Examining A World’s Record From The Age Of Steam

There aren’t many speed records that remain unbroken for the greater part of a century, but one of them is that of the fastest steam locomotive. As with so many such things, there’s a bit of controversy and more than one contender, but the one in the record books is the A4 Pacific, Mallard. In 1938, this locomotive thundered down an incline on the London & North Eastern Railway’s mainline in the north of England at 126 MPH. But can that number be taken as reliable? The Institute of Mechanical Engineers has a video in which they investigate.

It’s a fascinating look at the science of railway speed measurement as it existed in 1938, the record itself, and the paper dynamometer roll which recorded it. We’ve placed the video below the break, and in it, we see an in-depth analysis of the noise and inconsistencies in the recording, and see them come to the conclusion that a safer figure to quote would be 124 MPH.

Our assessment is that, of course, the LNER wanted to squeeze every morsel of publicity from it in a game of one-upmanship with their arch-rivals in the London Midland and Scottish railway, so it’s likely that their use of a momentary figure makes sense in that light. Even the best-laid 1930s jointed track would have been bumpy compared to modern continuous rail, and we are guessing that the ancient clerestory dynamometer car would hardly be as smooth-riding as a modern express coach. The achievement of measuring at all with mechanical instruments in such an environment at those speeds would have been tricky, to say the least. It leaves us wondering whether 1930s electronics could have produced some kind of trackside measurement device, but perhaps the LNER trusted their mechanical instruments more. Perhaps the Pennsylvania Railroad should have followed its example.

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100-Year Old Wagon Wheel Becomes Dynamometer

If you want to dyno test your tuner car, you can probably find a couple of good facilities in any  nearby major city. If you want to do similar testing at a smaller scale, though, you might find it’s easier to build your own rig, like [Lou] did.

[Lou’s] dynamometer is every bit a DIY project, relying on a 100-year-old wagon wheel as the flywheel installed in a simple frame cobbled together from 6×6 timber beams. As you might imagine, a rusty old wagon wheel probably wouldn’t be in great condition, and that was entirely true here. [Lou] put in the work to balance it up with some added weights, before measuring its inertia with a simple falling weight test. The wheel is driven via a chain with a 7:1 gear reduction to avoid spinning it too quickly. Logging the data is a unit from BlackBoxDyno, which uses hall effect sensors to measure engine RPM and flywheel RPM. With this data and a simple calibration, it’s possible to calculate the torque and horsepower of a small engine hooked up to the flywheel.

Few of us are bench testing our lawnmowers for the ultimate performance, but if you are, a build like this could really come in handy. We’ve seen other dyno builds before, too. Video after the break.

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Putting Some Numbers On Your NEMAs

It’s official: [Engineer Bo] wins the internet with a video titled “Finding NEMA 17,” wherein he builds a dynamometer to find the best stepper motor in the popular NEMA 17 frame size.

Like a lot of subjective questions, the only correct answer to which stepper is best is, “It depends,” and [Bo] certainly has that in mind while gathering the data needed to construct torque-speed curves for five samples of NEMA 17 motors using his homebrew dyno. The dyno itself is pretty cool, with a bicycle disc brake to provide drag, a load cell to measure braking force, and an optical encoder to measure the rotation of the motor under test. The selected motors represent a cross-section of what’s commonly available today, some of which appear in big-name 3D printers and other common applications.

[Bo] tested each motor with two different drivers: the TMC2209 silent driver to start with, and because he released the Magic Smoke from those, the higher current TB6600 module. The difference between the two drivers was striking, with lower torque and top speeds for the same settings on each motor using the TB6600, as well as more variability in the data. Motors did better across the board with the TBC6600 at 24 volts, showing improved torque at higher speeds, and slightly higher top speeds. He also tested the effect of microstepping on torque using the TBC6600 and found that using full steps resulted in higher torque across a greater speed range.

At the end of the day, it seems as if these tests say more about the driver than they do about any of the motors tested. Perhaps the lesson here is to match the motor to the driver in light of what the application will be. Regardless, it’s a nice piece of work, and we really appreciate the dyno design to boot — reminds us of a scaled-down version of the one [Jeremey Fielding] demonstrated a few years back.

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There’s A LEGO Suspension Dyno Now

When it comes to the development and testing of performance suspension, it’s helpful to have a test apparatus that lets you recreate certain conditions reliably. This LEGO suspension dyno does just that, and it’s clearly a big help for those doing R&D on minifig motorcycle suspension.

The build relies on four motors to overcome the resistance of turning a chunky conveyor belt, which acts as a rolling road. As the belt is built out of Technic beams, various LEGO blocks can be added to the conveyor to act as bumps or perturbations for testing suspension.

The video demonstrates the use of the dynamometer, showing how a simple LEGO motorbike design deals with bumps of various sizes. It’s easy to swap out forks and springs and change the geometry to tune the suspension, and the changes can be easily seen when running it through the same test conditions.

While we don’t imagine there are too many people working in this particular field, the lessons being taught here are valuable. This setup allows one to quickly visualize how changing vehicle parameters affects handling. It’s hard to imagine a better teaching tool for vehicle dynamics than something like this that lets you see directly what’s really going on!

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DIY Prony Dyno Properly Displays Power Production

When hackers in the US think of a retailer called Harbor Freight, we usually think of cheap tools, workable but terrible DVM’s, zip ties, and tarps. [Jimbo] over at [Robot Cantina] looked at the 212cc “Predator” engine that they sell and thought “I bet I could power my Honda Insight with that.” And he did, successfully! How much power did the heavily modified engine make? In the video below the break, [Jimbo] takes us through the process of measuring its output using a home built dyno.

The dyno that [Jimbo] has built is a Prony Dyno, and it’s among the oldest and simplest designs available. A torque arm is extended from a disk brake caliper and connects to a force gauge. The engine is ran up to its highest speed, and then he brake is applied to the crankshaft until the engine almost stalls. A tachometer keep track of the RPM, and the force gauge measures the force on the torque arm. Torque is multiplied by RPM and the result is divided by a constant of 5252, and voilà: Horsepower. A computer plots the results across the entire range, and the dyno test is complete.

That only tells part of the story, and the real hack comes when you realize that the dyno stand, the force gauge setup and pretty much everything that can be built at home has been built at home. You’ll also enjoy seeing the results of some driving tests between the 212cc engine and its bigger 420cc brother, how even minor changes to the engine affect the horsepower and torque curves, and how that affects the Honda that he calls his “Street legal go cart.”

Speaking of unusual power plants, how about plant some hobby sized jet turbines on the back of your Tesla for fun?

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Sanity Check Your Engines With This Dynamometer

As you get ready to pop the hood of your RC car to drop in a motor upgrade, have you ever wondered how much torque you’re getting from these small devices? Sure, we might just look up the motor specs, but why trust the manufacturer with such matters that you could otherwise measure yourself? [JohnnyQ90] did just that, putting together an at home-rig built almost from a stockpile of off-the-shelf parts.

To dig into the details, [JohnnyQ90] has built himself a Prony Brake Dynamometer. These devices are setup with the motor shaft loosely attached to a lever arm that can push down on a force-measuring device like a scale. With our lever attached, we then power up our motor. By gradually increasing the “snugness” of the motor shaft, we introduce sliding friction that “fights” the motor, and the result is that, at equilibrium, the measured torque is the maximum amount possible for the given speed. Keep turning up that friction and we can stall the motor completely, giving us a measurement of our motor’s stall torque.

Arming yourself with a build like this one can give us a way to check the manufacturer’s ratings against our own, or even get ratings for those “mystery motors” that we pulled out the dumpster. And [JohnnyQ90’s] build is a great reminder on how we can leverage a bit of physics and and a handful of home goods to get some meaningful data.

But it turns out that Prony Brake Dynamometers aren’t the only way of measuring motor torque. For a disc-brake inspired, have a look at this final project. And if you’re looking to go bigger, put two motors head-to-head to with [Jeremy Felding’s] larger scale build.

 

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This DIY Dynamometer Shows Just What A Motor Can Do

Back in high school, all the serious gearheads used to brag about two things: their drag strip tickets, and their dynamometer reports. The former showed how fast their muscle car could cover a quarter-mile, while the latter was documentation on how much power their carefully crafted machine could deliver. What can I say; gas was cheap and we didn’t have the Internet to distract us.

Bragging rights are not exactly what [Jeremy Fielding] has in mind for his DIY dynamometer, nor is getting the particulars on a big Detroit V8 engine. Rather, he wants to characterize small- to medium-sized electric motors, with an eye toward repurposing them for different projects. To do this, he built a simple jig to measure the two parameters needed to calculate the power output of a motor: speed and torque. A magnetic tachometer does the job of measuring the motor’s speed, but torque proved a bit more challenging. The motor under test is coupled to a separate electric braking motor, which spins free when it’s not powered. A lever arm of known length connects to the braking motor on one end while bearing on a digital scale on the other. With the motor under test spun up, the braking motor is gradually powered, which rotates its housing and produces a force on the scale through the lever arm. A little math is all it takes for the mystery motor to reveal its secrets.

[Jeremy]’s videos are always instructional, and the joy he obviously feels at discovery is infectious, so we’re surprised to see that we haven’t featured any of his stuff before. We’ve seen our share of dynos before, though, from the tiny to the computerized to the kind that sometimes blows up.

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