JCB: Advanced diesel engine development - Case Study

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Courtesy of Sierra Instruments, Inc.

JCB Power Systems is a global leader in construction and agricultural machinery and the largest company in the UK, where they are headquartered. In 2009, JCB implemented plans to build a world class advanced research and development center, near Derby in the UK, for low emissions diesel engines up to 300kW, with fast transient measurement capability plus the latest cycle emissions measurement systems. After a competitive bidding process against the leading global test system suppliers, Sierra-CP was awarded the multi-million dollar, 10 new high specification test cell project.

Challenge
The project’s success would hinge on the ability of the Sierra-CP team to work closely with JCB and the client architects and construction teams. It would require a solution that enabled high facility utilization while reducing the time involved in the capture and analysis of data. To meet ongoing key engine development and testing milestones during the 24-month construction time line, it would also be necessary to implement a rolling handover as test cells were completed and brought online.
 
Solution
Sierra-CP’s close working relationship with JCB and their research into client needs played an essential role in keeping design and production time to a minimum. Starting with a detailed 3D model, Sierra-CP was engaged in every detail of a construction process that would eventually result in a finished state-of-the-art facility with 10 turn-key test cells. Test cells were all built to uniform specifications with a capacity for interchangeability that enabled diesel engine variants to be tested with precise capability, correlation and repeatability. Test cells were also designed and built to have a high level of data acquisition and connectivity to third party smart instruments.

All instruments were integrated with Sierra-CP's advanced CADET V14 Test Automation System and CADET TLS enterprise software, which provides a complete automated solution for configuring and running tests, performing pre and post test data entry, automatically performing emissions calculations according to the regulatory standards, report generation and much more. Based on their trust in Sierra-CP’s recommendations and their belief that the EPA would soon legally approve Partial Flow Dilution (PFD) as an alternative to traditional CVS systems, JCB selected Sierra-CP’s BG3 PFD system for their particulate emissions development and validation. In late 2011, Sierra-CP made history, when PFD was signed into law and included in the United States Federal Register as a legally recognized alternative method to CVS in 40 CFR part 1065 for engine certification.

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