Post on 18-Dec-2015
transcript
BRAKE DYNAMOMETER BRAKE DYNAMOMETER DEVELOPMENT FOR DREXEL DEVELOPMENT FOR DREXEL
UNIVERSITY FSAE RACE TEAMUNIVERSITY FSAE RACE TEAM
MEM-01MEM-01Dr. Tein-Min TanDr. Tein-Min Tan
Frank DiMentoFrank DiMento Alfredo VitaleAlfredo VitaleAnthony TofaniAnthony Tofani John HenryJohn Henry
What is a Brake What is a Brake Dynamometer?Dynamometer?
A system used to duplicate track A system used to duplicate track braking scenarios in order to analyze braking scenarios in order to analyze a brake system design before the a brake system design before the components are implemented on a components are implemented on a race vehicle.race vehicle.
This piece of machinery can be This piece of machinery can be utilized by all Drexel University race utilized by all Drexel University race teams, including Formula SAE, Sonic teams, including Formula SAE, Sonic Cricket, and Mini Baja. Cricket, and Mini Baja.
Benefits of a Benefits of a DynamometerDynamometer Prototype costs loweredPrototype costs lowered
Flexible testing scheduleFlexible testing schedule No risk to driver or vehicleNo risk to driver or vehicle Quantified performance dataQuantified performance data Example:Example:
2005 Sinusoidal Rotor Design2005 Sinusoidal Rotor Design
Previous WorkPrevious Work
2005 FSAE Brake Team Designed a 2005 FSAE Brake Team Designed a Brake Dynamometer that was not Brake Dynamometer that was not completed.completed.
2006 FSAE Brake Team added a 2006 FSAE Brake Team added a power controller to obtain necessary power controller to obtain necessary three phase power.three phase power.
The dynamometer has never ran The dynamometer has never ran properly and lacks a data acquisition properly and lacks a data acquisition system.system.
Problem StatementProblem Statement Drexel SAE lacks the ability to perform in-Drexel SAE lacks the ability to perform in-
house testing on its braking system design; house testing on its braking system design; Prototypes must be complete systems Prototypes must be complete systems tested on completed car.tested on completed car.
Data from test runs of actual system Data from test runs of actual system components would be useful for design, components would be useful for design, including:including: Braking horsepower Braking horsepower Thermal loadsThermal loads Rotor and pad coefficient of frictionRotor and pad coefficient of friction Actual hydraulic operating pressureActual hydraulic operating pressure
Drexel SAE has a dynamometer that is Drexel SAE has a dynamometer that is incomplete and not operational. incomplete and not operational.
Available DynamometersAvailable Dynamometers
Extremely expensiveExtremely expensive
Requires large work Requires large work areaarea
Hard to relocateHard to relocate
Constraints and Constraints and ChallengesChallenges
Existing PartsExisting Parts We must integrate existing dyno parts. We must integrate existing dyno parts.
CostCost Funding must be allocated to produce product. Funding must be allocated to produce product.
TimeTime Must be completed within the requirements of Must be completed within the requirements of
Senior Design. Senior Design.
SafetySafety Must be safe for operator and environmentMust be safe for operator and environment. .
AdaptabilityAdaptability Able to test a wide variety of component designs. Able to test a wide variety of component designs.
New Rig Orientation
Hydraulic Actuator
Old Rig Orientation
Lower Center of MassLower Center of Mass Effective Tensioning Effective Tensioning Contained Hydraulic Contained Hydraulic
ActuatorActuator Single Chain Single Chain Secured/Cushioned Secured/Cushioned
FeetFeet
Initial DesignInitial Design
CalculationsCalculations
Determine correct sprocket sizes for Determine correct sprocket sizes for desired flywheel, motor, and rotor speedsdesired flywheel, motor, and rotor speeds
Complete Finite Element Analysis of Complete Finite Element Analysis of FrameFrame
Calibrate LabView based on comparison Calibrate LabView based on comparison of measured data and theoretical valuesof measured data and theoretical values Line PressureLine Pressure Coefficient of FrictionCoefficient of Friction Braking Torque and HPBraking Torque and HP
Manufacturability/Manufacturability/FeasibilityFeasibility
Team will require outside resources:Team will require outside resources: Machining operationsMachining operations ToolsTools
Single-unit production does not Single-unit production does not require mass-production methodsrequire mass-production methods
Team covers all necessary skills, Team covers all necessary skills, including welding.including welding.
Calibration and TestingCalibration and Testing Dynamometer will need to be calibrated Dynamometer will need to be calibrated
and tested to ensure accuracyand tested to ensure accuracy As-measured data will be compared to As-measured data will be compared to
hand-calculated values and data published hand-calculated values and data published by component manufacturers (Wilwood, by component manufacturers (Wilwood, etc.)etc.) Coefficient of FrictionCoefficient of Friction Line PressureLine Pressure Net System HPNet System HP
Calibration to be done by tuning values in Calibration to be done by tuning values in LabView simulationLabView simulation
Environmental & Societal Environmental & Societal ImpactsImpacts Brake Fluid ContainmentBrake Fluid Containment
System pressures will be kept within the limits System pressures will be kept within the limits recommended by component manufacturers to recommended by component manufacturers to prevent leakage.prevent leakage.
Operator SafetyOperator Safety Rotating components will spin in excess of Rotating components will spin in excess of
3000 RPM and will be well balanced to prevent 3000 RPM and will be well balanced to prevent vibration and fatigue. Safety guards will be vibration and fatigue. Safety guards will be installed to protect operator and area workers. installed to protect operator and area workers.
We will measure noise levels during machine We will measure noise levels during machine operation to verify that hearing damage will operation to verify that hearing damage will not be a concern.not be a concern.
Project DeliverablesProject Deliverables
An operating Brake Dynamometer An operating Brake Dynamometer System that will be used to System that will be used to determine the following data:determine the following data: System Braking HorsepowerSystem Braking Horsepower Operating and Maximum Temperatures Operating and Maximum Temperatures
and Pressuresand Pressures Pad-Rotor Coefficient of FrictionPad-Rotor Coefficient of Friction
Documentation that includes:Documentation that includes: Standard Operating ProceduresStandard Operating Procedures Maintenance Instructions and ScheduleMaintenance Instructions and Schedule
Economic AnalysisEconomic AnalysisComponent Cost Company
1 DAQ CARD $219.25 National Instruments2 SQUARE TUBING $215.44 McMaster Carr3 FASTENERS $32.50 Home Depot4 GUARDS $80.00 McMaster Carr5 TEMP SENSOR $150.00 Metris Instruments6 PRESS SENSOR $162.50 APG Automation7 LOAD CELL $327.50 Omega Engineering8 OPTICAL ENCODER $0.00 Previously Purchased9 MACHINING $300.00 Drexel / Cygnet Manufacturing
10 FORCE DEVICE MATERIAL $132.00 Hadco Aluminum Supply11 FORCE DEVICE ACTUATOR $259.00 Firgelli Automations12 FORCE DEVICE POWER $57.50 Power Supply Direct13 COMPUTER $459.00 Dell 14 RUBBER FEET $90.00 McMaster Carr15 SPROCKETS $60.55 Martin Sprocket
Project Overall Cost $2,545.24
2007 FSAE Brake Dyno Budget
Cost EffectivenessCost Effectiveness The current dynamometer has already exhausted The current dynamometer has already exhausted
the following funding:the following funding:
$500 – MEM Department Donation to Install Power $500 – MEM Department Donation to Install Power SupplySupply
$350 – ABB Power Controller Donation$350 – ABB Power Controller Donation $839 – DR-06 Design Team Dyno Development Cost$839 – DR-06 Design Team Dyno Development Cost $1400 – DR-05 Design Team Dyno Development Cost$1400 – DR-05 Design Team Dyno Development Cost
Thus Thus $3,089$3,089 has been ineffectively spent for a has been ineffectively spent for a machine that is inoperable to date. Granting our machine that is inoperable to date. Granting our funding request will allow us to validate funding request will allow us to validate previous funding by creating a working device previous funding by creating a working device for future SAE teams to use. for future SAE teams to use.
ConclusionsConclusions A Brake Dynamometer is a valuable tool A Brake Dynamometer is a valuable tool
in brake system development. in brake system development. We will deliver a complete and We will deliver a complete and
operational brake dynamometer within operational brake dynamometer within our projected timeline. our projected timeline.
Our dynamometer will be safe for Our dynamometer will be safe for operators and other area workers.operators and other area workers.
We will include documentation We will include documentation explaining operation and maintenance so explaining operation and maintenance so that the dyno may be used for years to that the dyno may be used for years to come. come.