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SUPERVISOR DECLARATION
I hereby declare that I have read this thesis and in my opinion this thesis is sufficient
in terms of scope and quality for the award of the degree of Bachelor of Mechanical
Engineering with Manufacturing Engineering.
Signature : ....................................................
Supervisor : Azizuddin Bin Abd Aziz
Date : ....................................................
DESIGN AND ANALYSIS OF PLATFORM MOTORCYCLE
DYNAMOMETER
MOHD HANIF BIN MOKHTAR
A report is submitted in fulfillment
Of the requirements for the award of the degree of
Bachelor of Mechanical Engineering with Manufacturing Engineering
Faculty of Mechanical Engineering
Universiti Malaysia Pahang
NOVEMBER 2008
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STUDENT DECLARATION
I declare that this thesis entitled “Design and Analysis of Motorcycle Dynamometer”
is the result of my own research except as cited in the reference. The thesis has not
been accepted for any degree and is not concurrently submitted in candidature of any
other degree.
Signature : ..............................................
Name : Mohd Hanif Bin Mokhtar
Date : 10 November 2008
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Dedicated to my beloved
Mother and Father,
Brothers and Sisters
My friends
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ACKNOWLEDGEMENT
First of all, I feel grateful to Allah S.W.T because this project has
successfully completed. In the process of completing this final year project, I was in
contact with many people that contributed toward my understanding and problem
solving. In particular, I wish to express my sincere appreciation to my project
supervisor, Mr. Azizuddin bin Abd Aziz for his guidance, advice and encouragement.
I also deeply thankful to everyone who assisted me on this project especially to all
staff FKM laboratory for their assistance and support.
Besides that, I also would like to dedicate my appreciation to all my fellow
friends for their support, advice and encouragement. Not forgetting my father and
mother in giving me lots of supports in the aspects of moral, social and financial
during my degree. This project definitely cannot exist without full encouragement
from them.
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ABSTRACT
The performance of a motorcycle usually measured by the producing of
horsepower, HP and torque force, TQ, due to maximum revolution of tire per minute,
RPM. In order to measure the HP and TQ of a motorcycle, the motorcycle
dynamometer is very suitable and efficient. This machine is quite new and latest
technology in Malaysia and still not be used wisely by the Malaysian until today
because lack of knowledge and technology of development of a motorcycle
dynamometer. Thus, there is a needed to study and understand the technology used
behind the development of a motorcycle to increase the use of it at any automotives
laboratories or workshops in Malaysia. This study was done in order to design and
analysis of platform motorcycle dynamometer due to the capability of machines and
materials available in Faculty of Mechanical Laboratory. In this study, the reverse
engineering was used to design the machine by review the available motorcycle
dynamometer which already exists and produced by various manufacturers around
the world. Then, design of a tough platform motorcycle dynamometer which can
support load and able to absorb the vibrations was produced. To design and analysis
this platform and its inertia roller, the CAD software and CAE software were used to
design and illustrate the structure. Lastly, as the results, the design analysis with
different materials of structure was done to illustrate the stress von Mises.
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ABSTRAK
Keupayaan sesebuah motorsikal dalam menentukankan prestasinya adalah
kebanyakannya diukur melalui jumlah penghasilan “kuasa kuda” (horsepower, HP)
dan juga “daya tujahan”(torque force, TQ) berdasarkan jumlah maksimum putaran
roda dalam seminit (revolution perminute, RPM). Untuk mengukur HP dan TQ
berdasarkan maksimum RPM sesebuah motorsikal, peralatan atau mesin yang paling
sesuai dan efisyen untuk digunakan ialah “motorcycle dynamometer”. Mesin ini
adalah merupakan satu teknologi yang masih baru, dan belum lagi digunakan secara
meluas di Malaysia, apatah lagi penerokaan ilmu pengetahuan dalam pembinaan
sesebuah mesin motorcycle dynamometer ini masih lagi kurang dikalangan rakyat
Malaysia. Oleh itu, adalah amat penting dan perlu untuk difahami dan diketahui ilmu
serta kajian tentang bagaimana teknologi disebalik mesin motorcycle dynamometer
ini dibangunkan demi untuk meningkatkan lagi pengunaannya dimana-mana sahaja
bengkel ataupun makmal automotif untuk dimajukan lagi sektor automotif di
Malaysia. Lantaran itu, kajian ini adalah dilaksanakan untuk tujuan merekabentuk
dan membangunkan sebuah mesin motorcycle dynamometer mengikut kemampuan
makmal dan peralatan yang sedia ada di makmal Fakulti Kejuruteraan Mekanikal.
Dalam kajian ini, kejuruteraan berbalik untuk rekabentuk mesin motorcycle
dynamometer yang sedia ada di makmal automotif di seluruh dunia dinilai dan
diambil rekabentuk dan kaedah pembangunannya. Seterusnya, kaedah melakar dan
merekabentuk platform motorcycle dynamometer yang kukuh semasa menampung
beban yang tinggi dan mampu menyerap getaran yang dihasilkan. Untuk
memodenkan rekabentuk platform dan tapaknya ini, perisian CAD (Computer Aided
Design) dan CAE (Computer Aided Engineering) diperlukan dan digunakan untuk
merekabentuk dan menganalisis struktur platform. Keputusan akhir platform dengan
berbagai bahan struktur ditunjukkan dalam bentuk stress von Mises.
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TABLE OF CONTENTS
CHAPTER TITLE PAGE
TITLE i
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES x
LIST OF FIGURES xi
LIST OF SYMBOLS xii
LIST OF APPENDICES xiii
1 INTRODUCTION 1
1.1 Project background 1
1.2 Problem statements 2
1.3 Objective of Project 3
1.4 Scope of Project 3
1.5 Flow Chart of Project 4
1.6 Organization of Project Report 5
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2 LITERATURE REVIEW 6
2.1 Introduction 6
2.2 History of Dynamometer 7
2.3 Dynamometer 8
2.4 Types of Dynamometer 10
2.5 Theory 11
2.5.1 Inertia Dynamometer 11
2.5.2 Absorption Dynamometer 12
2.5.3 Torque and Inertia 13
2.5.4 Power Output (Working Principal) 14
2.5.5 Power 15
2.6 Design of Project 16
2.7 Material of The Current Platform 18
2.8 Selected Design Concept 19
2.8.1 Objective Motorcycle Platform Dynamometer
Model Design 20
2.9 Basic Design of The Platform Motorcycle Dynamometer 21
2.10 Material Uses for Design Platform 22
2.11 Analysis Using Algor Software 23
3 METHODOLOGY 24
3.1 Introduction 24
3.2 Project Methodology 25
3.3 Designing 27
3.4 Selecting Materials 28
3.4.1 Basement of Platform 28
3.4.2 Upper Basement of Dynamometer 28
3.5 Analysis with Finites Element Analysis (FEA) 29
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4 RESULT AND DISCUSSION 31
4.1 Introduction 31
4.2 Design Analysis with Steel AISI 1020 Cold Rolled 31
4.2.1 Result Analysis of Weight 300kg 31
4.3 Design Analysis with Aluminum 1050-H14 34
4.3.1 Result Analysis of Weight 300kg 34
4.4 Design Analysis with Aluminum Steel ASTM A36 36
4.4.1 Result Analysis of Weight 300kg 36
4.5 Design Analysis with Stainless Steel AISI 1020,
Cold Rolled 38
4.5.1 Result Analysis of Weight 300kg 38
4.6 Result Discussion 41
5 CONCLUSION AND RECOMMENDATIONS 42
5.1 Conclusion 42
5.2 Recommendation 43
REFERENCES 44
Appendix A1-C1 45-47
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LIST OF TABLES
TABLE NO. TITLE PAGE
4.1 Properties of AISI 1020 Steel, cold rolled 32
4.2 Properties of Aluminum 1050-H14 34
4.3 Properties of Steel ASTM A36 36
4.4 Properties of Stainless Steel AISI 302, Cold Rolled 39
4.5 Result analysis with different material 41
4.6 Loads given on the platform dynamometer 41
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LIST OF FIGURES
FIGURE NO TITLE PAGE
1.1 Flow chart of project 4
2.1 The Tree Chart of Automotive Dynamometers 10
2.2 Power output chart 14
2.3 The previous research of motorcycle dynamometer 16
2.4 Dynojet 200i Inertia Dynamometer 16
2.5 Tree diagram of motorcycle chassis dynamometer 18
2.6 Basic design of motorcycle dynamometer 21
2.7 Dimension of the concept motorcycle dynamometer 22
3.1 The project flow chart 26
3.2 R1 using the dyno jet to measure the performance 27
3.3 Flow chart of finite element analysis 30
4.1 Result analysis of maximum weight 2943N 31
4.2 Result analysis of maximum weight 2943N 35
4.3 Result analysis of maximum weight 2943N 37
4.4 Result analysis of maximum weight 2943N 40
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LIST OF SYMBOLS
HP/ hp Horsepower
DC Direct Current
AC Alternate Current
TQ Torque Force
T Torque
R/r Radius
F Force
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LIST OF APPENDICES
APPENDIX TITLE PAGE
Appendix A1 3d View of Basic Platform Motorcycle Dynamometer 45
Appendix B1 Technical Drawing for Concept Design Of Platform
Motorcycle Dynamometer with Inertia Roller 46
Appendix C1 Gantt chart Of Project 47
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CHAPTER 1
INTRODUCTION
1.1 Project Background
Dynamometers are typically used by mechanics and tuners to evaluate the
change in power output of an engine before and after a modification are made to that
engine. Motorcycle dynamometer is developed in order to aid performance tuning of
motorcycle engines such as Horse Power (HP) and Torque Force (TQ).
Dynamometer consists on a metallic structure in which the bikes are placed through a
ramp. Bike is tied to the dynamometer by the front wheel through a clamp that can be
moved ahead and back with the purpose of fitting the position of the back wheel.
This wheel is placed over a solid roller of steel that is fixed on the structure with two
bearings. The main of any engine development program is an improvement in on-
track performance, but track testing engine changes can be difficult.
Dynamometer, or "dyno" for short, is a machine used to measure torque force
(TQ) and rotational speed (rpm) from which power produced by an engine, motor or
other rotating can be calculated. The dynamometer is a much more effective way of
evaluating engine changes, since non-engine variables can be eliminated from this
type test (Winther, 1975). There are many types of dynamometer exist in the world
today since it was an effective device in evaluating the performance of a machine. To
evaluate the motorcycle performance, chassis dynamometer is suite for us in order to
evaluate the horsepower (HP) and TQ.
Chassis dynamometer’s structure has three main parts; inertia roller, frame
and additional frame. This project will concentrate on the design, and analysis of
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motorcycle dynamometer which used recycles stuff as its material. As the main
mechanical part of a motorcycle dynamometer, the platform and the inertia roller or
the heavy roller is very important to be built accurately and precisely. The platform
important to support weight of motorcycle and person who on motorcycle.
1.2 Problem Statements
From the research and study by journal and article, it has been found that
there is various type of motorcycle dynamometer made from different manufacturer.
As it was a very effective device to evaluate the real performance of a motorcycle, it
is important to have right and good motorcycle dynamometer to give a real situation
of road and load since the motorcycle is run directly to the dynamometer. To get the
suitable or quality motorcycle dynamometer, one should refer to the established
manufacturer to test the performance of his motorcycle. In Malaysia, the motorcycle
dynamometer is still one of the latest devices which use in any workshop or research
centre.
As it still new and not easily found, this project is aimed to study the
development of a motorcycle dynamometer and how can it be developed with
another method and by using Faculty of Mechanical’s Laboratory equipments.
Although to develop a motorcycle dynamometer is really complex job and need
much consideration of many parameters, but a simple motorcycle dynamometer
which utilize the platform concept can be considered as a new found of knowledge in
this field of study.
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1.3 Objective of Project
The aims of this project are:
• To design a simple structure of platform for motorcycle dynamometer.
• To analysis the stress of the designed structural with the consideration of the
stability and with different material of platform motorcycle dynamometer.
1.4 Scope of Project
In order to achieve the list of objectives above, there a few constraints of
scopes that must be achieved. The scopes of this project are:
• Determination of the current platform design structures and the parameters.
• Design the platform motorcycle dynamometer using SolidWork software.
• To focus on material and shape of the design of platform for motorcycle
dynamometer.
• Analyze the design using Finite Element Analysis (FEA) software known as
ALGOR software for failure analysis.
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1.5 Flow Chart of Project
FYP 1
FYP 2
Figure 1.1 The project flow chart
Project Title confirmation
Determination of objectives, scopes
and problem statements
Literature study, list of the parameters
involved including the materials
Sketching of platform
Drawing using
SolidWork
Software
Analysis of product
performance using
Algor Software
Submit the draft report
Presentation of FYP 1
Define product, and then know all
parameter of platform with roller
Submit full report
Conclusion
Final presentation of FYP
No
yes
Recheck whether it suitable to
support motorcycle
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1.6 Organization of Project Report
This project report was organized with a few chapters which describe details
about the progress and time frame of making the platform dynamometer project.
The report was detailed in all five chapters and the project management (time
frame) is attached in the appendix.
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CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
The aim of this project is to develop a tool to aid performance tuning of
motorcycle engines. The tool should allow the user test a motorcycle, modify the
engine in some way, run a second test then compare the two sets of results and hence
evaluate the effect the modification to the engine intact if the result was satisfactory
or try something else if it was not. To give some overview information about the
motorcycle dynamometer which in the subject of platform motorcycle dynamometer.
In this chapter, the explanations and details of dynamometer histories, the previous
research and findings, the theories are included. It also will describe the basic design,
analysis and fabrication process of the platform motorcycle dynamometer.
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2.2 History of Dynamometer
One of the key to any engine development program is the ability to
effectively evaluate changes to the engine. The goal of any engine development
program is an improvement in on-track performance, but track testing engine
changes can be difficult. The dynamometer is a much more effective way of
evaluating engine changes, since non-engine variables can be eliminated from this
type test.
Dynamometer can be referred to the dyno inventor which success in their
project in order to measure the performance of machine or any particular part. The
earliest inventor of dynamometer is Gaspard de Prony. He invented the ‘de Prony
brake’ in 1821. The de Prony brake (or Prony brake) is considered to be one of the
earliest dynamometers in the world. Besides, Froude Hofmann of Worcester, UK
manufactures engine and vehicle dynamometers. They credit William Froude with
the invention of the hydraulic dynamometer in 1877 and say that the first commercial
dynamometers were produced in 1881 by their predecessor company, Heenan &
Froude (Winther, 1975).
In 1928, the German company "Carl Schenck Eisengießerei & Waagenfabrik"
built the first vehicle dynamometers for brake tests with the basic design of the
today's vehicle test stands. The eddy current dynamometer was invented by Martin
and Anthony Winther in about 1931. At the same time, DC Motor/generator
dynamometers had been in use for many years. A company founded by the Winthers,
Dynamatic Corporation, manufactured dynamometers in Kenosha, Wisconsin until
2002. Dynamatic was part of Eaton Corporation from 1946 to 1995. In 2002, Dyne
Systems of Jackson, Wisconsin acquired the dynamatic dynamometer product line.
Starting in 1938, Heenan and Froude manufactured eddy current dynamometers for
many years under license from Dynamatic and Eaton (Winther, 1975)
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2.3 Dynamometer
The ability to measure key performance characteristics such as fuel flow,
airflow, and blow-by, is the key to increase the understanding of the engine
combination. The dynamometer also allows us to analyze the shape of the torque and
power curves, something a stopwatch and the racetrack cannot do. The dynamometer
is not only a development tool but also the final quality control check before the
engine is shipped.
The purpose of using a dynamometer is to get accurate and repeatable data on
the engine being tested. If a dynamometer is not capable of returning consistently
repeatable test results day in and day out, it's not effective. The level of competition
in all forms of motorsports increases every year. Engine builders are challenged to
continually find more and more power. In the past, gains of 5 hp were common.
Today, the level of engine development is so high the only way you will find 5 hp is
to add together five gains of 1 hp each. To do this, a dynamometer must be able to
detect 1 hp consistently. Accurate and repeatable testing is the result of carefully
controlling the variables that affect engine performance so that only the planned
changes to the engine affect the torque and power (John Dinkel, 2000).
Dynamometers are typically used by mechanics and tuners to evaluate the
change in power output of an engine before and after a modification are made to that
engine. Motorcycle dynamometer is developed in order to aid performance tuning of
motorcycle engines such as HP and TQ. Dynamometer consists on a metallic
structure in which the bikes are placed through a ramp. Bike is tied to the
dynamometer by the front wheel through a clamp that can be moved ahead and back
with the purpose of fitting the position of the back wheel. This wheel is placed over a
solid roller of steel that is fixed on the structure with two bearings (Philip, 2004).
Basically, the dynamometers can be divided into two types; engine dyno and
chassis dyno. Both of them have similar functions and aim, but it’s quite different of
structure or machine due to the objective of research and power output obtain. These
two types of dynamometer is developed by a few ways and they are different each
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other due to the types. The common types of them are hydraulic and electric. For
electric dynamometer, it contains three types; DC Dyno, AC Dyno and Eddy Current
Dyno which explained at the next pages (Winther and Martin, 1976).
For this project, it has been concentrated on basic design of platform
motorcycle dynamometer and analysis the structure. A platform was needed to
support the motorcycle and the rider. The platform was used in which the front of the
motorcycle accelerates to provide a load on the engine.
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2.4 Types of Dynamometers
In addition to classify as absorption, motoring or universal as described
above, dynamometers can be classified in other ways. A dyno that is coupled directly
to an engine is known as an engine dyno. A dyno that can measure torque and power
delivered by the power train of a vehicle without removing the engine from the frame
of the vehicle is known as a chassis dyno. The tree chart of the types of dynamometer
can be viewed as in Figure 2.1.
Figure 2.1 The Tree Chart of Automotive Dynamometers (John Dinkel, 2000)
Dynamometers can also be classified by the type of absorption unit or
absorber/driver that they use. Some units that are capable of absorption only can be
combined with a motor to construct an absorber/driver or universal dynamometer.
The following types of absorption/driver units have been used:
Dynamometer
Chassis Dyno Engine Dyno
Hydraulic Electric
Eddy Dyno AC Dyno DC Dyno
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