Features

• Fully automatic tester for large starters up to 20 kW, measure starter performance curve and - or test with cranking profile duplicating the engine compression stroke
• Excellent choice for end - of line production testing of large heavy duty starters, durability testing, product quality assurance, component validation - verification, and warranty analysis centers.
• Define performance test conditions and evaluation limits via speed, torque or current
• Can be configured to test from one to four starter samples simultaneously
• Designed to deliver maximum level of functionality, flexibility and accuracy optimized with advanced measuring, statistical & reporting functions
• Fully programmable testing, measure complete starter performance in compliance with ISO 8856 section 4, type 1
• Test specifications easy to configure via SpecView Program. Results, limits, etc. are stored for purpose of statistical data processing, retrieval and archiving.
• Graphical display of starter performance curve or cranking profile with speed, torque, current, efficiency, solenoid contact voltage drop, ripple current and color mapped pass/fail indicators for every parameter
• Printed reports of performance test or cranking profile via any Windows printer, custom pass/fail reports with reporting software, interface to label printer
• Measuring electronics and control PC located in separated NEMA 12 enclosure
• Remote support and administration available
• Automatic rotation direction recognition (CW/CCW)
• Manual or optional pneumatic clamping system for starter clamping
  Exchangeable tooling (rings) to accommodate different starter models
• Separate power supplies for starter motor and solenoid with programmable characteristics, open terminal voltage and internal resistance have separate settings for free run and load test
• Windows operating system and PC with LCD monitor and user friendly interface
  Temperature Measuring unit available with 8 insulated channels

Specifications

Starter Power Supply  0 - 24V, up to  3,000  Amps
Starter Power Supply  0 - 32V, up to 2,400 Amps*
Starter Power Supply  0 - 64V, up to 1,200 Amps*
Starter Pinion Speed  0 -  30,000 RPM **
Starter Torque 0 - 250 NM **
Flywheel Shaft Torque up to 1000Nm
Solenoid Power Supply 0 - 24V: up to 240  Amps
Solenoid Power Supply 0 - 32V: up to 200 Amps*
Solenoid Power Supply 0 - 64V: up to 120 Amps*
Starter Input Power up to 24 kW
Connections for External Battery: 3000 Amps
* Optional
** Depends on the pinion to flywheel gear ratio

MEASURED PARAMETERS:

Starter & Solenoid Voltage up to 70 Volts
Starter Current up to 4000 Amps
Solenoid Current up to 300 Amps
Contact Voltage Drop 0 - 5 Volts
Motor Terminal Voltage up to 48 Volts
Engine Torque up to 1000 Nm
Flywheel Speed up to 4000 RPM
Starter Efficiency 0 - 100%
Starter output power up to 20 kW**
Temperature 8 Insulated Channels -40 to 200° C*

SEE Table IN DOC FILE FOR THE FOLLOWING:

Engine Simulator comparison to durability testing with live engine:

  ST-200
Engine Simulator Live Engine Testing Detailed Comparison
Cost of ownership $ $$$$ Overall the ST-200 has significantly lower cost of owner ship the system can be reconfigured to test new models or engine displacement, engine testing often requires costly purchase and configuration of engine etc…
Fuel cost - $$$$ The ST-200 does not require fuel, storage, handling or environmental issues.
Electricity cost $ $$$$ The load system is regenerative much of the power produced by the starter is recuperated and returned to the starter power supply so that the energy grid is only supplementing the losses.
Test time required low high The ST-200 can test up to four samples at a time, yields more data in less time; an engine can test only one.
Flexibility of cranking profiles high low The ST-200 can simulate engines up to 16 cylinders with programmable battery voltage and resistance, an engine is limited due to its mechanical configuration.
Flexibility of mechanics high low A gear or flywheel and a simple mounting fixture for the starter are all that is required to introduce a new starter model; a new engine can have very high cost.
Maintenance costs $ $$$$ The simple and effective design of the ST-200 requires a minimum of maintenance; engines will wear at an accelerated rate resulting in very high maintenance & replacement costs.
Stability vs. time high low ST-200 test conditions will remain stable, as an engine ages and wears the cranking profile will be affected.
Thermal chamber flexibility high low The thermal chamber on the ST-200 does not require reconfiguration for new models; a new engine may require a substantial investment.
Safety high low ST-200 operation is safe and secure, live engine testing can involve hazards such as fuel, high temperatures and exhaust emissions.

Engine Simulation Features:

Engine cranking profiles provide complete control of the compression stroke pulsations applied to the starter
Programmable limits for the quantity of individual and sequential starter failures before starter is excluded from the testing cycle.

Smart Delays for starter temperature monitoring, if the starter is above the maximum temperature the tester will skip the starter and continue with the next starter in the sequence. When the starter temperature returns to the limit it will be automatically inserted back into the test sequence. Individual starter cooling fans with programmable fan on and fan off settings

Pause test feature allows a sample to be removed for analysis, testing can continue and later the sample can be placed back on the tester and resume testing.

Expandable measuring system for custom requirements. Temperature inputs and auxiliary analog channels available for customer defined measurements.

Programmable flywheel stop position with gausian distribution

Provisions for external battery connections as the power supply

Individual statistical files for each starter, previous results retrievable for display and analysis.

Engine Cranking Profile Generator for creation of new cranking profiles

Options

Power Requirements:

Power Requirements: 208 - 240VAC, step down transformer required for higher voltages, 40 kVa

Weight & Dimensions:

Shipping Weight:    7,550 LBS. 3,424 KG
Shipping Dimensions:
   Test Bed: 145’ x 80’ x 102’ -  3683 x 2032 x 2591 mm
   Computer Cabinet: 33’ x 43’ x 76’ - 839 x 1093 x 1931 mm

Layout

Layout:

Software