Design, Development and Validation of Engine Dynamometer for FSAE

Abstract

The goal of this paper is to develop a low-cost yet accurate dynamometer for testing and validating the powertrain. With ever-advancing technologies, and zeal to develop more and more power and torque, there is no definitive limit for the operating boundary conditions. So, to set the definitive boundary conditions for our project, powertrain for Formula Society of Automotive Engineers (FSAE) applications is selected. The brake torque is calculated based upon the traction limit of FSAE race cars. The brake torque is determined to be 100 N-m. The goal is to develop a low-cost accurate dynamometer, thus hydraulic type, Steady-state dynamometer is considered. A top-down approach is considered for the project. With the determination of brake torque, the gear pump selection is done which is followed by pressure gauge selection, needle valve selection, design of final drive, which is followed by hoses and couplings. The RPM data is tapped from the ECU of the prime mover and the flow rate is computed. A pressure sensor is used to measure the pressure downstream of the gear pump. The data is then computed to obtain power and torque curves. Then the whole setup is tested and validated with FSAE standard powertrain