College - Author 1
College of Engineering
Department - Author 1
Mechanical Engineering Department
Degree Name - Author 1
BS in Mechanical Engineering
College - Author 2
College of Engineering
Department - Author 2
Mechanical Engineering Department
Degree - Author 2
BS in Mechanical Engineering
College - Author 3
College of Engineering
Department - Author 3
Mechanical Engineering Department
Degree - Author 3
BS in Mechanical Engineering
College - Author 4
College of Engineering
Department - Author 4
Mechanical Engineering Department
Degree - Author 4
BS in Mechanical Engineering
Date
6-2026
Primary Advisor
Rick Lasko, College of Engineering, Mechanical Engineering Department
Abstract/Summary
Students in ME 443: Introduction to Turbomachinery compete to design and build efficient small impulse turbines. The course lacks a standardized method to experimentally calculate turbine power output and mechanical efficiency from accurate measurements of torque and speed, for example. To support the learning goals of ME 443, a dedicated water-turbine dynamometer is needed to provide controlled hydraulic power, accurate mechanical and electrical measurements, and clear data for performance evaluation.
Our proposed system delivers a safe, repeatable, and educational testing environment that can be integrated into the Fluids Lab or used as a standalone instructional tool. Key stakeholders include Professor Frank Jumonville (sponsor), student turbine teams (end users), laboratory technicians (operators and maintainers), and Hydrosaur Dynamics (designers and manufacturers). Our prototype consists of two integrated subsystems: a constant-head water supply and a dynamometer. The water recirculation system maintains a steady water level in the main tank to provide constant total head to the student turbines. Students will mount turbines on the dynamometer shaft and connect custom nozzles for experimental testing. The frame structure supporting the water supply is made of slotted aluminum extrusions for strength and mounting. The penstock is easily serviceable with off the-shelf union threaded fittings. Flowrate and pressure sensors allow for data collection in the penstock. The dynamometer utilizes a 3 phase electric motor with a waterproof adjustable box and coupled mounting shaft. Motor control is achieved using VESC Software Tool, an open source speed control program with closed-loop PID control, using a Flipsky 75100 Pro v.2 electronic motor controller.
Design verification showed that the Turbine Dyno System was successful in meeting the main functional goals of the project. The water system maintained steady recirculating flow and an approximately constant head through the upper tank and overflow setup. The flow and pressure sensors produced usable initial readings, and the penstock valve allowed the flowrate to be adjusted for different testing conditions. The dynamometer system was also able to apply braking load through the VESC motor controller and slow multiple test turbines during operation. Overall, the prototype functioned as intended and demonstrated that it can support turbine testing for ME 443. Future work should focus on completing software integration and performing repeatability testing before regular lab use.
URL: https://digitalcommons.calpoly.edu/mesp/910