EPA-460/3-76-004-b
February 1976
                   DEVELOPMENT
             OF SPECIFICATIONS
             FOR A MOTORCYCLE
                  DYNAMOMETER
               AND MOTORCYCLE
               COOLING SYSTEM.
    VOLUME II- SPECIFICATIONS
     U.S. ENVIRONMENTAL PROTECTION AGENCY
         Office of Air and Waste Management
       Office of Mobile Source Air Pollution Control
         Emission Control Technology Division
           Ann Arbor, Michigan 48105

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                           EPA-460/3-76-004-b
         DEVELOPMENT
      OF  SPECIFICATIONS
     FOR A MOTORCYCLE
         DYNAMOMETER
       AND  MOTORCYCLE
       COOLING SYSTEM:
VOLUME II- SPECIFICATIONS
                   h>

               Robert J. Hcrling

              Olson laboratories. Inc.
              121 KIIKI CcrriloK Avenue
             Anaheim. California <)2ttOr>

              Contract No. 6»-(Ki-21 II
            Program Klcnirul No. 2-AH-lIiO


          KPA I'roj«>cl Officer: (plciin Tlioni|»M»n


                 I'r«'|>ar«'
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This report is issued by the Environmental Protection Agency to report
technical data of interest to a limited number of readers.  Copies are
available free of charge to Federal employees, current contractors and
grantees, and nonprofit organizations - as supplies permit - from the
Air Pollution Technical Information Center, Environmental Protection
Agency, Research Triangle Park,  North Carolina 27711; or, for a fee,
from the National Technical Information Service, 5285 Port Royal Road,
Springfield, Virginia 22161.
This report was furnished to the Environmental Protection Agency by
Olson Laboratories, Inc., Anaheim, California 92805, in fulfillment
of Contract No. 68-03-2141.  The contents of this report are reproduced
herein as received from Olson Laboratories, Inc.  The opinions, findings,
and conclusions expressed are those of the author and not necessarily
those of the Environmental Protection Agency. Mention of company or
product names is  not to be considered as an endorsement by the Environmen-
tal Protection Agency.
                Publication No. EPA-460/3-76-004-b
                                      11

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                        PREFACE
          This volume contains the specifications for a
motorcycle dynamometer system designed to meet the objectives
and criteria set forth by the United States Environmental
Protection Agency (EPA) in their Contract Number 68-03-2141
and Notice of Proposed Rulemaking dated October 22, 1975.
This system will be utilized for research, emission certifica-
tion and fuel economy applications.
          The specifications are divided into three cate-
gories:  performance, design, and procurement.  The design
specifications elaborate on the performance specifications
including aspects necessary for interfacing with existing
EPA equipment at the Mobile Vehicle Emissions Laboratory in
Ann Arbor, Michigan.  The procurement specifications describe
requirements for product assurance, warranty, maintenance,
and acceptance.  The specifications do not require the
incorporation of any components for which there is only a
single manufacturer or distributor.  Rather, they have been
designed to enable dynamometers to be built by various
manufacturers around the world while ensuring that the
systems provide equivalent performances.
                         iii

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            TABLE  OF  CONTENTS

Section                                                Page

          PREFACE	    iii

1         INTRODUCTION 	    1-1
1.1       General Discription	    1-1
1.2       Terminology	    1-3
1.2.1       Words and Terms	    1-3
1.2.2       Abbreviations	    1-4

2         PERFORMANCE	    2-1
2.1       Dynamometer	    2-1
2.1.1       Functional Description 	    2-1
2.1.2       Functional Speed Range 	    2-2
2.1.3       Functional Road Load Range and Accuracy.    2-2
2.1.4       Functional Inertia! Simulation Range
              and Accuracy	    2-2
2.1.5       Roller Characteristics 	    2-3
2.1.6       Distance Measurement 	    2-3
2.2       Cooling System	    2-3
2.2.1       Functional Requirements	    2-3
2.2.2       Functional Range 	    2-4
2.2.3       Functional Accuracy	    2-4
2.2.4       Outlet Duct Design	    2-4

3         DESIGN SPECIFICATIONS - DYNAMOMETER.  ...    3-1
3.1       Main Frame Assembly.	    3-2
3.2       Roll Assembly	    3-2
3.3       Inertia Simulation Assembly	    3-2
3.4       Motorcycle Restraint Assembly	    3-4
3.5       Power Absorption Unit (PAU) and Dyna-
            mometer Control Unit	    3-5
3.6       Driver's Display and Controls	    3-8

4         DESIGN SPECIFICATIONS - COOLING SYSTEM . .    4-1
4.1       Outlet Duct Design	    4-1
4.2       Blower/Fan Design	    4-1
4.3       Motor and Control System Design	    4-2
4.4       Fan Mounting Design. .	    4-3

5         DESIGN SPECIFICATIONS - GENERAL. 	    5-1
5.1       Applicable Documents 	    5-1
5.2       Environmental and Utility Requirements . .    5-2
5.2.1       Test Cell Environment	    5-2
5.2.2       Tes't Cell Dimensions	    5-3
5.2.3       Utility Requirements
5.3       Personnel and Equipment Safety  	   5-4
5.4       General Design and Construction	   5-5
5.4.1       Enclosures	   5-5
5.4.2       Exterior  Finish	 .   5-5
                           IV

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   TABLE  OF  CONTENTS  (CONT'D)

Section                                                Page

5.5       Wiring Design and Construction 	    5-5
5.5.1       Electromagnetic Interference 	    5-5
5.5.2       Cabling Construction 	    5-6
5.5.3       Cable Terminations/Equipment Interfaces.    5-6

6         PROCUREMENT SPECIFICATIONS - PRODUCT
            ASSURANCE	    6-1
6.1       Maintainability	    6-1
6.2       Reliabilility	    6-1
6.3       Product Support	    6-2
6.4       Recommended Spare Parts	    6-2
6.5       Installation Data	    6-3
6.6       Instruction Manuals	    6-3
6.7       Pre-Delivery Checkout	    6-3
6.8       Installation Supervision and Training.  .  .    6-3
6.9       Warranty .	    6-4

7         DELIVERY	    7-1

8         EVALUATION  CRITERIA	    8-1
               LIST  OF  TABLES

Table No.
8.1       Evaluation Criteria

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                       Section  1

                     INTRODUCTION
          This specification defines and establishes  the
required configuration, performance, and design charac-
teristics for a motorcycle dynamometer and cooling system to
be used during the measurement of exhaust emissions as
specified in the Environmental Protection Agency's (EPA)
Notice of Proposed Rulemaking (NPRM) dated October 22, 1975.
The specified equipment is intended for use by the EPA for
the purpose of conducting exhaust emissions certification
tests and fuel economy tests.  The equipment is used to
provide an accurate in-place simulation of road operating
loads and air-cooling velocities to enable measurement of
exhaust pollutant emissions and fuel economy from motorcycles
1.1       GENERAL DESCRIPTION

          The pending regulations to control the exhaust
emissions levels of carbon monoxide, hydrocarbons and
oxides of nitrogen from new model motorcycles presents the
need for the development of a dynamometer .that will simulate
typical dynamic road-load and environmental conditions for
motorcycles.  The regulations include all motorcycles of
engine displacement of 50 cc or greater which are manu-
factured for operation on public streets and highways.
          The problems of testing motorcycles are similar to
those  problems previously experienced with  testing passenger
                           1-1

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vehicles.  Since the motorcycles will  have no forward velocity
during indoor testing, the test device must provide a simulated
dynamic road bed and proportional cooling for the test
vehicle.   The test device must accurately simulate all
conditions normally encountered, such  as vehicle frictional
loss, vehicle rider mass, tire rolling resistance, and wind
resistance.  These can be simulated indoors by roller-type
dynamometers with the appropriate speed/power characteristics.
If the vehicle's normal  operating temperatures are substanti-
ally duplicated, the drive train and other parasitic losses
for each individual vehicle will be inherently the same,
both on the road and on  the simulated  test bed.   An additional
factor that affects indoor simulation  of actual  vehicle
loading conditions is tire roll losses.   These must be
quantified and corrected for if accurate simulation is to be
achieved.
          Any dynamometer has an intrinsic power absorption
as a result of frictional and aerodynamo losses  in the
system.  These dynamometer losses must be ascertained and
accounted for when establishing a calibration load curve,
and these must be kept to a minimum because of the inherently
small road loads produced by motorcycles with small displace-
ment engines.  Should these losses be  of a significant
magnitude, their power/speed characteristics would alter the
vehicle loading to an undesirable degree, particularly
during low-powered vehicle testing; These losses cannot vary
with time; otherwise corrective compensation would be
difficult.
          The equivalent inertial mass of the motorcycle and
rider also require simulation. The simulation must be con-
trollable in small increments to provide accurate dynamic
performance of the dynamometer.
          If the motorcycle dynamometer system is to  simulate
accurate road operations, it must possess a means of  duplica-
ting engine temperatures.  This is an  important requirement
                          1-2

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since the majority of motorcycle engines are cooled via  heat
transfer resulting from the. movement of air past the .engi.ne.
This condition can be duplicated during operation of a
motorcycle on a dynamometer by moving cooling air past  the
engine at the same velocity as the motorcycle's rear wheel
is moving on the dynamometer roll.
          This document defines the specification of a
motorcycle dynamometer which accurately simulates road
operational  conditions.  This system has been designed  to
meet the specific needs of the Environmental Protection
Agency's Motor Vehicles Emission Laboratory in Ann Arbor.
Additionally, its performance characteristics and major
design features should serve as a model for others who  wish
to duplicate the EPA system.
1.2       TERMINOLOGY

          For the purposes of this specification, wherever
any of the following words, terms, or abbreviations are used
herein, they shall have the meaning ascribed to them by the
following definitions:

1.2.1     Words and Terms

          Motorcycle - Any motor vehicle designed to operate
on not more than three wheels (including any tricycle arrange'
ment) in contact with the ground which is not a passenger
car or passenger-car derivative.
          Outlet Duct - The housing connected to the outlet
of the air-moving unit through which cooling air is directed
toward the motorcycle.
          Relative Humidity - The ratio of the quantity of
water vapor present 1n the atmosphere to the quantity of
water present in a saturated atmosphere at the existing
temperature.
                            1-3

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          Road Load (RL) - The force which must be applied

to move a vehicle over a level road at a constant speed.
          Road Load Power (RLP)  - The power which must be

applied to move a vehicle over a level road at a constant

speed.

          Static Pressure Loss - Pressure differential

associated with frictional and dynamic losses in ducting.


1.2.2     Abbreviations
          Celsius	C
          Degrees	°
          Fahrenheit 	F
          Hertz (cycles per second)	Hz
          Hour	hr
          Inches	in.
          Kilograms	kg
          Kilometers	km
          Kilometers per hour	kph
          Kilopascals	kPa
          Meter	m
          Miles per hour	mph
          Milliamperes	ma
          Millimeter	mm
          Newtons	nt
          Newton-meter	nt-m
          Phase	0
          Pounds per square inch	psi
          Revolutions per minute 	rpm
          Second	sec
          Volts alternating current	VAC
          Volts direct current	VDC
          Water	H0
                         1-4

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                       Section  2

               PERFORMANCE REQUIREMENTS
          This section of the specification defines the  per-
formance requirements of the dynamometer system.   It has
been divided into two subsections.   The first details the
performance characteristics of the  dynamometer and inertia
simulation system, and the second defines the performance
specifications for the cooling system.
2.1       DYNAMOMETER

2.1.1     Functional Description

          The motorcycle dynamometer specified herein is
designed to permit the operation of a motorcycle within the
confined spaces of a laboratory in a manner which simulates
actual operating conditions.  The dynamometer simulates all
road conditions such as vehicle frictional loss, vehicle and
rider inertia, tire rolling resistance, and aerodynamic
resistance.  Inertia simulation is achieved by utilizing a
flywheel set, and road load conditions are duplicated by a
power absorption unit (PAU) capable of adjustment to match
the specific characteristics of the test vehicle.
                         2-1

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2.1.2     Functional Speed Range

          The motorcycle dynamometer shall be capable of
simulating road load conditions for a motorcycle operating
at speeds between 0 kph and 100 kph.  The motorcycle will be
operating on the dynamometer in both steady state and
cyclic modes of operation.  Typical driving cycles include
the Federal  Test Cycle, and the Highway Fuel Economy Cycle.

2.1.3     Functional Road Load Range and Accuracy

          The road load (tractive force) characterisitics of
a motorcycle can be described by an expression.

          RL (nt) = FQ + FXV + F2v2       (2-1)

where "v" is the velocity of the motorcycle and FQ, F, and
F2 are characteristic constants.  These constants are affec-
ted by the geometrical design and performance characteris-
tics of the vehicle.  Therefore, they can vary from one
motorcycle model to another.
          The control  unit for the dynamometer power absorp-
tion unit (PAU) shall  be designed to match the desired RL
force of the test motorcycle as defined by equation 2-1 to
within ±5 percent throughout the test speed range.  The
commands to the PAU shall  have also been corrected to account
for the inherent parasitic losses of the dynamometer assembly,

2.1.4     Functional Inertia!  Simulation Range and Accuracy

          In order to duplicate road conditions during
cyclic modes of operation, it is necessary to simulate
equivalent vehicle mass.  Flywheels which can be selectably
engaged shall  be used.  A sufficient number of flywheels
shall  be provided to permit inertia simulation in the range
                          2-2

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between 100 kg and 700 kg in 10 kg increments.   The  accuracy
of the simulation of equivalent mass shall  be within ±1.5  kg
of the required setting as defined in paragraph 85.478-15
of the NPRM.

2.1.5     Roller Characteristics

          The roller assembly shall consist of a single,
smooth, cylindrical roll having a diameter of 530.5  mm (20.9
inches).

2.1.6     Distance Measurement

          The dynamometer roller shall be equipped with
suitable instrumentation to determine the distance traveled
by the rear tire of the motorcycle.  The accuracy of this
distance measurement shall  be ±2m.
          As  a result of the requirements imposed by the
test procedure,  the distance measurement apparatus must be
capable of  displaying a previously measured  distance while a
second distance  is being accumulated.
2.2       COOLING SYSTEM

2.2.1     Functional Requirements

          The motorcycle  dynamometer  cooling  system  speci-
fied herein  is  designed to  direct  cooling  air to  the  motor-
cycle  operating  on  the dynamometer in a  manner which  simu-
lates  actual operating conditions.  The  simulation of road
cooling  conditions  will result  in  motorcycle  engine  tempera-
tures  which  duplicate those encountered  during normal road
operation.   Cooling simulation  shall  be  achieved  by  direc-
ting cooling past  the motorcycle  at a velocity equal  to  the
simulated  vehicle's velocity.
                           2-3

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2.2.2     Functional Range

          The motorcycle dynamometer cooling system shall be
capable of simulating cooling conditions for a motorcycle
operating up to 100 kph.

2.2.3     Functional Accuracy

          The intent of the motorcycle cooling system is to
maintain, during the dynamometer operation, motorcycle
engine temperatures within the range of temperatures observed
during similar road operations.   In order to insure this,
the linear air velocity of the cooling air, as measured at
the center of the cooling air outlet duct, shall  be within
±10 percent of the simulated motorcycle velocity when this
speed is between 10 and 100 kph.  For speeds less than
10 kph, the air speed shall be within ±1 kph of the simulated
road speed.   Additionally, the cooling air outlet flow shall
be uniform to within ±20 percent across the outlet area, as
measured at the center of the outlet duct, as compared to
the center of each quarter area.

2.2.4     Outlet Duct Design

          The exit of the outlet duct shall be positioned
squarely in line with the motorcycle frame no further than
0.45m (1.48 feet)  in front of the vehicle's front wheel.
The cross-section  of the exit shall  have an outlet area of
             2          2
at least 0.5m  (5.4 feet ).  The exit cross-section shall be
square or other geometric shape  appropriate for cooling
diverse motorcycles.  The exit can be squarely positioned
before the front wheel  of the vehicle or can envelope the
front wheel.   The  bottom of the  duct exit shall be between
0.15m (0.49 feet)  and 0.2m (0.66 feet) above floor level.
                           2-4

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                       Section 3

          DESIGN SPECIFICATIONS - DYNAMOMETER
          In Section 2.1 the performance requirements which
this system must satisfy have been detailed.  In this section
some of these performance requirements are expanded and
design characteristics delineated.  These specifications
combine to describe the characteristics of a motorcycle
dynamometer capable of simulating road load conditions for
a motorcycle operating at speeds between 0 kph and 100 kph
in both steady state an.d cyclic modes of operation.  Typical
driving cycles will include the Federal Test Cycle, and the
Highway Fuel Economy Cycle.
          The design specifications for the dynamometer have
been divided into five sections; each section details the
specification for a major subassembly of the dynamometer.
These subassemblies are:

          •    Main Frame Assembly
          t    Roll Assembly
          •    Inertia Simulation Assembly
          t    Motorcycle Restraint Assembly
          •    Power Absorption Unit and Dynamometer
               Control Assembly
          0    Driver information display and driver controls
                           3-1

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3.1       MAIN FRAME ASSEMBLY

          The main frame assembly which supports the roll,
inertia simulation assembly and power absorption unit shall
be designed to be installed in a pit.  The main frame assembly
shall be of sufficient rigidity such that four mounting
points provide adequate support for the entire unit including
a motorcycle having a mass of 700 kg.
3.2       ROLL ASSEMBLY

          Type:  Single Roller
          Diameter:  530.5 mm (20.9 in)
          Width:  300 mm (11.8 in) minimum
          Material:  low carbon steel
          Surface:   cylindrical (uncrowned)
          Surface Texture:  Smooth
          Maximum Rotational Speed:  1500 rpm
          Maximum Weight Resting on Roller:  350 kg
3.3       INERTIA SIMULATION ASSEMBLY

          In order to duplicate road conditions during
cyclic modes of operation, it is necessary to simulate
equivalent vehicle mass.  Flywheels which can be selectably
     f
engaged shall be used.  A sufficient number of flywheels
shall be provided to permit inertia simulation in the range
between 100 kg and 700 kg in 10 kg increments.
          The inertia simulation assembly will consist of
the following components:

          •    Fixed flywheel simulating minimum vehicle
               weight
                         3-2

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          •     Flywheels  and engagement  control  system
          i     Drive components
          •     Protective covers

          Inertia system  specifications  are delineated
below.

          Inertia Simulation Range:   100 kg to 700 kg
               equivalent vehicle mass in 10 kg increments

          Inertia Simulation Accuracy:  ±1.5 kg for the
               total simulated inertia

          Maximum Acceleration/Deceleration Rate:  16 kph/sec
               (10 mph/sec)

          Flywheel Construction: Symmetric, fully machined
               and dynamically balanced

          Inertia assembly/Roller assembly coupling:  Posi-
               tive drive

          Inertia Selection Method:   Inertia  shall be selected
               by activating a thumbwheel, rotary or pushbutton
               switch located  on the  dynamometer control
               panel, which in turn activates  the inertia
               engagement  system.  A  method of  positively
               sensing proper  flywheel  engagement shall
               supply a  signal which  is  compared to  the
               inertia selector  signal.  A light on  the
               dynamometer control panel shall  indicate when
               the  selected flywheels have engaged.  An
               adjustable  signal from each flywheel  shall  be
               supplied  to the interface panel.  Nominal
               values will  be  18 VDC  at 60 ma for  an engaged
                          3-3

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               flywheel, - 18 VDC at 15 ma for a disengaged
               flywheel

          Flywheel and drive line bearings:  Average bearing
               life shall be in excess of 50,000 hours

          Safety Interlocks:  System shall be failsafe in
               case of loss of electric power or air pres-
               sure.  There shall also be an interlock
               to prevent the engagement or disengagement
               of flywheels during the operation of the
               dynamometer

          Fixed Trim Flywheel:  A flywheel if necessary
               shall be attached to the roller shaft.  The
               inertia of this flywheel shall be such that
               the vehicle mass equivalence of the inertia
               of the basic dynamometer system is 100 kg.
3.4       MOTORCYCLE RESTRAINT ASSEMBLY

          The restraint assembly is designed to position and
hold the motorcycle on the dynamometer.  It shall  lock the
motorcycle front wheel in place so that its rear axle is
positioned directly above the roller axis.  The restraint
assembly shall be sized to accomodate two-wheeled  motor-
cycles of all sizes and standard tire configurations without
damage to the motorcycle.
          Safety interlocks shall  be provided to prevent the
disengagement or engagement of the restraint while the
dynamometer roller is in motion.  Additionally when the
restraint is in an unlocked position, the roller shall be
locked in position.  Actuators for the restraint shall be
located alongside the restraint.  This actuator shall be a
                         3-4

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foot-actuated switch located at least 10 cm (3.9 inches)
above the floor.
          The restraint and positioning assembly shall  be
designed so that  not more than two technicians are required
to position and restrain the motorcycle within a 5-minute
period.
3.5       POWER ABSORPTION UNIT (PAU) AND DYNAMOMETER
          CONTROL UNIT

          PAU type:  Water-cooled eddy-current absorption
               unit or DC regenerative motor

          Maximum absorption load at 1000 rpm:  14.7 kw
               (20 Hp)

          Maximum rotational speed:  1500 rpm

          Speed Measurement:  Tachometer or tachometer
               generator; 50 m sec response time; 0-10 vdc
               output; ±0.5 km/hr accuracy.

          Distance Measurement:  Two independently actuated
               roller revolution counters shall be provided
               to determine distance traveled.  Accuracy of
               distance measurement  shall be ±2 m.  Controls
               and readouts for distance measurement shall
               be mounted on the drivers control panel.  Two
               signals from each counter shall be supplied
               to the interface panel. These signals shall
               be a square-wave digital of 0 to 30 VDC at
               20 may not to exceed  100 Hz.
                           3-5

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Torque Measurement:  Strain gauge load cell  or
     nonslip ring shaft torquemeter with appro-
     priate signal  conditioners; less than 50 m sec.
     response time  excluding adjustable dampening;
     ±1 percent accuracy, ±0.3 percent repeatability

Load Curve.  The PAU shall  be able to simulate the
     motorcycle's tractive  force curve which will
     be defined by  the polynomial expression

     R.L (nt.)  = FQ + FjV + F2v2    (3-1)

     Where:

     F. and F«  are  each 4-digit constants; FQ and
     F2 are positive numbers and F.  can be either
     positive or negative.   V is roller surface
     velocity expressed as  m/sec.

     The three  constants are set on 4-digit  thumb-
     wheel  or pushbutton switches located  on the
     dynamometer control panel.

     Accuracy of road-load  simulations shall be
     ±5 percent at  all  load conditions.  The
     accuracy constraint shall  apply to the  total
     simulated  road load and shall  include any
     calibration techniques or systems to  treat
     parasitic  losses in the PAU, roller assembly,
     or inertia system.

     Two types  of parasitic loss compensation
     systems are feasible.   In the first system,
     the dynamometer controller could be adjusted
     by a calibration system or by a memory  device
                 3-6

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     to compensate  automatically  for  the  parasitic
     losses.   With  this  system the  operator-
     inputed  constants  reflect the  desired  road
     load.   In the  second,  but less desirable
     approach, the  parasitic losses,  which  have
     been previously determined,  are  expressed  as
     function of speed  in a form  similar  to equa-
     tion 3-1.  The constants inputed into  the
     road-load simulator may then be  modified  to
     compensate for these losses.

Automated Coast-Down Equipment:  The  dynamometer
     shall  be equipped  with sufficient motoring
     capacity and instrumentation to  perform
     dynamometer calibration tests as described in
     paragraph 85.478-15 and Appendix II  of EPA's
     NPRM without using a motorcycle to drive the
     rollers  up to  speed

Computer Interface  Panel:  An interface panel
     shall  be provided  to allow connection of
     cabling  from a real-time computer.  The
     signals  to be  provided at the interface are:

     Velocity - 0 to 10 VDC analog
     Torque  - 0 to 10 VDC analog
     Roll Counter - Square wave  digital signal,
       +30 VDC 20 ma, not to exceed  100 HZ
     Flywheel Signals (6) +18 VDC  0  60 ma
                          -18 VDC  0  15 ma

     Load Algorithm     -10 VDC to  +10 VDC  with  a
     coefficients       voltage resolution  between
     FQ> F.,  Fg         consecutive coefficient
                        values of at  least  0.1 volt
               3-7

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3.6
DRIVERS'S DISPLAY AND CONTROLS

Driver's Display:  The driver's display shall
     consist of an analog and digital  display  of
     velocity;  an analog and digital  display of
     power, which may be switched by  interlocked
     illuminated pushbuttons to display torque;
     and two distance counters for measuring the
     distances  traveled during the cold transient
     and cold stabilized segments of  the FTP as
     defined by paragraph 85.478-15 of the NPRM.
     The appropriate counter is selected by an
     interlocked illuminated pushbutton.  A reset
     button for each counter shall be labeled  and
     located with respect to other controls so as
     to minimize accidental clearing  of the display,
     The approximate ranges for the displays are:
               Velocity - analog
               Velocity - digital
                              0 to 150 kph
                              XXX.XX
               Power, torque - analog   0 to 20 kw, torque,
                                        as required

               Power, torque - digital  XXX.XX
               Distance counters
                              XX.XXX in kilometers
               A button to activate a light and buzzer in
               the control room shall be located within easy
               reach of the driver.  Emergency stop and
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     reset buttons  shall  also be  located  within
     easy reach of  the driver.   The driver's
     display shall  be isolated  from motorcycle
     and/or dynamometer vibrations.  It must  be
     located within easy reach  of the motorcycle
     driver so that the distance  counters may be
     reset.

Dynamometer Control Panel:   As  a  minimum, the
     dynamometer control  panel  shall contain  the
     the following:

     Three, four-digit thumbwheel or pushbutton
     switches for selecting the load coefficients,
     plus a selector for the sign  (+ or -) of the
     coefficient of the term linear with velocity.

     A thumbwheel or pushbutton switch for selection
     of inertia

     A positive indicator that the correct inertia
     flywheels have engaged

     Dynamometer voltmeter and ammeter analog
     displays

     On-off buttons and indicating  lights for main
     power supply.   Reset and emergency stop
     pushbuttons for dynamometer.

Dynamometer Controls and Functions:  In addition
     to the controls and functions  defined above,
     the  system  shall  have the following  controls,
     features  and  functions  (*regenerative dc PAU
     only; **eddy  current PAU only).   These  controls
               3-9

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      and functions shall  be installed on the dyna-
      mometer control  panel  or control box.

 * 1.  Forward motor rotation only
   2.  Solid state excitation for dynamometer field
   3.  Speed regulation
   4.  Adjustable overspeed protection
 * 5.  Dynamometer field loss protection
** 6.  Dynamometer field overcurrent protection
 * 7.  Current limit adjustment
 * 8.  Instantaneous overcurrent protection
   9.  Short circuit protection at AC power circuit
  10.  Low voltage protection at AC power circuit
**11.  Cooling water low pressure protection
**12.  Inlet cooling water  high temperature
        protection
  13.  Emergency stop
  14.  Coast stop
 *15.  Auxiliary and Control  power disconnect
  16.  Dynamometer armature ammeter - analog  display
 *17.  Dynamometer voltmeter  - analog display
  18.  Dynamometer field ammeter - analog display
  19.  Dynamometer speedometer readout - digital
        and analog display
  20.  Dynamometer power readout - digital display
  21.  On-off pushbuttons and indicating lights for
        main power supply
  22.  Reset and emergency  stop pushbuttons for
        dynamometer
  23.  Recorder outputs, 0-100 mv, for speed, power
        and torque
                3-10

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                       Section 4

        DESIGN SPECIFICATIONS - COOLING SYSTEM


4.1       OUTLET DUCT DESIGN

          The exit of the outlet duct shall be positioned
squarely in line with the motorcycle frame no further than
0.45m (1.48 feet) in front of the vehicle's front wheel.
The cross-section of the exit shall have an outlet area of
             2          2
at least 0.5m  (5.4 feet ).  The exit can be squarely posi-
tioned before the front wheel of the vehicle or can envelope
the front wheel.  The bottom of the duct exit shall be
between 0.15m (0.49 feet) and 0.2m (0.66 feet) above floor
level.
          The outlet duct shall be designed to connect to
the exit of the vaneaxial blower defined in Section 4.2.   It
shall be so designed that the static pressure loss of air
flowing through it at maximum conditions does not exceed
0.750 kpa (3 inches H20).


4.2       BLOWER/FAN DESIGN

          A vaneaxial-style  fan shall  be used to provide  the
motorcycle cooling air.  It  shall  be capable of generating
air velocities at the exit  of  the  outlet duct (as described
in Section 4.1) of 100  kph.
          The fan shall  be  configured  for  operation  by  a
direct-drive motor,  foot-mounted,  or "C" flanged and  foot-
mounted.
                         4-1

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          The fan shall be equipped with vanes which shall
be foil-shaped and fabricated from high-strength cast
aluminum.  The rotational  speed of the fan wheel at maximum
flow condition shall be less than 1,750 rpm.
          The fan shall be equipped with a curved inlet
orifice which has been designed to minimize entrance losses.
A safety guard shall be installed on the inlet orifice to
prevent entrance of foreign objects.
          A wheel inspection door shall be installed to
facilitate the inspection  and cleaning of the wheel.  Sup-
port legs, which bolt to the inlet and discharge flange-
rings shall also be provided.  This support shall be capable
of supporting the blower and motor.
4.3       MOTOR AND CONTROL SYSTEM DESIGN

          The motor and control  system shall utilize either
a regenerative DC motor or an eddy current motor equipped
with an electromagnetic brake.
          The motor/control system shall  be able to deliver
sufficient power to drive the fan at the  maximum requirement
of 1,750 rpm and 100 kph air velocities through a duct
                                              2
having a cross-sectional area of at least 0.5m .  The motor
shall be rated at least 15 percent higher than needed to
achieve the maximum air flow.
          The motor/control system shall  be equipped with
tachometer or shaft follower circuitry with manual override
which will allow the fan to be accelerated at a rate equivalent
to maximum exit air velocity changes of 16km/hr/sec.  The
motor shall have sufficient torque capacity to achieve the
maximum acceleration rate at 1/30 maximum motor speed.  The
control system shall be capable of slowing the fan to follow
motorcycle decelerations as high as 10 km/hr/sec.  Accuracy
requirements have been defined in Section 2.3.2 of this
specification.
                         4-2

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          The motor design can be either drip-proof or
totally enclosed, but it must be compatible with the fan
selected.   It must be smaller than the fan hub and must not
interfere  with the flow of air through the fan.
          Motor leads shall be sufficiently long to extend
through the fan housing.  At least 8 meters of cabling shall
be provided between the motor and controller.
          An isolation transformer or comparable components
shall  be provided to minimize effects of voltage fluctua-
tions  and  RF and electromagnetic interferences.
          The motor and controller shall not require the use
of water or external compressed air.
4.4       FAN MOUNTING DESIGN

          The fan and motor system shall be mounted on
wheels or rails so that the fan can be positioned with
respect to the motorcycle.  Repositioning shall be accom-
plished by no more than one technician in less than a
5-minute period.  A safety interlock shall be provided so
that the fan and dynamometer cannot be operated until the
fan assembly is securely locked to the floor or track.
                         4-3

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                       Section  5

            DESIGN  SPECIFICATIONS  -  GENERAL
5.1       APPLICABLE DOCUMENTS

          The following documents form part of the equipment
specification to the extent defined herein.  In the event of
conflict between the documents referenced herein and the
content of this specification, the order of procedures shall
be:  first, the content of this specification; second, all
other documents in the order of listing below.

          (a)  Scope of Work, EPA contract No. 68-03-2141,
               Development of Specifications for Motorcycle
               Dynamometer and Motorcycle Cooling System -
               Established minimum requirements and design
               criteria.

          (b)  Regulations for New Motorcycles, Notice of
               Proposed Rulemaking October 22, 1975 defines
               motorcycles,  identifies emissions test
               equipment, and describes procedures for
               certification  and durability testing.

           (c)  Municipal and  State Building Codes and
               Regulations applicable  to Ann  Arbor, Micigan.

           (d)  Regulations of the  Occupational Health and
               Safety  Administration  - Establishes minimum
                         5-1

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               health and safety-related design and performance
               requirements.

          (e)  National Electrical Code - Defines uniformity
               and safety requirements for design and con-
               struction of electrical power circuits and
               electrical installation of equipment.

          (f)  Joint Industry Conference (JIC) Electrical
               Standards for Industrial Equipment - Defines
               uniformity and safety requirements for design
               and construction of electrical equipment.

          (g)  Air Moving and Conditioning Association,
               Inc., (AMCA) - Standard Test Code for air
               moving devices.   Performance standards for
               air moving equipment.
5.2       ENVIRONMENTAL AND UTILITY REQUIREMENTS

5.2.1     Test Cell Environment

          The dynamometer and cooling system specified
herein are integral parts of a dynamometer system which will
be installed in a test cell which will house the cooling
system, a dynamometer, the motorcycle being tested, a
vehicle driver, and auxiliary instrumentation for the measure-
ment of exhaust emissions.
          The environment of the test cell will be con-
trolled.   Test cell temperatures will be maintained between
20° and 30°C (68° and 86°F).  Relative humidity of the test
cell will be less than 80 percent.
          The altitude of the test cell  will be less than
1,000m.
                         5-2

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          Noise emissions from the system shall  comply with
applicable noise regulations as promulgated by the Depart-
ment of Labor Occupational  Noise Exposure Standards detailed
in the Code of Federal  Regulations, Title 29,  Chapter XVII,
Part 1910, subpart G, 36 FR 10466, May 29, 1971.

5.2.2     Test Cell Dimensions

          The system will be installed in existing labora-
tory cells located at the Environmental  Protection Agency's
Vehicle Test Laboratory in  Ann Arbor, Michigan.
          The dimensions of the test cell are  3.5 m (11.5 ft)
wide by 7.5 m (24.6 ft) long by 3 m  (9.8 ft)  high.  Maximum
pit depth is 76 cm (30 inches).
          The dynamometer shall be designed for installation
in this test cell.  Sufficient access shall be provided for
maintenance, accessibility  and movement within the test
cell.

5.2.3     Utility Requirements

5.2.3.1   Air

          A compressed air  supply having a minimum pressure
of 620 kpa (90 psi) will be available for use  with this
system.

5.2.3.2   Water

          A supply of city water will be available for use
in this system.  Water supply pressure is 340  kpa  (50 psi).
                           5-3

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 5.2.3.3    Electric  Power
           All  components  requiring  electric  power  shall  use
either  115  VAC,  10,  60  Hz  and  230 VAC,  3)9, 60 Hz;  208 VAC,
30,  60  Hz,  or  460  VAC,  30, 60  Hz power.
 5.3        PERSONNEL AND EQUIPMENT SAFETY

           The motorcycle dynamometer system shall be designed
 and constructed so as to comply with OSHA regulations  (Code
 of Federal Regulations, Title 28, Chapter XVII, Part 1910.
 Specific features shall be in accordance with the following
 paragraphs from these regulations:

           (a)  Mechanical Safety:  Mechanical features which
 could cause injury to operating personnel during operation
 or maintenance shall be avoided.  The projection of over-
 hanging edges and corners shall be minimized and any projec-
 tions shall be rounded.  The radius of corners shall be a
 3 mm (0.18-inch) minimum.
           (b)  Vertical Stability:  The vertical stability
 of free-standing equipment shall be such that the height of
 the center of gravity shall be no greater than two times the
 least base dimension.
           (c)  Guards, Barriers and Enclosures;  Guards and
 barriers shall be provided to protect personnel from acciden-
 tally contacting rotating or moving parts, exposed elec-
 trical  contacts, or terminals in circuits operating at more
 than 40V rms.
           (d)  Circuit Protection;  Failure of the system
equipments, or any portion thereof, shall not result in a
hazardous condition in externally-located circuits or other
equipments.
                        5-4

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5.4       GENERAL DESIGN AND CONSTRUCTION

5.4.1     Enclosures

          The controller enclosures shall  provide  dust-
protective housing.  Ventilating air-flow shall  be  filtered.
The enclosures shall provide complete dust-protecting  and
drip-proof housing of equipment.

5.4.2     Exterior Finish

          The equipment shall be  finished  with  durable,  low-
luster paint applied over a compatible primer coating.
Unpainted exterior surfaces shall  be stainless  steel  or
anodized aluminum.  Exposed fasteners shall  be  plated
(cadmium, chromium,  nickel, or galvanized) for  corrosion
resistance.  All  joining metals shall be electrochemically
compatible to prevent corrosion.


5.5       WIRING DESIGN AND CONSTRUCTION

          Wiring shall be designed and constructed using
first-quality commercial grade materials and installation
techniques so as to insure reliable, functional electrical
circuits and shall conform to standards listed in Section 5.1

5.5.1     Electromagnetic Interference

          Electronic equipment will  be designed and shielded
to prevent erroneous readings due  to conducted or radiated
interference, such  as from ignition  systems, fluorescent
lights, motors and  switching transients, nor shall elec-
tronic equipment within the  dynamometer affect the operation
or performance of other electronic components  located in  the
test and adjacent control room.
                           5-5

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5.5.2     Cabling Construction

          System cables shall  be designed of material  resis-
tant to gasoline, oil, water,  and engine exhaust components.
They will  be of heavy construction so as to survive abuse.

5.5.3     Cable Terminations/Equipment Interfaces

          Cable terminations and the corresponding equipment
interfaces shall employ plug and socket connectors where
necessary  to implement ready replacement.  Interfaces  to
nonfunctional  units (e.g., cabling to a junction box), or
interfaces to  functional  units involving less than twelve
terminations,  may be made by terminal blocks.
          All  terminations shall be identified by at least
one of the following means:   letter, number, or color  code.
          If edge connectors are used, cables shall be
strain-relieved and no exposed conductors shall be permitted,
                         5-6

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                       Section  6

    PROCUREMENT SPECIFICATIONS  - PROCUCT ASSURANCE
          This section of the specification  details  mainte-
nance,  warranty,  pre-delivery checkout and installation
requirements.   Prospective bidders must address  these  areas
of concern in  their response to this specification.
6.1       MAINTAINABILITY

          All  routine maintenance operations, including
inspection, lubrication, adjustments, and calibration, shall
be enabled by  provision for access by ports, doors,  and/or
quick-release  panels to all critical areas.   All  field-
replaceable components and adjustment points shall be acces-
sible without  removal or displacement of other components.
          Circuit boards, relays, and similar electrical
assemblies and components shall be modularly replaceable
without necessity for soldering or unsoldering.
          Any  part subject to wear must be capable of rapid
replacement by normally skilled mechanics without need for
machining, fitting and alignment operations.
6.2       RELIABILITY

          The equipment, when maintained per manufacturer's
specifications, shall provide a minimum service life of 10
years with an operating duty of 2,000 hours per year.  Where
                         6-1

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 necessary,  the  expected  time  of  replacement  of  any  component
 which  will  not  meet  the  service  life  shall be defined.
          Reliability  (MTBF)  estimates  shall be provided to
 substantiate  the  projected  equipment  life.   The estimates
 shall  be  based  on  accepted  reliability  modeling methods, if
 these  are available.   In  addition to, or  in  lieu of, the
 calculated  MTBF,  field experience data  shall be provided in
 support of  the  project equipment life.
 6.3       PRODUCT SUPPORT

          The  supplier shall provide the following informa-
 tion to substantiate adequate product support:
          (a)   Initial system calibration service and
 procedures.
          (b)   Capability and location of service and repair
 parts stations, including number and qualifications of
 personnel in the area of Ann Arbor; Michigan, where the
 equipment will  be installed.
          (c)   Product support activity planned for field
 personnel in support of this equipment installation, and
 list of charges for additional  support that may be required.
6.4       RECOMMENDED SPARE PARTS

          A list of recommended spare parts to be held in
inventory by the user shall be supplied with the bidder's
proposal.  This list shall identify those items that are
necessary to ensure that the equipment can be maintained by
local area personnel with local area equipment and supplies
without need for emergency direct factory support.
                           6-2

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6.5       INSTALLATION DATA

          Installation drawings shall  be furnished  within
45 days after contract award.   All  details  shall  be final
and shall  cover the excavation and  foundation requirements,
air, electrical requirements,  water supply  and disposal,  and
complete installation procedures.
6.6       INSTRUCTION MANUALS

          The supplier shall  furnish three copies of
instruction/maintenance manuals for each piece of equipment
supplied under these specifications.  The manual  shall
contain complete instructions for the proper installation,
operation, calibration and maintenance of equipment, including
detailed drawings and schematics, directions and  charts for
lubricating, wiring and piping diagrams, necessary drawings,
parts list, and any special  notes which are required.
6.7       PRE-DELIVERY CHECKOUT
          Prior to delivery to EPA, the hardware supplier
shall perform an engineering evaluation of the motorcycle
dynamometer and/or cooling system.  The contractor shall
compare actual equipment specifications, as represented by
suppliers' engineering data, to the original specification.
Variance to the purchase specification will not be allowed.
          The engineering evaluation shall include testing
of the dynamometer power absorber to demonstrate the ability
of the dynamometer to simulate empirical road-load force
versus speed curves to within the limits specified in the
Specifications.  The testing shall also include verification
                           6-3

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of the accuracy of the cooling air speed with respect to the
simulated roll speed to within the limits specified in the
Specifications.  The inertia simulation of the dynamometer
shall also be subject to test verification.  This acceptance
testing shall be observed by personnel from Olson Laboratories
and EPA.
          Upon the successful completion of the pre-delivery
checkout, the hardward supplier will be authorized to ship
the equipment to EPA's facility in Ann Arbor.  Final acceptance
of the hardware will  be made after the final system is
installed and operating satisfactorily in EPA's facility.
6.8       INSTALLATION SUPERVISION AND TRAINING

          The services of a field engineer shall be furnished
to supervise the installation of equipment, the start-up
equipment, and the training of customer's personnel in the
proper calibration use and maintenance of the equipment. The
system will  be installed in the EPA's Motor Vehicle Emissions
Laboratory in Ann Arbor, Michigan.
6.9       WARRANTY

          The supplier shall warrant equipment delivered
under this specification to be free of defects in materials
and workmanship for the supplier's standard period of
warranty or for at least a year's period following first use
(start of checkout at EPA's facility), whichever is greater.
          Should a defect occur within the warranty period,
the defective material or workmanship will be repaired or
replaced without cost to the Environmental Protection
Agency or Olson Laboratories.
                         6-4

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                       Section 7

                       DELIVERY
          The completed dynamometer system shall  be delivered
to EPA Motor Vehicle Emissions Laboratory, Ann Arbor, Michigan
within 5 months after the purchase order is issued.  Prior
to delivery, the manufacturer of the dynamometer and/or
cooling system shall perform preliminary acceptance tests in
the presence of Olson Laboratories or EPA staff engineers at
the site of manufacturer.  The minimum acceptance tests have
been outlined in Section 6.7.
                           7-1

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                       Section 8

                  EVALUATION CRITERIA
          Table 8-1 details the evaluation criteria estab-
lished by Olson Laboratories.   These criteria require exam-
ination of the performance, operational, maintenance, and
cost characteristics of the proposed designs.  Dynamometer
manufacturers responding to this specification should
provide sufficient details in their proposals so that an
accurate evaluation can be made utilizing the factors listed
in Table 8-1.
                          8-1

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                                                 Table 8-1.  EVALUATION CRITERIA
FACTORS W[.
FACTOR
I . Performance
1. Ability to Simulate Road
Conditions 1.0
2. Ability to Simulate Vehicle
Inertia 1.0
3. Ability to Accommodate
Various Motorcycles 1.0
4. Ability to Simulate
Cooling Conditions
5. Fail-Safe Provisions 1.0
6. System Repeatability 1.0
II. Operation
1. Operating Personnel Training 0.5
2. Pre-Test, Set-Up Procedures 0.6
3. Supporting Utilities Required 0.6
4. Test Data Acquisition 0.4
5. Facility Spatial Requirements 0.5
III. Maintenance
1. System Complexity 0.6
2. Maintainability of System 0.8
3. Reliability of Components 0.8
4. Preventative Maintenance 0.6
IV. Costs
1. Purchase Price 0.8
2. Installation Costs 0.5
3. Annual Operating Costs 0.6
V. Delivery Schedule 1.0
Cumulative Ratings
Ranking
DYNAMOMETER CONFIGURATION RATING
System 1
Unweighted Weighted





























System 2
Unweighted Weighted





























System 3
Unweighted Weighted





























O3
I
ro

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                                   TECHNICAL REPORT DATA
                            (Pkasc read Iiitttvctions en Hie reverse before completing)
1 REPORT NO.
 EPA-460/3-76-004-A
             3. RECIPIENT'S ACCESSION-NO.

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