RIT Formula SAE Data

Acquisition
Team 05109

February 18, 2005

 Team Members
z Justin LaChausse – Project Leader
z BS Mechanical Engineering, Auto Option
z Robert Doll – Chief Engineer
z BS Mechanical Engineering
z Zach Bush
z BS Mechanical Engineering, Auto Option
z John Howard Jr.
z BS Mechanical Engineering, Auto Option
z Shuangbo (Bo) Xu
z BS Electrical Engineering
z Hsiang Chi (Sean) Hui
z BS Electrical Engineering
z Dr. Alan Nye
z Coordinator/Faculty Mentor
 Agenda
z Sponsor Profile/Needs

z Project Goals

z Concept Development

z Feasibility Assessment

z Financial Overview

z Preliminary Design Overview

z Next Steps
 Sponsor Profile
RIT Formula SAE
z Approximately 20 students
z Design, Fabricate, and Race a
Formula-Style Race Car

z Compete Twice Annually at FSAE

Competitions in Detroit and
Australia
z Vehicle Specifications
z 4130 Steel Space Frame
z Unequal/Unparallel A-Arm Pull
Rod Suspension
z Honda CBR600 F2 Engine
z Autronic Engine Management
System
z Zexel-Torsen Type II Differential
z RIT Designed Brake System
z Three Piece Composite Body
Data Acquisition Overview
z Electronic devices used to
monitor vehicle parameters

z Sensor outputs recorded by

on-board data logger

z Data transmitted to PC for

analysis

z RIT FSAE currently owns a A data-acquisition processor (red box)

mounted in a CART car.
Competition Data Systems Source: http://www.machinedesign.com
http://www.machinedesign.com

(CDS) Commander II system

 Mission Statement/Goals
z Team Mission Statement
z Design, assemble, and implement a stand alone Data
Acquisition (DAQ) System for a Formula SAE racecar. Sensor
outputs will be recorded and manipulated to yield meaningful
data about vehicle performance. Design emphasis will be
placed on system layout, sensor integration, and electrical
system capability.

z Project Goals
z Provide fully functioning data acquisition package and
recommendations for improving electrical system
z Demonstrate system capabilities through design verification
z Provide RIT Formula SAE with an advantage over the
competition
 Project Requirements
z Redesign DAQ System
z Team shall use a CDS Commander II Data Logger
z Evaluate current system capabilities
z Determine feasible vehicle parameters to log
z Determine appropriate sensors for use
z Integration on Vehicle
z DAQ system shall not interfere with operation of car subsystems
z Components must be removable without affecting the vehicle’s ability to operate
z Optimize strength vs. weight of mounting pickups and sensors
z Electrical System Analysis
z Determine current system loads without DAQ system
z Determine added load on system, with DAQ incorporated
z Optimize electrical system to increase excess capacity for DAQ system and
other potential electrical systems without negatively affecting engine
performance
z Demonstration of DAQ Capability
z Demonstrate characterization of car capabilities
z Demonstrate optimization of car characteristics
z Document a procedure(s) used to demonstrate system capability
 Concept Development
Data Acquisition
z Long List
z Included all attainable vehicle parameters
z Basic System (Baseline)
z Minimum parameters needed to provide useful data
z Intermediate
z Combination of Long List, and Basic System
z Hybrid
z Intermediate system split into several optional configurations
z Makes efficient use of data logger capabilities through channel
allocation
 Concept Development
Electrical System
z Assess Problems With Existing System
z Battery is running at its limit
z Rectifier is running hot, may not handle the load
z Suspecting current drain somewhere in system
z Cannot integrate any more electrical components
z Obtain Measurements of System Loads
z Battery
z Quantify discharge rate of battery
z Rectifier/Regulator
z Determine temperature operating range in current setup
z Measure output current during vehicle operation
z Overall System
z Measure the current draws across each system component
 Feasibility Assessment
Setup 1 Setup 2 Setup 3
System Level Technology
Question 1 3 4 2
Question 2 3 3 3
Question 3 3 4 3
z Setup 1 – Current DAQ Box Question 4 3 4 4
Economics
z Setup 2 – Two DAQ Boxes Question 1 3 4 3
Question 2 3 4 4
z Setup 3 – Upgraded DAQ Box Performance
Question 1 3 3 2
Question 2 3 4 4
Schedule
z Results show upgraded data Question 1 3 4 2
logger is most feasible, given DAQ System Level Feasibility Assessment
available resources
TQ 1
4
z Hybrid system chosen due to SQ 1 3 TQ 2

efficient use of logger capabilities 2

1
PQ 2 TQ 3
0

PQ 1 TQ 4 Setup 1
Setup 2
Setup 3
EQ 2 EQ 1
 Feasibility Assessment
Sensor Level

z Video system will not be used Sensor Type

Technology
TQ 1 TQ 2 TQ 3 TQ 4
Economics Performance Schedule
EQ 1 PQ 1 PQ 2 SQ 1
Onboard Video System
z CDS Overlay System most Remote Camera 3 3 4 1 2 3 2 3
CDS Data Overlay System 4 3 4 4 1 3 4 3
valuable, but too expensive Lipstick Camera
Pitch/Roll Angle/Rate
3 3 4 1 2 4 2 3

CDS Software Calculations 3 3 4 3 3 4 2 3

Laser Ride Height Gages 4 4 4 3 1 3 4 3
Trailing Wheels 3 3 3 3 3 2 3 2
z Pitch/Roll calculated in software Gyroscope
Steering Wheel Angle
4 4 4 3 2 3 3 3

z Laser ride height sensors

String Dash Pot mounted on
2 4 4 4 4 4 4 2
Steering Rack
String Dash Pot with Pulley on
desired, but too expensive Steering Shaft
4 4 4 4 4 4 4 4

Corner Weights
Strain Gages on Push/Pull rods
3 3 3 3 3 3 3 3
with math using Motion Ratios
Strain Gages on Push/Pull rods
z String Potentiometer on steering with Calibration to Corner Loads
3 3 3 3 3 3 4 3

Ride Height
column Laser Ride Height Gages 3 3 3 3 1 3 4 3
Calculated in Trackmaster 3 3 3 3 4 4 3 3
Driveshaft Torque
Remote Torque Sensors 3 2 2 2 1 3 4 3

z Driveshaft torque sensors too

expensive
 Design – System Layout
Analog Channel Overall Competition Setup
z Hybrid System
z Competition System
z Simultaneous data collection
of necessary parameters
z Test Configurations
z Brake System
z Engine System
z Decision based on efficient
use of data logger capabilities
z Financial Considerations
Secondary Testing Concept
1
2
Front Brake Line Pressure
Rear Brake Line Pressure
Front Brake Line Pressure
Rear Brake Line Pressure
3 Front Brake Rotor Temperature Steering Angle
4 Rear Brake Rotor Temperature Lateral Acceleration
5 Front Brake Pad Temperature Longitudinal Acceleration
6 Steering Angle Vertical Acceleration
7 Lateral Acceleration Yaw Rate
8 Longitudinal Acceleration Left Front Shock Travel
9
10
Vertical Acceleration
Yaw Rate
Right Front Shock Travel
Left Rear Shock Travel
11
12
Left Front Shock Travel
Right Front Shock Travel
Right Rear Shock Travel
Left Front Pullrod Load
13 Left Rear Shock Travel Right Front Pullrod Load
14 Right Rear Shock Travel Left Rear Pullrod Load
15 Left Front Pullrod Load Right Rear Pullrod Load
16 Right Front Pullrod Load Throttle Position
17 Left Rear Pullrod Load Manifold Air Pressure
18
19
Right Rear Pullrod Load
Throttle Position
Air/Fuel Ratio
Oil Temperature
20 Manifold Air Pressure Water Temperature Inlet
21 Air/Fuel Ratio Water Temperature outlet
22 Flow rate through radiator
23
24
RPM Channel
1 Front Wheel Speed Front Wheel Speed
2 Left Rear Wheel Speed Left Rear Wheel Speed
3 Right Rear Wheel Speed Right Rear Wheel Speed
4 Differential Housing Speed Differential Housing Speed
5 Engine RPM Engine RPM
 Budget
Line # Vendor Description Item Total Line Total

Expenses

Equipment Purchases Under $1500

Supplies-Office (includes printing, copying, computer supplies) $ 50.00
Postage and Freight $ 75.00
Electrical w ire, connectors, heat shrink tubing $ 350.00
71551733 MSC (24) 0.220 Diameter/0.500 Thick Magnets $ 23.52
SEN-9 CDS 1-1000 psi Pressure Sensor $ 255.00
Tiger Direct Laptop Computer $ 700.00
MC5 CDS 4 mb Memory Card $ 575.00
Omega Strain Gauge Set $ 200.00
WBo2 2CO Tech Edge Wideband O2 Control Unit (includes w iring and connectors) $ 275.00
SEN-12S CDS (4) Strain Gauge Amplifiers $ 1,200.00 $ 3,703.52

Equipment Purchases Over $1500

COM2-30 CDS 24 Analog, 5 RPM Commander II Logger $ 4,250.00 $ 4,250.00

TOTAL EXPENSES $ 7,953.52

Income

Competition Data Systems Sponsorship $ 2,383.00

Discount on COM2-30 $ 2,180.00
10% off SEN-9 $ 25.50
10% off SEN-12S $ 120.00
10% off MC5 $ 57.50
RIT Formula SAE Project Sponsorship $ 1,000.00

TOTAL INCOME $ 3,383.00

TOTAL ACCOUNT STANDING $ 4,570.52

Design – System Overview
z COM2-30 Commander II Data
Logger
z 24 Analog, 5 Digital RPM
Channels
z Removable PCMCIA Memory
Card COM2-
COM2-30 Data Logger

z Track Master 2000 Analysis

Software
z Generate Course Maps
z User Configurable Math
Channels
z Export Data to Other Analysis
Programs

Track Master 2000 Analysis Software

 Design - Brakes
z Front and Rear Brake Line Pressures
z (2) CDS pressure sensors placed in-line
z Determination of brake bias, caliper clamping
force, pad coefficient of friction
z Brake Pad Temperature SEN-
SEN-9 Fluid Pressure Sensor

z Embedded K-Type Thermocouple

z Controlled durability and fade resistance testing
z Quantitative testing and analysis of pad material
performance
z Rotor Surface Temperature
z Infrared Pyrometer
z Data for heat transfer analysis, correlation to pad
performance
 Design – Drivetrain
z Torque on Driveshafts
z Remote Torque Sensors
z Characterizes differential performance
and under conditions of no wheel slip,
engine output torque
z Not economically feasible
Pi Research Torque Sensors

z Front/Rear Wheel Speed

z (3) Hall Effect Sensors
z Observe differential characteristics
z Integration with ECU for traction
control

Bosch HA-
HA-P Hall Effect Sensor
Design – Drivetrain

Front Wheel – Detail

Rear Wheel - Detail

 Design – Vehicle Dynamics
zLateral, Longitudinal, Vertical Acceleration Rates
zG-G Plots (Traction Circle)
zGyroscope can be used to measure yaw, pitch, or
roll rate depending on orientation
zOversteer/Understeer Balance
SEN-
SEN-28 Three Axis Accelerometer
zSkidpad Performance
zCorner Entry/Exit Performance

SEN-
SEN-37 Yaw Rate Sensor
 Design – Suspension
z (4) Coil over damper displacement
measurements

z (4) Linear Potentiometers

z Ride height at each corner
z Damper Stroke
z Damper Velocity
z Calculate Pitch Angle
z Approximate Roll Angle

z Integration considerations for proper

calibration
SEN-
SEN-20 Displacement Sensor
z Kinematic Model
Design – Suspension

Rear Suspension - Detail Front Suspension - Detail

Design – Steering

zSteering Wheel Angle

zString Rotary Potentiometer

zInside and outside tire steer angles

zDriver Feedback
zOversteer/understeer balance
zErgonomic packaging considerations
Design – Corner Loads

zDevelop system to measure vertical load on

each tire
zUse suspension pull rods
zLoad Cells Desired (high cost)
zStrain Gauges with amplifiers
zQuantify load transfer
zDesign loads
zPad and tire coefficient of friction
 Design – Corner Loads
z Strain Gage Measurement
z Extremely low change in
resistance
z In our case, roughly 0.17Ω
with a 350Ω gage
Wheatstone Bridge
z Wheatstone Bridge
Quarter-Bridge
z Quarter-Bridge
z 1 Active gage
z Half-Bridge
z 2 Active gages
z Full-Bridge
z 4 Active gages
z Half & Full-Bridge eliminate
temperature affects!
Half-Bridge Full-Bridge
 Design – Corner Loads
z Signal Conditioning
z Bridge completion
z High precision reference
resistors
z R2 = 350Ω
z R1 = 300Ω resistor + 100Ω
trim pot
z Allows for offset nulling
z Excitation voltage
z 3V – 10V power supply to
bridge
z Remote Sensing
z Voltage drop due to distance
from excitation source to
gage
z Negative feedback amplifiers
compensate for lead losses
z Continued
z Amplification
z Output from bridge is in mV
z CDS unit requires signal to be
in Volts
z AD8230 can amplify signal
z (G = 1 – 1000)
z Filtering
z Low pass filters can eliminate
noise
z Shunt Calibration
z Create a known ∆R
z Simulates an applied strain
z Compare results
 Design – Corner Loads
z Preliminary Design
z Half-bridge circuit
z Signal amplification with AD8230
z Concerns
z Not enough strain to produce accurate results
z Remote sensing may be required
 Design – Engine
z Engine RPM
z Existing hall effect sensor on
crankshaft
z Driver feedback
z Gear position
Bosch RP 86 Rotary Potentiometer
z Throttle Position
z Existing rotary potentiometer
z Driver feedback
z Manifold Air Pressure
z CDS MAP Sensor
z Engine load
z Air/Fuel Ratio
z Wideband O2 Sensor and
controller
z Engine tuning Tech Edge 2CO Wideband Unit
Current Electrical System+12V +

2 2 2
2 2

1
2

1
Cooling Fan Fuel Pump
Starter Relay Ign Relay Relay Relay
Kill Switch

2
1 1 1
1

2
1 1 1 2
Brake O/T Relay + SWitch

Ign
V1
12Vdc Ign Switch

Starter Signal

1
M
Starter Motor M
Fuel Pump Ign Switch
Cooling Fan Starter Button

2
0

+12V +12V

Ign Ign

1
T/C Enable

Brake Pressure Switch

2
+ + + +

+
1 3 49 45 40 15 17 18 6 12
L L

Neutral Light Oil Warning Water Temp Tacho Oil Temp Autronic SM2 Engine Management Autronic Capacitive Discharge
Light Ignition

R
1

Rectifier/Regulator 10 9 46 48 44 14 15 8 13 7

Ign(-)

Ign(-)
Sender Sender - - L -
-
Ign1

Ign2

Ign2

Ign1
Brake light
Neutral Switch Oil
A (Transmission) Pressure
2

Alternator Switch

0 Title
RIT Formula SAE, Race car wiring diagram

Size Document Number Rev

A Author: F. Fiore; Resource: www.autronic.com <RevCode>

Date: Thursday, January 27, 2005 Sheet 1 of 1

Current Electrical System
Primary Components
z 12V Battery
z Starter Motor
z Autronic SM2 Engine Control
Unit
z Autronic Capacitive Discharge
Ignition
z 0.77-2.9A Current Draw
z Charging System
z Alternator/Rectifier/Regulator
z SH693-12 from a Honda
CBR600 F2 Motorcycle
z Full Wave 3 Phase AC to DC Source: http://www.allaboutcircuits.com
http://www.allaboutcircuits.com

z Cooling Fan
z 6.6A Current Draw
z Fuel Pump
z 10A Current Draw
 Design – Electrical
Potential System Improvements

z Battery
z Move battery away from exhaust and add insulator
z Different cell technology
z Upgrade to higher capacity battery

z Rectifier/Regulator
z New rectifier/regulator
z Silicon paste to improve heat flow

z Reduce Weight
z Reducing sizes of wire, meanwhile supporting enough current
 Next Steps
z Finish electrical system analysis and finalize
recommendations for improvements

z Prototype fabrication of strain gauge amplifiers

z Fabricate parts and wiring harness, assemble system

z Develop basic optimization tests to prove system

functionality

z Document DAQ system use and calibration procedures

 Spring Quarter Timeline
Week - Spring Quarter
Item Breakdown 1 2 3 4 5 6 7 8 9 10
Completed System
Completed DAQ System
Final Bracket Design
Bracket Manufacture
Integration onto Car
Completed Electrical System
Final Schematics
Electrical Wiring
DAQ Calibration/Testing
Sensor/Software Calibration
Sensor Verification
Chassis Optimization
Documentation
Calibration Procedure
Testing Procedures/Report
Final Design Report
Poster
Website
 Acknowledgements

z Dr. Mark Kempski

z Mr. John D. Wellin

z Mr. Dave Hathaway

z Competition Data Systems Inc.

z Mr. Fernando Fiore (RIT Formula SAE)

z Mr. Robert Hammond (RIT Formula SAE)

Question Session
 Design – Corner Loads
z Strain Gage Basics
z Fine wire or metallic foil
z Arranged in grid pattern
z Maximize grid to strain parallel
to applied load
z Minimize cross-sectional area
z Reduce affect of shear and
Poisson strain
z Carrier
z Thin backing that connects
gage to test specimen
z Transmits any strain from
specimen to gage
z Purpose
z Convert mechanical strain to
electrical change in resistance
 Design – Corner Loads
z Selection Parameters
z Gage length
z 0.125 in – 0.25 in are common
z > 0.25 in
z Quicker and easier installation
z Easier to handle
z Better heat dissipation under cyclic loading
z Less expensive
z Grid Number and Layout
z Uni, bi, multi-axial
z Uni-axial are low cost
z Ideal for purely axial loading
z Planar or Stacked
z Planar
z Increase accuracy and stability
z Resistance
z 120Ω, 350Ω, 1000Ω
z Increase resistance, increase sensitivity
 Design – Corner Loads
z Selection Parameters Continued
z Gage Factor (GF)
z Overall sensitivity to strain
z Metal used plays important role
z Isoelastic alloys provide high GF (3.6)
z Common for dynamic measurements
z Extreme temperature sensitivity
z Carrier and Adhesive Materials
z Carrier – Glass fiber reinforced epoxy
z Excellent for dynamic loading
z Adhesive – epoxy
z High bond strength
z Options
z Pre-attached lead wire cables
z Encapsulation
 Design – Corner Loads
z Lead Wire Resistance
z Add offset error and desensitize bridge
z Wire resistance can be compensated for
z Resistance changes to due temperature
z 3-wire connection can eliminate this affect