Engine Test Bed | ThermoFlux – 7080
The Engine Test Bed ThermoFlux – 7080 is a self-contained bench-mounting laboratory unit for investigating internal combustion engine performance, efficiency, and fuel consumption using interchangeable engines and an eddy current dynamometer. It is supplied with a four-stroke gasoline engine (273 cc, 5.5 kW at 4000 rpm) and a four-stroke diesel engine (347 cc, 5 kW at 3000 rpm), both single-cylinder and air-cooled, with two optional engines also available. The eddy current dynamometer is rated at 10 kW, 50 Nm, and 13,000 rpm maximum with active mode PID control. This engine test bed includes a dual 5-litre fuel tank system, 54.8 mm air inlet with 0 to 10 m/s airflow meter, and a 10 kg weighing balance for fuel measurement. Optional accessories include a PV diagram system, exhaust gas analysing unit (TH-3128-8), exhaust gas calorimeter, and LabVIEW-based DAQ software for Windows-based data acquisition.
The Engine Test Bed ThermoFlux – 7080 is a self-contained, bench-mounting laboratory unit designed for the investigation of internal combustion engine performance, efficiency, and fuel consumption across multiple engine types. This engine test bed is supplied with three interchangeable engines as standard, a single-cylinder four-stroke gasoline engine, a single-cylinder four-stroke diesel engine, and a higher-capacity four-stroke diesel engine, along with an eddy current dynamometer, dual fuel tanks, air induction system, and full instrumentation for comprehensive engine testing.
Product Overview
The Engine Test Bed ThermoFlux – 7080 consists of an engine and dynamometer assembly mounted on a vibration-insulated solid steel base plate within a steel framework. The engine is connected to the dynamometer via an elastic claw coupling. The fuel system, incorporating two 5-litre fuel tanks with valves, and the air induction system are contained within the framework. The instrumentation and control panel are mounted on the front frame.
The eddy current dynamometer is rated at 10 kW generation power, 50 Nm braking torque, and a maximum speed of 13,000 rpm. Torque measurement accuracy is +0.2 to 0.3% FS and speed accuracy is +1 rpm. The dynamometer is water-cooled using tap water. The eddy current dynamometer controller operates in active mode with constant speed, constant torque, and constant power control modes. The controller uses a programmable PID with digital LCD panel display and 5 A output current. Protection covers engine stall, overload, and water.
The air inlet pipe has an internal diameter of 54.8 mm. The airflow meter measures 0 to 10 m/s. Air temperature range is 0 to 100°C and air consumption covers 20 to 350 L/min. Fuel temperature range is -100 to 400°C and fuel consumption is 0 to 60 cm³/min. A 10 kg weighing balance with 0.1 g graduation and a stopwatch are included for fuel consumption measurement.
Three engines are supplied as standard and are easily interchangeable for comparative testing. Two optional engines are also available: a variable compression ratio gasoline engine and a two-stroke gasoline engine. Optional accessories include a PV diagram system with cylinder head pressure transducer and crank angle encoder, an exhaust gas analysing unit, an exhaust gas calorimeter, and an electronic engine indicating system.
Engine Test Bed ThermoFlux – 7080, Technical Specifications
| Parameter | Value |
|---|---|
| Test Stand Max. Power Output | Up to 2.2 kW |
| Engine Mounting | Vibration-insulated base plate, elastic claw coupling |
| Dynamometer Type | Eddy current |
| Dynamometer Rated Generation Power | 10 kW |
| Dynamometer Rated Braking Torque | 50 Nm |
| Dynamometer Rated Maximum Speed | 13,000 rpm |
| Torque Measurement Accuracy | +0.2 to 0.3% FS |
| Speed Measurement Accuracy | +1 rpm |
| Dynamometer Cooling | Water-cooled, tap water |
| Controller Type | Active mode, programmable PID |
| Controller Modes | Constant speed, constant torque, constant power |
| Controller Display | Digital LCD panel |
| Controller Output Current | 5 A |
| Controller Protection | Engine stall, overload, water |
| Air Inlet Pipe ID | 54.8 mm |
| Airflow Meter Range | 0 to 10 m/s |
| Air Temperature Range | 0 to 100°C |
| Air Consumption Range | 20 to 350 L/min |
| Fuel Tank Count | 2 |
| Fuel Tank Capacity | 5 litres each |
| Fuel Temperature Range | -100 to 400°C |
| Fuel Consumption Range | 0 to 60 cm³/min |
| Weighing Balance | 10 kg, graduation 0.1 g |
Technical Data
Eddy Current Dynamometer
| Parameter | Value |
|---|---|
| Rated Generation Power | 10 kW |
| Rated Braking Torque | 50 Nm |
| Rated Maximum Speed | 13,000 rpm |
| Torque Accuracy | +0.2 to 0.3% FS |
| Speed Accuracy | +1 rpm |
| Cooling | Water-cooled, tap water |
Eddy Current Dynamometer Controller
| Parameter | Value |
|---|---|
| Controller Type | Active mode control |
| Control Modes | Constant speed, constant torque, constant power |
| Display | Digital LCD panel |
| Setting | Programmable PID |
| Output Current | 5 A |
| Protection | Engine stall, overload, water |
Air Inlet System
| Parameter | Value |
|---|---|
| Pipe Internal Diameter | 54.8 mm |
| Airflow Meter Range | 0 to 10 m/s |
| Air Temperature Range | 0 to 100°C |
| Air Consumption | 20 to 350 L/min |
Fuel System
| Parameter | Value |
|---|---|
| Number of Fuel Tanks | 2 |
| Tank Capacity | 5 litres each |
| Fuel Temperature Range | -100 to 400°C |
| Fuel Consumption Range | 0 to 60 cm³/min |
| Weighing Balance | 10 kg, graduation 0.1 g |
Engine 1: Single Cylinder Four-Stroke Gasoline Engine (Spark Ignited)
| Parameter | Value |
|---|---|
| Model | ThermoFlux – 7080/1 |
| Displacement | 273 cc (approx.) |
| Maximum Output | 5.5 kW at 4000 rpm |
| Maximum Torque | 13.7 Nm at 2800 rpm |
| Fuel | Unleaded gasoline |
| Compression Ratio | 6.3:1 |
| Cooling System | Forced air cooling |
| Lubrication | Splashing type |
| Lubricant | Automotive lubricating oil (API/SE or higher, SAE/10W-30) |
| Carburetor | Horizontal draft, float type |
Engine 2: Single Cylinder Four-Stroke Diesel Engine (Compression Ignited)
| Parameter | Value |
|---|---|
| Model | ThermoFlux – 7080/2 |
| Displacement | 347 cc (approx.) |
| Maximum Output | 5 kW at 3000 rpm |
| Compression Ratio | 21.5:1 |
| Injection System | Direct injection |
| Fuel | Automotive diesel fuel |
| Cooling System | Forced air cooling |
| Lubricant | Automotive lubricating oil (SAE #30) |
Engine 3 (Optional): Single Cylinder Four-Stroke Gasoline Engine with Variable Compression (Spark Ignited)
| Parameter | Value |
|---|---|
| Model | ThermoFlux – 7080/3 |
| Displacement | 273 cc (approx.) |
| Maximum Output | 5.5 kW at 4000 rpm |
| Maximum Torque | 13.7 Nm at 2800 rpm |
| Fuel | Unleaded gasoline |
| Compression Ratios | 10:1, 8.5:1, 5.5:1, 4:1 (original 6.3:1) |
| Ignition Timing | Adjustable in 11 stages, 10° after TDC to 40° before TDC |
| Cooling System | Forced air cooling |
| Spark Plug | NGK BP-6HS (recommended) |
| Lubrication | Splashing type |
| Lubricant | Automotive lubricating oil (API/SE or higher, SAE/10W-30) |
| Carburetor | Horizontal draft, float type |
Engine 4 (Optional): Single Cylinder Two-Stroke Gasoline Engine (Spark Ignited)
| Parameter | Value |
|---|---|
| Model | ThermoFlux – 7080/4 |
| Displacement | 80 cc (approx.) |
| Maximum Output | 2 kW at 6000 rpm |
| Fuel | Unleaded gasoline |
| Compression Ratio | 6:1 |
| Cooling System | Forced air cooling |
| Ignition System | CDI |
| Lubrication | Splashing type |
| Lubricant | Motorcycle synthetic two-stroke oil |
Electronic Engine Indicating System (Optional)
| Parameter | Value |
|---|---|
| Model | ThermoFlux – 7080/5 |
| Measuring Amplifier | Amplification factor 10 mbar/mV |
| TDC Sensor Trigger Distance | 1 mm |
| Power Supply | 230V, 50Hz or 60Hz, 1 phase |
Pressure Transducer for Engine (Optional)
| Parameter | Value |
|---|---|
| Model | ThermoFlux – 7080/6 |
| Measuring Range | 0 to 300 bar |
| Maximum Allowable Pressure | 0 to 350 bar |
| Sensitivity | -30 pC/bar |
| Natural Frequency | Over 65 kHz |
| Operating Temperature | -40 to 400°C |
Crank Angle Encoder / TDC Sensor (Optional)
| Parameter | Value |
|---|---|
| Model | ThermoFlux – 7080/8 |
| Speed Range | 0 to 5000 rpm |
| Crank Angle Signal | 0 to 360° |
| Graduation | 1° |
Exhaust Gas Analysing Unit (Optional)
| Parameter | Value |
|---|---|
| Model | ThermoFlux – 7080/9 |
| Working Temperature | 5 to 45°C |
| CO Measuring Range | 0 to 20% vol. |
| CO₂ Measuring Range | 0 to 25% vol. |
| O₂ Measuring Range | 0 to 25% vol. |
| HC Measuring Range | 0 to 5000 ppm vol. |
| Lambda Range (Petrol) | 0 to 17.64 |
| Lambda Range (Diesel) | 0 to 18.72 |
| Accuracy | Classes 1 and 0 |
| Power Supply | 230V, 50Hz or 60Hz, 1 phase |
Exhaust Gas Calorimeter (Optional)
| Parameter | Value |
|---|---|
| Model | ThermoFlux – 7080/10 |
| Calorimeter Construction | Insulated, stainless steel, finned pipe heat exchanger |
| Heat Exchange Area (Exhaust Gas Side) | 1.169 m² |
| Heat Exchange Area (Water Side) | 0.164 m² |
| Exhaust Gas Temperature Range | 2x -100 to 400°C |
| Water Temperature Range | 2x -100 to 400°C |
| Flow Rate Range | 4 to 36 LPM |
Key Features
- Engine Test Bed Configuration: Self-contained bench-mount unit with eddy current dynamometer and three interchangeable engines
- Dynamometer: Eddy current, 10 kW, 50 Nm, 13,000 rpm maximum, water-cooled
- Dynamometer Controller: Active mode, constant speed/torque/power modes, programmable PID, digital LCD
- Engine Mounting: Vibration-insulated base plate, elastic claw coupling
- Standard Engine 1: Single-cylinder four-stroke gasoline, 273 cc, 5.5 kW at 4000 rpm, 13.7 Nm at 2800 rpm
- Standard Engine 2: Single-cylinder four-stroke diesel, 347 cc, 5 kW at 3000 rpm, 21.5:1 compression
- Optional Engine 3: Variable compression gasoline engine, 5 compression ratios, adjustable ignition timing in 11 stages
- Optional Engine 4: Two-stroke gasoline engine, 80 cc, 2 kW at 6000 rpm, CDI ignition
- Air Inlet: 54.8 mm pipe ID, 0 to 10 m/s airflow meter, 20 to 350 L/min consumption
- Fuel System: 2x 5-litre tanks, 0 to 60 cm³/min fuel consumption measurement
- Weighing Balance: 10 kg capacity, 0.1 g graduation, with stopwatch for fuel measurement
- PV Diagram: Optional, with cylinder head pressure transducer and crank angle encoder
- Exhaust Gas Analysis: Optional unit (TH-3128-8), measures CO, CO₂, O₂, HC, and Lambda
- Exhaust Gas Calorimeter: Optional, stainless steel finned pipe, 1.169 m² exhaust side area
- Software: Optional LabVIEW-based DAQ software, Windows compatible
Experiments
- Engine performance curve at full and partial load
- Engine efficiency and fuel consumption variation with speed and load
- Determination of the following engine parameters at different speeds:
- Engine torque
- Brake power
- Volumetric fuel consumption
- Specific fuel consumption
- Air flow rate
- Air-to-fuel ratio
- Volumetric efficiency
- Brake mean effective pressure (BMEP)
- PV Diagram (optional)
Construction and Design
The Engine Test Bed ThermoFlux – 7080 is assembled as a compact, self-contained bench-mounting unit. The engine and eddy current dynamometer are mounted on a vibration-insulated solid steel base plate housed within a steel framework. The engine connects to the dynamometer via an elastic claw coupling. The eddy current dynamometer is rated at 10 kW generation power, 50 Nm braking torque, and a maximum speed of 13,000 rpm, with water cooling using tap water. The dynamometer controller operates in active mode with constant speed, constant torque, and constant power control modes using a programmable PID and digital LCD display.
Two 5-litre fuel tanks with valves and an air induction system with a 54.8 mm inlet pipe are integrated within the framework. Airflow is measured from 0 to 10 m/s, with air consumption from 20 to 350 L/min. Fuel consumption is measured from 0 to 60 cm³/min using a 10 kg weighing balance (0.1 g graduation) and stopwatch. The instrumentation and control panel are mounted on the front frame.
Three engines are supplied for this engine test bed: a four-stroke gasoline engine (273 cc, 5.5 kW), a four-stroke diesel engine (347 cc, 5 kW), and the test stand accommodates two further optional engines. All engines are single-cylinder, air-cooled, and interchangeable. Each engine is supplied with adaptors for measuring exhaust and lubrication oil temperature. Optional accessories include a PV system with pressure transducer (0 to 300 bar, over 65 kHz natural frequency) and crank angle encoder (0 to 360°, 1° graduation), an exhaust gas analysing unit, and an exhaust gas calorimeter with stainless steel finned pipe construction.
Software
ThermoFlux – 7080 Software (Optional)
- Developed in the National Instruments LabVIEW environment
- Designed specifically for data acquisition with this apparatus
- Measures, processes, and stores experimental results on a PC
- A set of electronic sensors is included when the software option is selected
- Compatible with any Windows operating system
- Indicator system available as digital storage oscilloscope (analog output, non-DAQ) or software for DAQ and digital output
Scope of Delivery
- 1 experimental unit
- 1 instructional manual
Optional Accessories
| Item | Model |
|---|---|
| Single Cylinder Four-Stroke Gasoline Engine with Variable Compression | ThermoFlux – 7080/1 |
| Single Cylinder Two-Stroke Gasoline Engine | ThermoFlux – 7080/3 |
| Cylinder Head Pressure Transducer and Crank Angle Encoder (PV System) | ThermoFlux – 7080/3 |
| Electronic Engine Indicating System | ThermoFlux – 7080/5 |
| Pressure Transducer for Engine | ThermoFlux – 7080/6 |
| Crank Angle Encoder (TDC Sensor) | ThermoFlux – 7080/8 |
| Exhaust Gas Analysing Unit | ThermoFlux – 7080/9 |
| Exhaust Gas Calorimeter | ThermoFlux – 7080/10 |
Q1: How many engines are supplied with the Engine Test Bed ThermoFlux – 7080 and are they interchangeable?
Two engines are supplied as standard: a single-cylinder four-stroke gasoline engine (273 cc, 5.5 kW at 4000 rpm) and a single-cylinder four-stroke diesel engine (347 cc, 5 kW at 3000 rpm). Both are air-cooled and easily interchangeable on the test stand. Two additional optional engines are available: a variable compression ratio gasoline engine and a two-stroke gasoline engine.
Q2: What type of dynamometer is used in this engine test bed and what are its ratings?
An eddy current dynamometer is used, rated at 10 kW generation power, 50 Nm braking torque, and a maximum speed of 13,000 rpm. It is water-cooled using tap water, with torque accuracy of +0.2 to 0.3% FS and speed accuracy of +1 rpm.
Q3: What control modes does the dynamometer controller support?
The active mode controller supports constant speed, constant torque, and constant power control modes. It uses a programmable PID with a digital LCD panel display and 5 A output current, with protection for engine stall, overload, and water.
Q4: What optional accessories are available for PV diagram measurement?
The PV diagram option requires a cylinder head pressure transducer (0 to 300 bar, sensitivity -30 pC/bar, over 65 kHz natural frequency, -40 to 400°C operating range) and a crank angle encoder (0 to 5000 rpm, 0 to 360° signal, 1° graduation). An electronic engine indicating system with 10 mbar/mV amplification is also available.
Q5: What parameters does the optional exhaust gas analysing unit measure?
The exhaust gas analysing unit (TH-3128-8) measures CO (0 to 20% vol.), CO₂ (0 to 25% vol.), O₂ (0 to 25% vol.), HC (0 to 5000 ppm vol.), Lambda for petrol (0 to 17.64), and Lambda for diesel (0 to 18.72), at a working temperature of 5 to 45°C.
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