Engine Testing
Your Partner for Comprehensive Engine & ATS Development & Validation
Excel Engineering offers wide-ranging engine testing capabilities to propel your engine development forward.
We operate more than 40 engine test cells across our two locations. These cells run 24/7 and are purpose-built to the special needs of large engines > 150 liters and 5,500 horsepower (HP) or small engines under 10 HP.
Our facilities are fully compliant with all applicable Environmental Protection Agency (EPA) and California Air Resources Board (CARB) requirements for emissions certification testing.
ICE/ATS Development:
We provide specialized development and validation services for ALL fuels and engines, from 5 horsepower to 5,500 horsepower. Our engine test cells are equipped with high-quality combustion analysis systems, including AVL INDICOM, to improve the efficiency of your development projects.
Our Development Capabilities Include:
- Combustion analysis – We use crank-angle based high-speed data to identify cylinder pressure limits, pre-ignition, and knock.
- Engine & component modifications – In-house machining capabilities allow us to modify cylinder heads and install pressure transducers to support your unique project needs.
- Advanced control – We can easily create safe and effective ignition calibrations and identify knock intensity for effective engine control functionality.
Altitude Simulation
ICE – We offer two dedicated altitude simulation test cells at our headquarters in Diagonal. These cells are commissioned for conventional engines as well as hybrids.
EV / xHEV / BESS – Our Mount Ayr facility is also equipped with an altitude simulation test cell for electric vehicle and battery storage system applications. These cells allow you to test under a wide range of simulated atmospheric pressures and conditions.
Emissions Testing, Development & Certification:
Excel Engineering offers a broad range of emissions testing services to meet EPA and CARB requirements. This includes both component-level and full vehicle or equipment-level testing.
• 40 CFR 1065
• 40 CFR 1066
• Part 86
• SHED
• IUVP
Our emissions capabilities and features include:
- 40 CFR §1065 compliant cells – Our cells are fully transient capable, and compliant with emissions regulations, with 40 cells supporting up to 5500 HP engines.
- Wide fuel & engine support – We test spark-ignited and compression-ignited engines running on gasoline, diesel, natural gas, or liquid petroleum gas. *ALL FUELS*
- Controlled testing environment – Our cells feature temperature and humidity-controlled combustion air for accurate and repeatable results.
- Comprehensive emissions measurement – We are equipped with advanced equipment for gaseous and particulate matter (PM) emissions analysis from brands like Sierra Instruments and AVL.
- Test cycles supported – We run a broad range of emissions cycles, including FTP, NRTC, WHTC, and various ISO 8178 cycles for stationary, mobile, marine, and lawn & garden applications.
Detailed Capabilities, Certifications & Instrumentation
Additional Exhaust Emissions Testing Services
Endurance & Durability
Our engine durability test cells are simple, reliable, and cost effective. We offer 24/7 service and average more than 140 run hours per week. Using advanced automation and flexible controls, we reduce the need for constant operator supervision. This saves you time and money while protecting your investment with automatic alarms and shutdowns.
Comprehensive Durability & Validation
- Flexible test cycles – We program any industry standard, proprietary, or custom-designed durability test cycles to meet your specific project needs.
- Validation services – Our capabilities include complete engine validation, component durability, and catalyst aging.
- Failure analysis – We perform detailed power checks, blow-by monitoring, compression and leak-down, oil consumption evaluations, and failure analysis to inform your development.
- Fuel & lubricant testing – Our services include evaluations for octane requirements, knock, and other fuel and lubricant characteristics.
Advanced Testing Capabilities
- Controlled environments – Our test cells feature combustion air control (temperature and humidity) and exhaust back pressure control to simulate a wide range of operating conditions.
- Vehicle simulation – We can perform road simulation cycles and vehicle drive cycle simulation to accurately replicate real-world usage.
- Conditioning & stress – We offer services like thermal shock and manifold cracking to test the limits of your engine and components.
- Instrumentation – Our cells are equipped with transient-capable Eddy-current dynamometers and automated data acquisition and control systems for accurate, reliable results.
Small Engine
Specialized small engine test cells at Excel Engineering are designed to perform simultaneous operation of multiple small engines, enabling further cost reductions.
Large Engine
We offer generously proportioned test cells at Excel Engineering built specifically for the needs of large engines > 150 liters and 5,500 horsepower. Our comprehensive facilities and in-house rigging support ensure you receive efficient testing from setup to final certification.
- High-powered testing – Our two 40 CFR §1065 compliant test cells feature a 5,500 HP dynamometer to handle the most demanding engines.
- Specialized air & temperature control – We provide a dual conditioned combustion air supply with controlled temperature and humidity for engines with twin turbocharging.
- Advanced fuel systems – Our dedicated municipal NG supply line, on-site gas chromatograph, and experience with gas blending (600 BTU to 2500 BTU/cubic foot) give you unmatched flexibility.
- Comprehensive cooling – We operate a low-temperature underground cooling system that can simultaneously feed engines with twin water-cooled radiators and twin low-temperature charge air coolers.
- Testing & emissions – We run a wide range of ISO 8178 test cycles for non-road, mobile, stationary, and marine engines. We also use electronic control valves to deliver a range of inlet air and exhaust restrictions for not-to-exceed (NTE) emissions testing.
- Engine & fuel support – We test spark-ignited and compression-ignited engines on diesel, natural gas (NG, CNG, RNG), liquified petroleum gas (LPG), and Hydrogen.
Tilt Stand
Excel Engineering offers unique off-level and tilt testing services to validate engine performance under extreme conditions. Our in-house test stand fabrication capabilities ensure we can accommodate your specific testing needs.
Specialized Tilt & Fabrication Services
- 50° tilt rig – Our tilt rig allows engine mounting and operation at up to 50° of inclination in any direction. This fixture accommodates engines up to 15L and includes dynamometer loading and oil aeration measurement.
- 360° rollover rig – We have a unique rollover rig that allows engines to fire while performing a full 360° rollover, in accordance with U.S. Coast Guard validation requirements.
- Custom test stands – If you have a unique testing challenge, we can fabricate a custom test stand or fixture in our in-house machine shop. We can use our own automated control software or integrate with any third-party software you choose.