility.
The Outcome
With ACS’ extensive experience in engine and generator testing, data acquisition, and PLC programming, the client received a turnkey solution that met their performance goals. The automated system significantly increased production efficiency while accommodating the wide variety of genset configurations and fuel types. By designing a flexible, high-performance test system, ACS helped the client streamline their operations and achieve their production targets without compromising on safety or quality.
Key Features
- Seven independent test enclosures with integrated control and data acquisition systems
- Fire-rated and blast-rated enclosures, supporting multiple fuel types
- Standardized test pallets with swappable components for fluid, control, and power systems
- Automated conveyor system managing multiple product lines and genset configurations
- Safety Instrumented System (SIS) for critical monitoring and compliance
- Fully automated test sequence, product tuning, and fluid/electrical connections
ACS Services
- Design and build of fully automated end of line systems for production testing
- Integration of controls and data acquisition systems
- Facility design and space management for efficient layout
