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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i

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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1

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

2

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