Vol-3 Issue-3 2017 IJARIIE-ISSN(O)-2395-4396

Design and Testing of Thrust Measurement

System for Rotary Engine
Mr. Kanawade V.B..1, Mr.Patil A.R..2
1
P. G. Student, Mechanical Engineering, SVCET, Rajuri, Maharashtra, India
2
HOD, Mechanical Engineering, SVCET, Rajuri, Maharashtra, India

ABSTRACT
Here, the scientific concepts in physics, thermodynamics, aerodynamics and mathematics are
combined with a hands-on experiment to demonstrate propulsion system concepts. The
experiment is conducted on a small-scale highly instrumented rotary engine. The experimental
measurements and physical observations are used to confirm the accuracy of the mechanical and
engineering models used to design and to build thrust cradle systems. The Thrust Cradle
experiment is designed to attach propulsion system hardware to computer simulations and
mathematic models often used to explain Thrust Force Measurement concepts.
Key Word: Thrust, Thrust Cradle, Estimate Propeller Static Thrust, Propeller Speed, Sea level,
High altitude

I INTRODUCTION
The goal of this project is to design, develop, and test on the thrust measurement test set
up. A variable helicopter rotary engine is used to study the effect of changing on the thrust, the
blade rotational speed, fuel required, Temperature of the engine. Motor speed and propeller pitch
are controlled by separate electronic speed controller device. The Thrust Cradle designed using a
Computer Aided Design (CAD) i.e. Auto-Cad. The model will help to test of rotary engine &
comparing the actual data with threshold data & also understand the principles of thrust and
various variables affect the thrust produced by propeller. The goal is to develop the entire system
for minimum cost. We get required information by designing the mechanical system, electrical
hardware and software. The experiment will be able to determine how the thrust varies as a
function of the design parameters. The design details, results and conclusion are discussed in the
paper.
The new developing structure has potential to a wide range of attractive design solutions.
In addition by substituting a Linear sliding ball bearing instead of roller bearing it will gives the
more efficiency to obtained the thrust of the rotary engine & also it will be the more sensitive &
weight reduction will be happen, these solutions can often bring space saving. Company is in
need of development of mobile thrust cradle platform to test the fuel injected rotary engine at
different high altitude locations.
To accomplish this, the following specific objectives are outlined-
1. Review the theory of Mobile Thrust Cradle.

5137 www.ijariie.com 589

Vol-3 Issue-3 2017 IJARIIE-ISSN(O)-2395-4396

2. Design and build a Mobile Thrust Cradle for a rotary engine.

3. Numerically determine the theoretical thrust in KG.
4. Generate models of Mobile Thrust Cradle Structure by using Auto-Cad.
5. Determine the Thrust of the engine with respective speed by using software ESTIMATE
PROPELLER‟S STATIC THRUST.
6. Compare Analytical and Numerical result of Thrust of the engine with respective speed.
7. Determine the deflection in Thrust power of the engine by using Thrust Cradle
8. Check the experimental and Analytical result of deflection of Thrust with respective speed.
9. Manufacturing of Thrust measuring device by selection of linear ball bearing block. .
II LITERATURE REVIEW
Extensive work has been carried out on the Thrust measurement various static models.
The purpose of this literature review is to go through the main topics of interest.
[1] Lu Jie, Zheng, Wang Zhiwu, Peng Changxin, Chen Xinggu Three kinds of thrust
measurement systems are integrated to carry out thrust measurements system. direct thrust
measurement with a force transducer, indirect thrust measurement impulse method. The force
transducer is mounted on the structure block and the moving frame is connected to the load
indicator through a spring which has a stiffness of 240 N/mm.
[2] Dr. Adeel Khalid In this research project, undergraduate students were involved in the
design and development of a variable pitch propeller based thrust measurement apparatus to be
used in the Aerospace engineering laboratory at Southern Polytechnic State University. The
undergraduate research helped the students in gaining theoretical and practical knowledge for
conducting and completing research. Through various research activities as part of the Peach
State LSAMP program. It helps to think critically, solve engineering problems, trouble-shoot,
and better understand engineering principles. The students presented the research at the Peach
State LSAMP annual conference in Savannah, GA. Although the students have submitted their
work, the apparatus needs to be improved and made more robust before it can be safely used in a
laboratory environment.
[3] S.Jeon, J. Kim, H. Choi. Data acquisition- The measured data in the test were summarized.
The mass flow rate measurement was noticed in any analysis due to a reason which the flow
meter could not operate properly in vacuum environment. Therefore the flow rate is calculated
from the chamber pressure, temperature, and regulated pressure along with the throat diameter.
The specific heat ratio is assumed to be 1.4 and the specific impulse is determined by the
calculated flow rate and the thrust.
[4] C.M. Jeruzal, K.D. Brinker author have been studied that , to determine theoretical and
measured engine thrust, efficiencies of the compressor, the combustion chamber, and the turbine.
He also determines the effect of engine speed on thrust-specific fuel consumption (TSFC) and
engine emissions. He also analyze the combustion process and to perform a complete energy
balance on the jet engine.
[5] Li Pengfei Wang ,Yang Wang author have been studied that, classical electromagnetic
theory, this paper introduces a new kind of propellant less microwave thrust measurement device
for use in space. This device is able to directly convert microwave radiation into thrust. It does
not need for any propulsion medium. The difference of this propulsion system is it does not
require carrying the large propellant tank. The problems of emissions polluting the space can be
eliminated.

5137 www.ijariie.com 590

Vol-3 Issue-3 2017 IJARIIE-ISSN(O)-2395-4396

III.METHODOLOGY
Design Procedure
1 Torque
T = F x L x FOS
2 Shaft Diameter

3 Bearing Life Span in Km:

L10 = fs (C/P) n X 100 Km
4 Life span in Hr:

Table1.Design Parameter
Parameter Values

Torque (N-mm) 919687.5

Diameter of Sliding shaft (mm) 36.05≈ 40

Bearing Life Span (Km) 415.864

Bearing Life Span (Hr) 173.276 X 106

5 Theoretical Propeller Thrust

We have the input data,
a) N = Propeller Revolution Speed = Variable from 3500 RPM to 6500 RPM
b) D = Propeller Diameter in inches = 39.37 inch
c) ρ = Air Density in Kg/m3 = 1.225 Kg/m3 at sea level and 1.053 Kg/m3 at high altitude
d) Kt = Static Trust Coefficient ≈ 0.53
e) T = Propeller Thrust
T= 1.283 X 10-12 X N2 X D4 X ρ X Kt
Table 2. Theoretical Thrust results at sea level and high altitude

Sr. RPM Thrust at sea Thrust at high

No. level (Kg) altitude(Kg)

1 3500 24.515 21.073

2 4000 32.019 27.524

3 4500 40.525 34.835

4 5000 50.031 43.006

5137 www.ijariie.com 591

Vol-3 Issue-3 2017 IJARIIE-ISSN(O)-2395-4396

5 5500 60.537 52.037

6 6000 72.044 61.929

7 6500 84.551 72.680

IV.PREPARING THE3-D MODEL

Thrust cradle is the main unit of the test set up. The actual engine is being mounted on the
thrust cradle to measure the thrust of the rotary engine. The relative rpm and temperature of the
engine also measured. Comparing the values of thrust, rpm and temperature with the threshold
value after the testing is completed. The whole assembly of the thrust cradle as shown in fig .3

Fig.1 Thrust Cradle

There are different components that are used to manufacture the thrust cradle are as follow,
a) Base mounting unit
b) Sensors and Testing arrangement
c) Blower unit
d) Thrust transfer arrangement

V. Propeller Thrust measured by using a software

Computer generated result can be find by using online software „Estimate Propeller‟s
Static Thrust.‟ The software requires the input parameter like weather conditions that is
temperature; density of air depends on altitude. RPM and the pitch of the propeller is very
important parameter to calculate the thrust of propeller. Thrust is also depends on the diameter of
the propeller. These all the parameters are required to calculate the thrust by using online
software Estimate Propeller‟s Static Thrust.‟ After putting the values of RPM from 3500RPM to
6500RPM, the result obtained is as under. Also the corresponding graphical results are shown.

5137 www.ijariie.com 592

Vol-3 Issue-3 2017 IJARIIE-ISSN(O)-2395-4396

Fig.2 Thrust at 3500 RPM at sea level

Similarly we getting the software results as shown in the table.
Table3.Computer generated Thrust results at sea level and high altitude

Sr. RPM Thrust at sea Thrust at high

No. level (Kg) altitude(Kg)

1 3500 23.552 21.789

2 4000 31.175 28.841

3 4500 39.648 36.935

4 5000 49.466 46.081

5 5500 60.428 56.292

6 6000 72.542 67.578

7 6500 85.821 79.947

VI. Experimental Propeller Thrust

The engine mounted on the thrust cradle to measure thrust of the engine at different RPM
of propeller of the rotary engine. The engine is run by using give the initial rotary motion with
the help of engine starting trolley. Once the engine starts it rotates for a few times at ideal
speed that is minimum speed of the engine. There is the load cell is connected to the

5137 www.ijariie.com 593

Vol-3 Issue-3 2017 IJARIIE-ISSN(O)-2395-4396

reciprocating plate which is mounted on the reciprocating shaft through linear ball bearing
block. The test set up as shown in fig. 14

Fig.3 Rotary Engine on test set up

Load cell absorb the physical signal from the engine force that is thrust. These physical signals
are converted into the electrical signal and give the output in milivolts. These milivolts signals
with the help of AD converter convert the signals into digital form and display on the screen in
the form of Kg. The Experimental test was carried out at different speed of propellers, at sea
level and high altitude and getting the results are as follow.
Table. 4. Experimental Propeller Thrust at sea level and high altitude

Sr. RPM Thrust at sea level Thrust at high

No. (Kg) altitude(Kg)

1 3500 22.53 20.73

2 4000 30.27 26.80

3 4500 38.57 33.93

4 5000 47.78 41.52

5 5500 58.98 50.10

6 6000 70.87 59.81

7 6500 83.18 69.23

5137 www.ijariie.com 594

Vol-3 Issue-3 2017 IJARIIE-ISSN(O)-2395-4396

VII. RESULTS & DISCUSSION

Fig. 5 Graphical Results at sea level

Fig.6 Graphical Results at high altitude

5137 www.ijariie.com 595

Vol-3 Issue-3 2017 IJARIIE-ISSN(O)-2395-4396

VIII.CONCLUSION
1. In this system the thrust transfer arrangement with roller is replaced by the thrust transfer
arrangement with Linear Ball Bearing Block. It will be more smoothly slide & transfer the more
thrust.
2. The actual thrust of the rotary engine at the sea level & high altitude is achieved very nearly to
the theoretical thrust and analytical thrust of the rotary engine.
3. The thrust is gradually increases with RPM of the propeller. The rotary engine at ideal speed
3500RPM give the minimum thrust 22.53Kg and at maximum speed 6500RPM gives the
maximum thrust 83.18Kg.
4. The thrust produced by the rotary engine at high altitude also increases with increase in speed
of the propeller of the rotary engine. The thrust produced by the rotary engine at high altitude
comparatively less than the thrust produced by the rotary engine at sea level.

VIII.CONCLUSION
1.The deflection and self weight of Web core sandwich structure is small as compare to the X
core and Vf core sandwich structure.
2.In sandwich structure the weight of web core sandwich sandwich structure is 221.34 kg is
small as compare to the Vf core and X core sandwich structure.
3.The deflection of web core sandwich structure is 1.0955 mm is also small as compare to I
section, Vf core sandwich structure, and X core sandwich structure.
4.Then web core sandwich structure is optimum sandwich structure.

REFERENCES

[1] Lu Jie, ZhengLongxi[1], Wang Zhiwu, Peng Changxin, Chen Xinggu “Thrust measurement
method verification and analytical studies on a liquid-fueled pulsedetonation engine School of
Power and Energy”, Chinese Society of Aeronautics and Astronautics & Beihang University
Chinese Journal of Aeronautics Northwestern Polytechnical University, Xi‟an 710072, China
Received 5 June 2013; revised 27November 2013; accepted 14 January 2014

[2]James E. Polk Anthony Pancotti, Thomas Haag, Scott King, Mitchell Walker, Joseph
Blakelyk, John Ziemer “Recommended Practices in Thrust Measurements”IEPC-2013-440
Presented at the 33rd International Electric Propulsion Conference,Washington, DC October 6-
10, 2013

[3] Timothy R. Conners and Robert L. Sims Full Flight Envelope Direct ThrustMeasurement on
a Supersonic Aircraft Dryden Flight Research Center Edwards,California July 1998 National
Aeronautics and Space Administration ,California

[4] S. Jeon, J. Kim, H. Choi “Development of a Thrust Measurement System” World Academy
of Science, Engineering and Technology International Journal of Mechanical, Aerospace,
Industrial, Mechatronic and Manufacturing EngineeringVol:6, No:3, 2012

5137 www.ijariie.com 596

Vol-3 Issue-3 2017 IJARIIE-ISSN(O)-2395-4396

[5] Professor C.M. Jeruzal, Graduate Assistant K.D. Brinker “Development of a JetEngine
Experiment for the Energy Systems Laboratory” A. Pourmovahed, , Graduate Assistant 2003
ASME International Mechanical Engineering Congress Washington,D.C., November 15–21,
2003
[6] Mary Fran Desrochers, Gary W. Olsen, and M. K. Hudson “A Ground TestRocket Thrust
Measurement System” Department of Applied Science and TheGraduate Institute of Technology
University of Arkansas at Little Rock, Little Rock,AR 72204 USA
[7] Yang Juan Wang Yuquan Li Pengfei Wang Yang Wang Yunmin Ma Yanjie “Net thrust
measurement of propellantless microwave thrusters” (Northwestern)34Polytechnical University,
College of Aeronautics, Xi'an 710072) (Received June 9,2011; revised manuscript received in
October 25, 2011).
[8] M. Tajmar1 and G. Fiedler2 Direct Thrust Measurements of an EM Drive and Evaluation of
Possible Side-Effects Institute of Aerospace Engineering, Technische University at Dresden,
01062 Dresden, Germany
[9] Chen Mingtai Static Thrust Measurement for Propeller-driven Light AircraftShanghai
Aircraft Design and Research Institute Shanghai, China The 2ndInternational Conference on
Computer Application and System Modeling (2012).

5137 www.ijariie.com 597