Objective: Design an in-house dynamometer from scratch to assist with motor data collection. The goal being to get torque and RPM data under set loads w/o the use of a tachometer.
Our team consisted of a senior EE and myself. We first established key specifications for the dyno (budget, load on the scooter motor, output information, not based on tachometer, etc.). Prior to diving into the full design, we developed a block diagram that we evolved and updated as the project progressed and components were decided upon (as pictured below).
As we researched component options, we logged them all in a slide deck along with their pros and cons – so if one option didn’t pan out we could quickly shift gears and find an alternative. Once components were selected, the block diagram got updated with names and key specifications to help cross check compatibilities. Additionally, the connection between components got mapped (red- power, blue/green- data & control, grey- physical)
After the dyno was thoroughly outlined, I created a full CAD model and drafted custom couplers and mounts to then be machined (also selected and included all hardware in the CAD model).
Below are snapshots of the CAD model (slideshow 1) and photos of the physical dyno itself (slideshow 2)- there are still a couple of adjustments we’d like to make though.
Kendall Ronzano 