What is dynamometer

A dynamometer is a device for simultaneously measuring the torque and rotational speed (RPM) of an engine, motor or
other rotating prime mover so that its instantaneous power may be calculated, and usually displayed by the dynamometer
itself as kW or bhp.

Although measuring the torque of engines has been a common use for
dynamometers, their use has evolved into a wide range of applications, including
the measurement of weight and tension. One of their primary uses is to measure
tension on telephone lines, suspension bridges, elevator cables, and ski lifts.

As tension measuring devices, dynamometers ensure the safe use of lifting rigs,
cranes, and cables by monitoring loads and preventing overloading. This type of
dynamometer comes in several designs to accommodate the needs of an
application. Tension dynamometers are used in place of crane scales since they are
easier to install and transport.

Since calibration is a critical aspect of a dynamometer’s function, they come with

various methods to ensure proper calibration for accurate and precise readings.
Dynamometers have a rugged design to be able to withstand the various
environments where they are used. This characteristic is one of the reasons that
they are a necessary tool for evaluating pull and push force.

When force is applied to a flexible metal ring on a dynamometer, it bends and

measures the applied force. The measurement of force is an essential part of
automobile production to determine horsepower, power absorption, and rotary
speed. In construction, the tension and pull force on components of a structure
have to be regularly monitored and assessed to determine strength and load
capacity.

One of the major benefits of dynamometers is their adaptability to a variety of

applications and uses. All types of dynamometers are exceptionally accurate and
reliable, whether they are measuring torque or pull force.

How a Dynamometer Works

The best explanation of how a dynamometer works is to envision a spring in a two

part mounting. One end of the spring is anchored to a base, with the other end
connected to the measured force. As the spring is stretched by the force, a reading
registers on a scale. This simplistic representation of a dynamometer is very similar
to a spring balance but provides readings in units of force or Newtons (N).

Though this simple example can provide a reading, it does not have the strength to
measure the power of a 250 hp engine. A more sophisticated and technical device
is required for that type of job, which is much larger and resembles an electric
motor or gas engine.

Uses with Motors and Engines

A large dynamometer is a variable load that is attached to the drive of an engine or

motor. As the motor powers up, the dynamometer absorbs the power being
produced to provide data on the torque and power of the motor. As the power is
absorbed, the dynamometer dissipates the massive amount of power generated
through electromagnetism.

As can be expected in the modern era, the data produced by a dynamometer is fed
into a computer. There are several varieties of software available to collect
dynamometer readings. Though DOS tends to be going out of existence, a few
versions of DOS software are still being used. The most common type is Windows
based.

The readings from the software include:

ambient temperature

barometric pressure

humidity

oil and coolant temperature

exhaust temperatures

airflow

exhaust oxygen

throttle position

engine RPM

manifold pressure

With the use of dynamometer software, it is possible to measure, record, observe,

and assess any kind of data from an engine. Most manufacturers and producers use
dynamometers for basic data readouts. Dynamometer producers know that the
more things you measure and quantify, the better will be the quality of the final
product. This is because, if every test is not performed consistently, any aspect of
the process can create variations in the results. Compiling a wide range of data can
account for any possible fluctuations and variables.

Uses as a Force Gauge

When a dynamometer is used as a force gauge, it measures pull force and push
force. The two types of dynamometer force gauges are digital and mechanical. A
digital dynamometer has a load cell that converts force into electrical signals,
which are displayed on an LCD display. With a mechanical dynamometer force
gauge, the applied force deforms a strain gauge that is converted into an electrical
signal.

The units measured by a dynamometer force gauge are recorded as Newtons,

pounds, or Pascals. These highly accurate devices can measure any amount of
force, from very small to very large.

Principles of operation of torque power (absorbing) dynamometers

An absorbing dynamometer acts as a load that is driven by the prime mover that is
under test (e.g. Pelton wheel). The dynamometer must be able to operate at any
speed and load to any level of torque that the test requires.

Absorbing dynamometers are not to be confused with "inertia" dynamometers,

which calculate power solely by measuring power required to accelerate a known
mass drive roller and provide no variable load to the prime mover.

An absorption dynamometer is usually equipped with some means of measuring

the operating torque and speed.

The power absorption unit (PAU) of a dynamometer absorbs the power developed
by the prime mover. This power absorbed by the dynamometer is then converted
into heat, which generally dissipates into the ambient air or transfers to cooling
water that dissipates into the air. Regenerative dynamometers, in which the prime
mover drives a DC motor as a generator to create load, make excess DC power and
potentially - using a DC/AC inverter - can feed AC power back into the
commercial electrical power grid.
Absorption dynamometers can be equipped with two types of control systems to
provide different main test types.

Constant force

The dynamometer has a "braking" torque regulator - the power absorption unit is
configured to provide a set braking force torque load, while the prime mover is
configured to operate at whatever throttle opening, fuel delivery rate, or any other
variable it is desired to test. The prime mover is then allowed to accelerate the
engine through the desired speed or RPM range. Constant force test routines
require the PAU to be set slightly torque deficient as referenced to prime mover
output to allow some rate of acceleration. Power is calculated based on rotational
speed x torque x constant. The constant varies depending on the units used.

Constant speed

If the dynamometer has a speed regulator (human or computer), the PAU provides
a variable amount of braking force (torque) that is necessary to cause the prime
mover to operate at the desired single test speed or RPM. The PAU braking load
applied to the prime mover can be manually controlled or determined by a
computer. Most systems employ eddy current, oil hydraulic, or DC motor
produced loads because of their linear and quick load change abilities.

The power is calculated as the product of angular velocity and torque.

2. bourdon tube manometers

The Bourdon gauge consists of a tube bent into a coil or an arc. As the pressure in
the tube increases, the coil unwinds. A pointer connected to the end of the tube can
be attached to a lever and a pointer calibrated to indicate pressure. A typical 50
mm diameter tube has a displacement of up to 4 mm.
Principle: When an elastic transducer (bourdon tube in this case) is subjected to a
pressure, it deflects. This deflection is proportional to the applied pressure when
calibrated. Construction: A C-type Bourdon tube consists of a long thin-walled
cylinder of non-circular cross-section, sealed at one end, made from materials such
as phosphor bronze, steel and beryllium copper, and attached by a light line work
to the mechanism which operates the pointer. The other end of the tube is fixed and
is open for the application of the pressure which is to be measured. The tube is
soldered or welded to a socket at the base, through which pressure connection is
made.

Working:

As the fluid under pressure enters the Bourdon tube, it tries to change the section
of the tube from oval to circular, and this tends to straighten out the tube. The
resulting movement of the free end of the tube causes the pointer to move over the
scale. The tip of the Bourdon tube is connected to a segmental lever through an
adjustable length link. The segmental lever end on the segment side is provided
with a rack which meshes to a suitable pinion mounted on a spindle. The segmental
lever is suitably pivoted and the spindle holds the pointer. Bourdon tubes are made
of a number of materials, depending upon the fluid and the pressure for which they
are used, such as phosphor bronze, alloy steel, stainless steel, “Monel” metal, and
beryllium copper. Bourdon tubes are generally made in three shapes: C-type,
Helical type and Spiral type.
What is thermometer?

A thermometer is an instrument that measures temperature. It can measure the

temperature of a solid such as food, a liquid such as water, or a gas such as air. The
three most common units of measurement for temperature are Celsius, Fahrenheit,
and kelvin.

The working principle of thermometer:

Thermometers work on the principle of thermal expansion of liquids. Heat

sensitive liquids are used as working liquids in thermometers. One of the most
commonly used ones are mercury and alcohol.

Thermometer:

A thermometer is a tool used to measure the temperature or temperature of an

object. It contains a glass tube inside that contains a liquid known as mercury. A
simple indoor thermometer is shown below:

Working principle:

A thermometer works on the principle that solids and liquids tend to expand with
temperature.

When a thermometer lamp is immersed in a given solution or substance, mercury

begins to rise. This increase in mercury is studied on a temperature scale.

Depending on the reading, the temperature of the given object or solution may be
determined.
Hence, A thermometer works on the principle that solids and liquids tend to
expand with temperature.

What is pyrometer?

A pyrometer, or radiation thermometer, is a type of remote

sensing thermometer used to measure the temperature of distant objects. Various
forms of pyrometers have historically existed. In the modern usage, it is a device
that from a distance determines the temperature of a surface from the amount of
the thermal radiation it emits, a process known as pyrometry, a type of radiometry.

Working Principle of Pyrometer

The basic principle of the pyrometer is, it measures the object's temperature by
sensing the heat/radiation emitted from the object without making contact with the
object. It records the temperature level depending upon the intensity of radiation
emitted.

The construction of the optical pyrometer is quite simple. The pyrometer is

cylindrical inside which the lens is placed on one end and the eyepiece on the other
end. The lamp is kept between the eyepiece and the lens. The filter is placed in
front of the eyepiece.

Working Principle of Pyrometer

Pyrometers are the temperature measuring devices used to detect the object’s
temperature and electromagnetic radiation emitted from the object. These are
available in different spectral ranges. Based on the spectral range, pyrometers are
classified into 1-color pyrometers, 2-color pyrometers, and high-speed pyrometers.
The basic principle of the pyrometer is, it measures the object’s temperature by
sensing the heat/radiation emitted from the object without making contact with the
object. It records the temperature level depending upon the intensity of radiation
emitted. The pyrometer has two basic components like optical system and
detectors that are used to measure the surface temperature of the object.

When any object is taken whose surface temperature is to be measured with the
pyrometer, the optical system will capture the energy emitted from the object.
Then the radiation is sent to the detector, which is very sensitive to the waves of
radiation. The output of the detector refers to the temperature level of the object
due to the radiation. Note that, the temperature of the detector analyzed by using
the level of radiation is directly proportional to the object’s temperature.

What is thermocouple?

A thermocouple is a device that comprises two dissimilar metallic wires joined

together to form a junction. When the junction is heated or cooled, a small voltage
is generated in the electrical circuit of the thermocouple and it can be measured by
temperature.

The amount of EMF generated in the device is very minute (millivolts), so very
sensitive devices must be utilized for calculating the e.m.f produced in the circuit.
The common devices used to calculate the e.m.f are voltage balancing
potentiometer and the ordinary galvanometer. From these two, a balancing
potentiometer is utilized physically or mechanically.

Thermocouple Working Principle

The thermocouple principle mainly depends on the three effects namely Seebeck,
Peltier, and Thompson.
See beck-effect

This type of effect occurs among two dissimilar metals. When the heat offers to
any one of the metal wires, then the flow of electrons supplies from hot metal wire
to cold metal wire. Therefore, direct current stimulates the circuit.

Peltier-effect

This Peltier effect is opposite to the Seebeck effect. This effect states that the
difference of the temperature can be formed among any two dissimilar conductors
by applying the potential variation among them.

Thompson-effect

This effect states that as two disparate metals fix together & if they form two joints
then the voltage induces the total conductor’s length due to the gradient of
temperature. This is a physical word that demonstrates the change in rate and
direction of temperature at an exact position.

Construction of Thermocouple

The construction of the device is shown below. It comprises two different metal
wires and that are connected together at the junction end. The junction thinks as the
measuring end. The end of the junction is classified into three type’s namely
ungrounded, grounded, and exposed junction.

Thermocouple Construction
Ungrounded-Junction

In this type of junction, the conductors are totally separated from the protecting
cover. The applications of this junction mainly include high-pressure application
works. The main benefit of using this function is to decrease the stray magnetic
field effect.

Grounded-Junction

In this type of junction, the metal wires, as well as the protection cover, are
connected together. This function is used to measure the temperature in the acidic
atmosphere, and it supplies resistance to the noise.

Exposed-Junction

The exposed junction is applicable in the areas where a quick response is required.
This type of junction is used to measure the gas temperature. The metal used to
make the temperature sensor basically depends on the calculating range of
temperature.

Generally, a thermocouple is designed with two different metal wires namely iron
and constantan that makes in detecting element by connecting at one junction that
is named as a hot junction. This consist of two junctions, one junction is connected
by a voltmeter or transmitter where the cold junction and the second junction is
associated in a process that is called a hot junction.

How Does a Thermocouple Work?

The thermocouple diagram is shown in the below picture. This circuit can be
built with two different metals, and they are coupled together by generating two
junctions. The two metals are surrounded by the connection through welding.

In the above diagram, the junctions are denoted by P & Q, and the temperatures are
denoted by T1, & T2. When the temperature of the junction is dissimilar from each
other, then the electromagnetic force generates in the circuit.
Thermocouple Circuit

If the temperate at the junction end turn into equivalent, then the equivalent, as
well as reverse electromagnetic force, produces in the circuit, and there is no flow
of current through it. Similarly, the temperature at the junction end becomes
imbalanced, then the potential variation induces in this circuit.

The magnitude of the electromagnetic force induces in the circuit relies on the sorts
of material utilized for thermocouple making. The entire flow of current
throughout the circuit is calculated by the measuring tools.