With assistance from the NASA-funded Space Alliance Technology Outreach Program (SATOP), an Albuquerque, N.M., small business has resumed production of its Pony Pack auxiliary engine
that uses a multi-patented process to power water, fuel, electrical and climate control systems, thus eliminating costly main engine idling.
“Pony Pack supplies electricity without expensive main engine idling,” said Pony Pack Inc., General Plant Manager Jim Gore. Pony Pack also keeps the main engine warm to avoid cold starts. Studies show that cold starts account for 85% to 90% of wear on an engine.
Pony Pack had sold several thousand units over 10 years when the company faced a technical challenge that ultimately halted production. The engine’s electronic control module kept causing it to shut down at unpredictable times and places. Then Pony Pack learned about SATOP New Mexico, a program of the Santa Fe-based Regional Development Corp. A request for technical assistance was submitted to program engineer Manuel Durán. TEAM Specialty Products, a SATOP Alliance Partner, volunteered to help resolve the technical challenge.
Electronics engineer Doug Webb determined that ground circuit voltage spikes triggered the malfunction. The module serves as a circuit breaker, shutting off automatically when this occurs. The spikes have countless origins, including starting the motor, vibration on the road, wear and tear on wiring and road contaminants.
To decrease the voltage sensor’s sensitivity, Webb pinpointed and implemented a
few software changes to the operating parameters, keeping the currents from
reaching the module. “It all came down to finding the glitches in real-world use
of the Pony Pack,” he said.
As a result, Pony Pack has continued production and implemented the recommended
changes on units in the field.
For more information about SATOP, or to request technical assistance, go to www.SpaceTechSolutions.com.