Purdue University Fort Wayne Department of Electrical and Computer Engineering ECE 40600 Capstone Senior Design Project II 5HP Dynamometer Retrofit Shehryar Azam <[email protected]> Benjamin Edwards <[email protected]> Joshua Durham <[email protected]> Matthew Gonzalez <[email protected]> Project Advisor: Dr. Chao Chen<[email protected]> Date: 05/03/2021 1 Table of Contents Acknowledgements . 7 Abstract . 8 1 Problem Statement . 9 1.1 Literature Survey . 9 1.2 Customer-Defined Constraints and Given Requirements . 9 1.3 Customer Needs and Functional Requirements for Design . 10 1.4 Applicable Engineering Standards . 11 1.5 Define Use Cases . 11 1.6 System Boundary . 12 1.7 Interface Requirements and Definitions. 1 4 2 Conceptual Design. 1 5 2.1 Product Design Decomposition (PDD). 1 5 2.2 Decision List. 17 2.3 Conceptual Design of Alternatives – Physical Solutions (PS) Selection . 18 3 Summary of the Evaluation of Design Alternatives. 20 3.1 Criteria for Selection and Testing Among Alternatives. 20 3.2 Evaluation of Software Design Alternatives . 21 3.3 Evaluation of Torque Transducer Alternatives . 22 3.4 Summary of Preliminary Design . .23 4 Detailed Design. 2 4 4.1 Design Description and Drawings . 2 4 4.2 Evaluation. 31 5 Cost Analysis. .. 32 5.1 BOM (Bill of Materials) . .. 32 6 Design Changes. .. 34 6.1 PC Hardware Change . .. 34 2 6.2 BOM Update. 35 6.3 Software Structure Change. 37 7 Building Process . .. 38 7.1 Hardware Construction . .. 38 7.2 Software Implementation. .. 46 7.3 User Interface. .. 51 7.4 Documentation. .. 54 8 Risk Analysis and Test Plan. .. 62 8.l Fault Tree Analysis. .. 62 8.2 Test Plan . .. 65 8.3 Test Procedure. .. 67 9 Final Product and Results . .. 69 9.1 Test Data . .. 69 9.2 Original Dynamometer Components . .. .80 9.3 Constructed Dynamometer Components . .. 85 9.4 Project Issues and Future Considerations. .. 91 10 Conclusions . .. 92 References. .. 93 Appendix. .. 94 3 List of Tables 1. Software Decision Matrix . .. 20 2. Torque Transducer Decision Matrix . .. 21 3. Torque Transducer Comparison Chart. .. 21 4. Cost of New Computer System . .. 22 5. Xeon Computer Build Parts . .. 28 6. BOM (Bill of Materials). .. 33 7. Updated BOM . .. 36 8. Project Needs Fulfilled. .. 69 9. Project Wants Fulfilled . .. .. .. 70 10. Appraisal of Testing Data . .. 71 11. Test Data . .. 72 12. Accuracy/Precision of Test Data. .. 72 13. Speed Curves Appraisal . .. 73 14. Speed Curves Data . .. 7 3 15. Speed Curves Error. .. 7 4 16. Torque Curves Appraisal . .. 7 5 17. Torque Curves Data . .. 7 5 18. Torque Curves Error. .. 7 6 19. Manual Speed Appraisal . .. .7 7 20. Manual Speed Data . .. 7 7 21. Manual Speed Error. .. 7 7 22. Manual Torque Appraisal. .. 7 8 23. Manual Torque Data . .. 78 24. Manual Torque Error. .. ..