PURPOSES
By Aditya Yohan
11401030
BACHELOR’S DEGREE in
MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
July 2018
Revision after the Thesis Defense on 17 July 2018
Aditya Yohan
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Aditya Yohan
_____________________________________________
Student Date
Approved by:
Leonard Priyatna Rusli, M. Sc., Ph. D.
_____________________________________________
Thesis Advisor Date
Dr. Rusman Rusyadi
_____________________________________________
Thesis Co-Advisor Date
Dr. Irvan Setiadi Kartawiria, ST., M. Sc.
_____________________________________________
Dean Date
Aditya Yohan
ABSTRACT
DESIGN AND DEVLOPMENT OF MINIATURE DYNAMOMETER FOR EDUCATIONAL LABORATORY PURPOSES
By
Aditya Yohan
Leonard Priyatna Rusli, M. Sc., Ph. D., Advisor Dr. Rusman Rusyadi, Co-Advisor
SWISS GERMAN UNIVERSITY
The purpose of this thesis is to design and develop a prototype of a miniature Dynamometer that later will be used for the internal combustion engine laboratory in Swiss German University. Dynamometer has been developed in the automotive world to increase performance and efficiency of the engine. The internal combustion engine rotates the main shaft which is connected to a set of mechanical levers which touches a load cell. The angular velocity of the shaft is also measured with an encoder and an IR sensor with an Optocoupler. Later, the captured data will be plotted creating a Dynamometer chart which later can be evaluated and improved which is use mainly to tune the engine.
Keywords: Dynamometer Test, Dynamometer Chart Torque, Power, RPM, Hydraulic Disc Brake, Load Cell, Encoder
Aditya Yohan
© Copyright 2018 by Aditya Yohan All rights reserved
Aditya Yohan DEDICATION
I dedicate this thesis to my family, my advisor, co-advisor, all my friends for their willingness to help and support to finish this thesis, and my beloved country Indonesia.
Aditya Yohan
ACKNOWLEDGEMENTS
First of all, the author would like to gives thanks to God for making this thesis possible through all of the problems and challenges faced
Special thanks to my parents for giving me encouragement, infinite support, and prayers.
I would like to thank Sir Leo, Sir Rusman, and Sir Benny for their patience, time, and advice in solving the problem in this thesis
I wish also to thank my friend Igantius Brian Timothy, Calvin Joseph, Adhiyasa Mahendra Putra, Mikael Adrianto, Renaldo Widianto, Joshua Bernard, Daryl Marciano, Aldrian Wiranata, Bob Edbert, Livia, Vieta, Derrin Matthew, Arfyan Rabbani, Renaldy Setiawan, Davin Tjandra, Thariq Hafidh, William Lieberty, Ivan Tedjakahana, Feraldo Lim.
I would also like to thank Olivia Putri Benartini to help me through all the ups and downs during the process of making this thesis project.
Thank you for all Swiss German University Mechatronics students batch 2014 for being the best classmates these past four years.
Last but not least, thanks to workshop supervisor Mr. Yohanes Fredhi Sangi Pratomo and Mr. Rizal Syaiful Afrizal
Aditya Yohan
TABLE OF CONTENTS
DESIGN AND DEVELOPMENT OF MINIATURE DYNAMOMETER FOR
EDUCATIONAL LABORATORY PURPOSES ... 1
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
LIST OF FIGURES ... 10
LIST OF TABLES ... 13
CHAPTER 1 – INTRODUCTION ... 14
1.1. Background ... 14
1.2. Thesis Objectives ... 15
1.3. Thesis Problems ... 16
1.4. Thesis Scope ... 16
1.5. Thesis Limitation ... 17
1.6. Thesis Structure ... 17
CHAPTER 2 – LITERATURE REVIEW ... 18
2.1. Theoretical Perspectives ... 18
2.1.1 Dynamometer ... 18
2.1.2 4-Stroke Internal Combustion Motorcycle Engine ... 20
2.1.3 Pascal’s Law of Fluid Mechanics ... 21
2.1.4 Hydraulic Disc Brake ... 22
2.1.5 Force, Power, Torque, and Angular/Linear Speed ... 23
2.1.6 Wheatstone Bridge and Load Cells ... 25
2.1.7 Torque Transfer Method on Shafts ... 26
2.1.8 Shaft Misalignment ... 27
2.1.9 Spider Coupler ... 28
2.1.10 Bearing ... 29
2.1.11 Arduino ... 31
2.1.12 Arduino IDE ... 31
2.1.13 Rotary Disc Encoder and Optocoupler ... 32
2.1.14 Solidworks Software ... 33
2.1.15 Newton’s Cooling Method ... 33
Aditya Yohan
2.1.17 Welding ... 34
2.1.18 Materials: Steel and Aluminum ... 34
2.1.19 Fritzing ... 35
2.1.20 Air Flow Rate Formula ... 35
CHAPTER 3 – RESEARCH METHODOLOGY ... 36
3.1. Introduction ... 36
3.2. Miniature Scale Dynamometer Explanation ... 36
3.3. Dynamometer Measuring Machine Process Step (Including safety procedures) ... 37
3.4. Initial Design Concepts ... 37
3.5. The Dynamometer Subsystems ... 40
3.6. Mechanical Design ... 42
3.6.1. Main Structure ... 42
3.6.2. Main Shaft and Mechanical Lever Construction ... 44
3.6.3. Mechanical Lever Design ... 47
3.6.4. Static and Dynamic Loading Analysis on The Shaft and The Mechanical Lever Connection ... 48
3.6.5. The Ball Bearings and Pillow Block Bearings Life Calculation ... 57
3.6.6. Bending Moment Diagram on The Shaft ... 58
3.6.7. Finite Element Analysis on The Mechanical Lever ... 59
3.6.8. Disc Brake, Temperature Rise, and The Automatic Breaking System ... 60
3.6.9. The Air Flow for The Ventilation ... 61
3.6.10. Temperature Rise Analysis ... 62
3.6.11. Pascal’s Law of Fluid Mechanics on The System ... 68
3.6.12. Power Screw Design and Calculations ... 70
3.6.13. Engine Parts Reparation and Installation ... 71
3.6.14. Sensor’s Mounting and Housing Construction ... 73
3.7. Electrical Design ... 74
3.7.1. Electrical System Wiring ... 74
3.7.2. Electrical & Programming Block Diagram ... 76
3.7.3. The Basic Electrical Components Used ... 76
3.7.4. Load Cells, Calibration, and Error Compensations ... 77
3.7.5. Rotary Encoder and Optocoupler ... 79
3.8. Programming and Overall Measuring System Design ... 80
Aditya Yohan
3.8.2 16x2 Arduino LCD with I2C module ... 84
3.8.3 FC-03 with LM393 Optocoupler RPM sensor ... 85
3.8.4 The Combined Program ... 87
3.9. Dynamometer Method/Testing Procedure ... 89
CHAPTER 4 – RESULTS AND DISCUSSION ... 91
4.1 Mechanical Result ... 91
4.1.1 Main Frame/Structure Issues and Performance ... 92
4.1.2 Main Shaft Misalignment Issues and Performance ... 93
4.1.3 Mechanical lever Issues and Performance ... 95
4.2 Electrical and Programming Result ... 97
4.2.1. Load Cell Calibration ... 97
4.2.2. RPM Measurement Sensor Calibration & Initial Testing ... 100
4.3 Initial Post-Assembly Test ... 102
4.4 Statistical Data ... 103
4.4.1 Dynamometer Test Data Set I ... 105
4.4.2 Dynamometer Test Data Set II ... 110
4.4.3 Dynamometer Test Data Set III ... 115
4.4.4 Dynamometer Test Method IV ... 118
4.4.5 Dynamometer Test Method V ... 120
4.4.6 Temperature Rise from the Dynamometer Tests ... 126
CHAPTER 5 – CONCLUSIONS AND RECOMMENDATIONS ... 129
GLOSSARY ... 131
REFERENCES ... 132
APPENDICES ... 134
CURICULUM VITAE ... 156
