1. Sam Crone, Brad Orr, Logan Williamson
Baja Dynamometer
ME Senior Design
Presented By:
Sam Crone, Brad Orr, Logan Williamson

2. Introduction What is a dynamometer? Client:
Measure vehicle’s power output at particular speeds
Expensive ($3800: 0-30 HP water brake kit)
Limited availability
Client:
SAE BAJA TEAM

3. Mechanical Friction Brake Proof of Concept
Design History
Engine Dyno
Inertial Wheel
Chassis Dyno
Water Brake
Electric Motor/Generator
Hydraulic Motor
Mechanical Friction Brake
Mechanical Friction Brake Proof of Concept

4. Objectives Measure Power Characteristics Safety
Absorb 10 HP Through Operating RPM’s
Safety
Analysis to Ensure Desired Function
Design for a Possible Business
Competitive Cost, Durable, User Friendly
Portable
Robust Design for Widespread Testing Locations

5. Friction Brake Theory 𝑃=𝑇∗𝜔 𝑇=𝐹∗𝐿 Rotor Force Power (P) Floating
RPM (𝜔)
Force (F)
Moment Arm Length (L)
Floating
Caliper
Moment
Arm
Load Cell

6. Mechanical Overview Floating Caliper Stand and Securement
Load Cell Platform
Rotor/Hub Coupler

7. Mechanical – Floating Caliper
Free Rotation
Constrained to Brake Surface
Pivot Around Axis of Rotation

8. Mechanical – Stand Center Lift for Wheel Removal Tie Down Slots
Load Cell and Caliper Support
Tie Down Slots

9. Mechanical - Load Cell Platform
Load Cell Limits:
Working Range : lbs (0-450 ft*lbs)
Maximum : 1100 lbs
Perpendicular Load Cell Reaction
Minimum Factor of Safety : 675 lbs (450 ft*lbs)
Maximum Deflection : 0.11 mm

10. Mechanical – Coupling Attach Brake Rotor to Vehicle Hub
Minimum Factor of Safety: 450 ft*lbs
Maximum Deflection : mm

11. Safety – Analysis for Stand Rotation
Vehicle Weight
ROTATION
Brake Force
Strap Force
Front O
Rear RF RR

12. Safety – Analysis for Stand Rotation
𝑇=450𝑓𝑡∗𝑙𝑏𝑠=5400 𝑖𝑛∗𝑙𝑏𝑠
𝑀 𝑂 =0=𝑇−𝑅𝐹∗20 𝑖𝑛
𝑅𝐹= 𝑇 20 = = 270 lbs FW T y
Front
Rear O x
20 in
RR = 0 lbs RF

13. Electrical Overview Sensors – Load Cell and Tachometers
Control – Throttle and Brake Stepper Motors
Arduino
LabVIEW Interface

14. Electrical - Sensors
Tachometer
Load Cell

15. Electrical - Control

16. Electrical – Arduino Mega 2560 – 16 MHz Upgradeability Serial Commands
Tachometer Circuit
Stepper Motor Drivers
Load Cell
Amplifier

17. Electrical -LabVIEW Power and Torque RPM Serial Commands
User Interface

18. Final Results- At Maximum Vehicle Output

19. Portability Mobile Control Unit Stand Storage- Brake, Jacks, Chocks
Housing- Control Assemblies
Stand
Manageable Weight (130 lbs)
Handles

20. Budget Proposed Budget: $1570 Remaining Budget: $467
Proof of Concept: -$287
Finalize Concept: -$816
Remaining Budget: $467
Total Cost : $1103

21. Market Considerations
DYNO-mite Dynamometer Water Brake Kit: $3800
Baja Friction Brake Dynamometer Kit: $1103
Difference: $2697

22. Conclusion Measure Power Characteristics Safety
Prototype Measured ~8 HP
Safety
FEA Analysis of Major Components
Static Analysis on Stand
Design for a Possible Business
Promising Cost
Portable

23. Main Future Recommendations
Enclose Mechanical Brake
Integrate Kill Switch with Final Baja Vehicle
Tune Data Acquisition Program
Create PCB for Electronics
Address Vehicle Oscillation Source

24. Special Thank You:
Division of Research Support – Marvin Perry and Cody Barritt
Dr. Kevin Kilty

25. Questions?