DAF starts construction of state-of-the-art engine lab

DAF Trucks N.V. is set to put a completely new, state-of-the-art engine lab into operation towards the end of 2007. The new facility will boast the most modern equipment and 20 test cells suitable for testing engines with a maximum output of more than 800 hp. Around 70 highly skilled workers will be employed at DAF's new engine lab.

With annual production of over 40,000 engines, DAF Trucks N.V. is one of Europe's largest manufacturers of heavy duty diesel engines. In order to meet the increasingly stringent emissions requirements and retain its place as an industry leader in the fields of reliability, durability and fuel consumption, engine development is a prime focus for DAF. The capacity of the existing engine testing facilities is no longer sufficient for handling both the current volume of engine projects, as well as those expected in the future; this is why capacity is being substantially extended to a total of 34 test cells.

Seven days a week
The new engine lab is currently under construction at the DAF site in Eindhoven. It will include 20 test cells and will supplement DAF's existing testing facilities. The new facility will feature a number of cells for durability testing, where engines will run 24 hours a day, seven days a week at ambient temperatures of up to 50o Celsius. Cold callibration tests — at temperatures of down to minus 20o Celsius — will feature among the activities carried out at the new lab, alongside a full range of noise, performance and emission measurements, all using state-of-the-art technologies. The lab will also be prepared to perform tests under changing conditions in order to simulate different altitudes.

Above-ground storage tanks
In addition to the 20 test cells with their respective control rooms, the new building will include an area for test preparation and a fully-equipped workshop. This workshop will be used to build and inspect engines and technologies under development which have been put through rigorous testing, in line with DAF’s testing procedures, often also in real operating conditions with customers. Above-ground, storage tanks will be situated right next to the new lab; all the fluids required for engine testing — e.g. fuels, urea and coolant — will be stored centrally in this area.

Environment is an important consideration
An important consideration when designing the new engine testing facilities was not only the implementation of state-of-the-art technologies, but also respect for the environment. Instead of the water brakes generally used in the truck industry, the test cells use electrical braking units. During testing, these subject the engines to loads comparable with those in actual use, but at the same time they act as electric generator and will be able to deliver up to 20% of DAF's total electrical power requirement in Eindhoven.

36,000m3 air per hour per cell
The new building, which will measure 60 m by 130 m, will comprise two tiers. All test cells will be located at the ground floor. The first floor will house the air and water treatment equipment. This equipment will be able to recirculate 36,000 m3 of air per test cell each hour, cool the engines with water, supply conditioned combustion air and remove exhaust gases in a controlled manner, with reduced noise levels.

The construction of DAF’s new state-of-the-art engine testing facility underlines DAF's position as a Centre of Excellence in the area of engine development within PACCAR, a global technology leader in the design, manufacture and customer support of high-quality light, medium and heavy-duty trucks under the Kenworth, Peterbilt and DAF name plates.