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BRAKE DYNAMOMETER DEVELOPMENT FOR DREXEL UNIVERSITY FSAE RACE TEAM

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

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BRAKE DYNAMOMETER DEVELOPMENT FOR DREXEL UNIVERSITY FSAE RACE TEAM

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  1. BRAKE DYNAMOMETER DEVELOPMENT FOR DREXEL UNIVERSITY FSAE RACE TEAM MEM-01 Dr. Tein-Min Tan Frank DiMento Alfredo Vitale Anthony Tofani John Henry

  2. 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.

  3. Benefits of a Dynamometer • Prototype costs lowered • Flexible testing schedule • No risk to driver or vehicle • Quantified performance data • Example: • 2005 Sinusoidal Rotor Design

  4. 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.

  5. Current Drexel Dynamometer

  6. 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.

  7. Available Dynamometers • Extremely expensive • Requires large work area • Hard to relocate

  8. Methods of Solution

  9. 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.

  10. Old Rig Orientation Hydraulic Actuator New Rig Orientation Initial Design • Lower Center of Mass • Effective Tensioning • Contained Hydraulic Actuator • Single Chain • Secured/Cushioned Feet

  11. Dynamometer Systems

  12. Dynamometer Systems

  13. 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

  14. 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.

  15. 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

  16. 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.

  17. 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

  18. Timeline

  19. Economic Analysis

  20. 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.

  21. 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.

  22. Questions?

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