The project as displayed on this page has been cancelled

Our current project can be found here.

http://www.twf8.ws/php/index.php?option=com_content&task=view&id=60&Itemid=186

All content on this page is for the idea of what we started with.

There are no drawing available for reproduction!

Why building a DYNO?
The answer is simple.
Many factories are claiming engine power ratings that can not be compared as we do not know how these figures are accomplished (this seems to be very TOPSECRET). 
Torque figures are something you will never get at all.
To make an end to this problem TEAM TWF8 will DYNO test engines and publish these figures.
If figures are provided by a factory then is the question is the power band usable or not?
Many racers say various thing about engines and how they perform even if this is the same engine.
As there is no standard yet TEAM TWF8 is in the process trying to make one. 
So this way world wide engines can be tested the same way according to this standard.

The whole project will be placed on TEAM TWF8 including mechanical drawings in AutoCad extensions (.DWG) or any industrial used  extension this to make it easy to reproduce the whole dyno system world-wide.

There are some options available to make a DYNO.

The cheapest and reliable one for high speed engines like we use is the INERTIA version. 
TEAM TWF8 is going to use this system to gather the information to produce the figures needed.

As said above the DYNO will become a so called INERTIA DYNO. 
This means that a flywheel with a certain weight will be powered by the engine to be tested. 
The time it takes to get this flywheel from 1.000 to his maximum rpm's will produce the data en graphs needed.
The coupling between the engine and the flywheel will exist out of the a RMV SPEED II clutch with the standard gearing of 13:43.
As running a flywheel at 40.000 rpm's can be a risky business we use this gear reduction so that maximum will be <10.000 rpm's.

The picture you see is the DYNO made by Kees Kuijt from the Netherlands.
He made the dyno as a graduation study project.
We have all data in Dutch (PDF file) to rebuild this one.
Currently (05-06-2004) this data is converted to a CAD file to be used for a CNC machine.

With clear graphs produced we can see the difference between engines if we make overlays.
Raw and only highest torque and power data is not needed.
We like to compare engines to each other and see how the torque and power bands are.

With overlay you can see the differences even in between measuring the same engine.

Both graphics are made by performance trends DYNO software and can be found here.
http://www.performancetrends.com/DTM-DYNO.htm

As there is no standard how to test we have to create one ourselves and publish.
The following is just an idea and might be changed while testing in progress.
What do we need to know more or really need for reliable and reproducible engine tests?

*Temperature of the engine @ 100 degrees Celsius.

*Outside temperature in degrees Celsius

*Humidity in %

*Rpm's of engine measured at the flywheel with opto couplers.

*Rpm's of INERTIA flywheel measured with opto couplers.

*Airfilter. This must be world wide available article. Standard part will be ?

*Muffler. This must be world wide available article. Standard part will be ?

*Glowplug. This must be world wide available article. Standard part will be ?

*Fuel. 25% Nitro, 10% oil brand not yet decided. This must be world wide available mixture!

Other items!

*Weight of flywheel still must be calculated.

*Fuel consumption will be measured with flow instrument @ 5.000/10.000/15.000/20.000 Rpm's provided by?

As a Dyno test run will only take a maximum 20 SEC's not much fuel will be used for testing J.

A data logger is not a bad thing working separate from a computer, but when all data goes direct into a laptop that is easier and direct result can be displayed while the test runs.

Main frame must carry an universal engine mount.

A standard 1:8 scale 2 shoe speed II clutch from RMV will be the standard clutch to use.

After the test runs with the standard parts like fuel, muffler, plug and filter a factory setting will be tested too if these are provide by the factory or distributor.

As of date 05-06-2004 for the data acquisition we can go two routes.

We have chosen to test first route one which is a set up with software program from ONTRACKDIGITAL we have purchased
The software is now installed on our laptop to get known to it and to see if there any things needed to be changed or adapt.
This program uses a soundcard from a computer to decode the pulses coming from a pickup sensor.
In our case the laptop will be connected with a optical sensor to the MICROPHONE input of the soundcard.
Cost of this route is 220$ for the software only.
Extra hardware for the optical sensor +/- 10 $
Down side it only measures one RPM in the program.

In a later stage we will add route two to see if this can do the same and/or more.
Route 2 is the one with more data to be collected.
Data acquisition system to be used will be DATAQ ID-148-U.
This unit has four A/D converters and can be hooked up to a USB port.
Input 1 will be used for measuring the RPM's of the inertia wheel
Input 2 will be used for measuring the RPM's of the engine
Input 3 will be used for measuring the engine temperature
Input 4 will be used for measuring the ambient temperature
All data received will then be converted to a Microsoft Excel spreadsheet during first testing.
Cost of a DATAQ ID-148-U datalogger 50$
Extra hardware for the optical sensor input 1 10 $
Extra hardware for the optical sensor input 2 10 $
Extra hardware for the temp sensor input 3 15 $
Extra hardware for the temp sensor input 4 15 $

SOFTWARE

We have chosen to use the ONTRACKDIGITAL software at first.
For more information about this product go to the ONTRACKDIGITAL homepage.

ELECTRONICS

For the electronics we have chosen to use an opto electronic device that is reading and providing pulses for the soundcard.
Reason for using opto electronics is the fact it will not unbalance the inertia flywheel running at 10.000 rpm's.
The design is simple and straight forward.
IC1 is a reflective optical device that has an optimal working distance of 3.81 mm.
This optical reflection device will send a light beam to the inertia flywheel.
One part of the track the beam is aiming at on the inertia flywheel will be non reflective so a ON/OFF pulse signal will be created.

IC2 is a smitt-trigger which optimizes the signal from IC1 as square as possible and makes a digital signal varying from 0 to 4.8 volt
The output is calculated at 170 mV to go to the microphone input of the soundcard.
LED1 and LED 2 are to confirm that a pulse signal is available.

The schematics:

We will use the +5 voltage directly from a standard 1.1 USB port onboard of the laptop
Type B USB Plug
Pin 1 is 5 Volt +
Pin 4 is 5 Volt -

A standard A-B USB cable can be used to power the electronics from the laptop or PC.

Mechanics

Drawings below are for reference only.
The construction was to complex and expensive to be rebuild by non skilled modelers.

Keith Henry (USA) is converting PDF drawings we have to real CAD design drawings so they can be used for every CNC machine worldwide.

These will consist of six main parts

	Drawing of base plate
	Drawing of inertia flywheel
	Drawing of flywheel stands
	3D model of the one way bearing adapter
	Drawing of gear coupler
	3D model of the one way bearing stand

below latest rendered update on the drawings

Links visited so far:
http://www1.cedar-rapids.net/tdkmotor
http://www.stirlingsouth.com/richard/develop/dynamometer.htm
http://www.sportdevices.com
http://www.dynomec.com
http://www.dataq.com
http://www.ontrackdigital.com/generic0.html

Currently busy on this dyno project:
Keith Henry/USA: converting draft drawings to CAD drawings
Tony Newland/USA: Advantage Racing Products :-)

If you know more links or guys who are willing to share info or more preferable who have software acquire programs or can program software ready to use for free let me know at info@twf8.ws
beware that all readers will benefit!

Paco

click here for more info!

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