1. Linear motor with real time data acquisition on the race car
The first design we came up with was the Linear Motor design. This motor utilizes neodymium magnets and an electrical input to control a solid core of electric steel in a linear motion. This motor is controlled by a computer and can produce peak forces greater than 4000 lbs and peak velocities around 160 in/sec.
A linear motor is accompanied by a motion controller and a power supply. This design can produce quick changes of direction within milliseconds, which can be supplemented by a data acquisition system put on the racecar. The data acquisition system on the car would record position of the shock and the velocities it would see as the car goes around the track. This system would then plug into the shock dyno and replay the real time data recorded. The shock on the dyno would then reproduce exact track conditions, which could revolutionize the current market. With further research there is one company already producing this style of shock dyno, so we would not have intellectual rights on this design. This design is also very costly since there is only one supplier of the linear motor. Building the motor is beyond the scope the client would like to see from this design team.
A linear motor is accompanied by a motion controller and a power supply. This design can produce quick changes of direction within milliseconds, which can be supplemented by a data acquisition system put on the racecar. The data acquisition system on the car would record position of the shock and the velocities it would see as the car goes around the track. This system would then plug into the shock dyno and replay the real time data recorded. The shock on the dyno would then reproduce exact track conditions, which could revolutionize the current market. With further research there is one company already producing this style of shock dyno, so we would not have intellectual rights on this design. This design is also very costly since there is only one supplier of the linear motor. Building the motor is beyond the scope the client would like to see from this design team.
2. Rotary
electric motor with scotch yoke
The design team next evaluated what the industry of shock analysis equipment is currently producing on the market. The team found two designs that are used commonly: the rotary electric motor with a scotch yoke and the rotary electric motor with a slider crank mechanism.
The rotary motor with a scotch yoke is used to produce perfectly sinusoidal force verses time graphs unlike the slider crank. The perfect sinusoidal motion of this system is seen as an advantage to its makers for the reason of natural frequency vibration. This vibration can create resonance within the shock dyno, which can hurt sensitive data recording, machine performance and safety of the structural integrity of the dyno.
This design has proven not feasible for our team and client. The reason is the client feels this design is too finite in tolerances for machining and would need a skilled design team to make the scotch yoke a perfectly sinusoidal unit. Also, this design has parts that are not easily replaceable and would take time and significant cost to reproduce.
The rotary motor with a scotch yoke is used to produce perfectly sinusoidal force verses time graphs unlike the slider crank. The perfect sinusoidal motion of this system is seen as an advantage to its makers for the reason of natural frequency vibration. This vibration can create resonance within the shock dyno, which can hurt sensitive data recording, machine performance and safety of the structural integrity of the dyno.
This design has proven not feasible for our team and client. The reason is the client feels this design is too finite in tolerances for machining and would need a skilled design team to make the scotch yoke a perfectly sinusoidal unit. Also, this design has parts that are not easily replaceable and would take time and significant cost to reproduce.
3. Rotary electric motor with slider crank
The final design the team has evaluated is the rotary electric motor with a slider crank mechanism. This unit provides the client with interchangeable parts that are more common than the previous two designs.
This unit will provide the client with a low maintenance mechanical system. He has expressed that with his skills in machining he will be able to replicate any parts on this dyno.
This is the design the client has approved.
This unit will provide the client with a low maintenance mechanical system. He has expressed that with his skills in machining he will be able to replicate any parts on this dyno.
This is the design the client has approved.