The Next Generation in Dynamometers
DS-2025 Race Engine Dynamometer
DA-2025 Dynamometer Data Acquisition System
DC-2025 Dynamometer Load Controller
DS-2040 Diesel Dynamometer System
DS-2020 Standard Engine Dynamometer
DS-2010 Small Engine Dynamometer
[Introduction] [Mechanical Design] [Software
[Specifications] [Research Grade Dynamometer Options]
[For more information]
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The Next Generation in Racing Dynamometers Bringing Research
Grade Technology to the Racing Industry....
want to thank you for being one of the many people to take a closer look at
our new line-up of data acquisition products.
Solutions has over 20 years of experience in high-performance data-acquisition
and control systems. Our experience includes such diverse applications as
sonar, nuclear power plant control and research-grade dynamometers.
When you made
the commitment to request this information you obviously felt the same way as
we did, there had to be something better on the market than what you are
presently using or considering purchasing. Let us assure you, you made a wise
decision. When you purchase a dynamometer from Excalibur Solutions Inc., you
are investing in the newest technology. We give you our commitment that
through our continuing research and development program you will stay one
step ahead of your competition. The DS-2025 gives you the value added
advantage that will keep your old customer coming back and gives new customers
a reason to give you that all important second look!
Excalibur Solutions Inc. we are rewriting the standards for Hi-performance
systems are no longer a luxury. With the widespread use of dynamometer
systems within the industry, it is nearly a requirement to have in-house
dynamometer facilities to be viewed as a viable engine builder. Although
tools do not make the engine builder, customer perception should be one of
you most important concerns, as the business becomes more competitive.
DS-2025 dynamometer is a fully integrated engine test system utilizing
state-of-the-art technology. We know there are several systems on the market;
many rely on older, more expensive technology. Some other commercially
available systems are just not complete, requiring add-ons to be purchased
later. Everyone has seen computers become increasingly more powerful while
the costs have plummeted. These decreasing costs have enabled Excalibur
Solutions to offer increased performance with the DS-2025 while keeping costs
After the test cell is built, the DS-2025 dynamometer can
be up and running in less than a day. All cabling and hardware is
pre-configured at the factory, wiring is just a matter of plugging the cables
The operator interface is implemented with the Windows 98 (Windows XP coming soon) operating system.
With the widespread use
of Windows, most operators will be familiar with the interface basics; it
gives you one less thing to learn. To prepare to make a 'pull' simply fill in
the blanks with run parameters, customer data and engine data. The operator
is alerted to any value that may be out of range or may cause costly engine
damage. During a run all operating data is displayed on one screen, no dials
to turn or screens to switch to see all engine conditions.
To help prevent costly engine damage, many engine operating
test conditions have settable safety limits. If a safety limit is exceeded,
the engine under test will be shut down and the brake load will be GENTLY
increased to stop the engine as soon as possible.
brake temperature is also monitored to prevent accidental brake damage.
Automatic Throttle Control
With the automatic throttle control option, the operator
can program tests for drivability and life cycle testing. The test can be
based on engine load, RPM or torque.
Automatic Data Collection
specific fuel consumption.
DS-2025 is engineered around a high performance data-acquisition sub-system
running at 100,000 samples per second. This high sample rate allows the
DS-2025 to minimize the effect of electrical noise from ignition systems and
Automatic Load Control
The automatic load control works in conjunction with the
data-acquisition sub-system, providing closed loop control for the applied
brake load. The automatic load control provides much finer control of loading
than a manual control valve can achieve. The automatic load control gives the
DS-2025 true automatic operation.
Manual Load Control
Although the automatic load control will be used most
often, there are times when you will want to preset a load and perform a
pseudo acceleration test. This can give some insight into the acceleration
characteristics of an engine.
The DS-2025 incorporates a powder-coated two piece test
stand with a reasonable size engine test cart, which is much more manageable
in a tight shop. The brake and engine support equipment stay in the
dynamometer room. A gear-reduction starter and brake-mounted flywheel are
included in the DS-2025, one less thing to worry about and enables testing of
engines with camshaft driven fuel pumps.
stand mounted starter battery tray.
stand mounted ignition tray.
oil drip pan on the engine test cart.
adjustable saddle mount supports.
and Chevy rear engine mounts supplied. Simple rear support design makes
adapters for other engines easy to fabricate.
engine cooling tower.
The supplied fuel system consists of a fuel pump, fuel
filter, pressure regulator, temperature sensor, flow sensor and pressure
sensor. The pressure regulator provides four outlet ports. For a carburetor
engine, there is nothing else to purchase.
The brake water supply pump is included with the DS-2025,
unlike most of the competition.
Two Lambda air/fuel ratio sensors are included with the DS-2025. As an option, up to eight Lambda sensor are available. .
Two airflow venturi style sensors are provided with the
DS-2025. These two sensors, which are 6.5" and 9" in diameter, will
cover 90% of all applications. Because the airflow sensors are based on
RTD's, this enables a truly unrestricted airflow, unlike some blade-based
sensors. Also housed within the flow venturi is the air inlet temperature
One engine coolant sensor is housed in the cooling tower;
one addition sensor is supplied, to be used at operator discretion.
One fuel flow sensor is included with a range and
sensitivity sufficient for gasoline and alcohol applications.
One 0-30 Lbs. Stainless steel pressure sensor is supplied.
One fuel temperature sensor is incorporated within the fuel
One high accuracy humidity sensor is included with the
One electronic barometric pressure sensor is included with
One 0-150 Lbs. Oil pressure sensor is mounted on the brake
One ½-20 Oil temperature sensor is included with the DS-2025.
8 K-type thermocouples are included with the DS-2025. All
sensors are continually monitored and displayed, switching between cylinders
is not required. The thermocouples are supplied with header clamps for
testing of car based engines, but the clamps may be removed for exhaust plate
installation (typically marine applications).
The engine torque readings are accomplished through the use
of supplied a precision strain gauge.
Engine RPM is monitored independently of the engine
ignition system with a magnetic pickup mounted on the brake stand.
The brake outlet water temperature is constantly monitored
to help prevent costly water brake damage.
testing cycles greatly reduce the test time required, lowering labor costs
and engine wear. Controllable Test Start Limits included to help prevent
wasted test runs. The test run cannot start until the following operator
settable engine parameters are met:
Corrected and uncorrected data available
A unique feature of the DS-2025 is the ability to correct
the data to any altitude, humidity and barometric pressure. This adds some
insight to predicting performance of your engines.
Filtered, raw and smoothed data displays available
If you have dynamometer experience, you have noticed that
when the raw data is charted, it 'jumps all over the place'. This is mainly
due to electrical noise at the sensors and sensor response times. The DS-2025
has the ability to perform software low-pass filtering and smoothing of the
charted data to make it more readable.
Unlimited Number of Runs Recorded
is cataloged by date, customer and engine description. Run Histories are
stored in a simple English language directory format for easy retrieval. Old
Runs May Be Recalled And Replayed.
Unlimited Number of Customers Recorded
All relevant customer data may be entered when setting up
for a run. I.e. name, address, and phone number&
Unlimited Number of Engines Recorded
To help maintain a history of engine combinations, all
pertinent engine specifications are recorded. I.e. cam specifications, intake
type, valve lash, runner specifications, stroke, bore&
Extensive graphics capabilities
Up to 9 data streams from 1 to 10 runs may be overlapped on
one chart for comparison purposes. Full color on-screen and printed graphics
included with the DS-2025, no additional equipment or software is required.
real-time data is displayed on one terminal screen in a combination of analog
over digital and digital gauges. The analog gauges are provided for fast
changing test conditions where the blurred numbers of a digital gauge would
horsepower 3- phase 240-volt 120GPM-brake water supply pump. Single
phase pump upgrade available upon request.
Computer data-acquisition and control system
class computer system. > 2GHZ
hard disk drive.
Floppy disc drive.
1024x768 resolution color monitors.
Jet Color Printer.
channels of A/D I/O.
Bit A/D multiplexed converter.
channels of digital I/O.
2 self heated Lambda Air/Fuel Ratio sensors.
8 stainless steel exhaust gas temperature sensors with stainless over
stainless steel strain gauge.
0-15 Lbs. Fuel Pressure sensor.
0-150 Lbs. Oil Pressure sensor.
6.5-inch airflow venturi style airflow sensor.
9-inch airflow venturi style airflow sensor.
engine coolant sensor is housed in the cooling tower.
general-purpose engine coolant temperature sensor.
fuel flow sensor is included with a range and sensitivity sufficient for
gasoline and alcohol applications.
0-30 Lbs. Stainless steel pressure sensor is supplied.
fuel temperature sensor.
high accuracy humidity sensor is included with the DS-2025.
electronic barometric pressure sensor is included with the DS-2025.
0-150 Lbs. Oil pressure sensor is mounted on the brake stand.
½-20 Oil temperature sensor is included with the DS-2025.
RPM magnetic pickup.
brake water temperature sensor.
The DS-2025 is shipped in three cardboard containers via
common carrier on wooden skids.
To order your DS-2025, contact Excalibur Solutions at any
of the contacts listed on the enclosed price schedule. A 50% deposit is
required to secure a delivery date. The balance is due at the time of
The DS-2025 is covered by a limited warranty by Excalibur
Solutions Inc to be free of defects in material and workmanship. The warranty
does not included misuse, abuse, operator neglect, improper installation,
inadequate water supply, and excessive water brake load, excessive water
brake RPM or modifications not performed by Excalibur Solutions. This
warranty covers parts only, labor to troubleshoot/repair any component at the
customer site is not included. Any component, which the customer believes to
be defective, must be returned postage pre-paid to Excalibur Solutions Inc.
All returns must have prior approval by Excalibur Solutions Inc. Under no
circumstances will Excalibur Solutions Inc. be held responsible for
incidental and consequential damages arising from the installation or use of
any Excalibur Solutions Inc. product.
Brake 1 year.
equipment - 1 year.
pump - 90 days.
control value - 1 year.
Mechanical assemblies 1 year.
On-site installation by Excalibur Solutions can be quoted
Software support, phone operator support and on-site
maintenance contracts available upon request.
Existing Dynamometer Systems
If you wish to bring your existing dynamometer system up to
date, the DS-2025 electronics and computer packages are available separately.
Due to the large number of mechanical design differences possible, quotations
are only available upon request.
pressure for injector applications.
Flow sensors for smaller engines, and for injected applications that
cannot utilize the standard airflow sensors.
Automatic Throttle Control for life cycle and drivability
Combustion Pressure Probes
A Pressure transducer contained within a custom spark plug
monitors cylinder pressures during the combustion cycle. Combustion pressures
give insight into detonation problems, valve timing and flame travel in the
Computer Controlled Spark Timing
The optional spark timing control system enables the
computer to vary the spark timing during a 'pull'. During the run, the
computer will vary the spark timing within the selected range to plot the
optimal ignition curve to produce maximum horsepower. After the test is
completed, the system will graph the optimal spark-timing curve. This curve
can then be programmed into any of the on-board timing control computers
readily available on the market.
Intake runner temperature/flow probes
These eight probes will monitor each intake charge
temperature; this will give an indication of fuel and air distribution within
the intake system. This in conjunction with exhaust temperatures will give a
better understanding of what is occurring in each intake runner.
The optional camshaft control system enables the computer
to vary the cam timing during a 'pull'. During the run, the computer will
vary the camshaft timing within the selected range to find the optimal
camshaft-timing curve to produce maximum horsepower. After the test is
completed, the system will graph the optimal camshaft-timing curve. This
curve can then be interpreted to yield the desired torque and horsepower
curve for your application and racetrack.
Intake Pulse Monitoring
The intake pulse monitoring sub-system includes eight
probes installed in the intake runners to monitor the reversion pulses that
occur after the closing of the intake valve. With the intake pulse
information, runners and ports can be redesigned to minimize this adverse effect.
Camshaft intake closing ramps can also be altered to minimize the reversion
One of the shortcomings of most modern water-brake
dynamometer systems is lack of acceleration testing capabilities.
Acceleration testing can show why two motors making the same horsepower,
produce different on-track performance. Never before has accurate inertia
testing been possible with a water brake based dynamometer system.
Optical Flame Monitoring
One of the latest developments in the advanced engine
research field is real-time monitoring of the flame travel in the combustion
chamber. Thirty-two optical probes are placing in the cylinder wall to
monitor the flame travel during the combustion cycle. This will give detailed
information regarding optimal chamber and piston design.
Protects high RPM engines from harsh tortional loads sometimes experienced with dynamometer systems.
A Camshaft profiler is an invaluable tool that can alert
you to mis-ground camshafts much more quickly and accurately than measuring
the camshaft in the block. In block measurements are difficult and time
consuming. Also repeatability is nearly impossible due the block and fixture
variables. The *CP-2025 cam profiler attachment to the DS-2025 gives you a
valuable tool at the lowest cost possible. Because the CP-2025 utilizes the
DS-2025 computer and data acquisition equipment, you get a cam profiler at a
much more affordable cost.
Windows98 and WindowsXP are trademarks of Microsoft Corp.
*CP-2025 is manufactured by Excalibur Solutions
Excalibur Solutions Inc.
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