Turbo Testing Solutions aims to provide a testing bench for Turbogen’s turbo generator assembly. This test bench will allow the turbo to be tested up to 120,000 rpm, which is the max speed required in the turbos duty cycle. There are a few product requirements, these include the workbench size, minimal vibrations, and electric input and outside digital display for the rpm. The aluminum build and soundproof barrier allows the product to be safely used. The main factors required to allow successful testing is easy and secure mourning, and minimal vibrations up to the required speed.
Turbogen’s current product will be in the market industry for automotive research and development. Mercedes is the only known company that has created a similar design and concept, however, they are only used on their formula 1 vehicles. The team has done patent and literature searches on similar products, market analysis for potential market viability of the product and have created 5 separate design concepts so they can compare. This test bench is a one-off product made strictly for research and development by the University of Nevada, Reno and Turbogen so there no real market competitors, distribution patterns or competition or buying patterns.
Proof of Concept
Turbo Testing Solutions designed a testing bench for Turbogen’s turbo generator assembly. Turbo Testing Solution has come up with a design that meets all product requirements including workbench size, electric input, and outside digital display for the rpm, as well as a high level of stability. The team placed the most importance on stability, as the turbo needs to be tested up to 120,000 rpm for a duration of time. The final design chosen combines a sturdy base with mounts that attach to the endcaps of the electric motor. The robustness of the mounts will help to stabilize any vibrations created by the spinning shaft. Two unique end mounts each are specified to one side of the electric motor. In Fig. 1, on the turbo attachment side, there is room for a shaft to go from the electric motor to the turbocharger. This side also features a hole to allow for an accelerometer attachment to measure the speed the shaft is rotating. The opposite test bench mount is the power supply side. This side has three holes along the face for the positive, neutral, and ground wires that are to be connected to a power supply. Overall, this is a robust design that allows for all required sensors and wires to be connected. Based on TTS’s assumptions, this design should easily be able to withstand any vibrations or forces caused by the shaft spinning inside the electric motor for a prolonged period of time.
Turbo Testing Solutions main design specification was to keep the cost below the $1000 dollar limit provided from the funding. Turbo Testing Solutions also had to work with the provided design from Turbogen, the sponsor of the project. From a standpoint of physical testing, there were a few goals specific to project success. The electronics and software needed to control the GMU (electrical motor) needed to be used within a confined space of the testing facility. This would be a 10×8 foot cube. The most important specification was to reduce the vibration in the system in general. Turbo Testing Solutions needed to create a design to allow this to be possible. After a few designs, the final design can be seen in the SolidWorks 3D model. The designed parts are the end caps holding the rod together. To prove that this was an effective design, Turbo Testing Solutions used ANSYS for a vibrational analysis of the system. The tests were successful and the results allowed Turbo Testing Solutions to move forward with the project. The design specifications should finally be made from a low vibrating material such as Aluminum or Steel and should be able to withstand many uses. The project characteristics consisted of creating a design that would satisfy all of the requirements given to TTS by TurboGen. Once this was done and one design was chosen, the team began doing dynamic testing of the parts to test for vibration analysis. Once this design was proven to be stable in the simulations, the team has then prepared to move into the phase of fabrication and assembly of the design. Therefore the project characteristics for Turbo Testing Solutions’ e-turbo testing apparatus are: design creation, vibrational analysis and fabrication/assembly of the overall test bench.
The purpose of Turbo Testing Solutions’ project was to create a robust and highly stable turbo testing bench for testing of the E-turbo designed by Turbogen. The test bench will be able to test this turbo at speeds reaching up to 120,000 RPM for a sustained period of time. This bench has fixtures that are precisely machined in order to ensure the stability of the spinning components during testing. Successful testing of the E-turbo will allow continued research and development of this E-turbo, and potentially different models as well. The E-turbo is a highly promising piece of technology that is currently quite relevant with the focus today on electric and hybrid vehicles. The E-turbo will allow another resource for energy reclamation in a vehicle, and ultimately will create a more efficient hybrid vehicle. TTS plans to further the success of the E-turbo development by providing a robust and easy-to-use E-turbo testing bench in order to ensure successful testing, development, and optimization of the E-turbo.
The project consisted of creating a design that would satisfy all the requirements given to TTS by TurboGen. Once this was done and one design was chosen, the team began doing dynamic testing of the parts on SolidWorks to test for vibration analyses. Once this design was proven to be stable on SolidWorks, the team has then prepared to move into the phase of fabrication and assembly of the design. Therefore the project characteristics for Turbo Testing Solutions’ e-turbo testing apparatus are: design creation, vibrational analysis and fabrication/ assembly of the overall test bench.
The assembly of these parts is rather simple. First the MGU is fastened with the stabilizing mounts that also replace the MGU end caps given to TTS by TurboGen. Once the MGU is fastened, the bolt holes in the stabilizing mounts are to be lined up with the holes in the base of the bench. Once the mounts are properly connected to the base, the motor is connected to one end of the composite shaft running through the MGU and the other end connects to the quail shaft that meets the turbocharger compressor. Once all of this is done, the setup is complete and the system is ready for testing. The fabrication of the test bench apparatus is also very simple. The team began with a 7x7x7 inch block of aluminum. The team will then use the manufacturing lab on campus to begin and complete the fabrication process. The CNC Mill, CNC lathe, and heavy duty drill are a few of the machines used in order to successfully fabricate the parts. These are used to cut the aluminum, smooth the parts as well as drill the holes in the parts. The SOLIDWORKS design the team created will be used by the CNC programs.
Testing and Results
Turbo Testing Solutions, or TTS, unfortunately had complications during the testing process. In order for TTS to test the final design, the motor had to be connected to a 480V outlet to run. This high voltage outlet is difficult to find, so the faculty at the University agreed to convert one of the outlets on campus. There was a 220V outlet in the manufacturing lab, where TTS planned to conduct all testing. The faculty at the University were in the process of converting the standard outlet to 480V and had issues. The conversion was unsuccessful, and TTS could not test their product in time. If the conversion was successful and the motor was functional, the team could then secure the test bench apparatus to the block. From there, the electric motor would be attached to the test bench apparatus and the team could test the turbo at different rpms to ensure there was no shaft or bearing failure. Due to the conversion being unsuccessful, the team could not reach this point to complete testing. The completed tests were through simulations on computer programs. The problem this product would solve is the failure of the electric turbo provided by TurboGen. This product would make it easier for this company, as well as future companies to test the electric turbo. If successful, TurboGen would be very pleased with this product because they would be able to complete testing of the electric turbo, and resolve the issue of bearing and shaft failure. The products design would match the purpose of this project. Unfortunately there is no video as the testing was not completed.
Meet the Team
Born and raised in Novato, CA, Kyle Albertini is a senior at the University of Nevada, Reno. Currently majoring in Mechanical Engineering and minoring in Electrical Engineering. Kyle has had two different internships, one at Universal Analyzers and the other at American Air Racing. During his academic career, Kyle has improved on his ability to problem solve. Outside of school and work, Kyle has accomplished a restoration of a 1973 Jeep CJ5. When he was rebuilding the engine, he noticed many cracks in the head of the engine. Using his analytical techniques to problem solve, he designed a solution to minimize costs and researched different outcomes to fix the cracked head problem. Kyles goals now is to graduate on time and finish with his degree and minor. In the future, Kyle is looking to find a job in an engineering power company and pursue a Masters in Electrical Engineering in the future.
Dan is a fifth year senior mechanical engineering student at the University Nevada, Reno from Fairfield, California. His most challenging engineering project was working with his dad to build the lightest, custom 1976 Suzuki TM400 motorcycle. He used the understanding of strengths and materials to make the decision where lighter metals could be used. The engineering skill Daniel has developed the most is his CAD skills. Coming to college, Daniel had no idea how to use CAD software and now he is quite proficient. After receiving his degree in May 2018, Daniel is looking for a career in firearms or automotive engineering in the Sacramento or Reno area.
Naima Valentin is a Senior in Mechanical Engineering at the University of Nevada, Reno, and she plans to graduate in May 2018. She has experience working with engines and engine components, as she has spent two Summers interning at Cummins, Inc. She has had a lot of experience working with hands on engineering projects, both in industry as well as in school. She enjoys leadership and working on teams, and she is the current president of the Society of Women Engineers at the University of Nevada, Reno. She plans to pursue a career in the automotive industry upon graduating in May 2018, and she is particularly interested in test engineering as she hopes to continue to work on hands-on engineering projects. Naima is originally from Northern California and hopes to remain on the West Coast to begin her professional career.
From Las Vegas, Jared Walker is a senior Mechanical Engineer at the University of Nevada, Reno. Coming from a math and science background due to attending magnet schools, he has a lot of experience working with others and problem solving. Jared grew up around cars and dirt bikes, which includes fixing any issues that would arise. He and his father have restored several old school vehicles including a 69’ Volkswagen, 81’ Datsun 280ZX, and 83’ Silverado. Jared is a hard worker and aspires to have a career in the automotive or construction industry, after graduating in May, 2018.
Kyle Guilliams was born in Folsom, Ca and is currently a senior at University of Nevada Reno pursuing a BS in mechanical engineering. Kyle has experience in mechanics of autos and has knowledge of multiple topics studied during his academic career. Kyle’s goals are to find an internship and graduate and find a job at an engineering firm.