Project Overview
This project focused on developing a benchtop flywheel testing system to simulate real-world loading conditions for motor and drive assemblies in a controlled environment. In the full robotic systems, motors experience inertial loads that are difficult to replicate at the component level, creating a gap between lab validation and actual operating conditions.
The objective was to design a system that could accurately reproduce in-system loading behavior, enabling controlled evaluation of motor performance, current response, and failure thresholds while maintaining safety and repeatability.
Design & System Implementation
I began by translating system-level loading conditions into equivalent flywheel-based inertia models for two separate product lines, SureSort and PerfectPick, each with distinct operating characteristics. This required developing independent load calculations to ensure the bench-top system accurately reflected real-world behavior for both platforms.
The final design consisted of a table-mounted flywheel assembly capable of interfacing directly with motor and driver units. The system allowed incremental speed ramping while monitoring electrical and mechanical response.
Key design elements included:
-
Precision-balanced flywheels, which I manually balanced and assembled to ensure smooth high-speed operation and minimize vibration
-
A rigid mounting fixture to provide stability and repeatability across test cycles
-
A modular architecture allowing the same platform to support multiple product configurations
To address safety concerns associated with high-speed rotating components, I designed and fabricated a sheet metal enclosure to contain the flywheel assembly and mitigate risk in the event of component failure.
Validation & Performance Testing
The system enabled controlled testing by incrementally increasing motor speed while monitoring current draw and system response, allowing identification of performance limits and failure thresholds under realistic loading conditions.
Testing provided insight into:
-
Motor efficiency and current behavior under inertial load
-
Driver limitations and thermal response
-
Failure modes during high-speed operation
The controlled setup ensured repeatable and comparable results, supporting both validation and quality control efforts across product lines.
Results & Impact
The benchtop flywheel system provided a reliable and scalable platform for validating electromechanical performance under realistic loading conditions, effectively bridging the gap between component-level testing and system-level behavior. Its ability to support both SureSort and PerfectPick systems increased its utility and impact across the organization.
The system improved confidence in motor and driver performance prior to full integration while enabling safer and more efficient testing workflows.
Key Takeaways
-
Real-world system behavior can be effectively replicated through inertia-based modeling
-
Designing for multiple product lines requires adaptable and well-validated load translation
-
Precision balancing is critical for high-speed rotational systems
-
Safe test design must account for failure containment and operator protection
-
Controlled test environments enable reliable identification of performance limits and failure modes