TeLC since 1976

Training of Technologies
With TeLC made equipment

Metal Machining Technologies

hydraulic machines, properties of fluids
Heat technologies
Heat Engines
Heat transport,-transfer
Heat exchange,-absorption,-efect
Automatic Control
Quotation texts roomwise costs

Copyright:
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-fon 02303 239999 -facs 239990 [email protected]
 The wide field of Technologies for which TeLC 2
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Index
page
index 2
Introduction 4
A Metal Machining Technologies
Universal Test Press 120kN 5
Casting 5
Forming pressing deepdrawing bending 5
Testing compression tensile- hardness 7
Cutting shearing punching , wedge as tool 8
Connecting welding soldering glueing riveting clinching 10
shaft and hub screwing
Chip removal
Cutting Force Measurement 14
Software 15
Tool Dynamometers 15
General properties 15
Turning Dynamometer 17
Measure reports 18
Evaluation aspects 20
Drilling Dynamometer 21
Measure reports 22
Milling Dynamometer 23
Measure reports 24

B hydraulic machines, properties of fluids 25

Centrifugal pump & fluids measurement 26
Software and measure reports 27
Centrifugal Fan 28
Software and measure reports 29
Pump-turbine aggregate 30
Pump-turbine Test Stand 31
Airpower station with Wind machine 32
Pelton and centripetal turbine with Föttinger brake 33

C Heat technologies 36
C1 Heat Engines
Transparent Engine Technic Stand 38
Functional Engines 43
Engine test brake Hydrobrake 150 kW / 7000 rpm 45
Data acquisition and control software 46
Diagnosis of vehicle engines 47
FumoControl test screen 49
FumoControl fault setup 50
FumoControl organigram 51
TANDEM Engine Test bench for 2 engines alternatively 52
control- and data presenting screen Test report 53

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Index page 2
page
C2 Heat transport, transfer, exchange, absorption, efect 54
Fan and thermic test-stand 55
Fluidized bed dryer 56
Fluidized bed dryer software and measure reports 57
Dehumidifier 58
Airheating and humidifier 59
Heat pump 1000W with reservoir 60
Heat pump 250W 61
logp / h diagram of heat pump cycle 62
Solar Collector 63
Solar Collector artificial radiation 64
Teststand Heatexchanger 65
control and data acquisition screens 66

D Automatic Control 67
Level- and flow control LFIC 2000 68
Step and disturbance resposes of LFIC PC software Controller 59
Interactive miniplant 70

E Quotation texts
Material Test Machine and accessories 73
Cutting Tool Dynamometers 74
hydraulic machines, properties of fluids 75
C1 heat engines ( internal combustion engines) 76
C2 Heat transport, transfer, exchange, absorption, efect 78
D Automatic Control 79

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Introduction
Philosophy of TeLC :
• Training should teach principles not specialties
• Training should activate own logical thinking
• Laboratory practice should be near to reality, should demand preparation and
evaluation . This efects maximum netbuilding in brain.
The learned matter remains useable.
• The imprint of these fundamentals makes capable for own relations, experiments
and developments
• Practica in this context should be in level between the physics experiment and
the scientific experiment.
• The same Training equipment should make possible a profund and a less
profund treatment of the matter.

A Metal Machining Technologies

1. Casting
2. Forming pressing, deepdrawing, bending
3. Testing compression, tensile-, hardness
4. Cutting shearing, punching, wedge as tool
5. Connecting riveting, clinching, shaft and hub
6. Chip removal drilling, turning, milling

Common feature of these technologies is the need of a machine that can efect force.
And as force comes along with a deformation this machine should be able to perform
a movement.
The most useful machine for the operations 1 to 5 is a PRESS.
TeLC supplies the Universal Test Press 120kN

Hydraulically driven Universal Material

Testpress 120 kN / 150 mm stroke for
tensile-, compression-, hardness and
technological tests of all kind.

Machine is equipped with fast and highly

resolving electronic measure systems for
force and travel and with electrically
controllable actors.

Machine has got a controlsystem for

speed, forcecreation, force start and
ending, testcycles, testseries, operator
guidance,

The inbuilt intelligency is operated from

the touchscreen or the serially connected
PC.

Singular is the Video Measure System for

Contraction. See below

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Technologies which can be practiced with this equipment are not presented as
phenomena . It is important for the learning efect that the parameters responsible for
the performance are recognized related to amount, efect, direction and variation.
TeLC herefore use modern Multimedia Systems

For realization of the respective technology with the press it is necessary to install the
corresponding tool .

Casting of plastics is performed with the plastics injecting device and suitable
moulds

Forming is done f.e. with the deep-drawing tool

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Testing should be understood as the testing of properties.

That can be executed in the form of a tensile, compression, shear or bending
procedures adopted for the gain of values of stress resistance and elasticity until
destruction or failure.
Thus the test object is classically material but also structure (form) or a combining
method like welding, soldering, glueing or riveting or a modern one “clinching” or the
old one screwing or the test of a force efected shaft and hub combination.

Tensile Testing of material is made with the Clamps for Tensile Test Specimen.

Singular is :
the Video Measure System for Contraction
For many cases of properties
testing the standard clamping
devices for tensile,
compression and shear are
useable

The characteristic shape of a Cutting Tool is the wedge.

To test efects of different wedge angles TeLC supply one set and another set of
different materials so to keep in focus the materials which behave different.

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The Test Press is controlled from the software of the external PC. Many configurations
are possible. But all the princible experiments are allready. They can be modified easily.

Below :Screen after Tensile Test with Contraction measurement

With Contraction measurement True Stress is measured and visible.
True Stress means: Traction Force is related to the true diminishing square area

Configuration example wedge angle test Configuration series tests

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Draft for user guidance Results of series tests

Drafts of Punching Tests with respective tools

A Report of Stamping series tests with the non conducted punching tool above
and different metal thickness see next page

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Punching series tests with different metal thickness

Report
With configuration, comparison plot and characteristic values
characteristic values are the max. forces

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5. Combining with help of a Press is a modern process for thin (car body-)
metalsheets.

Clinching

The amount of press force defines the load which the combination can carry.

Test procedure uses different forces for combination.

With shear force measurement is tested afterwords which forces the combinations stand.

Following picture guides trainee through the series test.

The Report is on the following page

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Report

Power of the Clinching Combination

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Similar like before test serieses of shaft-hub combinations are made

Clamping sets are used which combine only by force efect.

Power of the combination is dependant of the friction force.

The friction force is the higher the higher is the torque which was used for the screws
tightening.

The transmittable torque is tested by efecting a torque with lever and force on the
combination.

Parameter setting guidance

Report on following page

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Report

Sustainable torque of the shaft-hub combination

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It was demonstrated that the following machining technologies

Casting injection moulding

Forming pressing, deepdrawing, bending
Testing compression, tensile-, hardness
Cutting shearing, punching, wedge as tool
Connecting riveting, clinching, shaft and hub
Are well performed with double acting Press manufactured by TeLC
For Chip removal drilling, turning, milling, grinding
the construction of a press is not useable

Nevertheless also on chip removing Force has to be produced to penetrate a wedge into a
material.
And also movement is made.

Every metal worker knows how drilling- turning- milling and grinding-machines look like.
These machines belong to the inventary of every training work-shop.

Training must invest many time into the programming of automated machines.
Many also cutting now-how is integrated in the softwares.

Nevertheless is accepted: without principle knowledge of the cutting process that

means knowledge of force creation regarding amount and direction and chip forming
the operator is a risk.

Undouptable it is important to know when lowest forces are obtained, when a perfekt work
results, how lifetime of a tool is prolongated, how energy is saved.

Cutting Force Measurement on drilling, turning, milling, grinding and systematic test
serieses is looked at as the method to understand the relations.

Different from the cutting process on the press on turning a high process temperature is
created which in one aspect supports the process, but on the other hand wears the tool.

Temperature Measurement on the tool tip is a singular addition of the Force meters from
TeLC . Which draws attention upon wear in all experiments.

As everywhere there exist favourable and less favourable ways to perform a process.
These to filter out is the final aim of the practical lessons.

The manufacturer of these cutting-force meters may design his equipment to be versatile,
frindly to handle, robust, modern and also price worthy.

TeLC mean they do.

The modern on all the equipment of TeLC is the Data Acquisition Software with its
Serial data transfer to a Windows PC.

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Tool Force Measurement and Data Acquisition by means of a good Software.

Features of a good software:

XKM software from TeLC needs only a normal Windows PC with serial Terminal either
RS232 or USB. Screen design is well arranged, easyly accessable.

XKM software recognizes the connected device and switches over to the corresponding
screen layout.

drilling

turning simulation

milling forces x y z tecnological data

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Tool force meters BKM and DKM from TeLC have got a local digital indication.
Automated hold servs for easy reading of average values on stop of machining..

BKM DKM

Tool force meter FKM milling has got a remote indication box including the same features
as with BKM and DKM. This box can serve as big indicator for BKM and DKM.

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Clamping on machine table is easy with BKM and FKM. It is like with a vice. Workoiece
is also clamped similar.

Turning Tool Dynamometer carries the tool. The dynamoeter itself is clamped in a tool
holder of common form.

There are multiple ways to clamp may be a tool holder of a conventional or automated
machine. Feed may be left or right way.

Picture below displays different clampings and Temperature measure device, which
works on radiation basis for temperatures between 300 and 800 ° C on a spot of 1mm.
Also visible are power supply and test systematically varied indexible inserts.

Technical data DKM2010 Temperature measure device

5 components tool dynamometer On radiation principle
Fc, Ff left, Ff right, +/-Fp = 2000 N With adapters for DKM2010 left and
Resolution: 1 N 2x overload protected right
Feed angle variation 45,60,75,90° Quick reaction
LCD including wear indicator Range 300 to 800 ° C
RS232/USB terminal Spot area 1mm
Transfer rate 5 – 100 Hz To be used also with cooling liquid
CCMT 09 or SNU 12 inserts seat
Left and right hand

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Picture below explains variation of feed angle 45,( 60,75),90° and displays left and right
hand tool seat of the type CCMT09

Measure report about cutting experiments with DKM

Head of the protocol contains: subject, data name, date, and all registrated values in
bandwidth. Also free text can be inserted.
Upper graph shows always the 3 components of force related to the varied parameter.
Lower graph shows specific tool force kc and tool tip temperature related to the varied
parameter.
From both graphs can be read, that kc decreases degressively in spite of rising load.
Temperature increases degressively.

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Turning protocol left side:

Condition is ap* f = const.

Which means chip is slim at
low feed rate and compact at
high feed rate. Square area is
equal.

The efect is:

The higher feed the lower
forces. But also:
The higher tool temperature
means the higher wear

Protocol left shows

if feed angle increases then

-Fc higher
-Ff higher
-Fp lower

-kc higher
-T higher

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A lot of further experiments are provided to undergo.

It is relinquished out of space reasons here.

Further dependencies are:

Speed, material, lubrication/cooling, cutting angle, tool material (-coating and form) edge
radius and others.

The extended set of test systematic tools contains inserts, which are varied with respect
to coating and profile.

A graph as result has to be evaluated, otherwise the practical use is missing.

F is the force, T the tool temperature, Par is the varied parameter f.e. feed rate.

progressions 1
linear proportional increasing, more or less highly, or decreasing
evaluation:
fast increasing means attention! With slow increasing Par limit is never reached

progressions 2
progressive and degressive increasing, or decreasing
evaluation:
if progressive then Par can have values only until F limit
if degressive then Par is out of interest, because remains always below F limit

progression 3
Maximum and minimum
Evaluation:
Minimum: only Par inbetween the hatched region can be used
Maximum: only Par outside the hatched region can be used

Turning process is the best to learn about cutting properties.

Turning process should be the one to start with.

Drilling process is different to the turning

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There exist only 2 components. Measured is on the work-piece.

On drilling passive forces are not efective (normally), because they are pairwise directed
against each other and so compensated.
If the grinding of the tip is false however then passive forces are not balanced. Drill
makes bigger holes than geometrically.

Cutting force on drilling is cutting torque, Feed force is efected axially with the drill.

Cuting angle is created by the drill angle.

Drills have the cross lip a region in the centre tip which only scrapes if not being grinded
or avoided by pilot boring.

If drilling depth of more than 3xD shall be obtained then process and tool must be
specially prepared.

Final properties of a bore are obtained f.e.by reaming or thread cutting

For the training and testing of the efect of the divers parameters TeLC have the

Drilling Dynamometer BKM2010

BKM2010 is a 2-components meter

Range Ff +/- 5000 N resolution 1N
Range M +/-3000 Ncm resolution 1 Ncm
Overloadprotection 1,5x
RS232/ USB terminal for the data transfer
Rate 5 to 100Hz
To external PC for data acquisition and
parametering of the wear detection
function.
LCD on the unit for indications Ff + T and
wear rate
Automatic hold for comfortable direct
readings.

List of parameters which influence the drilling process is as long as with turning.
Principle cutting characteristica should be elaborated with turning, specific drilling
properties afterwords. These are listed in the chapter above.

Following pages with some drilling cutting reports.

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Efect of speed efect of feed rate

efect of drawing into workpiece (brass) thread cutting

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Measuring forces on milling

In a milling process normally many cutters are in action. Follows research on the process
will look upon an integrated efect.

Milling takes place on a surface of 70x70 mm² which the milling dynamometer provides.

Milling tests correspond with usual operations, executed with shaft mills and knife heads.

There are favourable and less favourable performances of the milling process.
Some use less force, which means less wear , less power consumption ,less infliction of
the workpiece. This is important for the result (quality) , economics and sometimes for
mere makability.
To learn this is the aim of these practcal lessons.

The following experiments are executed.

Fz is normally varied 3x within one progression over the 70mm long surface.

1. shaft mill D 30mm equal chipvolume, slim and thick chip

2. shaft mill D 30mm equal chipvolume, slim chip synchronous and asynchronous
milling
3. shaft mill D 30mm equal chipvolume, thick chip synchronous and asynchronous
milling
4. shaft mill D 30mm ridge W10mm midst, left flange, right flange
5. shaft mill D 30mm groove directly
6. shaft mill D 30mm groove directly equal chipvolume, slim and thick chip
7. Face mill comparison of inserts ap varied

FKM2010 3-components Milling Dynamometer

Measure range (Fx, Fy, Fz): +/- 3000 N resolution 1N
1,5x overload protected
RS232 / USB terminal for measure data transfer
Transfer rate 5 to 100 Hz
Direct indicating box with large display option with automatic hold
Workpiece is cube of 70x70x80 mm³ is clamped hydraulicalle like in a vice
Fixing of whole unit on machine table with 2 screws only

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measure reports

descriptions and evaluations

Slim chip synchronous and Groove milled in one Stepp

asynchronous milling are compared. Evaluation:
Evaluation: Enormous sideforce Fy
On asynchronous milling
High force is Fx That means:
On synchronous milling Groove is not situated in place
High force is Fy Follows
result of vektor addition of forces is: groove must be made with smaller
synchronous milling is favourable mill in 3 steps.

Up to here chapters end about chipless and chipmaking machining methods, which were
studied with help of TeLC Testpress and TeLC Tool dynamometers.

Next is chapter B hydraulic machines, properties of fluids,

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B hydraulic machines, properties of fluids,

Fluids are to be transported from one place to an other.

If this has to be done against gravity then pumping is requested.
But not only gravity is an obstacle but also the resistances caused by pipelines and
fittings.

The other case: a fluid is residuated on a higher place wherfrom it can flow down. This
potential energy can produce work.
Or the liquid is in motion f.e. the extraordinary thin liquid air, if it has kinetic energy then
can also be created work.
The machine which uses this is the turbine

Target of this chapter is to make clear:

o What is energy, what is work, what is power

o What form(ula) have w and P in hydraulics, in mechanics, in electrics
o As energy can not be lost only questions regarding transformations are looked at.
o Important in this context is how well this is done, what is the efficiency.

There are pumps in use of multiple forms and for the different applications.
Displacing pumps f.e. piston pumps are well known for hundreds of years.
Modern form of volumetric pump/ compressor is the screw-spindle
While the piston pump seems easy to be understood, this is different for the screw-
spindle pump.
The different characteristics and reasons for them between dynamic pumps like the
centrifugal pump and the volumetric like the screw-spindle are pointed out.

Following the motto to create intelligent multi purpose designs of laboratory equipment
TeLC designed the following unit

Centrifugal Pump and fluids measurement

This Training Stand shall transport the following knowledge:

o Inner builtup pumpwheel is in transparent housing

o Efficiency of the energy transformation
o Characteristica of the centrifugal pump
o Characteristica of the screw-spindle pump
o Total characteristic of serially oder parallel connected pumps
o Energy losses in pipeflows
o Force creation by flow deviation = principle of hydraulic machines

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picture with second pump in tank

Experimental line

pumpwheel
in tranparent housing
watching cavitation

Impulsforce measurement

screw-spindle water-pump

Measure systems: measure values are indicated on direct LCD or on PC using

TeLC data acquisition software

Pressure measurement by electronic differential pressure sensor which is connected

with tubes to the respective places in the pipework

Flow measurement uses el. impulse sending instruments or hydraulic resistance

creating instruments in the experimental line like orifice, nozzle
and pitot-static pipe.

Mechanical power from torque and speed of the electric drive

Impulse force kinetic energy of the flow is directed on a flat plate 90°
deviation or into a hollow 180° deviation. The nozzles of
diffenerent diameter can be interchanged
An electronic force sensor to which the deviators are screwed
transduces the values to the indicators LCD or PC

Interchanging of different pumps made easy by screw connections

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View of the acquisition software screens

Process picture with table or bargraphs and plotter

Headline serves for remote speed control and switchings

Measure results Reports

f.e. pump characteristic curve orifice-plate, nozzle, pitot tube signals

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Treating the 1000x thinner fluid air also centrifugal principle is used.

Herefore TeLC designed the Training Stand Centrifugal Fan

Features of the test Stand:

• Speed controlled drive and torque measurement

• Outlet with iris restrictor
• Airflow measurement with pitot-static pipe and differential pressure sensor
• Pt100 thermometer for density calculation
• Multifunctional display with navigation knob for value selection and controls
• Determination of characteristic curves of a radial fan including efficiencies
• PC data acquisition with TeLC software, serial data transfer

Remarks: TeLC supply Fan and Thermic Teststand which combines investigations
on fan with heat exchange and control. See page 44

For data acquisition PC screen see next page

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Screen Process picture

Process picture contains bargraphs of all relevant values.

On the right side table of all definated values, scrollable

Screen Plotter

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Pumpturbine
The Pumpturbine uses kinetic energy of a fluid for the creation of work
if operated as turbine
Pumpturbine can regenerate lost potential energy of a high situated water reservoir if
operated as pump.
Both is possible here with one machine.
Working as turbine the coupled el. Generator creates current.
Working as pump the coupled el. Machine is switched over to drive and the electric
energy is dissipated again. It is understood that this transformations are connected with
energy losses.
What is this procedure good for?
It is sensfull to provide peak power with turbine operation and
to regenerate this energy during times of low consumption.
Not only a propeller machine is able to perform this. But the propeller machine is a
cheap machine to do.
Pump-turbine aggregate

The axial type hydraulic machine is the predestined object for studies in mechanical and
civil engineering. Incorporated in a pipework, with supply pump or vessel in some height
and equipped with flow-meter and pressure transmitter then a test stand is created which
is an ideal field for basic experimenting. See next page.

Technical details:
• Axial flow type 100mm diameter

• Hub only 40mm diameter

• Flow-rate 30-70 m³/h

• Rotor blade adjustment > 30° during operation

• Stator blades synchronously adjustable +/- 30°

• Perspecs pipe window with 5 relevant pressure tappings

• Electric motor/generator swiveling with torque meter
• Frequency converter for speed control
• LC-display and interface for torque and speed

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Pump-turbine Test Stand
Uses Pumpturbine aggregate described on page before

This moveable test stand bases on a pump-turbine with variable, during run adjustable
blades in rotor and stator. The Centrifugal pump in the circle is the feeder-pump. It serves
also as restrictor and operates as a (non-perfect) centripetal turbine. Flow (Cavitation)-
observations can be made through the perspex pipe section. The 4-quadrants frequency
speed control for the axial- and radial-machine makes a restrictor valve dispensable and
allows axial pump performance near zero pressure.

Measuring systems:

• The measuring devices are digitally connected to the internal controller, sending
serial data to the comprised portable PC. Stand control and data acquisition is
performed by Windows-software. Measured quantities are:

• Torque of the axial engine with force sensor on the swivel engine

• Rotational speeds

• Volume-flow

• Pressures

• Electric energy consumption and production for both machines

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Use of Wind energy is performed with help of the (axial flow) turbine principle.
Characteristic for this principle (and all these applications) is the force creation by
deviation in the way which was executed on test stand Pump and Fluid.

The laboratory stand Airpower station with Wind machine brings (new ?) wind into the
laboratory. So studies are independant and windpower can be regulated.

Outstanding is the possibility to elaborate power and efficiencies dependant from

different blade bends, -numbers, -diameters and to compare with calculations won
through the speed triangles.

Airpower station with Wind machine

Variable parameters:
• Diameter
• Number of blades
• Form of blades (pitch , bow)
• Load and herewith speed
•
Properties:
Wind controllable up to 100 miles/h
Calculations according to Euler and the speed triangles
Turret axis turnable, provision against storm

Measure systems
• torque
• speed
• power

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Pelton- and Centripetal- Turbine
Power controlled by waterbrake (Föttinger principle)
Supplied by speed controlled centrifugal pump 1,5 kW.

Peltonturbine

Centripetalturbine

Föttinger Brake

The Teststand contains in outstanding way principles of water power machines.

Fully visibility throug perspex fronts.

Measure technics :
• Torque , brake is mounted on
• swiveling table
• speed automatically controlled by
• pump speed i.e. volume flow
• flowrate
• pressure
• Impuls on entry nozzle see pic. right

Measure data on display or serially transmitted to PC see page 2

Waterbrake is available separately for use on other power machines

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Technical Data of the brake: power 1,5- 25 kW speed up to 10000 rpm

Process screen
Remote control of the pump´s speed, Measure values are displayed as bars, digitally
or as table.

Plotter of selectable values ; control line remains

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Reports
Pelton Turbine at different loads flow-Impuls-torque-pressure

Reports
Centripetal Turbine at different loads flow-Impuls-torque-pressure

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C Heat technologies
Different from the pure physical or even chemical view of the matter TeLC provide
Training equipment, which is more object related.

Internal combustion engines is one object.

Details under that headline are:

1. principles of internal combustion engines

2. diagnosis of vehicle engines
3. power and energy conversion tests on vehicle engines

Heat transport, transfer, exchange, absorption, efect (airconditioning) is the

second complex for which TeLC offer training stands.

C1 Heat Engines

Following pages describe TeLC ´s famous

Transparent Engine Technic Stand

principles of internal combustion 4-and 2-stroke engines
with fully variable valves actuation

further:

• Functional Engines
• Diagnosis of Engines
• Hydrobrake Power Test bench
• Tandem Engine Test bench for 2 engines alternatively

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Transparent Engine

Fully variable valves actuation – timing and lift – for a laboratory

4-stroke internal combustion engine for the practical education.

The 4-stroke engine which is well known for many years in laboratory practice was
equipped with a piezo-pneumatic valve actuator. The performance is controlled with the
mouse pointer of the PC during running. The engine is incorporated in a test rig whose
control, data acquisition and data display is exclusively executed on the PC. The real-time
data acquisition includes the permanent indicating with displaying in p/V or p/α - diagram
and with the calculation of the averaged indicated pressure.

1. The engine
The engine base is a mono-cylinder with 70
ccm stroke volume and a compression ratio of
1:4. The cylinder wall is glass. The piston runs
dryly. The connection-rod bearings are dryly
running needle rollers. The transparent design
of the engine allows observation of crankshaft,
piston, valves, ignition and combustion.The
usable speed range is between 350 and 2500
rpm. The hanging valves are directly operated
by cup-like pneumatic pistons
(Figure 1). The auxiliary pressed air flow is
conducted by a way-valve that is driven by a
piezo-actuator. The high flow-rate of this fast
way-valve makes this functionality possible
Figure 1

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The mixture is made by an injection pump in A status- and a speed shifter control the
the intake. The pump performs a mono-stroke of engine performance.
adjustable height, driven by a piezo-actuator. The engine needs a high resolution
Partial load is preferably executed by “Early field of characteristic data sets for all
intake valve closure” or “Late intake valve operation conditions. These have to be
closure”, but it is also possible to activate one elaborated by the student and are
throttle situation in the intake for comparison. saved as data files. With loading of
Reducing the pressure of the auxiliary air from such a data file the engine is
2,8 down to 2.0 bar effects a reduction of the immediately driven into the operation
valve lift and thus a reduction of the time point, including the set speed. The
opening square. The electronic ignition is also control elements for saving and loading
fully variable in terms of timing and dwell. can be found in the control panel of the
The upper panel of the software screen screen. (Figure 2).
contains the control elements (Figure 2) :

Figure 2

2. The test rig 3. Measured quantities

Important part of the test rig is the directly
coupled electric motor/generator. A special Torque Force sensor at the
elastic shaft joint governs the extremely swivel support
disharmonic force transmission of the mono- Speed Encoder on the
cylinder. The electric motor/generator is in crankshaft
swivel bearings and has got a torque adaptor Fuel Directly calculated from
which is combined with a force sensor. The consumption the injection pump
electric engine governs the combustion engine stroke and the speed
and functions as power absorber and engine Exhaust gas Thermocouple in the
starter. temp. exhaust unit
The engine needs an additional piston cooling Ox. probe Oxygen probe
by an air ray similar to the piston cooling with oil voltage
spray. This is automatically controlled by the Intake air flow Differential pressure
test stand depending on exhaust temperature measurement on
and power. The exhaust gas is cleaned by a nozzle
special catalytic converter. A fan leads the Internal Cooled sensor on
exhaust gas through a pipe and a flex hose to cylinder cylinder head
the outside. pressure
Trigger Encoder 100 Imp./rev.
and UDC on the
crankshaft
Piston stroke Calculated value
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4. The measuring display. Figure 3

All measured quantities as well as the
derivative quantities power, specific fuel
consumption and average internal pressure are
displayed by bargraphs. A fast refreshing table
displays all quantities as exact digitals. All
values can be selected for plotting. An
extraordinary feature is the test stand's indicator
mode which works simultanously to all other
functions. The data is displayed on a software-
oscilloscope. Figure 3 shows a minimized
p/alpha-diagram and an enlarged one in figure
4. The indicator diagram can be configured as
p/ or p/V diagram with optional focus on the Figure 4
gas exchange phase ((Figure 5).
Not only the internal cylinder pressure is
indexable, but also torque ((Figure 7), intake air
flow ((Figure 6)
Indicator diagrams can be saved with the
indicator diagram browser, presenting the
recently captured diagrams for further
evaluation. Stored data files includes the values
of all quantities, especially the control timings. A
powerfull export function provides easy export
to external software. The software package
includes powerfull functions for the post editing
Figure 5
of recorded data and preconfigured evaluation
templates (Figure 8).

The data acquisition captures 40 samples of

each non-indicated measured quantity per
revolution. The quantities value is equal to the
arithmetic average. The resolution for the
indicator diagram is 200 values per power
cycle. The control timing actions are refreshed
400 times per power cycle.
Figure 6
Figure 7

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Figure 8 Torque and Power, absolute and related fuel consumption

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First internal combustion engine to be operated as 4-stroke and 2-stroke

The small engine for laboratory practice, which is data acquisition is done from PC screen same
already famous for its fully variable valves like before. Also loading and saving of data
actuation , was redesigned so that it can be sets of performance conditions like coldstart,
operated either in 4-stroke or in 2-stroke mode. fulload800, partialload800 etc. are done same
This is possible, because all its functions are way as before during running. So can be
controlled completely electronically. The new switched completely freely also between 2-
direct injection, which was realized with the stroke and 4-stroke data sets. Flushing air
reinforced piezopump, allows injection into supply however should be disconnected in 4-
compression stroke after ending of the flushing stroke mode. Otherwise the engine would be
phase. Flushing is made by the correct setting of overcharged.
the valves open phase around LDC and with Regarding this the new design provides not
flushing air which is taken from the pressed air only the 2-stroke operation but also the
supply, always used with the engine. Control and overcharging of the engine.

Left:
View of the engine with flushing accu
volume, piezopump direct injection, valves
actuator, indicating pressure sensor etc.

Below:
Screen with:
In headlines control diagram for IVO-IVC,
Injection ON-OFF, Ignition ON-OFF, OVO-
OVC etc.
Bargrafhs for measures, plotter as small
display.
Left:
Indicating as big display P/V
20 plots for saving selection
right:

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Diagnosis of vehicle engines

Todays vehicle engines have muted to real electronic monsters.

All the effords to clean the exhaust gas for environmental purpose lead to the introduction of more
and more electronic features.

Sensor-actor and inbetween the intelligency. Working with TeLC ´s Transparent Engine gave an
idea about what the intelligency in an independent system has to solve.

The elements are not failsave .It is necessary to check, to detect faulty parts and to replace .
The inbuilt intelligency helps detecting and in combination with an external test device the
necessary work can be done.

In the Automotive Laboratory situation is different from that of a workshop:

• the object must be present:; one or more vehicles ?
• the vehicles must have switchable faults in their control systems
• the training should be in groups and communication and presentation systems are
requested

Instead of vehicles TeLC provide

Functional Engines
This are complete engines on a rollable support having all the environment to be operated under
idling conditions.
A power situation is not possible, because a power brake is not present. But the situation is
comparable with that of a vehicle in a workshop.

Advantage of which is
• much less room request
• the elements are not hidden
• the elements are easy accessable and close to each other
• tests are repeatable
• training is concentrated on the engine

Typical faults are switchable so checks can be made under nearly realistic conditions.

TeLC build up Functional Engines of different manufacturers and types.

Next page informs .

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Functional Engines are the necessary training object for automotive service technicians.
With help of the test- equipment engine functions are verified, faults are found and can be
repaired. All components are close together and easy accessable.

systems are complete for engine operation including

• Multifunctional instrument, ignition key, starter, generator and battery
• Water cooling with original radiator are installed, charger intercooler and
• oilcooler mostly are not, while the sensors belonging to the system do exist
• Exhaust system and catalyst etc. in shorted form
• Fuel supply as originally f.e. with tank pump
• Accelerator pedal mostly direct or with its electric governor

Faults insertion box

Faults insertion box with 8 faults interrupt, short break or shorten to body
depending on well known disturbances of the model.

Miscellanous
dimensions (LxWxH): 1.2x1.0x1.4m³
weight: 150 – 230 kg
Electrical supply: independent
Water: independent
Dangerous engine parts are covered

Modification of Functional engines:

Functional engines, which are only operated under idling conditions ,

can easily be modified for power- and consumption testing..

Water / water heat exchanger with tube connection with water supply
or brake. Fly-wheel plug-in adapter for flexible coupling shaft with brake
power controller is connected with the remote control drive of the brake
fuel supply tubes are connected with the TeLC fuel Consumption Meter

.Example see next pages

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Hydrobrake Powerbrake for easy coupling

Hydrobrake 150 kW / max 7000 rpm / 200Nm from 800 Rpm is an

engine testsystem for easy coupling of different functional engines

• Coupling by means of a plug-in flexible shaft.

• Frame connection by two bolts

• Cooling water connection with thermostate of the brake

• Fuel supply by TeLC fuel Consumption Meter

• Load- and power control from brake panel or PC

• Display in panel for direct indication of Torque, Revs. and fuel consumption

• Remote power and load control from PC

• Control and data acquisition by serially connected external PC

• Indidicating and other options

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Hydrobrake 100 kW / 6000 rpm in sectioned version

Hydrobrake 100 kW / 6000 rpm in sectioned version is an engine test-

system for easy coupling of different engines .

• Coupling by means of a plug-in flexible shaft.

• Frame connection by two bolts
• Cooling water connection with thermostate of the brake
• Fuel supply by TeLC fuel Consumption Meter
• Load- and power control from brake panel or PC
• Display in panel for direct indication of Torque, Revs. and fuel consumption
• Remote power and load control from PC
• Control and data acquisition by serially connected external PC
• Indidicating and other options

Functional engines, which are only operated under idling conditions , can easily be modified
for power- and consumption testing..

Modification of Functional engines:

• Water / water heat exchanger with tube connection with water supply or brake
• Fly-wheel plug-in adapter for flexible coupling shaft with brake
• power controller is connected with the remote control drive of the brake
• fuel supply tubes are connected with the TeLC fuel Consumption Meter

Engine- test- and Control- Software

Serially connected external PC allows control and data acquisition (see TeLC Engine-Test- and Control-
Software)
Engine power is controlled with mouse shift with help of a positioning drive. Setpoint of speed is also set with
mouse shift and kept constant with automatic controller.
Dissipating heat and power are transmitted to cooling water, controlled by automatic thermostate.

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View of PC screen
Top line with
left part power controller of engine -servo drive for throttle
right part speed controller - servo valve for controlled filling of the hydrobrake

left right
view of the wheel for engine power control view of the valve for speed control of the brake
by hand by hand
Down under the servo drive behind servo control valve for
automatic speed control
Also visible thermostate for engine cooling water
And resolver on shaft of the brake

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Training in Diagnosis on functional engines can be optimised by using TeLC ´s

Control- and Communication Unit for Functional Engines

(FuMoControl and FuMoWin32)

Better Training in Automotive Practice workshop to match the skill requests modern
engine electronic equipment demand.
TeLC developed FuMoControl a new scope on training engine control electronics.

Main features of FuMoControl are:

• Trainee can use foremost his Windows-PC

• Screen contains all he needs:
Wiring scheme, oscilloscope, cable connections, faultgenerator, report,
• Working methods are virtually but on the loop which means really connected with
the engine control circuits.
• OBD signals can be read all the usual procedures can be executed
• Actions are possible: ignition on, start engine, operate accelerator
• PC´s can be connected in a network, trainer has got interaction- and control rights.

Advantages

• Engine electronics are protected optimally

• Multiple workingplaces are installed on one single engine
• Maximal 128 faults can be switched on commanding the unit on the engine
• Multiple categories of faults are generated: cable break, cable miscontacting
(resistance), unlogical value (defected sensor), hasardous misfunctions under
vibrations, heat or current loads (cold junction)
• Report: test steps of the trainee are documentated

Interfacebox

On the engine support contains the control- , switching and communication unit with
terminals(RS232, USB, Ethernet) as well as an LCD and a navigation- turnknob for the
execution of basic functions.

Following pages inform about screen displaying, saving actions and Organigram

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Trainee view

Fault setup and trainee supervisor view of FuMoWin32 Software

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Scheme

Supervisor
workstation:
- Fault setup
- Trainee setup
- User observation
- Presentation
- Server service
Router Trainee 1
Supervisor
RS232(USB/Ethernet

Functional engine
Fault setup 128 Display
Trainee 2

Ethernet
EOBD / OBD II -
FuMoControl

Diagnosis

Control wheel

Measurement
Trainee 3

Radio remote More Trainees

Ignition, starter, control
speed control

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TANDEM Engine Test bench for 2 engines alternatively

Engine test cell "Tandem 100kW / 6500 Rpm" includes a Diesel and a Petrol engine,
the one or other is connectible with the power absorber just on knob-turn. So provides fast
and profund comparison of both engine types with no need of resetting work.
TANDEM includes measurement not only of power and fuel consumption but also :
• Exhaust gas temperatures
• Energy losses by engine cooling
• Average indicated pressures
• Indicating graph as p-alpha or PV-form

Tandem is fully controlled by PC

Specialties:
• Hydraulik brake, 200 Nm created at lowest speeds
• Installed engines ready for use
• Movability and changeability also after combination at place
• Starting and connecting of resp. engine by ignition turnkey
• Closed engine cooling by means of heat exchanger against fresh water
• Fuel supply through TeLC Fuel Consumption Meters
• Display on operator panel for direct reading of torque, speed and fuel consumption
• Control values readable from the original car combi Instruments
• Load and speed control by mouse shift from of PC
• Serial connection to external PC
• Indicating
• Control desk with incorporated PC
• Modern engine technique software
• Engine electronics trouble infliction switches
• test socket on every engine

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View of the control- and data presenting screen

View of the Test protocol

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Heat Technologies continued

C2 Heat transport, transfer, exchange, absorption, efect

These technologies mix often one into the other.

A domestic heating system uses water for the heat transport from burner into the rooms.
Inside the vessel heat from the combustion is transferred to the water through the wall.
Within the rooms heat is transferred to the objects in there by radiator or convector.

Here again TeLC designed equipment for multipurpose use.

Unit Fan and thermic test-stand includes:

• heat transport
• heat exchange solid/water water/air
• Fan and fan characteristic and efficiency
• Electric heater with temperature control

Unit Fluidized bed dryer includes:

• heat transport
• heat exchange
• side channel compressor
• electric air heater
• control procedures

Units aircooling and airheating (airconditioning)include:

• heat transport
• heat exchange by mixing
• speed controlled Fan
• Electric heater with temperature control

Units Heat Pump include:

• heat transport
• heat exchange refrigerant/air refrigerant/water
• aggregate status exchange liquid/vapor

Unit Solar Collector include:

• heat transport
• heat exchange

Unit Heatexchanger includes :

• heat transport
• heat exchange water/water, water/air
• speed controlled axial Fan
• Electric water heater with temperature control

Details in following pages

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Fan and thermic test-stand

The unit is a combination of fan test and heat transfer technics. Heat from circulating
hot water is exchanged to an air flow. This provides wide thermodynamical
investigations:
• Radial fan characteristics
• Radial fan efficiencies
• Characteristics of a circulating pump
• Heat exchange efficiencies

Properties:
• Centrifugal 4-speed waterpump
• 3-kW electric heater with on/off control
• Iris air flow restrictor

Measuring systems:
The measuring devices are digitally connected to the internal controller, sending serial data
to the comprised portable PC. Stand control and data acquisition is performed by Windows-
software. Measured quantities are:
• Torque and speed of the motor
• Water flow-rate
• Pressures
• Pitot static tube in the air duct for pressures and flowrate measurement

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Fluidized bed dryer

This moveable device is designed for the creation, observation and research of fluid bed
drying processes.
It supports continous and batch processing in open system and closed cycle system with
optional bypass operation. It is designed for educational purposes and provides versatile
studies in thermical, mechanical process engineering, measuring and control technique.

Measuring systems :
The measuring devices are digitally connected to the internal controller, sending serial data
to the comprised portable PC. Stand control and data acquisition is performed by Windows-
software. Measured quantities are:
• 3 x dry bulb temperature 0-120°C
• 3 x relative humidity, humidity ratio
• 2 x Quantity and mass flows
• Pressures up to 100 mbar

Systems:
• PID-Controller for temperature (3- stage on/off control with feedback). The controller
parameters can be set by the software. The proportional, integral and derivative
actions of the output value can be extra recorded.
• Speed controlled side channel compressor
• Fresh air- / recirculating air control flaps
• Glass cyclone for bypass operation
• In-, back-, outlet, cell wheel sluices
• Regenerative bag filters
• Seeve-vibrator

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Fluidized bed dryer software

Control and data acquisition software package for test stand "Fluid bed dryer":
Serial data transfer, temperature controller setup and monitoring, evaluation, data export

Control panel with shifters, bar displays and plotter. Process scheme with measured quantities displayed
as bar graphs and table with exact digitals of all
quantities.

Evaluation of a drying process. Evaluation of a temperature control performance.

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Dehumidifier

For profund training in air-conditioning it is necessary to understand the processes aircooling

and airheating. Aircooling is a necessity for dehumidifying and airheating a necessity for
humidifying. These physical facts base on the effect that air absorbs the more water the
higher is its temperature . Exceeding the limits effects condensate or rain. TeLC has
designed two units to do training in these subjects. Both devices can be used in combination
or isolated. The above photo shows the aircooler.

Systems:
• Aircooled evaporator
• Aircooled condenser
• Speed control of both axial fans
• Manometers for liquid and vapor pressure
• Wattmeter for the compressor electric power consumption
• Turnflap for the reheating using the compressor heat dissipation

Measuring systems:
The unit can be equipped with electronic sensors digitally connected to the internal controller,
sending serial data to an external PC. Stand control and data acquisition is performed by
Windows-software. Measured quantities are:
• Volume measurement of the dehumidifying (condensate)
• Dry bulb temperature 0-120°C
• Relative humidity, humidity ratio

Details:
• Benchtop unit 2m x 0.5m x 1.1m
• Weight: 63kg

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Airheating and humidifier

For profund training in air-conditioning it is necessary to understand the processes aircooling

and airheating. Aircooling is a necessity for dehumidifying and airheating a necessity for
humidifying. These physical facts base on the effect that air absorbs the more water the
higher is its temperature. Exceeding the limits effects condensate or rain. TeLC has
designed two units to do training in these subjects. Both devices can be used in combination
or isolated. The above photo shows the combined build-up. The airheater unit on the right is
blowing into the aircooler unit on the left.

Systems:
• Steam generator with drowned electrodes
• Processor- and selfcontrolled system with fast reaction on steam-requests
• Overtemperature and airflow safety system
• Axial fan with continous speed control
• Removable steam mixing channel
• Transparent channel side wall
• 3-stage low temperature heating system

Measuring systems:
The unit can be equipped with electronic sensors digitally connected to the internal controller,
sending serial data to an external PC. Stand control and data acquisition is performed by
Windows-software. Measured quantities are:
• Dry bulb temperature 0-120°C
• Relative humidity, humidity ratio

Details:
• Benchtop unit 2m x 0.5m x 1.1m
• Weight: 74kg

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Heat pumps

Heat pump 1000W with reservoir

Heat pumps allow the utilization of free environmental energy. Their build-up is equivalent to
a cooling unit. With the help of electric energy they can use existing free environmental
energy from wells, soils or ambient atmospere for heating purposes, by pumping it on higher
temperature level. The test stand demonstrates practically the dependencies of the thermo-
dynamical cycle process. Above photo shows on right heat pump producing hot water for air-
heating (Test stand "Fan- and thermic measurements").

Systems:
• 1000W compressor
• Fan and thermic heat pump
• Air-cooled evaporater
• Coaxial condenser = heatexchange to water
• 50l reservoir
• Efficiency up to 4

Measuring systems:
The measuring devices are digitally connected to the internal controller, sending serial data
to a PC. Stand control and data acquisition can be performed by Windows-software.
Measured quantities are:
• 3 x temperatures: Before and behind condensator and reservoir
• Temperature and pressure of refrigerant agent
• Water flow rate
• Electrical power consumption

Extension:
The stand is moveable and can be connected to a warm water consumer like Test stand
"Fan and thermic measurements"

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Dimensions: 1.1m x 0.8m x1.6m Weight:50 kg Services: 240 VAC, water

Heat pump 250W

Heat pumps allow the utilization of free environmental energy. Their build-up is equivalent to
a cooling unit. With the help of electric energy they can use existing free environmental
energy from wells, soils or ambient atmospere for heating purposes, by pumping it on higher
temperature level.

Systems:
• 250W compressor
• Air-cooled evaporater
• Coaxial condensator against water
• Control of water flow-rate
• Manometer, usable in cold environments
• Efficiency up to 4

Measuring systems:
The measuring devices are digitally connected to the internal controller, sending serial data
to a PC. Stand control and data acquisition can be performed by Windows-software.
Measured quantities are:
• 3 temperatures: Before and behind condenser, and in reservoir
• Temperature and pressure of refrigerant
• Water flow-rate
• Electrical power consumption

Extension:
The stand is moveable and connectable to Solar collector.

Technical details:
Dimensions: 1.1m x 0.8m x1.6m Weight: 50 kg Services: 240 VAC, water

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logp / h diagram of heat pump cycle:

qc is the effective heat at level tc.

qo is the usable refrigerating capacity for cooling processes

In the diagram you can see that efficiency E depends on tc and on the quality of the
plant's devices. This dependency can be shown with this test stand.

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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Solar Collector

Natural solar radiation 0,5 m²

This test stand implements a solar collector for warm water generation. There are two
different versions available: One for natural solar radiation and outdoor use and another for
indoor use with artificial radiation. The scheme shows the build-up. T1,T2 and T3 are
temperature sensors. Valve V1 controls the water flow-rate. V2 provides water outlet and V3
controls the water supply. The heat-up test demonstrates all influencing variables. The
collector size is 0,5 (0,25) m², the flow direction is from down to up. The heated water flows
into the accumulator. The pump sucks from the accumulator's bottom and feeds the water
through a rotameter into the collector.

Systems:
• Accumulator 2l
• Infeed and outlet of the water
• Flow control
• Impressive results are obtained within one hour with natural radiation.
• Power absorption > 500 W/m²
• Temperatures > 70° C
• Artificial radiation with vitalux spectrality (nearly natural); 4 thyristor controlled lamps
• Inclination horizontally and variable distance.

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Artificial radiation 0,25 m², 1200 W

Control and measuring systems:

The plant comprises usual sensors, connected to a long time data-logger with radio
controlled clock. The logger can be connected serially to a PC and the logged and current
data can be read out and evaluated with the included Windows-software. Measured
quantities are:
• 3 x Temperatures
• Flow-rate
• Real time calculation of derivative quantities i.e. power.

Extensions:
Moveable test stand, connectable to Heat pump.

Dimensions: 0.8m x 0.8m x 1.6m Weight: 65 kg Services: 240 VAC, water

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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Teststand Heatexchanger

4 different heatexchangers are installed on the teststand:

Koaxial- HE A
Plates - -HE B
Tube bundle -HE C
Ribbed radiator water-air -HE D

Koaxial- HE is equipped with 4 additional temperaturesensors on its primary- and

secondary side

enables counter-, parallel- and cross-flow connection and different flowrates of

water and air . HE D is for exchange to air.
The HE have similar exchange areas of 0,22 ..0,28 m²

Digital multifunctional Control and Display Unit

If no PC is connected then it displays
Temperatures
flowrates
differential pressures
control station for temperature setting of the cold circuit
On /Off of the Pumps
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Serial PC Connection for control and data acquisition with TeLC Software

Process Screen

Plotter Screen

electric supply: 3ph. 400V

watersupply ½ “ tube
water drain ½“ tube
dimensions: 1600 x 600 x 1700 mm³
weight: 180 kg
TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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D Automatic Control

Living today is not imaginable without Automatic Control . Exists in nearly every technical
device at least in its simpliest form as two-position control.

Automatic control consists always of the elements:

• value x of the controlled member
• value w set point
• value xw control difference
• value y output to actor

where the controller compares the difference between x and w (xw) and outputs y using
the control algorithm which was configurated for the purpose.

Classical Algorithms are

P-control : action proportional to kp*(XW) kp is an amplifcation factor
PI-control: action proportional and integral. Integral means : to integrate the XW by time
and output an additional value y to the proportional y until the deviation xw is eliminated.
PID-control : action proportional and integral and derivative: derivative means to derive
xw by time. The efect is a reaction upon tendencies of xw.

The actor in a control loop can be a continous, stepwise or on-off device.

Independent of the type of actor the control strategy can be successful with the above
algorithms.

Testing the control loop is normally done by

• starting the process and watching swinging into set value, step response
• disturb and watch recovery, disturbance response

Adjusting controller is possible through

• amplification kp,
• integrating time Tn
• derivative time Tv

Many of the equipment, which was described before, have control inside
• speed control (testpress, engine test beds)
• temperature control (Fan & thermic, Heatexchanger, Dryer)

In these Training stands the subject “Automatic Control” can be treated in a special
didactic way: the partial efect of the P, the I, and the D can separately be plotted.

But TeLC make also specialized Automatic control Training plants

The outstanding type LFIC is described on the following page.

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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Level- and flow control LFIC 2000

"The Unit" to learn about two typical controlled members level & flow and to study the
PID algorithms using original industrial components.

Control modes:
• 2-Position control switching pump on/off
• 3-Position step control with slow motor valve
• Continous control with speed controlled pump
• Feed foreward
• Cascade

Controlled members:
• Waterlevel measured by bottom pressure
• Waterflow measured by magnetic flow-meter

Controller:
Industrial controller or PLC
PC and TeLC software controller, special features when using PC and TeLC software
controller: Time plots of I/O and of PID - actions of output value (Windows-software).

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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Step and disturbance resposes of LFIC PC software Controller

On-off control

3-Position step control

Y: calculated output action of PID-controller. Y3: Transformed step-output for

slow motorvalve

Continous control

Control of pump speed

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Interactive miniplant

Philosophy of TeLC Miniplants:

TeLC Miniplants follow a standardized design principle which adopts to some extent the real situation
in an industrial plant.So is found the field department and the control department. Field and control are
both equipped with original industrial instruments. The control department contains the mimetic display
and the control instruments. Deviating from reality the field which is concentrated in the mimetic display
is to be physically connected with the control instruments
may be with pneumatic hoses or electric wiring. So the trainee has got an additional task to solve. This
connecting is eased in that way that especially for the wiring needs be taken no care with normal
bipolar wiring and polarity. Connecting of pneumatics and electrics feels equal. The abbreviation
naming of the unit indicates the control task and instrumentation so e.g. here FLTPIRCA means: Flow–
Level- Temperature- Pressure- Indication - Registration - Control - Alarm

Wide range of Training Tasks:

• identification of the process elements and their connection

• put in action and calibration of elements

• connection of the process with the control terminal

• structurizing and configuration of transmitters and controllers

• running of the process (start & stop )

• study and optimize the control performance by adjusting the parameters

This mini plant combines the control of water flow, water level, water temperature and
air pressure. The unit principle is similar to a steam generation and heat consumption
process. Because of safety the heat generation indeed is a hot water generation. All
elements can be connected by PROFIBUS to an automation system.

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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Sensors:
• Limit sensors
• Capacitive level transmitter
• Magnetic flow transmitter
• Pt 100 temperature transmitter
• Piezo-resistive pressur transmitter

Controlled members:
• Pneumatic valves
• Fast electric motor valves
• 21 kW resistor water heater

Power control:
• By boiler-temperature
• By mixing ratio of boiler- and bypass-wate
• Flow-rate of used water

Control:
Discrete electronic controllers and automation system
Enable to execute the following controlls:
fixed set point- (pressure in split range)
three components- (level)
ratio- (mixing)
cascade- (temperature 2)
ratiocascade (temperature 2)
feed foreward- (temperature 2)
two-position-step- (temperature 1)

Scheme of FLTPIRCA interactive training stand

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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E Quotation texts

Material Test Machine and accessories

description Qty.
Material Testing Equipment Mp12 120 kN 3
Tensile/Compression motorhydraulic press with
TeLC electronic control and measurement.
With electric measurements of high accuracy,
solution force +- 50 N , measuring in the oil; travel
incrementally +- 2.5 um over total travel = 150mm;
Touchscreen control panel for all functions; inbuilt
intelligency for speed-, force-, prolongation control
and data indication / storage / serial transfer.
Windows program for interpretation and protocol
printout included.
Set of test devices and tools for Material Test 3
machine MP12
including:
Grips 120 kN tilting jaws; set of 4 tensile test pieces
ea.25 pcs.
Tensile screw insets; set of 7 tensile test pieces M10
Wedge angles test ;Adhasion test device ; fixing
device; fixing device flat mat.;
hardness test device; compression test device; set
of 2 compression pieces
Shear test device ; Cold forming device; set of 5
extrusion mouldings; set of 6 stamps 540,- ; set of 2
matrix for ; Sheet metal cutting device; set of 8
stamps & matrix ; set of 4 materials for cutting 40 kg
Cutting tool 50 mm dia; set of 4 sheet metals for
cutting 40 kg ;Deep drawing tool cpl.
Screws test device ; Bending device
MAZE Cam Video System for numerical acquisition 3
and visualization of traverse contraction and
prolongation of the testpiece during test
measurement of the actual square
calculation of the true stress
photo ducumentation of the test
resolution 640x480, 30fps
includes camera, holder, backlight
requested hardware Pentium 3, 600 MHz, USB
WIndows 98SE,ME,XP
Portable Low-Cost Computer (Notebook) for data 3
acquisition and control on TeLC test press
Room total cost 110 000,-

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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Cutting Tool Dynamometers

description Qty
BKM2000 4 components drilling tool dynamometer 3
Ff= +/- 5000N M= +/- 3000Ncm with programmable
wear detection.
Measuring range Ff : +/- 5000N Resolution 1N
Measuring range M : +/- 3000Ncm Resol. 1 Ncm
1,5 times overload protection
Sampling rate: 10SPS
RS232 compatible interface for measuring data
transfer and wear parameter setup.
Backmounted LC-Display indicating Ff, T and wear
progress.
Automatic average and hold function for manual
data acquisition.
DKM 2010 5-components Turning dynamometer 3
Fn=2000N , 4-step feed angle adjustment, LC-
Display & Dataterminal, wear detection.
Resolution: 1N; 2times overload protection
Sampling rate: 5 - 100 SPS adjustable
USB compatible interface for measuring data
transfer and wear parameter setup.
Backmounted LC-Display indicating Fc,Ffleft Ff
right, + - Fp, Tool tip temperature (option) and wear
progress.
Instrument for Temperature Measurement on tool tip
is option.
Automatic average and hold function for manual
data acquisition.
By clamping-bars left & right fixable with
conventional or CNC toolholder
quick feed angle adjustment 45, 60, 75, 90°
CCMT 09 tools seat.
Set of lathe cutting tools (indexable inserts) for 3
systematic tests,
3 rake angles, 2 nose radius, 50 carbides
Left holder for indexable inserts for cross turning 3
/CNC plus indexable inserts enhanced set including
special nose geometries and surface coatings
Temperature measurement on turning tool tip on
radiation principle with fixation set for
DKM2000
fast reacting sensor measures 90mm (3.6”) distant
from tool tip on 1mm spot.
Measuring range: 300-800°C (570 °F - 1472 °F)

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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FKM2000 6-components milling cutting tool 3

dynamometer Fmax = +/- 3000 N
Measuring range (Fx, Fy, Fz): +/- 3000N Res.: 1N
1.5 times overload protection
Sampling rate: 5 - 100 SPS
USB interface for data transfer to PC
Workpiece , cube of 70 mm side width, is
hydraulically clamped like in a vice. The unit itself is
fixed on the machining table with two bolts. The
workpiece is processed by milling or grinding.
Large external display suitable for all tool 3
dynamometers of our series XKM2000x readable
from distances up to 4m.
Software für die Schnittkraftmessung, passend zu 3
den Schnittkraftmessgeräten der Serien XKM2010
für RS232 / USB
Portable Low-Cost Computer (Notebook) for data 3
acquisition and control on TeLC test press
Room total costs 75 000,-

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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B hydraulic machines, properties of fluids

description Qty
Pump Teststand & fluid measurement with 1
var.speed centrifugal pump in acrylic housing &
hydr.resistances set
with electronic torque-, speed-, pressure-, flow-
measurement
digital indications
serial data terminal for PC data collection.
win-software “ pump-test”
independant unit on rollable trolley.
Second pump for HPE04 for parallel- and serial 1
connection; under-water-pump with constant speed
Stroboscope 2000 N/D 2,5-300 Hz 350 Lux mit 1
Digitalanzeige,220V-Vers
Impulsstrecke mit Kraftmesser zur Darstellung der 1
Kraftwirkung durch Umlenkung der Strömung 90 u.
180° mit verschiedenen Düsen
Axial Pump/Turbine NG 100 ; blades of rotor and 1
stator fully adjustable during operation ; speed
controlled motor / generator
fully electronic measurement of speed, torque,
flowrate, pressures on 6 positions
speed controlled supply pump (centrifugal pump)
for the propeller in turbine operation; acts as
pressure generator for propeller in pump operation (
no valve necessary)
provided for data acquisition with TeLC software.
PVC pipe circuit 100mm dia.
Unit on rollable frame.
Pelton Turbine coupled with waterbrake Teststand 1
with speed controlled supply pump 1,5 kW torque-
speed- pressure- flow- impulse measurement
digital indications serial data terminal for PC data
collection. win-software “ turbine-test”
independant unit on rollable trolley.
Centripetal turbine interchangeable with Pelton 1
turbine
Radial Fan test stand with torque- speed and 1
hydraulic measuring instrumentation provided for
data acquisition ; fan drive on swivel bearings with
torque meas. on basis of strain gages.Digital rea-
dings of torque and speed. Iris throttle ,pitot -static
tube for pressures and flow meas.
Temperature indication. Part on rollable trolley.
Airpower unit iwith windmachine wind speed up to 1
30m/s;diff.rotors with diff. blades ; generator
with.torque and speed measurement
Room total costs 90 000,-

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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C Heat technologies, C1 heat engines

Transparent Engine Technic Stand : power brake,

sensors, indicating, fuel injecting, variable valve
actuator ,PC control
detailed: torque, revs, fuel consumption, exhaust
temperature, oxygene probe voltage measures
Indicating module: inner pressure and stroke volume
200 values / 4-stroke play
also indicating of torque and intake flow
Fully variable valve actuator (VVA) timing and
opening working with piezopneumatics
Intake fuel injection w. piezo actor combined with
throttling device for 1 partial load
Intake volume measure by orifice pressure
measurement
All indications and controls by computer.
Software and notebook computer included,
printer not included
Serial and parallel datatransfer with standlogic
On rollable stand
Integrated exhaust fan with 3m hose
Transparent Engine “Megatech”, new, 70cc, 1
compression 1:3, 300 W , max 2500 rpm,
unlubricated, standing valves
Functional engine OTTO, ready for operation, on 2
rollable stand with original instrument panel, original
cooler,
starter key, power control, 10 L Tank fuel supply ,
exhaust assembly with cathalyst and silencer,
protective screens, elastic fixation on stand
Functional engine DIESEL, ready for operation, on 2
rollable stand with original instrument panel, original
cooler,
starter key, power control, 10 L Tank fuel supply ,
exhaust assembly with cathalyst and silencer,
protective screens, elastic fixation on stand
Hydrobrake 100kW/6000 Rpm for coupling with 1
Functional engines, LCD for measures torque, revs,
fuel consumption, serial data terminal
with remote controlled power and load actors;
ready for quick connection with engine watercooling,
fuel consumption meter
indicating and aspirated air-massflow-m. (Options)
with flexible shaft for coupling with functional engine
with Dimm interface for serial data communication
with external PC for data acquisition and Control by
TLC-software “Engine”
on rollable support

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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FuMoControl for modern petrol- and diesel vehicle 1

engines Elektronic Tests ; Interfacebox with Actors
and Windows software
Notebook network for FuMoControl 10 places 1
Engine Test Bench TANDEM with hydraulik brake 1
100 kW, 200Nm for 2 engines to brake alternatively
with key-turn , PC-control + data acquisition
detailled with the following properties;
brake watercooled, watercooling of engines from
one source and controlled at the brake.
Speed and load control from PC (Notebook
included) with mouse shift.
Coupling of engines with solenoid clutches,
actvation with respective starter key.
Remote speed-pedal from PC
Process visualisation and data acquisition in the
form of bar-graphs and plotter or as table also of
PV-diagram permanently.
Presentation of torque, speed fuel-consumption,
cooling water flow, cooling water differential
temperature, exhaust gas temperature
Security functions against over speed and over
temperatures with forced stops.
Prepared for the indicating.
System allows complete thermodynamic calculation
of the process.
Price of the engines is extra.
Petrol engine, used, not older than 4 years, 1
1.4- 2,0 L ; prepared for use on TANDEM
Diesel engine, used, not older than 4 years, 1
1.4- 2,0 L ; prepared for use on TANDEM
Indiicating device for petrol- or Diesel- engine 1
including realtime p-V / p/alpha chart and
calculation of inner work pmi
including amplifier, cable, stroke sensor and internal
pressure sensor
Room total costs 1 210 000,-

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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C2 Heat transport, transfer, exchange, absorption, efect

Fan and Thermic test stand for study of fluid, heat 1

exchange and measuring technics
in detail with:
in heater circuit circulation pump ; 3-way motorvalve;
el. heater 3kW thermostate controlled
security installations:
flow meter; thermometers pt100; in air duct radial
fan speed controlled: ielectric drive with torque
measurement;
water / air heat exchanger
on outlet iris restrictor ; Pitot/Static pipe and electric
differential pressure meter for air flow measurement;
hermometers pt100 ; LCD and navigation knob for
indications and hand control ; Software-controller
PID with 2-position, 3-position step , continous
output: serially communication with external PC for
remote controls and data acquisitions
unit on rollable stand
Fluidized Bed Dryer for open-flow, closed cycle and 1
bypass recirculating flow in batch or continous
operation at 120° + 1 m³/ min airflow.
1,5 l drying room, glass bypass cyclone, seeve
vibration, motor cell wheel sluice, inbuilt logic and
notebook as well as Windows program included for
operation, parametering, observation in form of bars
, table and plotters of measured and calculated
values temperatures, rel. and absolute humidities ,
pressures and flow rates. The PID controller well
useful for control performance studies. Unit on
rollable stand ready for use.
Aircooling and Dehumidifying Training unit with 1
refrigerant cycle full instrumentation and control
w/ speed control of condenser and evaporator
fan,settable nozzle meas. of electric power
consumption , pressures , volume of the
dehumidifying , turnflap for the reheating , all
industrial components
Airheater and Humidifier training unit with industrial 1
components with full control and safety system
against overtemperature
w/ airflow fan speed control,3-step heater control
steam generator processor controlled drowned
electrodes system ; mixing channel with perspecs
side walls

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]
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Heat Pump air / water 1000W ;Compressor, 1

Condenser Evaporator, pressures, Temperatures,
flow- and el. power measurement
indication and controlls on LCD and with navigation
knob; 50 l reservoir;
connection with external consumer possible
serial communikation with extternal PC incl.
software; unit on rollable stand

Solarcollector 0.5 qm with reservoir,3 Temperatures 1

indication on LCD; controllogic incorporated;serial
data terminal for data acquisition
Heat exchangers test bed with double koax 1
tube,plate.tube bundle and water/air radiator
in detail: rollable framework with inbuilt hot water
boiler up to 60°,2 pumps,2 flow- controllers,
2 temperature controllers, measurement of
flows,temperatures and pressures
electronic,digit.reading, registrator/computer outputs
counter,parallel + cross current
local LCD for control and measure values;
serial connection to PC for data acquisition and
remote control
Room total costs 110 000,-

D Automatic Control

Automatic Control Training Stand LFIC Level & Flow 1

members; el.valve; for 2-position-, 3-position step-
and continous control; rollable independent unit
Soft-Ware-Controler continuous PID, 2-Position, 3- 1
Position Step-, seriel connected with Windows- PC.
Notebook (included)
Registrates also the P-I-D parts of the output ! as
well as swiched outputs
Interactive Control Plant FLTPIRCA simulating 1
steam power plant and control
using discrete controllers
to execute following controlls:
lfixed set point- (pressure in split range)
three components- (level)
ratio- (mixing)
cascade- (temperature 2)
ratiocascade (temperature 2)
feed foreward- (temperature 2)
two-position-step- (temperature 1)
serial interface for connection with automation
system
Room total costs 67 000,-

TeLC, A. Kutschelis & Sohn, Hochstr. 8 D 59425 Unna Industriepark West -fon 02303 239999 -facs 239990 [email protected]