BRAKE DYNAMOMETER DEVELOPMENT FOR DREXEL UNIVERSITY FSAE RACE TEAM - PowerPoint PPT Presentation

Brake dynamometer development for drexel university fsae race team l.jpg
Download
1 / 22

  • 369 Views
  • Uploaded on
  • Presentation posted in: General

BRAKE DYNAMOMETER DEVELOPMENT FOR DREXEL UNIVERSITY FSAE RACE TEAM. MEM-01 Dr. Tein-Min Tan Frank DiMentoAlfredo Vitale Anthony TofaniJohn Henry. What is a Brake Dynamometer?.

I am the owner, or an agent authorized to act on behalf of the owner, of the copyrighted work described.

Download Presentation

BRAKE DYNAMOMETER DEVELOPMENT FOR DREXEL UNIVERSITY FSAE RACE TEAM

An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -

Presentation Transcript


Brake dynamometer development for drexel university fsae race team l.jpg

BRAKE DYNAMOMETER DEVELOPMENT FOR DREXEL UNIVERSITY FSAE RACE TEAM

MEM-01

Dr. Tein-Min Tan

Frank DiMentoAlfredo Vitale

Anthony TofaniJohn Henry


What is a brake dynamometer l.jpg

What is a Brake Dynamometer?

  • A system used to duplicate track braking scenarios in order to analyze a brake system design before the components are implemented on a race vehicle.

  • This piece of machinery can be utilized by all Drexel University race teams, including Formula SAE, Sonic Cricket, and Mini Baja.


Benefits of a dynamometer l.jpg

Benefits of a Dynamometer

  • Prototype costs lowered

  • Flexible testing schedule

  • No risk to driver or vehicle

  • Quantified performance data

  • Example:

    • 2005 Sinusoidal Rotor Design


Previous work l.jpg

Previous Work

  • 2005 FSAE Brake Team Designed a Brake Dynamometer that was not completed.

  • 2006 FSAE Brake Team added a power controller to obtain necessary three phase power.

  • The dynamometer has never ran properly and lacks a data acquisition system.


Current drexel dynamometer l.jpg

Current Drexel Dynamometer


Problem statement l.jpg

Problem Statement

  • Drexel SAE lacks the ability to perform in-house testing on its braking system design; Prototypes must be complete systems tested on completed car.

  • Data from test runs of actual system components would be useful for design, including:

    • Braking horsepower

    • Thermal loads

    • Rotor and pad coefficient of friction

    • Actual hydraulic operating pressure

  • Drexel SAE has a dynamometer that is incomplete and not operational.


Available dynamometers l.jpg

Available Dynamometers

  • Extremely expensive

  • Requires large work area

  • Hard to relocate


Methods of solution l.jpg

Methods of Solution


Constraints and challenges l.jpg

Constraints and Challenges

Existing Parts

  • We must integrate existing dyno parts.

    Cost

  • Funding must be allocated to produce product.

    Time

  • Must be completed within the requirements of Senior Design.

    Safety

  • Must be safe for operator and environment.

    Adaptability

  • Able to test a wide variety of component designs.


New rig orientation l.jpg

Old Rig Orientation

Hydraulic Actuator

New Rig Orientation

Initial Design

  • Lower Center of Mass

  • Effective Tensioning

  • Contained Hydraulic Actuator

  • Single Chain

  • Secured/Cushioned Feet


Dynamometer systems l.jpg

Dynamometer Systems


Dynamometer systems12 l.jpg

Dynamometer Systems


Calculations l.jpg

Calculations

  • Determine correct sprocket sizes for desired flywheel, motor, and rotor speeds

  • Complete Finite Element Analysis of Frame

  • Calibrate LabView based on comparison of measured data and theoretical values

    • Line Pressure

    • Coefficient of Friction

    • Braking Torque and HP


Manufacturability feasibility l.jpg

Manufacturability/Feasibility

  • Team will require outside resources:

    • Machining operations

    • Tools

  • Single-unit production does not require mass-production methods

  • Team covers all necessary skills, including welding.


Calibration and testing l.jpg

Calibration and Testing

  • Dynamometer will need to be calibrated and tested to ensure accuracy

  • As-measured data will be compared to hand-calculated values and data published by component manufacturers (Wilwood, etc.)

    • Coefficient of Friction

    • Line Pressure

    • Net System HP

  • Calibration to be done by tuning values in LabView simulation


Environmental societal impacts l.jpg

Environmental & Societal Impacts

  • Brake Fluid Containment

    • System pressures will be kept within the limits recommended by component manufacturers to prevent leakage.

  • Operator Safety

    • Rotating components will spin in excess of 3000 RPM and will be well balanced to prevent vibration and fatigue. Safety guards will be installed to protect operator and area workers.

    • We will measure noise levels during machine operation to verify that hearing damage will not be a concern.


Project deliverables l.jpg

Project Deliverables

  • An operating Brake Dynamometer System that will be used to determine the following data:

    • System Braking Horsepower

    • Operating and Maximum Temperatures and Pressures

    • Pad-Rotor Coefficient of Friction

  • Documentation that includes:

    • Standard Operating Procedures

    • Maintenance Instructions and Schedule


Timeline l.jpg

Timeline


Economic analysis l.jpg

Economic Analysis


Cost effectiveness l.jpg

Cost Effectiveness

  • The current dynamometer has already exhausted the following funding:

    • $500 – MEM Department Donation to Install Power Supply

    • $350 – ABB Power Controller Donation

    • $839 – DR-06 Design Team Dyno Development Cost

    • $1400 – DR-05 Design Team Dyno Development Cost

      Thus $3,089 has been ineffectively spent for a machine that is inoperable to date. Granting our funding request will allow us to validate previous funding by creating a working device for future SAE teams to use.


Conclusions l.jpg

Conclusions

  • A Brake Dynamometer is a valuable tool in brake system development.

  • We will deliver a complete and operational brake dynamometer within our projected timeline.

  • Our dynamometer will be safe for operators and other area workers.

  • We will include documentation explaining operation and maintenance so that the dyno may be used for years to come.


Questions l.jpg

Questions?


  • Login