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Introduction Modern engine testing produces a dense mix of thermal, mechanical, electrical, and visual data across multiple cells. The Engine Test Cell Data Acquisition System (DAS) consolidates these inputs into a single, time-synchronized stream with robust signal conditioning, precise hardware synchronization, and secure, centralized storage. Operators work with live, role-based dashboards and a guided “start–run–annotate–report” workflow; quality teams get full traceability with calibration and audit logs; and management receives consistent KPIs and automated reports. Designed for new facilities and brownfield upgrades alike, the system integrates cleanly with existing sensors and PLC/SCADA infrastructure, scales from a few benches to 15+ cells, and is engineered for reliable operation in demanding test-room environments. The result is faster setup, fewer errors, and defensible data—every run, every cell. What it is A turnkey, industrial-grade platform for multi-cell engine testing. It captures, time-locks, visualizes, and archives high-fidelity measurements and synchronized video, then publishes structured results onto the plant network for downstream analysis and reporting. It minimizes wiring and operator workload, preserves compatibility with existing information systems, and produces audit-ready records. System architecture • Sensor layer — Thermocouples (T/K/J), RTDs, bridge/strain pressure transducers, magnetic/Hall speed pickups, torque meters, air/fuel/coolant flowmeters, IEPE accelerometers, discrete I/O, and safety/interlock lines. • Signal conditioning — Channel-level isolation and protection; cold-junction compensation; 4-wire RTD; programmable bridge excitation; IEPE; 4–20 mA / 0–10V; anti-aliasing; surge/over-voltage protection. • DAQ chassis & timing — Modular multi-slot chassis per cell; simultaneous-sampling where required; deterministic hardware sync with ≤1 μs inter-chassis skew; absolute timestamps (GPS/PTP optional). • Edge compute — Industrial PC(s) for acquisition, local buffering, alarms, and dashboards; fanless options for harsh test rooms. • Networking — Redundant Ethernet; VLAN segmentation per cell; secure publish/subscribe to the control room and plant LAN. • Software stack — - Real-time charts (trend, XY, FFT/PSD, waterfall, polar) - Test sequencing, event tagging, and operator checklists - Limit checking/alarms with latching and acknowledgement - Run management with metadata, operator e-signatures, and audit trail - Automated reports (PDF/CSV/JSON/SQL) and APIs (OPC UA/REST) for PLC/SCADA/MES/IMS - Synchronized video capture and playback tied to timebase and events • Data management — Central historian with compression and checksums, role-based access control, retention & backup policies, and controlled report templates. Key capabilities aligned to the brief • Multi-cell orchestration — Unified console for up to 15 engine test cells; per-cell channel maps; concurrent run control; cross-cell comparisons. • Measurement accuracy — System engineered for high precision measurement chains; channel-by-channel calibration tracking and verification to meet tight accuracy targets. • Synchronized video — Record and index video alongside data for diagnostics and review; bookmarks and event-based snapshots. • Publish to plant LAN — Automated data upload to the designated production/plant LAN segment; structured datasets suitable for statistical analysis and dashboards. • Information system compatibility — Clean interfaces to existing plant IMS/DB stacks (e.g., via ODBC/SQL gateways, connectors, or file drop pipelines) without disrupting current operations. • Operator-first UX — Guided workflows that reduce setup time, enforce tag/metadata completeness, and prevent common run mistakes. • Quality & traceability — Calibration certificates, instrument serials, change logs, user roles/permissions, and audit trails. • Brownfield friendly — Reuse of existing sensors, junction boxes, wiring routes, and PLC interlocks where feasible; protocol bridges (Modbus/TCP, OPC UA, EtherNet/IP). Typical scope of supply • Per-cell hardware: Modular DAQ chassis, signal-conditioning modules, counter/tacho inputs, video capture interface, and pre-terminated harnesses. • Control-room hardware: Industrial PCs for acquisition and historian; operator HMIs with multi-monitor setup. • Cabling & cabinets: Field cables, labelled JBs, racks/cabinets with power distribution, earthing, and surge protection. • Software & licenses: Acquisition, historian, reporting/analytics, user/role management, and API connectors. • Services: Site survey, detailed design, installation, loop checks, commissioning (FAT/SAT), operator & maintenance training. • Documentation: Wiring diagrams, I/O lists, interface specs, calibration records, operating & maintenance manuals, acceptance test procedures. Representative technical specifications (Final counts and speeds are engineered per cell and per program.)
