4-2020
ABE/TSM 363 Dynamometer
ABE/TSM 363 Dynamometer
Michael Schulte
Iowa State University, [email protected]
Kyle Plach
Iowa State University, [email protected]
Christian Van Sloun
Iowa State University, [email protected]
Dylan Wood
Iowa State University, [email protected]
Michael Anderson
Iowa State University, [email protected]
See next page for additional authors
Follow this and additional works at: https://lib.dr.iastate.edu/tsm416
Part of the Bioresource and Agricultural Engineering Commons, and the Industrial Technology Commons
Recommended Citation Recommended Citation
Schulte, Michael; Plach, Kyle; Van Sloun, Christian; Wood, Dylan; Anderson, Michael; and Koziel, Jacek A., "ABE/TSM 363 Dynamometer" (2020). TSM 416 Technology Capstone Projects. 72.
https://lib.dr.iastate.edu/tsm416/72
This Report is brought to you for free and open access by the Undergraduate Theses and Capstone Projects at Iowa State University Digital Repository. It has been accepted for inclusion in TSM 416 Technology Capstone Projects by an authorized administrator of Iowa State University Digital Repository. For more information, please contact [email protected].
Problem Statement Problem Statement
The current dynamometer, a machine that measures electric motor outputs, used in ABE/TSM 363 lab has been used for many years and should be improved in several key areas, including safety, appearance, and function capabilities. The goal of this project is to develop a manufacture-ready electric motor
dynamometer based on a prototype system. This system will be replicated and utilized in ABE/TSM 363 lecture and lab for demonstrations and student testing.
o The ABE Dynamometer project is led by Timothy Shepherd, an Associate Teaching Professor at Iowa State University. He will directly be using the final product to aid in his teaching.
o The current dynamometer could be improved upon in several major aspects:
▪ The dynamometer needs to be updated so that it is safer than the current one being used in the lab. The current model does not fully shield users from getting tangled up in the rotating shaft. ▪ The functionality of the current dynamometer is limited to manual measurements through voltmeters, tachometers, and amp clamps. This does not allow easily measuring power factor. ▪ The dynamometer currently being used lacks precision in output readings due to the analog measurement constraints. ▪ The dynamometer currently being used leaks oil, making it harder to see the machine and requires clean up.
o The new dynamometer should be designed so that it is safer and updated to give the capability of either digital or manual readings to measure power factor, voltage, current, and motor speed. This will give future students and faculty the opportunity to better learn and teach the fundamental electrical power theory and applications.
o This design has the potential to be utilized in similar labs to teach students about the fundamental electrical power theory and applications.
Disciplines Disciplines
Bioresource and Agricultural Engineering | Industrial Technology
Authors Authors
Michael Schulte, Kyle Plach, Christian Van Sloun, Dylan Wood, Michael Anderson, and Jacek A. Koziel
ABE/TSM 363 Dynamometer
Michael Schulte a, Kyle Plach b, Christian Van Sloun c, Dylan Wood d, Michael Anderson e*and Jacek A.
Koziel f*
a Agricultural Systems Technology, ABE, ISU, [email protected]
b Industrial Technology, ABE, ISU, [email protected]
c Agricultural Systems Technology, ABE, ISU, [email protected]
d Industrial Technology, ABE, ISU, [email protected]
e Dept. of Agricultural and Biosystems Engineering, ISU, 2358 Elings Hall, Ames, IA 50011,
[email protected], 515-294-2129
f Dept. of Agricultural and Biosystems Engineering, ISU, 4350 Elings Hall, Ames, IA 50011,
[email protected], 515-294-4206
*course instructors and corresponding authors.
Client: Tim Shepherd, ABE/TSM 363, 4358 Elings Hall, Ames, IA, 50011
● Contact(s): Tim Shepherd, Associate Teaching Professor, [email protected], 515-451-7383
1 P
ROBLEM
S
TATEMENT
The current dynamometer, a machine that measures electric motor outputs, used in ABE/TSM 363 lab has been used for many years and should be improved in several key areas, including safety,
appearance, and function capabilities. The goal of this project is to develop a manufacture-ready electric motor dynamometer based on a prototype system. This system will be replicated and utilized in
ABE/TSM 363 lecture and lab for demonstrations and student testing.
o The ABE Dynamometer project is led by Timothy Shepherd, an Associate Teaching Professor at Iowa State University. He will directly be using the final product to aid in his teaching.
o The current dynamometer could be improved upon in several major aspects:
▪ The dynamometer needs to be updated so that it is safer than the current one being used in
the lab. The current model does not fully shield users from getting tangled up in the rotating shaft.
▪ The functionality of the current dynamometer is limited to manual measurements through
voltmeters, tachometers, and amp clamps. This does not allow easily measuring power factor.
Department of Agricultural and Biosystems Engineering (ABE) TSM 416 Technology Capstone Project
▪ The dynamometer currently being used lacks precision in output readings due to the analog measurement constraints.
▪ The dynamometer currently being used leaks oil, making it harder to see the machine and
requires clean up.
o The new dynamometer should be designed so that it is safer and updated to give the capability of either digital or manual readings to measure power factor, voltage, current, and motor speed. This will give future students and faculty the opportunity to better learn and teach the fundamental electrical power theory and applications.
o This design has the potential to be utilized in similar labs to teach students about the fundamental electrical power theory and applications.
Business Case Statement - The current dynamometer used in ABE/TSM 363, a required class for all majors throughout the ABE department, requires manual measurements by using tools such as
tachometers, amp clamps, and voltmeters. This project works to give students a better understanding of electrical motors and electricity concepts. This project works to develop an updated dynamometer that can give the option to collect motor output data manually or through a digital data acquisition system.
2 M
AIN
O
BJECTIVE
Main Objective(s) and Specific Objectives
The main objective is to create a manufacture-ready dynamometer for use in Electricity Lab in Sukup
Hall, room 3220. Specific criteria include: o Ease of manufacturability and replication o A visually appealing final product
Constraints
o Metal surface must resist rust so either aluminum or powder-coated steel is to be used
o A complete, clean, and operational mechanical system including appropriate safety shielding and electrical protection
o A functioning instrumentation system incorporating a user interface and data collection system o Must be able to measure current, voltage, power factor and rpm digitally and manually
Rationale
o Teach students fundamental electrical power theory and applications
o Allows students to utilize this dynamometer to get hands-on experience with electrical concepts o Replace the outdated dynamometer
Project Scope
o Must be a professional appearance and easily manufacturable design
o Redesign adjustable components such as shaft supports and brake housing to fixed dimensions o The scope slightly changed throughout the project to meet time constraints and clarification of
customer needs
o Due to timeline constraints and the added challenge of COVID-19, this project was altered to focus on assembly design and manufacturing. The instrumentation and data acquisition aspect are not included in this project.
3 M
ETHODS
/A
PPROACH
Reference Material
o This project improved upon a prototype design from a previous project
o Discussed with ISU lab staff to order required parts and the most effective way to produce parts.
Data collection:
o Met with client biweekly to clarify project requirements, update progress and, approve designs components
o Determined functionality and exact component placement using a prototype with a pine baseboard
Skills:
o Experience with motor performance testing and analysis from TSM 363: Electrical Power Systems
gave background knowledge on the concepts being measured
o TSM 216: ADV technical interpretation and CAD gave software knowledge and experience to aid in the assembly designing
o TSM 493: Applied Instrumentation gave background knowledge for instrumentation and controls systems
Solutions:
o A prototype was already established by a previous project group; we based our model on that prototype and refined it with input from our sponsor. The previous prototype consisted of variable components, including shaft supports, and brake housing. These were converted to fixed
dimensions for ease of repeatability and professionalism.
o Created 3 assembly design options for the client’s approval. Aspects of multiple designs were combined to create the final design
o Purchased parts from the previous prototype were reused in the final design, see the bill of materials in the appendix.
o Ordered additional parts and materials from CyBuy vendors.
o Manufactured select parts in-house and documented them for repeatability.
Organization:
o We met weekly, and we used GroupMe to communicate outside of meetings and class.
o There were communication struggles with our client when emails were primary means of contact. This greatly improved when meetings were in person.
o The workload was discussed in meetings and evenly distributed.
o Major milestones for the project included design of individual parts, assembly designs approved by client, manufacturing parts, and assembling.
Timeline(see appendix)
4 R
ESULTS
Results/Deliverables
o Final dynamometer design consists of:
▪ Lexan bent with heat guns and a jig for the shielding of the rotating shaft and main senor holding area. *Note this did not get tested with timeline constraints
▪ T-Slot aluminum (8020) was used to attach the Lexan to the base to firmly secure and give a
professional appearance.
▪ Shaft supports were waterjet cut from 5052 aluminum and bent to 90 degrees using 3/8 bend
radius brake located in Boyd Lab.
▪ The Love-Joy bearings are mounted floating inside the 2 support brackets.
▪ System wiring runs underneath baseboard and up through waterjet holes.
o Technical drawings and instructions to replicate can be found in the appendix
Recommendations
o The product needs to be improved upon to incorporate sensors and data acquisition to the design.
5 B
ROADER
O
PPORTUNITY
S
TATEMENT
o There are current dynamometer designs available to purchase as a complete set. This design is focused on teaching and understanding of electrical concepts.
o This will enhance students learning in TSM363 or similar courses for engineers at Iowa State and other universities.
6 G
RAPHICAL
A
BSTRACT
Shields are bent from one piece instead of multiple pieces attached together. Adjustable components of previous design were converted to fixed dimensions for ease of repeatability
Brake knob rotated 90degrees and paced outside of main shielding to shrink board dimensions and keep oil off the shielding.
Shaft supports were bent instead of welded like on previous prototype.
All shielding attached to base using T-slot aluminum.
Future sensor locations with the wiring running the waterjet cut holes and underneath the base board.
7 R
EFERENCES
Department of Agricultural and Biosystems Engineering. “TSM 415/416 PROJECT DEVELOPMENT FORM: ABE Dynamometer.” 9 July 2019.
Grainger. “OSHA Requirements: Machine Guarding.” Grainger Industrial Supply, 31 Mar. 2017, www.grainger.com/know-how/safety/machine-safeguarding/people-protection/kh-osha-requirements-machine-guarding.
