Prony Brake Dynamometer Dual Quad Stator Pressure Control
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Solution Overview
Problem
Existing prony brake dynamometers face limitations in applying uniform pressure over the rotor surface, leading to unequal pressure distribution and reduced torque capacity, and they lack advanced power control and efficient cooling systems, resulting in limited power settings and reduced useful life.
Innovation Solution
The introduction of a dual quad power stator with a hydraulic pressure equalizer plate provides constant and equal hydraulic pressure over the rotor surface, combined with an electronic load control system and a 270-degree water distribution manifold for enhanced cooling, allowing for precise power control and extended dynamometer life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single piston brake shoe design is used, then the structure is simple, but the pressure distribution over the rotor surface is unequal resulting in reduced torque capacity
Solution Approach 1:
The stator is divided into multiple independent piston units (typically four or more) arranged around the rotor circumference. Each piston can be independently controlled and applies pressure to a separate section of the brake shoe, enabling uniform pressure distribution across the entire rotor surface and maximizing torque capacity.
Solution Approach 2:
Different sections of the brake shoe are assigned to different pistons with independent control. This allows localized pressure application and adjustment at different positions around the rotor, ensuring uniform pressure distribution and optimizing the coefficient of friction at each kinetic point of energy contact.
2Device complexity
If manual load control valves are used, then the system is simpler, but the number of power settings is limited
Solution Approach 1:
Manual mechanical control valves are replaced with electronically controlled valves (such as proportional or servo valves). This substitution enables precise electronic adjustment of hydraulic pressure to achieve thousands of discrete power settings, providing fine-grained control over the dynamometer load while maintaining system simplicity through electronic rather than mechanical complexity.
Solution Approach 2:
The control system transitions from static manual adjustment to dynamic electronic control. The electronic valves can be continuously adjusted through computer control, allowing real-time modification of load settings and enabling the system to adapt to various power measurement requirements with high precision and flexibility.
3Device complexity
If traditional cooling systems are used, then the system is simpler, but the cooling efficiency is insufficient reducing useful life
Solution Approach 1:
The cooling system is segmented into multiple independent cooling circuits, with dedicated cooling channels for the stator, rotor, and hydraulic system. This segmentation allows targeted cooling of specific high-heat-generation areas, improving overall cooling efficiency and extending component life without requiring a completely complex cooling architecture.
Solution Approach 2:
A heat exchanger serves as an intermediary component between the hydraulic system and the cooling system. The heat exchanger efficiently transfers heat from the hydraulic fluid to the cooling medium, providing effective thermal management for both the hydraulic system and the mechanical components, thereby extending the dynamometer's useful life.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration maximizes torque capacity, increases the number of power settings, and extends the dynamometer's useful life by ensuring uniform pressure distribution and efficient cooling, enabling more accurate power measurement and longer operational durability.
Implementation Method 1
The dual quad power stator (DQPS) in conjunction with a hydraulic pressure equalizer plate (HPEP) eliminates this possibility and drastically improves the performance of the dynamometer by applying equal pressure over the entire rotor surface
Implementation Method 2
friction material to make contact with the brake drum rotor. The retarding force is a function of the stator pistons being forced outward from the stator cylinders by way of hydraulic force, putting pressure on a brake shoe, which applies force onto a frictional material, which makes contact with the inner surface of the brake drum rotor creating a retarding force
Implementation Method 3
the brake drum rotor being partially submerged in a sealed water tank, with a manifold to distribute incoming cold water across the brake drum rotor and then exiting the hot water through a top drain
Implementation Method 4
When a dynamo meter stator applies force to a rotating brake drum rotor, the result is heat (converting mechanical energy of a prime mover back into heat). The heat needs to be dissipated
Implementation Method 5
The stator force is measured by a torque arm directly attached to the end the stator shaft and connected to a load cell. This force is displayed in foot pounds or newton meters of torque
Implementation Method 6
On the front of the dynamometer is an RPM magnetic pickup reading a sixty-tooth sprocket on the input shaft
Data Source
AI summary
An improved prony brake dynamometer capable of measuring the power of a prime mover's rotating shaft connected to a cylinder brake drum rotating around a newly designed dual quad power stator (DQPS), with hydraulic pressure equalizer plate (HPEP), controlled by an electronic load control system with inline cooling system (ELCS), cooled by a 270-degree water distribution manifold (WDM). The improvements of the DQPS and HPEP result in maximizing the pressure applied by the stator over the entire surface area of the rotor drum, thereby maximizing the coefficient of friction at the kinetic point of energy and increasing load capacity over previous models. The addition of the ELCS increases the number of potential settings of hydraulic pressure, resulting in thousands of power settings, as opposed to previous models using manual load control valves. The WDM cools the dynamometer load absorption unit more efficiently than previous models.