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Overview
This paper describes a flexible platform for dynamometer tests that you can build using National Instruments products.
Table of Contents
1. Introduction
2. Automotive Dynamometer Applications
3. Dynamometer Technologies
4. Example Applications
5. Integrated Control System
6. Conclusions
7. Contact Information
8. Appendix A Common Test Parameters
9. Appendix B Relating Torque to Horsepower
1. Introduction
Executive Summary
This paper describes a flexible platform for dynamometer tests that you can build using National Instruments products.
Design and validation applications have widely varying objectives, and especially so when using a dynamometer to test motors, engines, or vehicles. However, most dynamometer test solutions
suffer from limitations related to:
Manual operation
Integration of control, measurement, and operator interface functions
Channel expansion capacity
Compatibility with new signal types and protocols
Compatibility with third-party devices
This paper discusses tools that overcome these obstacles and describes solutions based on the National Instruments platform.
For automotive engineers and system integrators who build test cells for measuring engine and chassis performance, the National Instruments Automotive Test Platform consisting of LabVIEW
software and PXI hardware is a platform for building real-time control and measurement systems. Unlike proprietary solutions, users can build fully customized applications with the Automotive
Test Platform, incorporating a wide variety of National Instruments and third-party components integrated as a single system.
While the examples in this paper focus on power-train test applications, the technologies and approaches can also be used to test the safety, durability, and performance characteristics of other
components such as hoses, brakes, belts, or electric motors.
About National Instruments
National Instruments is an industry leader in PC-based data acquisition and control products. With National Instruments hardware and software, engineers and scientists can automate test
procedures, data collection, and analysis, and can present the results in an easy-to-understand manner.
Customers in many different industry and research settings use National Instruments products to create a wide variety automated test and measurement systems using methods that result in
significantly higher productivity and lower development and maintenance costs.
3. Dynamometer Technologies
A dynamometer is an energy-absorbing device capable of applying a controlled load to a test article. The load is applied as torque (rotating force) to an engine shaft or to the wheel of a vehicle.
There are several braking technologies that dynamometers use to generate a controlled load, including:
Inertial A large spinning mass provides a load that is proportional to acceleration. Torque can be calculated from the acceleration rate. Average torque can be derived from the time that it takes
to accelerate the mass to a given rpm.
Water Brake The load is produced by a water pump. An impeller connected to the shaft mechanically forces the water through the pump. A valve fitted in the output line of the pump regulates
the backpressure and resulting load.
Eddy Current The load is generated by eddy currents induced in a rotating metallic disk immersed in a magnetic field.
AC or DC Motor The load is created by an electric motor. The electric motor can also serve as a drive motor to generate torque.
Hydraulic The load is created by smooth disc power elements that absorb power by viscous shear
Each of these technologies can be classified according to cost, power, speed, dynamic response, control stability, internal inertia, and other characteristics. Eddy current and electric motor
dynamometers are best suited for automotive testing because of their responsiveness and power/torque capacity at high speeds. Motor dynamometers provide the best control response, while
eddy current dynamometers can handle higher power at higher speeds.
Many dynamometers have built-in sensors that measure torque and speed, which can be used to calculate power (see Appendix B). One recent trend is to extend torque measurements to include
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Many dynamometers have built-in sensors that measure torque and speed, which can be used to calculate power (see Appendix B). One recent trend is to extend torque measurements to include
torsional vibrations generated by pistons or other mechanical components.
Some dynamometers (particularly AC and DC motor dynamometers) have motoring capability, which means that they can drive shaft with a positive load in addition to generating a braking load.
Operating Modes
Dynamometers can be operated in either open-loop or closed-loop control modes.
Open-Loop Mode
In open-loop mode, the dynamometer control is set to a percentage of available dynamometer output or load. In this mode, the resulting load is independent of throttle position, rpm, or vehicle
speed. While it is possible to manually operate a dynamometer in open-loop mode, computer automation enhances the reliability and repeatability of test results.
Closed-Loop Mode
In closed-loop mode, the load is referenced to a feedback signal defined by the test procedure. For example, in constant-speed mode, the user can set the speed at which to hold the vehicle. An
increase in throttle position is counteracted by an increase in load, preventing the vehicle from exceeding the selected speed point. Several speed points may be programmed versus time so the
operator can slowly step the vehicle through the speed range of the engine while monitoring engine parameters and their relation to torque output.
Another example of closed-loop operation is terrain simulation, in which the load is varied under computer control to simulate hills, turns, or other driving scenarios.
Continuous load adjustments cannot always be implemented consistently with manual methods, so an automated control system is essential for test procedures that require closed-loop control.
4. Example Applications
Lets consider the control system requirements for two typical dynamometer applications.
Chassis
You are probably familiar with chassis dynamometers, which measure vehicle performance using torque and speed measurements taken from roller drums that load the vehicle drive train through
contact with the wheels
The chassis dynamometer shown here uses a control system to automate the test procedure while making measurements and logging them for postanalysis. In some configurations, the control
system drives the vehicle directly, using throttle and brake actuators. In other applications, it will provide a drivers aid to guide the actions of a human driver during the test.
To maximize reliability, the control system should be built using real-time software tools. Simply put, real-time software can perform automated tasks within a predictable response time. Because
Microsoft Windows and other popular operating systems are not predictable in this sense, they are a poor choice for controlling high-performance dynamometer test systems.
Because of graphics and networking capabilities, however, PCs are often used as the operator console. Having a separate computer also prevents operator actions from affecting the
responsiveness of the real-time system.
Creating the software application can be one of the most difficult tasks in building an integrated control system. Most real-time software tools require someone to develop and maintain special
software libraries for handling real-time I/O interfaces and communications between the real-time system and the operator interface. Turnkey system vendors can provide a solution that that they
have developed, but such solutions are often based on proprietary hardware and closed software tools that are expensive and offer limited expansion capability.
To provide for future expandability, the control system should be built using software tools that are inexpensive, easy to use, and compatible with a wide variety of sensors and systems. In a later
section, we will see how National Instruments products achieve this goal.
Engine
Now, lets look at an engine test application, where the engine is tested by itself (that is, out of the vehicle), with the dynamometer typically connected directly to the engine drive shaft at the
flywheel. The test cell controller manipulates throttle position and other engine inputs. In this case, the dynamometer has its own controller, which communicates with the cell controller through a
serial connection.
The diagram shows a typical engine test cell, with separate pieces of equipment that emulate fuel, coolant, oil, electrical, and other vehicle systems that are normally connected to the engine.
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The diagram shows a typical engine test cell, with separate pieces of equipment that emulate fuel, coolant, oil, electrical, and other vehicle systems that are normally connected to the engine.
These systems may also have their own parameters (such as temperature, pressure, and flow) that the cell controller must manage. The test cell usually includes safety interlocks and other
facility-related interfaces that are also managed by the cell controller.
While this diagram does not illustrate them, the engine is often instrumented with sensors that provide information on internal operating conditions. In production environments, the engine may also
supply the test system with information about itself through bar codes or embedded flash memory.
The integrated control system configuration shown above is typical of systems delivered by systems integrators using National Instruments products. Notice that, unlike other approaches, the
real-time control system and signal I/O connections are all within the test cell. Long, bulky cable runs through the test cell bulkhead are replaced with a single network connection, which reduces
installation and debugging time while improving operational reliability and common-mode noise rejection.
Drive Train
In a drive train application, the objective is to measure the performance of the transmission, differential, and/or other drive train components. A drive motor applies a controlled torque at the input to
the assembly under test.
Development Tools
The following sections describe the National Instruments tools and approaches that you can use to build a test cell system platform. These tools are available directly from National Instruments.
Low-Cost Options
A high-performance control system is not required or appropriate in all situations. For customers that need less capability, options available from National Instruments include
LabVIEW Real-Time Module running on FieldPoint modules
LabVIEW Real-Time Module running on PC-based or PXI-based data acquisition devices
Running all control and acquisition processes under Microsoft Windows
You can learn more about real time controllers, data acquisition and signal conditioning at http://www.ni.com/rt, http://ni.com/measurements and http://www.ni.com/scxi.
Signal I/O
In the process of specifying your control system, you must consider all of the parameters that it will need to handle.
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This is not an exhaustive list, but it summarizes most of the parameter types commonly encountered in dynamometer applications.
The measurement and control I/O for these signals can be implemented in several ways. Two commonly used approaches are to connect sensors and actuators directly to the cell controller or to
devices that perform a specific task (such as the AC dynamometer controller in the engine test example). As a result, the data may be communicated to the control system in the form of simple
voltages or currents or through communication protocols such as RS-232, CAN, or GPIB.
This variety of signal interfaces creates another potential problem in building the control system. While it may be easy to inventory the I/O requirements for sensors and equipment that you are
using today, it is much more difficult to predict the parameter types or channel counts that you will need a year from now. Proprietary solutions can limit your options, particularly with respect to
special sensors, third-party instruments such as emissions analyzers, or even expanding the existing system to include additional I/O channels.
Here is a sampling of sensors and signal types that can be measured with National Instruments PXI modules. While you probably do not need all of these options now, they are available if you
need them in the future. Native GPIB, RS-232 and RS-422/485 communications provide compatibility with most third-party instruments and subsystems.
Certain sensor and signal types require conditioning before they are connected to the control system. National Instruments SCXI modules provide excitation, isolation, multiplexing, and other
signal conditioning features required when using the sensor and signal types shown below.
6. Conclusions
In this paper, we have reviewed some of the requirements that drive the need for flexible dynamometer test.
We have seen how the LabVIEW Real-Time Module can be combined with PXI and SCXI hardware modules to create an integrated control solution with the flexibility to meet your changing
requirements. With the PXI platform, users can build fully customized applications using a wide variety of National Instruments and third-party components, integrated as a single system.
7. Contact Information
This document is only a brief introduction to the tools and products offered by National Instruments for dynamometer test. If you have questions or would like to schedule a discussion of your
specific needs, please contact us at:
Rick Ary
National Instruments
11500 N. Mopac Expwy.
Austin, TX 78759, USA
(512) 683-6800
rick.ary@ni.com
See Also:
For more information on National Instruments products.
Engineering Units
Device
Actuator
lb ft, N m, %
Dynamometer
Engineering Units
Sensor
Force
lb, N
Load cell
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Torque
lb ft, N m
Torque meter
Rotation speed
rpm
Tachometer
Flow
liters/s
Flow meter
Pressures
Pressure sensor
Temperatures
C, F
Thermocouple, RTD
Emissions
ppm, %
Electrochemical, Infrared
Vibration
Accelerometer
Noise
Pa
Microphone
Engineering Units
Derived from
Torque
ft lb, N m
Power
hp, W
Torque, rpm
Speed
mph, km/h
Acceleration/Deceleration
m/s2, ft/s2
Speed
Braking force
Fuel Efficiency
mpg
Vehicle Controls
Vehicle and engine control values can include
Throttle position
Brake position
Gearshift position
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Emissions
Low emissions levels are important for achieving compliance with environmental regulations. Typical emissions measurements include:
Oxygen
Carbon dioxide
Carbon monoxide
Nitrogen oxides
Methane and other hydrocarbons
Third-party gas analyzers are used in test applications that require emissions measurements.
Note: It is important to distinguish between pounds of force and pounds of mass. A 1 pound mass experiences a 1 pound vertical force (weight) in a 1 g gravitational field. In the case of the horse
lifting the weight, the lifting force opposes the gravitational force. Obviously, if the horse were pulling the weight along the ground on a cart, the force involved in moving the weight would be
significantly different. So, for the purpose of this discussion the term pound refers to force, not mass or weight.
Work is force applied over a specific distance. In Watts example, the work is lifting the 150 lb weight a distance of 220 feet.
WORK = FORCE x DISTANCE (lb ft)
Power is the rate at which the work is performed. In Watts example, you can lift the 150 pound weight 220 feet in 60 seconds if you use a 1 hp engine, 30 seconds using 2 hp, etc.
POWER = WORK/TIME (lb ft/s)
= FORCE x DISTANCE/TIME
For a wheel,
DISTANCE = CIRCUMFERENCE x REVOLUTIONS
= 2 P x R (radius or moment arm in ft) x REVOLUTIONS
so
POWER = FORCE x 2 P x MOMENT ARM x REVOLUTIONS / TIME
= TORQUE x 2 P x REVOLUTIONS / TIME
= TORQUE x 2 P x rpm (revolutions/minute)/60(s/minute)
= TORQUE x rpm x 2 P /60
HORSEPOWER = POWER / 550 (lb ft/s)
= TORQUE x rpm x 2 P /(60 x 550)
HORSEPOWER = TORQUE x rpm / 5252
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