Building a Dynamometer for RC Cars (GearGauge)
In an exciting venture, I constructed a dynamometer tailored specifically for RC cars, meticulously designed to gauge essential metrics such as speed, power, and torque. Throughout this endeavor, I diligently chronicled my progress on Reddit, offering real-time insights into the development stages. Now, consolidating all my Reddit posts into this comprehensive Medium article, I aim to provide a cohesive narrative that merges every aspect of the project seamlessly.
Building a Dyno for RC Cars (Part 0)
I am RC enthusiast, I have an RC Car and was eager to discover its maximum speed. Initially, I thought about purchasing a speedometer, but after some contemplation, I decided to take a more hands-on approach and build my own solution.
After a bit of research and brainstorming, I’ve decided to take on the exciting project of building a homemade dynamometer (dyno) specifically designed for RC cars. This way, I can not only determine the top speed of my RC Car but also have a fun DIY project to work on.
My plan is to create a Dyno (short for dynamometer) tailored for RC cars. This dynamometer will allow me to measure not only the top speed but also power consumption, and ultimately, visualize the data through various analysis and graphs.
The project will consist of several key components:
- Building the Dyno Mechanism: This will involve constructing a reliable and accurate dynamometer setup that can effectively measure the Traxxas Slash’s performance.
- Designing the Electronic Component: The electronic aspect of the project is crucial. I’ll be working on sensors and data acquisition systems to gather precise measurements.
- Software Development: To process and visualize the data in a professional manner, I will be developing custom software. This software will enable me to calculate and display performance metrics, allowing for a deeper understanding of my RC car’s capabilities.
Throughout this project, I’m excited to share my progress with this community. I believe that by documenting each step of the process, we can all learn and grow together. Additionally, I’d greatly appreciate any advice, tips, or suggestions from the experienced members here.
I’m excited to share the first steps of my dyno project, particularly the development of the mechanism. To bring my design to life, I’ve been utilizing Fusion360 for the design phase and a 3D printer to fabricate the components. Please note that the project is still a work in progress, and the printing is ongoing.
Building a Dyno for RC Cars (Part 1)
Hello,
In the previous post, I shared the beginning of my new dyno printing journey. Now, after dedicating 1.5 weeks to this project, I’m thrilled to announce that the dyno printing is nearly complete.
- The stability of the dyno has exceeded my expectations. During a test drive with my RC car on it, the performance was flawless without binding the car to the dyno. The car remained stationary on the dyno, showcasing its robust functionality.
- Looking ahead, I envision the possibility of adjusting the dyno’s size in the future. However, for the time being, I possess only one RC car, so I’ve opted for a static size configuration.
- My next step involves focusing on the electronic components. I plan to initiate a proof of concept (PoC) for reading rotations using an encoder, followed by processing the PoC. Once complete, I’ll proceed to design a PCB board.
Upon finalizing the PCB design, I will print a piece to attach to the encoder on the dyno.
As mentioned earlier, achieving this milestone has fueled my enthusiasm to delve into the electronic aspect of the project.
Building a Dyno for RC Cars (Part 2)
Hello from Part2 ,
In the provided link above, you’ll observe significant progress in completing the mechanical aspect outlined in part 1. Following part 1, I made several critical changes and continued the development of the dyno. This involved enhancing the wheel system of the dyno, creating more stabilized pieces for smoother rolling. Additionally, I produced specialized pieces to immobilize the hall effect sensor and designed a magnet holder for improved functionality. On the electronics front, I designed a preliminary electronic setup using a breadboard for proof of concept, and successfully began reading initial data and conducting essential calculations. The project is steadily advancing, and I’m eager to share these exciting updates with you.
Here is some details about the progress…
Wheel Holder Revision
While my old wheel holders may have been capable of handling the task, they comprised three distinct pieces that were fused together, resulting in an unfortunate loss of stabilization. Recognizing this issue, I decided to create a new wheel holder designed and 3D-printed as a single piece. This approach significantly mitigated the stability problem, minimizing any potential disruptions in the system. The enhanced design promises to optimize performance and streamline the overall functionality of the setup.
Producing the piece to immobilize the hall effect sensor
In my pursuit of effective data reading, I initially attempted to utilize encoders but faced challenges with data loss and imperfect results. Recognizing this hurdle, I opted for an alternative approach and decided to use magnets in conjunction with hall-effect sensors to capture the data accurately. To facilitate this, I crafted a specialized sensor holder and successfully produced two pieces, each tailored for the respective wheels. This adjustment in approach promises to enhance data capture reliability, addressing the issues encountered earlier and enabling a more robust system for data acquisition.
Magnet Holder
During the magnet holder design phase, I initially opted for strip magnets, believing they would suffice for my project requirements. However, upon testing, I observed a recurring issue of data loss. To address this, I decided to invest in new neodymium magnets and redesign the magnet holder accordingly. This adjustment proved successful, eliminating any data loss and ensuring seamless and accurate data reading. The upgrade has significantly enhanced the functionality and reliability of the system, allowing for a smoother project progression.
Electronic Part and First Measurements
I successfully designed the electronics and tested them on a breadboard. As a next step, I plan to design and produce a PCB for a more refined setup. The Arduino program has been completed, enabling me to efficiently retrieve data from the sensors and calculate the speed. Excitingly, I’ve even managed to calculate the maximum speed of my Traxxas Slash for the first time, hitting 36 kph in slow gears! :)
I’ve successfully completed outlining the calculations for speed, acceleration, force, power, and torque. Currently, I’m in the process of both software development and dashboard design, aiming to present my results comprehensively. Of course, I plan to further enhance the project by designing a PCB. All in all, I’m thrilled to share that I’ve obtained my initial results, and their accuracy brings me immense joy. Stay tuned for more updates in subsequent parts. I’m eagerly open to any advice, questions, or engaging discussions. See you in the upcoming posts!
Building a Dyno for RC Cars (Part 3)
I wanted to share the latest developments in my ongoing project. If you’ve been following my previous posts, you’ll notice that in Part 2, I successfully extracted data from Arduino. Following that, I made some minor adjustments in the mechanical aspect of the project.
Now, let’s dive into the details of Part 3, where my primary focus has been on the software side of things.
Mechanical Updates
Specifically, I’ve made a crucial enhancement in reading the rotation value of the wheel holder. In the earlier stages, I designed 4 magnets per rotation, but now, I’ve successfully increased the count to 10 magnets per rotation. This modification has significantly boosted the sensitivity of the dynamometer.
Software
The software part of the dyno consists of two fundamental elements: the User Interface (UI) and the Backend.
- The UI plays a pivotal role in displaying the current state of the dynamometer (dyno).
- Users can easily access speed information and interact with the UI to input essential vehicle details.
- While it doesn’t showcase detailed values, the UI focuses on presenting clear states and basic speed information.
IAfter the user finishes the measurement process, they can initiate the report generation by clicking the “Generate Report” button on the user interface. This will produce a comprehensive PDF-format report encompassing a wealth of information and graphical representations.
The report includes dynamic friction details and corresponding graphs, speed information presented in units of kph, mph, and meters per second, acceleration data, force metrics, power information in both horsepower and wattage, as well as torque specifics.
All this data is meticulously displayed in tables and graphs, each section dedicated to a specific wheel. Additionally, a table highlighting the maximum values attained during the measurements is incorporated for quick reference.
Note: These data are sample data, it cannot be correct.
The final stage of the project, there are several crucial steps to take for further improvement. Firstly, on the software front, I’ll prioritize fixing any existing bugs and implement a comprehensive testing strategy to catch potential issues early in the process. I’ll also consider user feedback to enhance the overall user experience and explore ways to optimize performance. Turning to the mechanical aspects, especially in the area housing the sensors on the dyno, I’ll evaluate potential upgrades to boost accuracy and reliability. It’s essential to ensure that mechanical components are robust enough to withstand the intended usage conditions. In the electronic realm, I’m gearing up to design my own PCB. I’ll focus on meticulous layout planning to optimize signal paths, minimize interference, and carefully select components that align with my project’s requirements.
Building a Dyno for RC Cars (Part 4)
End of the Process
This post is likely the last one in the series. I’ve been sharing the step-by-step process of my project in earlier Reddit posts, so you can catch up on the details there. Now, as we near the end of the project, my future posts will mainly feature videos and promotions about the dyno. This marks the final technical update about the dyno project, closing this chapter in the series.
Goal
In the earlier posts, I showcased the dyno with all its technical features in action. You can watch a video of the dyno in action [video of dyno]. However, in this post, the focus shifts towards cosmetic improvements aimed at enhancing the dyno’s usability. Tune in to witness the adjustments and enhancements that make the dyno not only functional but also more user-friendly.
Process
Cable MessThe initial challenge addressed was the tangled mess of cables. Previously, sensors were connected to the control unit using jumper cables, resulting in a chaotic arrangement. To remedy this, a more organized approach was adopted by utilizing 3-pin cables. Additionally, a cable stabilizer, crafted through 3D printing, was introduced, relocating the sensor pins to the rear of the dyno in a tidy and transparent manner.
To further enhance the aesthetics and eliminate any visible cable clutter, I printed a cable hider with 3d printer. This innovation ensures that there is no unsightly cable mess, contributing to a cleaner and more polished appearance.
Control Unit
As previously noted, the dyno communicates with the computer through its control unit, which initially resided on a breadboard. To enhance efficiency and organization, a printed circuit board (PCB) was designed for the control unit. This allowed for the soldering of all components onto the PCB, streamlining the configuration and minimizing clutter. Additionally, a dedicated controller stand was 3D printed, serving as a centralized management point for all dyno operations through the integrated control unit. This systematic upgrade contributes to a more robust and orderly setup for seamless communication between the dyno and computer.
Coming to the end
In summary, my recent efforts have primarily focused on addressing cosmetic concerns. With these enhancements, I believe the dyno is now accessible and user-friendly for anyone interested in utilizing it. The introduction of the PCB and revamped cable system not only enhances stability but also significantly improves ease of use
Appreciate all your input and support. The technical opinions shared by Reddit users have been invaluable, and I genuinely value the insights provided. Taking the time to reflect on these comments has been a crucial part of my process, and I’m grateful for the constructive input received.
