BRAKE DYNAMOMETER DEVELOPMENT FOR DREXEL UNIVERSITY FSAE RACE TEAM

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BRAKE DYNAMOMETER DEVELOPMENT FOR DREXEL
UNIVERSITY FSAE RACE TEAM

• MEM-01
• Dr. Tein-Min Tan
• Frank DiMento Alfredo Vitale
• Anthony Tofani John Henry

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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.

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Benefits of a Dynamometer

• Prototype costs lowered
• Flexible testing schedule
• No risk to driver or vehicle
• Quantified performance data
• Example
• 2005 Sinusoidal Rotor Design

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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.

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Current Drexel Dynamometer
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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.

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Available Dynamometers

• Extremely expensive
• Requires large work area
• Hard to relocate

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Methods of Solution
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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.
  

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New Rig Orientation
Initial Design

• Lower Center of Mass
• Effective Tensioning
• Contained Hydraulic Actuator
• Single Chain
• Secured/Cushioned Feet

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Dynamometer Systems
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Dynamometer Systems
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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

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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.

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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

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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.

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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

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Timeline
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Economic Analysis
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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.

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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.

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Questions?