Industry and university interaction
Introduction
For the important topic of the interaction between industry and university, we went to power engineer Qadratoleh Hamze Nava, a member of the academic staff and an instructor of the Faculty of Mechanical Engineering of Tehran University of Technical Faculties. At the same time, he is the CEO of a company that manufactures all kinds of dynamometers needed by the industry. Undoubtedly, he can be considered as one of the people who bear the heavy burden of industry-university interaction or industry-university relationship. Designing and manufacturing test equipment requires a lot of effort and little financial benefit. The love of creating things that affect the world around us and make this world a more beautiful place to live in and improve the quality of people’s lives is the main motivation for establishing knowledge-based companies, including test equipment manufacturers.
In line with the company “Mobtakeran Pars Andish” was established in 1375 and its main activity was based on the production of technical knowledge for the design and manufacture of engine power test equipment (dynamometer) and its accessories.
This company initially studied Edicarnet dynamometers and has experience in the design and production of heavy-duty dynamometer samples for engines used in the automotive industry. In addition to the dynamometer, the design and construction of other equipment for the dynamometer test room includes stands, fuel consumption, dynamometer cooling system, engine oil temperature control system, pressure measurement of different points of engine parameters, temperature measurement and control of different engine points, dynamometer loading control system. And the software for controlling and recording dynamometer and engine data has also been done in this company. Such capabilities have been established in this company and currently it is possible to design and manufacture any type of Edicarnet dynamometer in different sizes in this company. So far, many Edicarnet dynamometers from 10 watts to 400 kilowatts have been produced and supplied to customers. Also, in the continuation of the activity, the knowledge of design and construction of dynamometer for testing electric motors with Edicarnet dynamometer has been created in this company and is being used.
In recent years, Parsandish Innovators have studied high-power dynamometers, which are hydraulically manufactured in the world and are mostly used for diesel engines and gas turbines, and their design and production has been completed in a number of power ranges. The title of the dynamometer sample is made about 1 megawatt. The recent dynamometer was designed and built for heavy diesel engine testing in Desa company located in Amel city and also high power electric engine testing in Roshd Sanat Niro company and is currently working in these companies.
The company has the knowledge of designing and producing hydraulic dynamometers for higher powers as well, so that now the design and construction of a 3.6 megawatt dynamometer is in the work plan of this company based on the requirement and order of one of the country’s turbine manufacturing companies.
This company has the ability to design and produce all kinds of Edicarnet, hydraulic and AC dynamometers. The acquired knowledge is completely indigenous and is not under the license of any foreign company, and famous dynamometers from Sheng Germany, AVL Austria, Borghisavari Italy, McTroll America, Taylor etc. have been used to control the design.
Also, the design and construction of a hysteresis dynamometer (a type of Edicarnet dynamometer), which is widely used for testing small DC motors, is included in the new work program of this company, so that in the near future, this capability will be added to the capabilities of Pars Andish Mobtakeran.
In addition to the above, the necessary technical documents for the mechanical repair of foreign dynamometers available in Iran have been collected and this knowledge has been used to improve the design and production of dynamometers. Also, at the request of customers, major repairs of foreign dynamometers available in Iran such as AVL Austria, Sheng Germany , Italy Burghi, Italy API and similar things are done according to their instructions and even if needed, their spare parts and sets are produced and supplied.
Another field of activity of Mobtakeran Pars andish Company, in addition to the manufacture of dynamometers, is the design and manufacture of devices related to the measurement of torque, power and engine-related parameters. As an example, the construction of a device for measuring thrust, torque, power and parameters of fuel consumption, cylinder temperature, exhaust temperature, environmental conditions and engine speed without the use of a dynamometer and using a propeller in an aircraft industry engine has been carried out as a successful project in this company. . It can be said that Mobtakeran is one of the examples of successful companies in the field of interaction between industry and university.
The accessories of the engine test room include the construction of the engine test stand, the design of various shafts connecting the engine to the dynamometer at high speed, the software and hardware of the P-V drawing device for the engine cycle, measuring and recording the temperature in different parts of the engine, measuring and recording the pressure in different parts of the engine, Measurement and adjustment of temperature and pressure for engine fuel consumption and measurement of physical parameters of electric motors are done in this company with the help of dynamometer.
In the upcoming interview, Engineer Hamze Nava, the CEO of Mobtakeran Pars Andish Company, tells us a little about the process of establishing the company and the difficulties of working in this field and the field of industry-university interaction.
history of the company
The beginning of interaction between industry and university: Please mention the history of the company at the beginning.
After graduation, I became a member of the faculty of Mazandaran University in 1372. In addition to teaching, I was looking for a series of practical activities in the field of mechanics. Therefore, I proposed the design and manufacture of test devices to the university. But due to the limited facilities of the university, it was difficult to do industrial work in the university. In the university, as research, it was only possible to design a new work. Therefore, I thought that in parallel, I would establish a company where I could engage in industrial activities. At first, together with my other colleagues, we planned to build general test equipment in 2015. But after we examined the problems of the industry, we saw that the engine assembled from several hundred parts, itself as a product, needs quality control.This is what made us think of making an engine test machine and we saw that no one in Iran has worked on it in a corporate and focused manner. There were those who repaired a test device or made a small sample from it, but they were not considered as an institution that could provide public services. Since the famous Iranian dynamometer is Schenck and has been considered the most appropriate in Iran’s industry since the 1950s, in 1976 we disassembled some examples of the Schenck dynamometer and considered its mechanical details. It was not the intention to copy, but we wanted to complete our information and complete the plan we have in front of us.We made a model similar to the Shank W130 in the size used by car manufacturers. Then we went to sell it. It was obvious that at first the customers did not trust us to buy the engine test machine from us for the first time. As the company that produced the first device that had not yet been tested by a customer, we sold that test device with a purchase guarantee agreement. Our first client was Itrak. We talked to them and they, as buyers, had the right to ask us for a quality guarantee. Their words were also logical. They said how do we know if your device is a good device?In response, we said that we will make the device according to the specifications you need, and then we will receive the money at that time, subject to the correct functioning in the first few months and the approval of your experts. In other words, we undertook the quality guarantee of their purchase. That is, this is how we started our work and the hard way of interaction between industry and university began for us.
How did you feel so confident about your work?
We had to accept the risk ourselves and gave the right to the customer. It is natural that there were shortcomings in that device that we fixed. We tried to satisfy the customer. As far as I know, this device has been used for several years and this collaboration is still ongoing. After that we made the next dynamometers and gave them to Megamotor company.Fortunately, the management and experts of Megamotor company treated us very well. The price and as a result our profit was low in that machine. It is interesting to know that now when the same dynamometer is brought to us for service, the money paid for it is more than the initial price of the device. For example, the initial price of the device was about three million tomans, and the current service fee for the device is more than twice this amount. They themselves admit that the initial purchase of the device was very cheap.After the first dynamometer was built, subsequent devices were produced in both larger and smaller working ranges. Since we were always dependent on the customer, we could not build and stock dynamometers. It is the same in the world. Our production is based on customer needs and it is not possible to store our products and equipment. Because the devices vary in terms of size and scope of work based on customer needs. So we design and manufacture the devices based on the customer’s order and according to his specifications. Different dynamometers differ in terms of kW, rpm, inertia and accessories.
question and answer
Dear readers, please explain how exactly a dynamometer works?
A dynamometer is a device that can controllably load a rotating shaft and change its rotation. The loading can be continuously controlled and the torque and speed are measured by the dynamometer. The engine under test can be an electric, diesel, gasoline or even solar engine. The dynamometer itself only measures revolutions and torque, but it has some accessories that go back to the type of engine. For example, in the gasoline engine test, we need to measure the temperature of the spark plug, cylinder head, fuel consumption, etc. In the electric motor test, in addition to measuring speed and torque with a dynamometer, we also measure other parameters such as voltage and current. The main dynamometers are of three types;
Eddy Current dynamometers, which are more popular in the world, hydraulic dynamometers that are used for very high powers, and AC dynamometers that are used for accelerated tests and the like. The power of an engine changes in a hot area and in a cold area or by the sea or mountains, and related to this, there are formulas defined in the standard that the dynamometer software uses and corrects the engine’s output power to sea level and standard conditions. As an example, Peugeot car engine is about 73 kW. This 73 kW engine will have a power of sixty kilowatts at sea level in Tehran. This power difference can be measured with a dynamometer.
Eddy Current dynamometers, which are more popular in the world, hydraulic dynamometers that are used for very high powers, and AC dynamometers that are used for accelerated tests and the like. The power of an engine changes in a hot area and in a cold area or by the sea or mountains, and related to this, there are formulas defined in the standard that the dynamometer software uses and corrects the engine’s output power to sea level and standard conditions. As an example, Peugeot car engine is about 73 kW. This 73 kW engine will have a power of sixty kilowatts at sea level in Tehran. This power difference can be measured with a dynamometer.
What types of dynamometers are mostly produced by your company?
A dynamometer is very similar to a generator or a pump. That is, hydraulic dynamometers work in the same way as pumps, and their design is almost identical to pump design. Eddy Carnet dynamometers are similar to generators. That is, they have a series of electrical calculations and mechanical calculations. AC dynamometers are exactly generators. That is, AC dynamometers are generators in addition to drivers.
Usually in the world, dynamometer companies do not make AC dynamometers, they procure drive, motor and generator from other companies and assemble the set and add software, sensors and chassis to it. In other words, the big dynamometer companies in the world usually do not produce generator dynamometers themselves, but they produce eddycarnet and hydraulic dynamometers. Eddycarnet and hydraulic dynamometers and AC dynamometers are designed and assembled in our company.
Usually in the world, dynamometer companies do not make AC dynamometers, they procure drive, motor and generator from other companies and assemble the set and add software, sensors and chassis to it. In other words, the big dynamometer companies in the world usually do not produce generator dynamometers themselves, but they produce eddycarnet and hydraulic dynamometers. Eddycarnet and hydraulic dynamometers and AC dynamometers are designed and assembled in our company.
What do you consider the difference and similarity or the strength and weakness of your collection?
We are now the only company that designs the dynamometer exclusively. As it was said at the beginning, the consumption of this device is low, about three to four devices per year, and it does not have an unusual price. Therefore, no one works exclusively on dynamometers. There are many test device manufacturing companies and they design and implement the test device in a general way. If you ask them for a dynamometer, they may agree, but we work exclusively in this field .One of the aspects of our differentiation from the customers’ point of view based on the feedback they have given us is that they are very easy to reach us. European dynamometers are not available due to embargo, Chinese dynamometers may not be much different in price from our dynamometers, but their access to after-sales service is very poor and due to low quality, they often remain unused after a short period of time. But in our case, even the first series dynamometers that we gave to our customers are still working well after twenty years. Of course, they may need two or three major repairs when customers bring them to us and are using them again. Our second strength from the point of view of our customers is the price issue, which is very reasonable compared to European dynamometers, and the other point is easy access to our after-sales service.
One of the other characteristics that the customers told us was that since the dynamometer manufacturing started in Iran, foreign dynamometer manufacturers consider easier conditions in providing proforma to Iranian buyers and offer a more suitable price for the Iranian market. Of course, we have not yet reached the quality level and production capacity of the big European dynamometer manufacturers, but at least this price reduction has benefited the country.
question and answer
It might not be bad to split the force or torque parameter calibration method, especially the difference between dynamic and static calibration. In the country, we are facing the limitation of the possibility of dynamically calibrating the power parameter. In the absence of such calibration, the results of the dynamometer cannot be relied upon. One of the problems with dynamometer equipment is the issue of validating its results, since you are using rotary torque meters anyway.
We don’t have this problem in Edicarnet and hydraulic dynamometers, because a rotary torque meter is not used at all and we use a load cell instead. For calibration, we use the same famous method of creating static torque with weights and calibration arm. The customer is given a calibrated weight along with the device, and the torque parameter can be calibrated with a specified arm. In other words, we calibrate the torque statically. During use, the torque is transferred from the rotor to the stator.
It is changed from its dynamic state to static state and is also measured in static state. For example, we measure the torque when the engine stabilizes at a certain point, say 2000 revolutions per minute (rpm). So, we don’t need dynamic torque calibration in Edicarnet and hydraulic dynamometers. In this type of dynamometers, this method is accepted as a principle in the world and is considered as an advantage for Edicarnet and hydraulic dynamometers.
So what do you do with the problem of noise resulting from the dynamic behavior of the part?
In Edicarnet and hydraulic dynamometers, there may be electrical noise. But we don’t have mechanical noise. But we have this problem in AC dynamometer. Of course, I need to remind you that this problem exists in dynamometers that use a rotating tachometer, and its calibration is difficult. This is one of the problems with AC dynamometers. Customers who buy such dynamometers sometimes only mean to perform dynamic tests. That is, they buy the device for the acceleration test.
They want to see how much the acceleration from 0 to 100 will be if the engine under test is installed on a car that weighs, for example, two tons. That is, in their own simulation software, they want to check the dynamic behavior of the engine using this dynamometer before building the car. This work cannot be done with a hydraulic dynamometer and eddy current, and an AC dynamometer should be used. In this case, the rotary torque sensor must be used and dynamically calibrated.
What power range does the dynamometers of your collection include?
The smallest dynamometer we have made is 5 watts, which is currently working in Qom industrial city, and it is made for 220 volts and 5 watts electric motors. These motors are non-automotive and are used by electric motor manufacturers. One of our customers are electric motor manufacturers who need a dynamometer. Their dynamometers are similar to the dynamometers used in the automotive industry, although their software, sensors and test standards are different.
The biggest dynamometer we made, a dynamometer of 900 kW, i.e. about one megawatt, was built for the Desa Amel company to test diesel engines, and we gave the same dynamometer to Roshd Sanat Niro, which tests electric motors above 500 kilowatts. This dynamometer is used to test and confirm domestically produced anti-explosion engines. Therefore, we have made dynamometers from 5W to 1MW and we are ready to make dynamometers up to 3.6MW now. It is interesting to know that currently turbine manufacturing and repair companies need this dynamometer power, which is being designed in our company.
What are the dimensions and size of the 3.6 MW dynamometer compared to smaller ranges?
The size of the device depends on the type of dynamometer. Eddy Carnet dynamometer of one floor in the world is usually below 1 megawatt. In this company, it is manufactured up to 400 kW with a weight of less than 1 ton. Dynamometers with the highest power in the world are made of hydraulic type, and the 3.6 MW dynamometer weighs about 3.5 tons.
One of the main foundations of any test device is the software designed for that device. Especially the dynamometer, which relies heavily on software. Please explain how to design the software.
In dynamometer design, it is common in the world to write a basic software that does not change in different dynamometer sizes. Of course, our electric motor test software is different from internal combustion engine test software. In the internal combustion test device, indicators such as fuel consumption, air consumption, cylinder head temperature and power difference compared to sea level should be seen with standard formulas.
Also, it should be possible to define the work cycle of life and performance. In the dynamometer software of electric motors, indicators such as input power, frequency, voltage, current, active power, reactive power and finally the energy label should be considered. No one is looking for the energy label that is in electric motors in internal combustion engines. The software writer must know the engine, that is, have the mechanical knowledge of the engine. Otherwise, there will be many problems. Fortunately, our software designers are completely familiar with the control equipment and have excellent experience in the engine field.
In dynamometer design, it is common in the world to write a basic software that does not change in different dynamometer sizes. Of course, our electric motor test software is different from internal combustion engine test software. In the internal combustion test device, indicators such as fuel consumption, air consumption, cylinder head temperature and power difference compared to sea level should be seen with standard formulas.
Also, it should be possible to define the work cycle of life and performance. In the dynamometer software of electric motors, indicators such as input power, frequency, voltage, current, active power, reactive power and finally the energy label should be considered. No one is looking for the energy label that is in electric motors in internal combustion engines. The software writer must know the engine, that is, have the mechanical knowledge of the engine. Otherwise, there will be many problems. Fortunately, our software designers are completely familiar with the control equipment and have excellent experience in the engine field.
question and answer
Mr. Engineer, in the field of test equipment, after-sales service plays an important role. That is, one of the advantages that attract customers to you is how well you provide after-sales service. Explain a little about your approach and plans in after-sales service.
The devices manufactured by our company include a one-year warranty. But sometimes it has happened that even up to two years and more than two years we have replaced a part and we have not demanded money in return. Fortunately, we have not had any problems with the customer regarding this issue. We even repair and warranty foreign dynamometers. As far as I know, few people can repair a working foreign dynamometer.
Not only do we have the ability to repair them, but we also offer a six-month warranty on a machine that has been working and repaired for fifteen years. We repair the 3.6 MW Desa dynamometer and warranty it for six months. It’s been a few years now and still no problem. The customer was given a six-month warranty, for a device that was not ours at all and had been working for ten or fifteen years. Usually no one does this, but we do it in our company, to create this confidence in the customer, we have not had any problems so far.
Some of the problems that exist are that customers are usually weak in the field of technology and standardization. That is, sometimes they want a device to perform a test, while they neither know the specifications of the test nor its standard. How do you help them in this field?
When a customer orders a machine, we first show him the dynamometer we have in our workshop, because some dynamometer buyers have never seen a dynamometer before. They don’t know what they want from day one. Then, in our own company or at the buyer’s place, we carefully analyze the specifications of the device they need with meetings so that they know exactly what they want to buy. Because if the contract is closed, although it is good for us financially, but we cannot satisfy the customer at the time of delivery and we will face problems.
At the time of delivery, the customer just tells his needs that, for example, he needs a certain test, while this dynamometer does not perform that test. For example, the test characteristics of electric motor dynamometers are known according to the standards. We tell the customer what tests this device can perform, now if he needs a high voltage test or ohmmeter, we tell him that the dynamometer is not supposed to perform these tests. These tests have other corresponding devices that must be procured from other places. On the very first day, we determine the accuracy of the device and the error rate of the sensors.
Don’t expect unusual precision until later. These accuracies are all within the standard range. Sometimes, electric dynamometer customers ask us for a device without a computer, so that the cost is lower. Only manual control. We tell them what they need the dynamometer for. If they want to test during production, there is no problem, but if they want to get approval from the standard department for accreditation for the laboratory, they definitely need a computer. The difference in the price of a dynamometer with and without a computer is about forty percent.
You can read and see the services of this company to get more information about the performance of the Mobtakeran company in the field of industry and university interaction.