MSD P15280 RIT HOT WHEELZ TEST BENCH

AGENDA Detailed Design Review Mechanical Electrical Dyno Interface Motor Mount & Baseplate Modular Cart Design Motor Coupling Design Electrical Dyno Interface Sourced Components Jenn

PROGRESSION TIMELINE Maura

PROJECT TIMELINE

MECHANICAL Eric

CURRENT KGCOE DYNAMOMETER Maura

CURRENT KGCOE DYNAMOMETER-CONTROLS ROOM Maura

UPDATED DESIGN CONCEPT CONT. Maura

Dynamometer CAD

Mounting Design Concept- Baseplate 4” X 4” Hole Pattern 0.25” AISI 1020 Steel Plate

Mounting Design Concept- Motor Mount 0.25” AISI 1020 Steel Plate Hole Pattern to Match Motor Rounded Corners to Minimize Stress Concentrations

Mounting Design Concept- Motor Mount 100 N/m Torque on Each Bolt Hole ~700 N/m combined loading 0.04 mm of displacement max Does not exceed yield strength of AISI 1020 Steel Minimum Factor of Safety of 2.215 629 TIMES EXAGGERATED

Mounting Design Concept- Motor Mount 100 N/m Torque on Each Bolt Hole ~700 N/m combined loading Centrifugal Force → 3000RPM Exceeds Yield Strength Further Optimization to avoid exceeding Yield will be done 17 TIMES EXAGGERATED

Mounting Design Concept- Hinge 0.25” AISI 1020 Steel Plate Slotted Holes for adjustability Welded onto Motor Mount

Mounting Design Concept- Assembly Easily change position to mount to the chain Adaptable to different configurations

Mounting Design Concept- Assembly

UPDATED DESIGN CONCEPT Maura

DETAILED CART DESIGN A 30” X 60” cart was sourced from Global Industrial bases on the cost saving between building a cart and buying one. ~$700 for raw materials & mounting accessories ~$500 for base cart & mounting accessories Cart Specifications 1000 lb capacity 5” Wheel Diameter Removeable Handle can be mounted on either side http://www.globalindustrial.com/p/material-handling/platform-trucks/wood/steel-bound-wood-deck-truck-60x30-1000-lb-capacity

DETAILED CART DESIGN CONT. Baseplate and Motor will be attached to the cart utilizing a modified second handle with a wood insert supported by L brackets. http://www.globalindustrial.com/p/material-handling/platform-trucks/wood/steel-bound-wood-platform-truck-handle-30

DETAILED CART DESIGN CONT.

NEXT STEPS Mounting options to the cart platform for modularity of the Hot Wheelz electrical components Layout options for the Hot Wheelz Components

MOTOR COUPLING DETAILED DESIGN Current Dyno Existing Idler / tensioner system Eric

MOTOR COUPLING DETAILED DESIGN Chain Heavy Duty, ⅝” pitch, 1620 lb working load Tension set and maintained through adjustable idler *images from McMaster-Carr Idler Sprocket OD not critical Built-in bearing for ease of mounting to shaft Eric

MOTOR COUPLING DETAILED DESIGN Transmission Sprockets Hot Wheelz team gear ratio Pinion (~2.5” OD) Machinable to fit motor output shaft Gear (flat, ~8” OD) Machinable to fit existing dyno mount *images from McMaster-Carr Eric

MOTOR COUPLING DETAILED DESIGN Idler Creating our own *images from McMaster-Carr Eric

ELECTRICAL Eric

Sensor Sourcing

Overall Preliminary Wiring Diagram Dyno Room Control Room Power Supply Spec: 24±0.1V CAT II Isolation for Voltage Sensors

Custom PCB Diagram 1N5818: Schottky diode with maximum reversed voltage of 30V, and nominal forward voltage of ~0.5V L78S10CV: Linear 10V 2A voltage regulator AD595AQ: cold junction compensation, amplifier & output buffer IC for Type-K thermocouple Equivalent Resistances determined by maximum supply current for corresponding sensors

Test Communication With Controller Developed Terminal Application which reads user typed commands and sends them to controller through RS232 using set properties. Once commands are sent application waits 2 seconds for reply from controller.

Planned Test Procedure 1. Set controller to computer and RMP mode \MD COMP,RPM 2. Set rate of change of LAC \LAC 100 3. Set the RPM set point \SP 1000 4. Turn the Dyn-Loc on \MD DON 4. Take 200Hz Sample of Speed - verify 1000rpm \H0 5. Set RPM set point to 0 \SP 0 6. Turn Dyn-Loc off \MD DOFF

Test Results -Determined baud rate - 256k -Connection was made, i.e. no error indication from terminal app -Attempted to send command -No reply from controller -Test inconclusive

QUESTIONS? FEEDBACK? SUGGESTIONS?