Mansura University

Faculity Of Engineering
Production Engineering & Mechanical Design Department

Course Name
Production Laboratory

Course Code: Fall2021_PRE5415_Course

Student Name: Ahmed Sameh Kandil
Instructor Name: Dr. Mohamed El-Keran
Report name: Force Dynamometer
What is a Dynamometer?
A dynamometer is a measuring device used to determine the torque, force, speed,
and power required to operate the drive on a machine or motor, which can be
measured by evaluating the torque and rotational speed of a motor simultaneously.
Beyond the common use of dynamometers, there are other uses for them, such as
tests of engine management controllers and the examination of combustion.

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

measures the applied force. The measurement of force using dynamometers is an
essential part of automobile production to determine horsepower, power
absorption, and rotary speed.

To maintain their instruments and ensure the accuracy of readings, users regularly
calibrate and test dynamometers.
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 force to be measured. 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.

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
➢ crankcase blowby
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. With every test being performed consistently since 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 for Dynamometers

During the design process, engineers want to know how big an engine or electric
motor will be necessary to operate a machine. The type of dynamometer for such
an application is a driving one, which is an engine or electric motor that has
monitors and meters that are able to measure the power, force, and speed being
used by the motor.

Though the use of dynamometers may seem to be restricted to motors, engines, and
other mechanical devices, in reality, they have found use in other fields as a means
for measuring power and force. Dynamometers may seem to be a valuable
technical instrument that is necessary for manufacturing. As modern as they are,
dynamometers began over 220 years ago to measure the pulling force of horses.
Dynamometer Uses
Emission Testing
Emission testing measures the emissions and power of a motor when it is on the
road. The results of the testing are compared to chassis tests. A dynamometer for
this purpose is portable and placed on the vehicle with devices for measuring
emissions, performance, and driving. The data is downloaded to a chassis
dynamometer to produce the loads that were seen on the road test. Required real
time compensations include grades, wind, temperature, and altitude.
Motor Testing
Motor testing using a dynamometer takes place in a controlled setting. The vehicle
to be tested is placed on roller beds, which provide the driving force to the wheels,
with the motor’s torque being the primary source of power. Data recording and
collecting devices are attached to the vehicle that establishes a controlled, accurate,
and precise set of readings about the motor. The nature of the setting allows for
control of the amount of force that can be distributed using a variety of methods as
well as the speed. Measurements are taken at static power at a constant velocity.

Medical Testing
In the medical field, practitioners need to know
the muscle strength of a patient to determine
mobility and the ability for self-care. Hand held
dynamometers provide data regarding a patient's
ability to hold a standard position. The testing
includes a length tension of a muscle, which is
the relationship between maximum tension
versus the length of the muscle. For the best
results, the muscle is tested in its maximum
length tension position.
Hand Strength Testing
A specialized form of dynamometer is a
hand strength tester that is used to
measure the amount of loss of muscle
strength in the hands. The reasons and
concerns regarding hand testing include
carpal tunnel syndrome, nerve and
tendon damage, and various forms of
neuromuscular disorders. Hand strength
dynamometers serve a variety of
purposes, such as diagnosing diseases,
evaluating treatments, and providing
data regarding the improvement of
muscle strength during recovery.

Speedometer Dynamometer
A speedometer is a form of dynamometer that uses
electromagnetism to provide data. A metal disc that
is connected by a cable to the wheels of a car causes
a magnet to rotate inside a metal cup. While the
magnet is rotating, it creates eddy currents that work
to slow down the magnet. In the process, the cup
rotates and produces a speed reading by making the
needle on the speedometer move or creating a digital
readout.

Towing Dynamometer
A towing dynamometer is a mechanized trailer
that is towed behind a vehicle. It uses an eddy
current absorber connected to an axle system to
absorb energy. Measurements are taken by a
load cell on the drawbar of the trailer. A towing
dynamometer is used to determine a vehicle’s
performance and develop any adjustments that
may be necessary.
Electric Motor Testing
The testing of electric motors using a dynamometer is very similar to tests
performed on other motors. A dynamometer provides data regarding the torque,
force, power, and rotation of an
electric motor. Dynamometers do full
and variable testing to determine the
optimum performance of an electric
motor.

One form of electric motor testing

involves the application of water flow
that is proportional to the load, which
creates resistance in the motor. The
acceleration and deceleration of the
water flow allows the dynamometer to
adsorb the power generated by the
motor.

Locomotive Dynamometer Testing

The different aspects of a locomotive
are tested using a dynamometer car.
The main purpose of a dynamometer
car is to measure the power output of a
locomotive, which include pulling
force, power, brake pipe pressure, and
drawbar pull. The main pieces of data,
which are force and speed, are used to
calculate the effectiveness of a
locomotive.
Power Take Off (PTO) Dynamometer Testing
PTO testing is a series of tests performed
by a dynamometer when connected to an
engine’s output shaft. The parameters for
the testing are much like those of other
engine tests and include speed, torque,
power, and fuel consumption. PTO
dynamometers are easy to connect and
disconnect. Accurate and detailed PTO
readings assist in lowering maintenance
costs and improving equipment
reliability.

Electric Vehicle Motor Dynamometer Testing

Several tests are performed on the motors of electric vehicles using a
dynamometer. The most important part of the testing includes the performance
parameters, which are calculated by the dynamometer.

The measures tested on an EV

motor include rotor current,
temperature rise, continuous
electrical operation, max speed,
and over speed. Each
dynamometer for testing EV
engines is specially designed to
meet the parameters of the engine
to be tested. The specifications of
the motor are identified such that
they apply to the specific motor.
Dynamometer Types
Absorption Dynamometers
Absorption dynamometers create torque
by placing constraints on a turning shaft
through mechanical or fluid friction or
electromagnetic induction. The torque
inducing components are arranged in
pairs such that the effects of a transverse
load is avoided. Absorption
dynamometers are very accurate and are
used where continuous transmission of
the load is required.

The purpose of absorption dynamometers

is to measure and absorb power. Eddy
current, hydraulic, and Prony dynamometers use the power absorption principles as
their means of measurement.

Alternating Current (AC) Dynamometer

An AC dynamometer applies power to an
engine and absorbs power, such as braking
force, from the driveshaft. This
permits the dynamometer to
simulate the external forces on the
engine. AC dynamometers can use
direct current (DC) as well as AC
and can be a load or prime mover to
measure rotational power and
torque. The prime mover can be an
electric motor, or a turbine driven
by wind, water, or steam. It is a
simple testing device that can
provide a range of torque values.

AC dynamometers are a convenient method for developing a comparison between

actual execution and design specifications. They have been a major step in
improving marketable products and enhancing product life and performance.
Chassis Dynamometers
Chassis dynamometers are torque measuring
devices that measure what is produced by the
movement of a vehicle's wheels. They are available
in fixed configurations or portable units. The
purpose of chassis dynamometers is to simulate
road conditions, including all the forces that attack
a vehicle during operation. The test includes
accelerating, braking, and decelerating the test
vehicle to get the necessary data. There are several
designs of chassis dynamometers designed to test
several driving conditions and challenges for
vehicles.

Driving Dynamometer
A driving dynamometer is used to determine
what type of a motor is necessary to operate
an engine or electric motor. The components
of a driving dynamometer include a motor
with measuring meters and monitors that are
attached to the device to be measured. The
readings from the monitoring equipment
supply information regarding how much
power, force, and speed are being used.

Eddy Current Dynamometer

An eddy current dynamometer measures the torque and
power of the prime mover, which is a motor or engine.
The rotor turns by the force of the prime mover shaft,
and voltage is applied to the stator housing. Magnetic
flux is generated, which is cut off by the rotor. An eddy
current that is opposite to the change in the magnetic
flux is generated in the rotor. The rotor attempts to
contain and reduce the rotational speed, while the prime
mover maintains speed using its torque. The amount of
torque is measured by an eddy current dynamometer.
There are a wide range of functions that use eddy current dynamometers including
various turbines and mining and drilling equipment.

Engine Dynamometer
The process of using an engine dynamometer is slightly more complicated than the
use of other dynamometers. The size, weight, and performance of the engine are
the determining factors related to selecting a proper dynamometer. Unlike chassis
dynamometers, engine dynamometers test and tune engines.

Engine dynamometers produce a great deal of

information and require a computer interface to
record and display what is ascertained by the
dynamometer. The main dividing factor between
the different types of engine dynamometers is
whether the engine is for street use or heavy duty
use, such as race cars or trucks since there is a
great deal of variance in torque between the two
classes of engines.

Hydraulic Dynamometer
A hydraulic dynamometer has semicircular vanes placed in a
rotor and stator. Water flows in a toroidal vortex around the
vanes and creates a torque reaction in the dynamometer
casing that is resisted by the dynamometer and measured by
a load cell. The construction of a hydraulic dynamometer is
similar to a fluid flywheel that measures the frictional force
between impeller vanes and a moving fluid.

Prony Brake Dynamometer

A Prony brake dynamometer is the simplest form of
dynamometer that Prony developed at the beginning of the
first industrial revolution. It is made up of brake blocks that
press against a rotating wheel attached to the motor. The
braking blocks create friction force to slow the velocity of the
wheel. The purpose of a Prony brake dynamometer is to
measure braking power.
Rope Brake Dynamometer
A rope brake dynamometer is another method for measuring the power of an
engine and includes a rope that is wound around a drum that is attached to the
output shaft. One side of the rope is connected to a spring balance, with the other
side attached to a loading device.

In a rope brake dynamometer, power is absorbed

between the rope and the drum. The amount of
friction produced by the interaction of the rope
and drum necessitates some form of cooling
mechanism. The mechanics of a rope brake
dynamometer can be easily made, but the device
does not provide accurate data due to the changes
in the friction coefficient.

Universal Dynamometers
A universal dynamometer is different from an absorption
dynamometer in that it can measure absorption and drive
of the device being monitored. As the dynamometer
absorbs the force and power, it drives the engine to
measure friction and pump loss, to name a few factors.

Water Brake Dynamometers

Water brake dynamometers are designed to work
with high torque low speed diesel engines that
are used in mining, marine, and naval
applications. They can test engines with
clockwise and counterclockwise rotations. Water
brake dynamometers are hydraulic type
absorption dynamometers, which are connected
to the crankshaft of the engine while water is fed
into the meter.

A rotating blade in the dynamometer turns the

water to create the braking force against the
crankshaft. The measure of the power of the engine is decided by the heat that is
generated. As the amount of water increases, the necessary braking force increases .
Dynamometer Test Procedures
The basic processes of a dynamometer are to measure torque or force and power.
Each of these functions is completed following a set of procedures: step test, sweep
test, and transient test. The various procedures are used in conjunction with the
type of data to be collected.

A dynamometer has a data acquisition system that includes a commander and

workstation. As with all modern testing devices, the dynamometer is linked to a
computer that sends commands to the workstation. Once the commands have been
implemented, the workstation operates the dynamometer and collects the
programmed data that is fed back to the command computer.

Types of Dynamometer Test Procedures

Step Test Procedures
Step testing procedures are performed by brake dynamometers and are tests where
an engine is kept at a set RPMs for a predetermined amount of time. After
collecting data at one level of RPMs, it is stepped up to the next level. The
advantage of the step test is the lack of acceleration so that inertia and the
dynamometer do not influence the torque readings.

Sweep Test
The sweep test accelerates the engine at a constant steady rate, such as 100 rpms
per second. Its purpose is to simulate as closely as possible actual driving
conditions. The key to the success of the sweep test is precise control of the
acceleration such that it remains constant and consistent. The dynamometer control
system is responsible for the reliability of the acceleration rate.

Types of Sweep Tests:

Inertia Sweep Test
The inertia sweep test is as close as possible to actual driving conditions. Though
the test does not provide the same type of data that can be acquired during driving,
it does come very close. The purpose of the test is to measure the inertial resistance
of an engine.
Loaded Sweep Test
The loaded sweep test has two versions, which are simply fixed and controlled.
With the simple fixed test, the engine accelerates at its own rate. Power is
determined by the power required to accelerate the dyno. As the name indicates,
the controlled version of a sweep load test controls the acceleration rate.

Transient Test
The transient test was developed to examine various driving patterns that a vehicle
will encounter during its use. The testing procedure is designed to include throttle
movements, speed changes, and other engine patterns.

Variations in the transient test include cold starts that are immediately followed by
hot starts. The test’s main purpose is to measure emissions as outlined in Federal
Test Procedure (FTP) documentation. Under FTP guidance, the load factor during
the test should be 20% to 25% of the maximum engine power.

Reading Results
In the majority of cases, the first place an analyst looks when reading data from a
dynamometer is at peak power. Though this is an essential statistic, it is more
important to examine the average power that covers a useful rpm range. The
provided readings of the useful range are the minimum rpms of an engine at wide
open throttle.

Benefits
A concern for managers and supervisors in industry is to ensure top performance
from the equipment being used. Inspecting, assessing, examining, and testing of
machines and engines is a necessity. A dynamometer is an ideal tool for
determining the power and capabilities of essential equipment. The use of a dyno is
a way of guaranteeing that a procedure works smoothly and efficiently.

A dynamometer is a tool that can scientifically calculate the speed, torque, and
power of any engine, machine, or powered tool. The general use of a dynamometer
includes collecting data on motors, engines, pumps, and generators, making them
applicable in a wide range of industries.
The Advantages of Using a Dynamometer
Accuracy Advantage
An important function of a dynamometer is providing accurate and precise data.
They are an ideal instrument for determining the best use of fuel and whether fuel
is being wasted. The provided data assists in fine tuning and adjusting machines
and motors at little cost.

Providing Precise Data

Though testing devices are an excellent idea, they are only as good as the data they
provide. Dynamometers provide the highest quality of precise and accurate data in
a clear and concise manner. They are capable of examining large and small weight
equipment and are available as portable units.

Variety of Types of Dynamometer

Manufacturers of dynamometers have a wide range of sizes to fit any type of
application. Water brakes are ideal for large engines while eddy current brakes
measure engines up to 250 hp. The many options make it possible to purchase a
dynamometer that specifically fits your needs.

Strength and Durability

The key attribute for any industrial instrument is the ability to withstand and
endure the conditions where they are used. Dynamometers are solidly built from
metal alloys. Producers are well aware of the conditions where their devices will
be used and plan them to be durable and strong.

Benefits to Lifting and Rigging Equipment

There are general parameters regarding the performance of engines that require
testing to provide data for making adjustments and maintenance. The requirements
for rigging and lifting operations are slightly different than those of engines and
motors. Specially designed dynamometers provide data that assist lifting and
rigging operations to be efficient and safe.
Reference

https://en.wikipedia.org/wiki/Dynamometer

https://www.iqsdirectory.com/articles/dynamometers.html

https://mechanicalengineering.blog/dynamometer-introduction-types/

https://www.uhs.nhs.uk/Media/Southampton-
ClinicalResearch/Procedures/BRCProcedures/Procedure-for-measuring-
gripstrengthusing-the-JAMAR-dynamometer.pdf

https://www.dynamometers.org/#read

http://www.engineeringslab.com/tutorial_electrical/advantages-anddisadvantages-
of-dynamometer-type-1680.htm