Frame design and fabrication of Engine Dynamometers for FSAE cars

Authors

  • Pranaya Pokharel Midwestern State University
  • Trevon Antoine
  • Garvin Joseph
  • Nedabiah Warner

Keywords:

FSAE, FEA, Design, Dynamometers, Engine Testing

Abstract

Engine dynamometers (dynos) are used to test and validate design concepts in cars. In our application, we will test engines 710cc and under, as per Formula Society of Automotive Engineers (FSAE) guidelines. To do this, a cost effective, and efficient dyno was designed. The dyno is modular which allows it to mount different size engines. To achieve this modularity, the front and rear engine mounts were made moveable. The dyno consists of components such as an engine, radiator, fuel tank, dynamometer control, laptop, and the eddy current brake. The eddy current will provide resistance to the engine via a shaft to simulate the load that the engine will be under in the FSAE car. From this project, we are able to tune the engine and collect information for various sub-teams before the designs are integrated into the car. The dyno collects powertrain data such as the cylinder pressure, oil pressure, and power output. We are also able to test electrical sensors, plan electrical system design, and log data. The car’s drivetrain system can test final drive ratios and obtain power values being sent to the differential. The eddy brake is calibrated to match values from the tire data for the tires we will be using on the car. The output of the brake equates to a certain slip angle which tells us how the tires are behaving under certain engine loading. Currently the team is in the manufacturing and wiring phase of the project. Finite Element Analysis (FEA) indicated that the design of the frame is safe for the loads it experiences. During this phase, the structure is being welded and assembled together while electrical components such as thermocouples, Arduino, inverter, and the power supply are being tested and wired.  Future work includes running steady state and dynamic tests as well as publishing the progress and the results.

Downloads

Published

2024-08-01

How to Cite

Pokharel, P., Antoine, T., Joseph, G., & Warner, N. (2024). Frame design and fabrication of Engine Dynamometers for FSAE cars. Journal of Innovative Ideas in Engineering and Technology (ISSN: 2563-3678), 1(1), 33-97. Retrieved from https://jiiet.com/index.php/jiiet/article/view/103

Issue

Vol. 1 No. 1 (2024): Innovations in Engineering and Technology

Section

Scholar

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