Part of the design and development of the new Bentley Bentayga SUV was the requirement for the transmission and powertrain durability validation. I was responsible for Project Managing this process, including selecting suppliers, planning the program and preparing for the tests. This also included monitoring the budgets, reporting test progress and compiling the results.
In addition I organized some chassis parts testing, using internal and external suppliers. Coordinating the supply of parts and programming of the tests. Monitored the daily test reports and reported the test conclusions.
Cummins are increasing the capacity of their technical centre in Seymour to support the development of their high horespower engines ranging from 3000–7000 Hp. The modification of the facility are been managed by ACS and I was responsible for supplying eight dynamometers over a four year period. The supply had to coincide with the manufacture of each test cell.
Project to modify the 20 hot test beds to incorporate the next development of the Ford Ecoboost engine as a 1.5ltr engine.
Using lesson learnt from previous projects, I managed the build and installation of a complete mock up bed to fully test all the control electronics, before they were installed at site.
Rolls Royce are producing a development of their RB211 engine for the use as generating sets and mechanical drive units. To test the equipment Rolls Royce required an dynamometer capable of the power and speed requirements. The solution selected was a tandem dynamometer unit and I visited the site in Ohio to ensure that the specifications were in line with the customer’s expectations.
Ford have two containerised hot run cells for the testing of the new Ecoboost 1.0ltr engine for the Ford Focus and B-max. This project was to increase the flexibility of the hot run cells to also test the new 1.5ltr version of the Ecoboost engine. This involved providing the additional electrical and coolant connections for the 4 cylinder engine and I had to ensuring the installation, did not disrupt the production of the current engine.
Royal Navy of Oman has two diesel engine test cells for testing their ship engines and generators. After nearly thirty years of reliable use, the decision was taken to upgrade the cells to incorporate modern technology and new engine types. In running the project I was involved in the final negotiation of the scope of supply and planning the delivery schedule. I also took part in the negotiation with the local contractors to maximise the use of local labour and resources to minimise costs.
As part of the building of a new engine manufacturing plant outside Beijing, BAPC required an end of line engine hot test cell. Incorporating a lot of additional technology including and AC dynamometer, the cell was capable of a variety of testing. In ensuring the product was in line with the customer’s requirements, I visited Beijing to negotiate the final specifications . When the test cell was completed I hosted the customer visit to Worcester to complete the Factory Acceptance procedure. I then organised the transportation to site and installation resource on site in China.
Ford Engine plant in Bridgend was originally commissioned in 1980, producing the CVH engine. Since then there have been several new engines produced, which currently includes the Sigma engine. This project was to modify the 20 Hot test beds to incorporate the first version of the Ford Ecoboost range. This involved the engineering challenge of incorporating both natural aspirated engines and turbo charged engines into the same automated exhaust connection system. I planned the installations to minimise the disruption to production, as demand for the current engine was very high.
As part of Hyundai’s new production plant in the Czech Republic for the production of the i30, Hyundai required a Chassis dynamometer for production evaluation.
I project managed the design manufacture and installation of the dynamometer. Visited site both before delivery to enable planning the installation and after installation to ensure customer was satisfied the product.
With the introduction of the new Mulsanne and its new V8 engine Bentley took the opportunity to upgrade their V8 hot test beds and R&D facility. New control systems were fitted to the hot test beds and additional equipment to allow the testing of the new engine and previous models.
The R&D facility was updated with two new dynamometer systems including ventilation and fuelling to allow increased development capability.
Purchased for use by China Aviation, I project managed the supply of a high speed hydraulic dynamometer.
Capable of 9000rmp & 1640kW, this was the most suitable machine for their application. The project included organising a customer inspection visit and training in the UK.
As part of their new diesel engine manufacturing facility near Derby, JCB purchased a ‘Conformity of Production’ test cell.
I project managed the design, manufacture and installation of the test cell to JCB stringent standards.
As part of the development of Honda’s manufacturing plant in Alabama, I project managed the manufacture and installation of a 4 WD NVH (Noise Vibration and Harshness) dynamometer.
This included visiting site to negotiate the final design characteristics and planning the manufacturing, delivery and installation schedule.
To extend their testing capability Kia purchased a 4 WD independent chassis dynamometer, to be incorporated into a climatic chamber, for their facility in South Korea.
I coordinated the design and build and liaised with the local agent to coordinate delivery and installation.
In a large scale modification program of their engine test cells at their plant in Zavolzhye, I managed the manufacture, transportation and installation of the equipment for several test cells.
These two cells were equipped with AC dynamometers and control systems to allow transient and endurance testing.
I project managed the complete build and installation of the engine test facility for the new W12 engine for the Continental GT. This included - selecting sub-contractors for the building work and installation requirements. Coordination design meetings between the customer and engineering departments, ensuring final acceptance was achieved to Bentleys exacting standards.
To increase the capability of their R&D facility Honda purchased a new 4 wheel drive NVH chassis dynamometer. I project managed the manufacture, transportation to site and the installation of the equipment. This included a facility for under vehicle inspection which required detailed negotiation with customer and supplier to ensure the correct result. Several weeks were spent on site coordinating the installation and commissioning efforts.