1. MSD P15280 RIT HOT WHEELZ TEST BENCH

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

4. PROGRESSION TIMELINE
Maura

5. PROJECT TIMELINE

6. MECHANICAL
Eric

7. CURRENT KGCOE DYNAMOMETER
Maura

8. CURRENT KGCOE DYNAMOMETER-CONTROLS ROOM
Maura

9. UPDATED DESIGN CONCEPT CONT.
Maura

10. Dynamometer CAD

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

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

13. 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

14. 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

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

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

17. Mounting Design Concept- Assembly

18. UPDATED DESIGN CONCEPT
Maura

19. 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

20. 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.

21. DETAILED CART DESIGN CONT.

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

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

24. 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

25. 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

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

27. ELECTRICAL
Eric

28. Sensor Sourcing

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

30. 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

31. 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.

32. 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 \SP 0
6. Turn Dyn-Loc off \MD DOFF

33. 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

34. QUESTIONS? FEEDBACK? SUGGESTIONS?