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Principles of operation of torque power (absorbing) dynamometers

An absorbing dynamometer acts as a load that is driven by the prime mover that i
s 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 d
rive roller and provide no variable load to the prime mover.
An Absorption dynamometer is usually equipped with some means of measuring the o
perating torque and speed.
The dynamometer's Power Absorption Unit absorbs the power developed by the prime
mover. The power absorbed by the dynamometer is converted into heat and the hea
t is generally dissipated into the ambient air or transferred to cooling water w
hich is dissipated into the air. Regenerative dynamometers, in which the prime m
over drives a DC motor as a generator to create load, make excess DC power and p
otentially, using a DC/AC inverter, can feed AC power back into the commercial e
lectrical power grid - where the power produced is eventually converted back int
o heat (as in an oven or light bulb, etc.).
Absorption dynamometers can be equipped with two types of control systems to pro
vide different main test types.
Constant Force
The dynamometer has a "braking" torque regulator, the PAU (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 an
y other variable it is desired to test. The prime mover is then allowed to accel
erate the engine through the desired speed or rpm range. Constant Force test rou
tines 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 t
orque x rpm / 5252 + calculated power required for the acceleration rate that oc
curred.
Constant Speed
If the dynamometer has a speed regulator (human or computer), the PAU provides a
variable mount of braking force (torque) that is necessary to cause the prime m
over to operate at the desired single test speed or rpm. The PAU braking load ap
plied to the prime mover to can be manually controlled or determined by a comput
er. Most systems employ eddy current, oil hydraulic or DC motor produced loads b
ecause of their linear and quick load change ability.
Power is calculated based on torque x rpm / 5252.
A motoring dynamometer acts as a motor that drives the equipment under test. It
must be able to drive the equipment at any speed and develop any level of torque
that the test requires. In common usage, AC or DC motors are used to drive the
equipment or "load" device.
In most dynamometers power (P) is not measured directly; it must be calculated f
rom torque (τ) and angular veloci y (ω) values or force (F) and linear veloci y
(v):
or
here
P is he poer in a s
τ is he orque in ne on me res
ω is he angular veloci y in radians per second
F is he force in ne ons
v is he linear veloci y in me res per second
Division by a conversion cons an may be required depending on he uni s of meas
ure used.
For imperial uni s,
here
Php is he poer in horsepoer
τlb•f is he orque in pound-fee
ωrpm is he ro a ional veloci y in revolu ions per minu e
For me ric uni s,
here
PkW is he poer in kiloa s
τN•m is he orque in ne on me res
ωrpm is he ro a ional veloci y in revolu ions per minu e
De ailed dynamome er descrip ion

Elec rical dynamome er se up shoing engine, orque measuremen arrangemen and


achome er
A dynamome er consis s of an absorp ion (or absorber/driver) uni , and usually i
ncludes a means for measuring orque and ro a ional speed. An absorp ion uni co
nsis s of some ype of ro or in a housing. The ro or is coupled o he engine or
o her equipmen under es and is free o ro a e a ha ever speed is required
for he es . Some means is provided o develop a braking orque be een dynamom
e er's ro or and housing. The means for developing orque can be fric ional, hyd
raulic, elec romagne ic e c. according o he ype of absorp ion/driver uni .
One means for measuring orque is o moun he dynamome er housing so ha i is
free o urn excep ha i is res rained by a orque arm. The housing can be m
ade free o ro a e by using runnions connec ed o each end of he housing o su
ppor he dyno in pedes al moun ed runnion bearings. The orque arm is connec e
d o he dyno housing and a eighing scale is posi ioned so ha i measures he
force exer ed by he dyno housing in a emp ing o ro a e. The orque is he fo
rce indica ed by he scales mul iplied by he leng h of he orque arm measured
from he cen er of he dynamome er. A load cell ransducer can be subs i u ed fo
r he scales in order o provide an elec rical signal ha is propor ional o o
rque.
Ano her means for measuring orque is o connec he engine o he dynamome er
hrough a orque sensing coupling or orque ransducer. A orque ransducer provi
des an elec rical signal ha is propor ional o orque.
Wi h elec rical absorp ion uni s, i is possible o de ermine orque by measurin
g he curren dran (or genera ed) by he absorber/driver. This is generally a l
ess accura e me hod and no much prac iced in modern imes, bu i may be adequa
e for some purposes.
When orque and speed signals are available, es da a can be ransmi ed o a d
a a acquisi ion sys em ra her han being recorded manually. Speed and orque sig
nals can also be recorded by a char recorder or plo er.
Types of dynamome ers
In addi ion o classifica ion as Absorp ion, Mo oring or Universal as described
above, dynamome ers can be classified in o her ays.
A dyno ha is coupled direc ly o an engine is knon as an engine dyno.
A dyno ha can measure orque and poer delivered by he poer rain of a vehic
le direc ly from he drive heel or heels (i hou removing he engine from he
frame of he vehicle), is knon as a chassis dyno.
Dynamome ers can also be classified by he ype of absorp ion uni or absorber/d
river ha hey use. Some uni s ha are capable of absorp ion only can be combi
ned i h a mo or o cons ruc an absorber/driver or universal dynamome er. The f
olloing ypes of absorp ion/driver uni s have been used:
Types of absorp ion/driver uni s
• Eddy curren or elec romagne ic brake (absorp ion only)
• Magne ic Poder brake (absorp ion only)
• Hys eresis Brake (absorp ion only)
• Elec ric mo or/genera or (absorb or drive)
• Fan brake (absorp ion only)
• Hydraulic brake (absorp ion only)
• Mechanical fric ion brake or Prony brake (absorp ion only)
• Wa er brake (absorp ion only)
Eddy curren ype absorber
EC dynamome ers are curren ly he mos common absorbers used in modern chassis d
ynos. The EC absorbers provide he quick load change ra e for rapid load se lin
g. Mos are air cooled, bu some are designed o require ex ernal a er cooling
sys ems.
Eddy curren dynamome ers require an elec rically conduc ive core, shaf or disc
, moving across a magne ic field o produce resis ance o movemen . Iron is a co
mmon ma erial, bu copper, aluminum and o her conduc ive ma erials are usable.
In curren (2009) applica ions, mos EC brakes use cas iron discs, similar o v
ehicle disc brake ro ors, and use variable elec romagne s o change he magne ic
field s reng h o con rol he amoun of braking.
The elec romagne vol age is usually con rolled by a compu er, using changes in
he magne ic field o ma ch he poer ou pu being applied.
Sophis ica ed EC sys ems allo s eady s a e and con rolled accelera ion ra e ope
ra ion.
Poder dynamome er
A poder dynamome er is similar o an eddy curren dynamome er, bu a fine magne
ic poder is placed in he air gap be een he ro or and he coil. The resul in
g flux lines crea e "chains" of me al par icula e hich are cons an ly buil and
broken apar during ro a ion crea ing grea orque. Poder dynamome ers are yp
ically limi ed o loer RPM due o hea dissipa ion issues.
Hys eresis dynamome ers
Hys eresis dynamome ers, use a s eel ro or ha is moved hrough flux lines gene
ra ed be een magne ic pole pieces. This design, as in he usual "disc ype" edd
y curren absorbers, allos for full orque o be produced a zero speed, as el
l as a full speed. Hea dissipa ion is assis ed by forced air. Hys eresis and "
disc ype" EC dynamome ers are one of he mos efficien echnologies in small (
200 hp (150 kW) and less) dynamome ers. A hys eresis brake is an eddy curren ab
sorber hich, unlike mos "disc ype" eddy curren absorbers, pu s he elec roma
gne coils inside a ven ed and ribbed cylinder and ro a es he cylinder, ins ead
of ro a ing a disc be een elec romagne s. The po en ial benefi for he hys er
esis absorber is ha he diame er can be decreased and opera ing rpm of he abs
orber may be increased.
Elec ric mo or/genera or dynamome er
Elec ric mo or/genera or dynamome ers are a specialized ype of adjus able-speed
drives. The absorp ion/driver uni can be ei her an al erna ing curren (AC) mo
or or a direc curren (DC) mo or. Ei her an AC mo or or a DC mo or can opera e
as a genera or hich is driven by he uni under es or a mo or hich drives
he uni under es . When equipped i h appropria e con rol uni s, elec ric mo or
/genera or dynamome ers can be configured as universal dynamome ers. The con rol
uni for an AC mo or is a variable-frequency drive and he con rol uni for a D
C mo or is a DC drive. In bo h cases, regenera ive con rol uni s can ransfer po
er from he uni under es o he elec ric u ili y. Where permi ed, he opera
or of he dynamome er can receive paymen (or credi ) from he u ili y for he
re urned poer.
In engine es ing, universal dynamome ers can no only absorb he poer of he e
ngine bu also, drive he engine for measuring fric ion, pumping losses and o he
r fac ors.
Elec ric mo or/genera or dynamome ers are generally more cos ly and complex han
o her ypes of dynamome ers.
Fan brake
A fan is used o blo air o provide engine load. Changing gearing or fan or sim
ply measuring he max rpm a ained.
Hydraulic brake
The hydraulic brake sys em consis s of a hydraulic pump (usually a gear ype pum
p), a fluid reservoir and piping be een he o par s. Inser ed in he piping i
s an adjus able valve and be een he pump and he valve is a gauge or o her mea
ns of measuring hydraulic pressure. Usually, he fluid used as hydraulic oil, b
u recen syn he ic mul i-grade oils may be a be er choice. In simples erms,
he engine is brough up o he desired rpm and he valve is incremen ally close
d and as he pumps ou le is res ric ed, he load increases and he hro le is
simply opened un il a he desired hro le opening. Unlike mos o her sys ems,
poer is calcula ed by fac oring flo volume (calcula ed from pump design specs)
, hydraulic pressure and rpm. Brake HP, he her figured i h pressure, volume an
d rpm or i h a differen load cell ype brake dyno, should produce essen ially
iden ical poer figures. Hydraulic dynos are renoned for having he absolu ely
quickes load change abili y, jus sligh ly surpassing he eddy curren absorber
s. The donside is ha hey require large quan i ies of ho oil under high pres
sure and he requiremen for an oil reservoir.
Wa er brake ype absorber
The a er brake absorber is some imes mis akenly called a "hydraulic dynamome er
". Wa er brake absorbers are rela ively common, having been manufac ured for man
y years and no ed for heir high poer capabili y, small package, ligh eigh ,
and rela ively lo manufac uring cos as compared o o her, quicker reac ing "po
er absorber" ypes.
Their drabacks are ha hey can ake a rela ively long period of ime o "s ab
ilize" heir load amoun and he fac ha hey require a cons an supply of a
er o he "a er brake housing" for cooling. In many par s of he coun ry[here?
], environmen al regula ions no prohibi "flo hrough" a er and large a er
anks mus be ins alled o preven con amina ed a er from en ering he environme
n .
The schema ic shos he mos common ype of a er brake, he variable level ype
. Wa er is added un il he engine is held a a s eady rpm agains he load. Wa e
r is hen kep a ha level and replaced by cons an draining and refilling, h
ich is needed o carry aay he hea crea ed by absorbing he horsepoer. The ho
using a emp s o ro a e in response o he orque produced bu is res rained by
he scale or orque me ering cell hich measures he orque.
This schema ic shos a a er brake hich is ac ually a fluid coupling i h he h
ousing res rained from ro a ing. I is very similar o a a er pump i h no ou l
e .
Ho dynamome ers are used for engine es ing
Dynamome ers are useful in he developmen and refinemen of modern day engine
echnology. The concep is o use a dyno o measure and compare poer ransfer a
differen poin s on a vehicle, hus alloing he engine or drive rain o be mod
ified o ge more efficien poer ransfer. For example, if an engine dyno shos
ha a par icular engine achieves 400 N•m (300 lbf•f ) of orque, and a chassis
dynamo shos only 350 N•m (260 lbf•f ), one ould kno o look o he drive rai
n for he major improvemen s. Dynamome ers are ypically very expensive pieces o
f equipmen , reserved for cer ain fields ha rely on hem for a par icular purp
ose.
Types of dynamome er sys ems

Dyno graph 1

Dyno graph 2
A Brake dynamome er applies variable load on he Prime Mover (PM) and measures
he PM's abili y o move or hold he rpm as rela ed o he "braking force" applie
d. I is usually connec ed o a compu er hich records he applied braking orqu
e and calcula es he poer ou pu of he engine based on informa ion from a "loa
d cell" or "s rain gauge" and rpm (speed sensor).
An Iner ia dynamome er provides a fixed iner ial mass load and calcula es he po
er required o accelera e ha fixed, knon mass and uses a compu er o record
rpm and acc. ra e o calcula e orque. The engine is generally es ed from some
ha above idle o i s maximum rpm and he ou pu is measured and plo ed on a gr
aph.
A Mo oring dynamome er provides he fea ures of a Brake dyne sys em, bu in addi
ion, can "poer" (usually i h an AC or DC mo or) he Prime Mover (PM) and allo
 es ing of very small poer small ou pu s. Example, duplica ing speeds and loa
ds ha are experienced hen opera ing a vehicle raveling donhill or on/off h
ro le opera ions.
There are essen ially 3 ypes of dynamome er es procedures
1. S eady S a e (only on brake dynamome ers), here he engine is held a a
specified rpm (or series of usually sequen ial rpms) for a desired amoun of i
me by he variable brake loading as provided by he PAU (poer absorber uni ).
2. Seep Tes (on iner ia or brake dynamome ers), here he engine is es e
d under a load (iner ia or brake loading), bu alloed o "seep" up in rpm in a
con inuous fashion, from a specified loer "s ar ing" rpm o a specified "end"
rpm.
3. Transien Tes (usually on AC or DC dynamome ers), here he engine poe
r and speed are varied hroughou he es cycle. Differen es cycles are used
in differen jurisdic ions. Chassis es cycles include he US ligh -du y UDDS,
HWFET, US06, SC03, ECE, EUDC, and CD34. Engine es cycles include ETC, HDDTC,
HDGTC, WHTC, WHSC, and ED12.
Types of Seep Tes s:
1. Iner ia Seep: An iner ia dyno sys em ha provides a fixed iner ial mas
s fly heel and compu es he poer required o accelera e he flyheel (load) fro

m he s ar ing o he ending rpm. The ac ual ro a ional mass of he engine or en
gine and vehicle in he case of a chassis dyno is no knon and he variabili y
of even ire mass ill ske poer resul s. The iner ia value of he flyheel is
"fixed", so lo poer engines are under load for a much longer ime and in ernal
engine empera ures are usually oo high by he end of he es , skeing op ima
l "dyno" uning se ings aay from he ou side orld's op imal uning se ings.
Conversely, high poered engines, commonly comple e a common "4 h gear seep" e
s in less han 10 seconds, hich is no a reliable load condi ion as compared
o opera ion in he ou side orld. By no providing enough ime under load, in er
nal combus ion chamber emps are unrealis ically lo and poer readings, especia
lly pas he poer peak, are skeed lo.
1. Loaded Seep Tes s (brake dyno ype) consis of 2 ypes:
1. Simple fixed Load Seep Tes : A fixed load, of someha less han he en
gine's ou pu , is applied during he es . The engine is alloed o accelera e f
rom i s s ar ing rpm o i s ending rpm, varying in i s on accelera ion ra e, de
pending on poer ou pu a any par icular rpm poin Poer is calcula ed using o
rque * rpm / 5252 + he poer required o accelera e he dyno and engine's / veh
icle's ro a ing mass.
2. Con rolled Accelera ion Seep Tes : Similar in basic usage as he above
Simple fixed Load Seep Tes , bu i h he addi ion of ac ive load con rol ha
arge s a specific ra e of accelera ion. Commonly, 20fps/ps is used.
Con rolled Accelera ion Ra e es is ha he acc. ra e used is con rolled from
lo poer o high poer engines and over ex ension and con rac ion of " es dura
ion" is avoided, providing more repea able es s and uning resul s.
In every Seep Tes , here is s ill he remaining issue of po en ial poer readi
ng error due o he variable engine / dyno / vehicle o al ro a ing mass. Many m
odern compu er con rolled brake dyno sys ems are capable of deriving ha "iner
ial mass" value o elimina e he error.
In eres ingly, A "seep es " ill alays be suspec , as many "seep" users igno
re he ro a ing mass fac or and prefer o use a blanke "fac or" on every es ,
on every engine or vehicle. Simple iner ia dyne sys ems aren' capable of derivi
ng "iner ial mass" and are forced o use he same assumed iner ial mass on every
vehicle.
Using S eady S a e es ing elimina es a Seep Tes ro a ing iner ial mass error
, as here is no accelera ion during a S eady S a e es .
Transien Tes Charac eris ics: Aggressive hro le movemen s, engine speed chan
ges, and engine mo oring are charac eris ics of mos ransien engine es s. The
usual purpose of hese es s are for vehicle emissions developmen and homologa
ion. In some cases, he loer-cos eddy-curren dynamome er is used o es one
of he ransien es cycles for early developmen and calibra ion. An eddy cur
ren dyne sys em offers fas load response, hich allos rapid racking of speed
and load, bu does no allo mo oring. Since mos required ransien es s con
ain a significan amoun of mo oring opera ion, a ransien es cycle i h an e
ddy-curren dyno ill genera e differen emissions es resul s. Final adjus men
s are required o be done on a mo oring-capable dyno.
Engine dynamome er

HORIBA engine dynamome er TITAN


An engine dynamome er measures poer and orque direc ly from he engine's crank
shaf (or flyheel), hen he engine is removed from he vehicle. These dynos do
no accoun for poer
Chassis dynamome er

Saab 96 on chassis dynamome er


A chassis dynamome er measures poer delivered o he surface of he "drive roll
er" by he drive heels. The vehicle is of en parked on he roller or rollers, 
hich he car hen urns and he ou pu is measured.
Modern roller ype chassis dyne sys ems use he Salvisberg roller,[2] hich impr
oved rac ion and repea abili y over smoo h or knurled drive rollers.
On a mo orcycle, ypical poer loss a higher poer levels, mos ly hrough ire
flex, is abou 10%[ci a ion needed] and gearbox chain and o her poer ransferri
ng par s are ano her 2% o 5%[ci a ion needed].
O her ypes of chassis dynamome ers are available ha elimina e he po en ial 
heel slippage on old s yle drive rollers and a ach direc ly o he vehicle's hu
bs for direc orque measuremen from he axle. Hub moun ed dynos include uni s
made by Dynapack and Ro o es .
Chassis dynos can be fixed or por able.
Modern chassis dynamome ers can do much more han display RPM, horsepoer, and
orque. Wi h modern elec ronics and quick reac ing, lo iner ia dyne sys ems, i
is no possible o une o bes poer and he smoo hes runs, in real ime.
In re ail se ings i is also common o " une he air fuel ra io" , using a ide
band oxygen sensor hich is graphed along i h RPM.
Some, dyne sys ems can also add vehicle diagnos ic informa ion o he dyno graph
as ell. This is done by ga hering da a direc ly from he vehicle using on-boar
d diagnos ics communica ion.[3]
Emissions developmen and homologa ion dynamome er es sys ems of en in egra e
emissions sampling, measuremen , engine speed and load con rol, da a acquisi ion
, and safe y moni oring in o a comple e es cell sys em. These es sys ems usu
ally include complex emissions sampling equipmen (such as cons an volume sampl
ers or ra exhaus gas sample prepara ion sys ems), and exhaus emissions analyz
ers. These analyzers are much more sensi ive and much fas er han a ypical por
able exhaus gas analyzer. Response imes of ell under one second are common an
d required by many ransien es cycles.
In egra ion of he dynamome er con rol sys em along i h au oma ic calibra ion
ools for engine sys em calibra ion is of en found in developmen es cell sys e
ms. In hese es cell sys ems, he dynamome er load and engine speed are varied
o many engine opera ing poin s, and selec ed engine managemen parame ers are
varied and he resul s recorded au oma ically. La er analysis of his da a may
hen be used o genera e engine calibra ion da a used by he engine managemen so
f are.
Because of fric ional and mechanical losses in he various drive rain componen s
, he measured rear heel brake horsepoer is generally 15-20 percen less han
he brake horsepoer measured a he crankshaf or flyheel on an engine dynamom
e er.[4] O her sources, af er researching several differen "engine" dyno sof a
re packages, found ha he engine dyno user can in egrally add "fric ional loss
" channel fac ors of +10% o +15% o he flyheel poer, raising he claim ha
20% o 25% or even more poer is ac ually los be een he crankshaf a high po
er ou pu s.
Horsepoer figures are a s rong predic or bu do no guaran ee a specific 0-60 m
ph, 1/4 mile elapsed ime (ET) or 1/4 mile speed. An engine accelera ing in a ve
hicle experiences differen condi ions han on a dyno. G forces and differen e
mpera ures as ell as differen modes of vibra ion in a vehicle can cause signif
ican differences in poer ou pu .
Inexpensive "iner ia dynamome ers" commonly provide insufficien loading, and co
mple e heir " es " in less ime han he real orld 1/4 mile akes, causing inh
eren poer value errors, due o unrealis ic in ernal engine empera ures.
More sophis ica ed dyne sys ems are capable of "loaded es ing", hich can po en
ially recrea e he same empera ures as on he drag s rip.
In engineering uni s, he poer figures used should be "True" or "Effec ive" hor
sepoer scale.
Engine damage: Can dyno es ing damage engines?
A brake dyno, in s eady s a e mode only provides a load ha is equal he amoun
of poer ha he engine is making a any specifically selec ed rpm poin . If
he engine makes 200 brake HP a 5000 rpm, he dynamome er's brake or poer absor
ber ill provide exac ly 200 hp (150 kW) of load agains i , keeping he RPM a
5000 rpm.
Tha 's a realis ic load, i 's as if he engine as in a vehicle pulling a large
railer up a hill. Should be no problem on he dyno - if here's no problem on
he road.
The apprehension over dyno es ing and engine damage does have solid roo s in fa
c . Old s yle dynamome ers commonly used an inexpensive a er brake ype of poe
r absorber. Load as increased or decreased by filling and draining a er in he
housing o change he amoun of in ernal a er volume o change he load, all
he hile draining and refilling he a er o keep he a er from boiling - I o
uld some imes ake qui e some ime for he opera or or compu er o ge inflo an
d ou flo ra es s abilized and ha is he problem. I 's no he "amoun " of loa
d, i 's he amoun of " ime" spen rying o s abilize he load a he desired r
pm.
Wa er brakes are s ill commonly used in applica ions here heir small size and
ligh eigh are impor an and engine orque curves are rela ively s raigh , as
in large au omo ive and boa s.
Engine es ing may damage engines primarily due o insufficien ins rumen a ion,
insufficien safe y moni oring sys ems, and insufficien cooling. An engine on
a dyno does no receive air cooling due o engine speeds. Au omo ive engines are
no ypically designed for ide-open hro le opera ion for ex ended periods of
ime; in ernal componen s may overhea and fail.
His ory
Gaspard de Prony inven ed he de Prony brake in 1821. The de Prony brake (or Pro
ny brake) is considered o be one of he earlies dynamome ers.
Froude Hofmann of Worces er, UK, manufac ures engine and vehicle dynamome ers. T
hey credi William Froude i h he inven ion of he hydraulic dynamome er in 187
7 and say ha he firs commercial dynamome ers ere produced in 1881 by heir
predecessor company, Heenan & Froude.
In 1928, he German company "Carl Schenck Eisengießerei & Waagenfabrik" buil h
e firs vehicle dynamome ers for brake es s i h he basic design of he oday'
s vehicle es s ands.
The eddy curren dynamome er as inven ed by Mar in and An hony Win her in abou
1931. A ha ime, DC Mo or/genera or dynamome ers had been in use for many ye
ars. A company founded by he Win hers, Dynama ic Corpora ion, manufac ured dyna
mome ers in Kenosha, Wisconsin un il 2002. Dynama ic as par of Ea on Corpora i
on from 1946 o 1995. In 2002, [2] Dyne Sys ems of Jackson, Wisconsin acquired
he Dynama ic dynamome er produc line. S ar ing in 1938, Heenan & Froude manufac
ured eddy curren dynamome ers for many years under license from Dynama ic and
Ea on.[5]

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