p16221 – fsae shock dynamometer problem definition review
Post on 19-Jan-2016
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P16221 – FSAE Shock DynamometerProblem Definition Review
• Aung Toe – EE• Jim Holmes – EE
– Project Manager
• Sal Fava – ME– Chief Engineer
• Chris Batorski – ME– Facilitator
• Andrew Dodd – ISE
P16221 – MSD Team
• RIT Formula SAE (FSAE) develops an open-wheel single seat race car for the Formula SAE collegiate design series.
• One of the more complicated parts of the car that the team does not produce in-house is the dampers.
• While the springs in the suspension are sensitive to displacement, shock absorbers (dampers) are used to control the relative velocity between the wheels and chassis.
Project Background
Dampers can be very hard to understand• Very nonlinear, with different damper shaft speeds
controlling different aspects of the car. • Speed dependent, and affected by temperature, air
pressure, etc. • Having the ability to test the dampers in-house
would open a lot of opportunities for tuning and testing the car not currently available to the FSAE team.
Project Background
Current State• A shock dynamometer is a measurement device that
can supply an input and measure the response (both displacement and force) of a damper.
• Similar machines in the mechanical engineering building labs do not meet the frequency requirements, size constraints, and mobility requirements.
Problem Statement
Desired State• The goal is to design a device that is better equipped for shock
measurements– Analyze closest in house solution (Instron 8801 in
Mechanics Lab)• Larger eye to eye distance• Input track data• Faster control speeds• Customizable user interface• Save data in a common format
Problem Statement
• Actuation Type– Actuator
• EMA• Hydraulic• Air
– Cam• Motor driven
Dynamometer Solutions
Example of Track data
Standard Performance Chart
Desired Output Chart
Use Scenarios
1. Cost less than $4,0002. Able to be moved in the shop easily3. Reproduce damper displacements from track data4. Measure damper forces5. Measure damper shaft position6. Measure damper temperature during test7. Save and recall test data for post processing8. Maximum footprint of 4’ x 4’9. Accommodate wide range of damper sizes
Customer Performance Requirements
Stakeholders
• RIT Formula SAE Team– Customer and End users– Want a working, affordable and user friendly Shock Dyno
• Dr. Alan Nye (Formula Team Advisor)– Concerned with development and funding
• RIT and KGCOE– Potential end users– Provide space for Dyno– Fabrication support
• Calibration Team– Who will calibrate the stand when necessary?
• Local External companies– Potential end users/sponsors
Key Engineering Requirements
• Input – Displacement (inches) and time (sec) profile (cam profile
or a course map) >100Hz control frequency
• Record:– Force (max 2500lb)– Distance (.25-7in)– Time (s) – Temperature (150˚C max)
Key Engineering Requirements Cont’d
• Binary Requirements – must meet customer user approval– Save all data so it can be easily processed externally– Easily customized real time data display
• Safety Requirements– Fully enclosed test area– Emergency stop switch
• Budget– Senior Design Donation $500– Additional Funding TBD
Importance Cost
Sturdy
base and mounting
to withstan
d vibrations
Able to be moved to different locations in
the shop
Overall
footprint
Save and recall test data to a wide
ly used form
at
Stand-
alone
data acquisitio
n and control
unit
Create
graphs
usable for testing
and tuning
dampers
Replay
test data back
in real time
Measure damper
forces
Measure damper
shaft position
Measure damper temperature during
test
Variable
stroke
range
Min/Max
eye to eye
distance
Reproduc
e frequencies
seen on
track
Measure fluid temperature
if possible
Cost less than $4,000.00 9 Sturdy base and mounting to withstand vibrations 9 Able to be moved to different locations in the shop 6
Maximum foot print of 4' x 4' 6 Save and recall test data to a widely used format 9
Stand-alone data acquisition and control unit 6 Create graphs usable for testing and tuning dampers 3
Replay test data back in real time 3 Measure damper forces 9
Measure damper shaft position 9 Measure damper temperature during test 9
Variable stroke range 9 Ability to accommodate different sizes of dampers 6
Reproduce frequencies seen on track 6 Measure fluid temperature if possible 3
Unit of Measure $$ in BI in BI BI BI BI lb in ˚F in in Hz ˚F
Ideal Value <4000
<.005 48' x
48' >1500
.25 - 7 <250 .25 -
7 9 - 31 >100 <250
House of Quality
• Conclusions: Develop a dyno with Roehrig Capabilities, ½ price of the Intercomp.
• Other option is to use the Instron
Benchmark Existing Systems
Project Timeline
Questions?
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