P16221 – FSAE Shock Dynamometer Problem 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 $4,000 2.Able to be moved in the shop easily 3.Reproduce damper displacements from track data 4.Measure damper forces 5.Measure damper shaft position 6.Measure damper temperature during test 7.Save and recall test data for post processing 8.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 withstand vibrations Able to be moved to different locations in the shop Overall footprint Save and recall test data to a widely used format Stand-alone data acquisition 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 Reproduce frequencies seen on track Measure fluid temperature if possible Cost less than $4, Sturdy base and mounting to withstand vibrations9 Able to be moved to different locations in the shop6 Maximum foot print of 4' x 4'6 Save and recall test data to a widely used format9 Stand-alone data acquisition and control unit6 Create graphs usable for testing and tuning dampers3 Replay test data back in real time3 Measure damper forces9 Measure damper shaft position9 Measure damper temperature during test9 Variable stroke range9 Ability to accommodate different sizes of dampers6 Reproduce frequencies seen on track6 Measure fluid temperature if possible3 Unit of Measure$$inBIinBI lbin˚Fin Hz˚F Ideal Value <4000 < ' x 48' > < >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?