Stemac
New Engine Products – 2006/2007
25 de maio de 2006
APECS 0225 Linear Actuator
Cost Effective Roller Bearing
¼ Pound Linear Actuator
June 2006
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APECS 0225 Linear Actuator
• Precise engine control
Ball bearing design
• Consistent output at high duty
cycles
Thermally effective coil design
for efficient heat dissipation
• Versatile
Push or pull applications
Flange or base mount
One full inch of stroke
• Cost effective
Designed for China
manufacturing
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APECS 0225 Linear Actuator
Proportional fuel control for power generation, construction,
industrial, and agricultural equipment
• Spring return to minimum fuel
• Precise repeatability
• Mounts in any position
• 2-hole, 4-hole, and base mount
flanges for drop-in replacement
of DYNA 2000 actuators
• Meets INR & EMP for moderate tactical
battlefield environment
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0225 Product Application
• Engine speed control
for JLG man lifts
• Precise control for
hydraulic pump and
lift positioning
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0225 Benefits Summary
• Ball bearing design reduces friction, resulting
in more precise engine control
• Minimizes heat buildup, resulting in consistent
force and improved position repeatability
• Push or pull actuation
• Mounts in any position
• 2-hole, 4-hole, and base mount flanges for
drop-in replacement of DYNA 2000 and
functional replacement for the APECS 2500
actuators
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APECS 0275 Linear Actuator
Cost Effective Roller Bearing 1/2 Pound Linear
Actuator
June 2006
APECS 0275 Linear Actuator
• Precise engine control
Ball bearing design
• Consistent output at high
duty cycles
Thermally effective coil
design and heat dissipation
• Versatile
Push or pull applications
Flange or base mount
One full inch of stroke
• Cost effective
Designed for China
8 manufacturing
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APECS 0275 Linear Actuator
Proportional fuel control for power generation,construction,
industrial, and agricultural equipment
• Spring return to minimum fuel
• Precise repeatability
• Mounts in any position
• 2-hole, 4-hole, and base mount
flanges for drop-in replacement
of DYNA 2000 actuators
• Meets INR & EMP for moderate tactical
battlefield environment
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0275 Product Application
• Kohler standby generator
• Precision engine control
over a wide range of
temperatures and load
variations
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0275 Benefits Summary
• Ball bearing design reduces friction, resulting
in more precise engine control
• Minimizes heat buildup, resulting in consistent
force and improved position repeatability
• Push or pull actuation
• Mounts in any position
• 2-hole, 4-hole, and base mount flanges for
drop-in replacement of DYNA 2000 actuators
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Linear Actuator Rationalization
Strategy
Current Linear Actuators Future Linear Actuators
Notes:
APECS 0175 Continue with potential
0.8 in. travel shift to China prod. or 1. The 0225 and 0275 are a family of
4 lbs. Net force replacement by 0175MM actuators that are designed with linear ball
0.3 ft-lb. Work rating bearings for manufacture in China. These
? units offer less force loss with temperature,
0175A R & D lower cost and improved resolution than
DYNA 2000 0.5 in. travel units they replace.
0.8 in. travel 8 lbs. Net force
6.5 lbs. Net force 0.33 ft-lb Work rating 2. The 0175MM is a currently experimental
0.25 ft-lb Work rating Moving magnet
Do Not Promote No target 06 earliest moving magnet design having a moving
magnet that offers the potential of more
APECS 0250 APECS 0225 precise control and greatly reduced cost at
1 in. travel 1 in. travel
6 lbs. Net force 6.5 lbs. Net force
a reduced stroke but increased work rating
0.5 ft-lb. Work rating 0.5 ft-lb Work rating compared to today’s 0175.
Ball bearing
Proto avail. March 05 3. The 0225 offers better force and work
DYNA 2500 Launch June 06
0.8 in. travel
ratings than the current 0250 in a smaller
13 lbs. Net force package.
0.5 ft-lb Work rating
Do Not Promote 4. The 0275 offers a slightly lower work
APECS 0300 APECS 0275 rating at reduced size and cost compared to
1 in. travel 1 in. travel the current 0300.
15 lbs. Net force 13 Lbs. Net force
1.25 ft-lb Work rating 1.0 ft-lb Work rating 5. Net force defines force without spring,
Proto avail. Feb. 05
Launch June 06 actual available force TBD by spring
selection.
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Proprietary Information
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F-Series Actuator and
Integrated Throttle Body
(ITB)
Customer Update
F-Series – Replacing FloTech
• FloTech Summary
Limited Angle Torquer (LAT) technology
Basic positioner – drives to a position between 0 and 70°
corresponding to the input command
33, 48, 60, 68 and 75mm bores
-40 to 105°C on engine environment
Analog electronics technology
Position feedback is only
communication
ITB only – no actuator model
Today’s FloTech
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F-Series Actuator/ITB
• F-Series Summary
Primary goal is replacement of the Flo-Tech
ITB
- 40 to 105° C on engine environment
ITB versions will have the same throttle body
geometry as the existing Flo-Techs
(48, 60 and 68mm bore sizes)
Limited Angle Torquer (LAT) technology
Updated digital control and communications ITB Version
technology
ITB and modular actuator versions
On-board position control electronics
Platform for other F-Series derivatives
including integrated speed control, mass flow
control and other generic actuator applications
Modular Actuator Version
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ITB Orientation Options
• Design Improvement
to Facilitate Engine
Fit
The ITB has been
designed such that the
same parts can be built A B
up in any of four
quadrants to help with
customer fit issues
when replacing a
FloTech.
C D
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Proprietary Information
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F-Series Actuator/ITB
• Versions
The F-Series project will develop three versions of the
product.
• F-Series Throttle
Simple, lower cost ITB with limited inputs and outputs.
PWM command only
• F-Series Throttle Plus
Higher functionality ITB with full set of inputs and outputs plus
CAN.
• F-Series Modular Actuator
Same functionality as the Throttle Plus in a stand-alone
actuator package.
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F-Series Actuator/ITB
• Review of the
Overall Packaging
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F-Series Actuator/ITB
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F-Series Actuator/ITB
• Internal Structure
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F-Series Actuator/ITB
• Internal Structure
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F-Series Actuator/ITB
• Project Status
18 Beta Units Delivered to 7 Customers
30 Units Built for Internal Testing
Random Vibration Testing Complete
• RV3 On-Engine Mobile random profile, .3G2/Hz, 10-
2000Hz, 22.1 Grms
• All three units passed and are currently being
inspected
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F-Series Actuator/ITB
• Project Status – Internal Testing Continued
Highly Accelerated Life Testing
(HALT) Complete
• Unit functioned well beyond
temp and vibe spec. limits
Unit stressed from –100 to 145°C
and 50G’s
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F-Series Actuator/ITB
• Project Status – Internal Testing Continued
Currently Performing EMC Testing
• Near completion
F-Series Beta Torque Output
• Correcting small findings
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Actuator Output
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Testing Complete
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• Meets spec. Steady State
Transient
Torque (in-lbs)
• Linear output 15
10
0
0 10 20 30 40 50 60 70
-5
Angle (deg)
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F-Series Actuator/ITB
• Project Status – Internal Testing Continued
Initial engine testing in Loveland engine lab
• Good control results
• Improved shut-off
characteristics
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F-Series Actuator/ITB
• Project Status – Internal Testing Continued
Other Testing to be Completed
• Continue engine testing
• Temperature testing for thermal mapping and performance
• Long term reliability testing
• Enclosure protection
• Dynamics performance
• Mechanical and Electrical subsystem testing
• Listings testing
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Proprietary Information
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EGS
The Only Fully Integrated Control
System for Large High Speed Gas
Engines
Gas Engine Control
Start / Stop KW feedback
Knock
Detection
Power
Management
Controls
Integrated
Spark Throttle Bodies
Plugs
Ignition By-pass /
Coils Waste gate
High Energy TecJet
Ignition Gas Control
Valve
March 2006
EGS
• Allows an engine to
maintain peak efficiency
with varying fuel quality
Speed/Load Control
• Integrated Throttle Bodies
Gas Engine Control
• Bypass/ Wastegate control Start / Stop KW feedback
Air Fuel Ratio Control
Knock
• Gas quality closed looped control (fuel Detection
energy compensation) Power
Management
• Mass fuel rate calculated and delivered Controls
Ignition Spark
Integrated
Throttle Bodies
• High Energy for poor fuel quality Ignition
Plugs
By-pass /
• Energy (coming soon) and Ignition timing Coils Waste gate
control for each fuel
Diagnostics/Prognostics
• Knock Detection
• Misfire Detection High Energy TecJet
Gas Control
Full Compatibility with EasyGen Ignition
Valve
Power Management product line
All products communicate via CanBus
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EGS Speed/Load Control
•Control
•Motorola 565 Micro Processor
Gas Engine Control
•128 Pins of I/O
•Three Speed Dynamics
•Generator Breaker open
•Generator Breaker closed
•Utility Breaker closed
•Independent Load Dynamics
•Boost Control (new)
•Engine Calibration and Troubleshooting
made easy
Integrated By-pass /
•Software Trending Feature’s (new) Throttle Bodies Waste gate
•Full Range of Throttle and Actuator Sizes
•ITB sizes 16mm-185mm
•Specialty valves available for bypass and wastegate
applications
•Actuator Work Output
•L-Series 0.34 joules
•F-Series 1.7 joules
•P-Series 2.2 joules – 17.4 joules
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EGS AFR Control
Gas Engine Control
• Gas Quality Closed Loop
Control (kw feedback)
More than 2000 systems
operating with GQCL on EGS-
01 platform
Improved Transient Model
Able to switch between 2 gases
Input for external CH4 analyzer TecJet 50+ TecJet 110
Easier to calibrate
• Automatic learning of Te and Ve
tables
• Gas Properties Calculated
3 Tecjet sizes
Tecjet Precision Low Flow
• Future Work
Tandems
Stereo control
Fuel Blending
Cost reductions
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EGS Ignition Control
• EGS Control Gas Engine Control
Controls Ignition Timing
Controls Ignition Energy
Timing and Energy limits are
based on fuel quality, knock
and misfire limits
• Ignition Control IC92X Ignition Controller
IC920 180 mJ system
• Competes with Altronic CPU 95
IC922 360 mJ system Ignition Coils
• Highest energy system on the
market
Up to 24 cylinders
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EGS Diagnostics/Prognostics
• Knock Control Gas Engine Control
Closed loop timing control to keep out of
knock regime
Load rejection if timing change does not
keep engine from knocking
Safety shutdown if knock is uncontrollable
8 accelerometer inputs per firefly
• Misfire detection
Crankshaft accelerations are used for
detecting misfire
Firefly Knock detection module
Energy control for increased spark plug
life based misfire limits (future work)
• Status level of all components in
system
• Troubleshooting made much
easier with updated interface
Trending analysis
Export data to Excel spreadsheet
Multi level password access
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Product Application
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Proprietary Information
World’s largest independent
designer, manufacturer, and service provider
of energy control solutions for
aircraft engines, industrial engines and turbines,
power generation, and process automation equipment
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