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A Unified Approach
A TOTALLY UNIFIED SYSTEM APPROACH: TAKE DATA WITHIN MINUTES NOT HOURS
RS Technologies has combined its 25 years of e xperience in designing and developing wheel force sensors with the latest in modern, modular electronic data acquisition systems from Caesar DataSystems. The result is the most modern and complete data acquisition system for road load data collection and handling tests available. This powerful measuring system features extremely easy and simple installation and continuous checkout during operation, which significantly reduces setup, alignment, and adjustment time, and gives instant real-time results during testing. Road load data is one of the best sources of fundamental information necessary for analysis of the d esign, reliability, and structural integrity of vehicle components. All elements of the measuring system must have high accuracy and resolution to ensure reproduction of the test conditions. This demand requires that you combine a durable, highly accurate wheel sensor with an electronics package that can record and process the data quickly and accurately. The RS Tech-CAESAR approach fully integrates the design of the Wheel Force Transducer (WFT) with the hardware and software that supports Computer Aided Data Acquisition (CADA). This includes the onboard signal conditioning, shunt calibration, angular position resolution, and signal transmission to the data acquisition equipment. The result is a unified system that features rapid, a ccurate calibration and alignment of the wheel sensor with the vehicle data acquisition system. The complete system has many outstanding and unique features: Ease of use of the overall system Full integration of sensor with the data acquisition for high-speed setup, recording, analyzing and report generation of the test Well-designed, linear, durable, and waterproof 6 component wheel sensors and electronics Extremely short mounting and setup time: less than 10 minutes per wheel! Wireless telemetry data and power transfer, friction free with absolute data security a no sernd vicing required Compact electronics package with capability to expand to any number and type of signal conditioning channels Rolling zero and shunt cal: alignment, zero, and gain adjustments while driving 16-bit resolution w/20 kHz sampling and calculation speed for all channels Precise, uncompensated vector force resolution for all rotating axes Online calculation of resolved signals with outputs of resolved and unresolved signals in both analog and digital form Capability of creating files directly for fatigue analysis and test rig simulation
WFT System, Exploded View Because the mechanical design of the transducer provides full linearity with minimal crosstalk, the WFT system allows online calculation of the resolved force and torque signals in the signal conditioning and control electronics. Calibration information is stored in the transducer and is automatically trans ferred into the calculation algorithm of the data processing.
FY Lateral Force
MY Torque
FZ Vertical Force
Mz Turning Moment
A Unified Approach
Through use of our unified approach, the mounting, adjustment, and setup of the WFT using the CADA system is very straightforward and easily accomplished. When proper cabling and restraints are available, initial start up takes less than 20 minutes per wheel. From a cold start, 10 minutes are required to warm up the system. The initial non-running adjustment takes 3-5 minutes per wheel. A full recheck and readjustment can be done as needed dynamically while driving. Rapid setup techniques allow verification of proper operation of all measuring elements and the same sequence can be used immediately following a test run to verify that the equipment has maintained original setup. Light Truck FWD Application
-Lab Software
-Lab provides real time display and data recording. It is very flexible and powerful and can be programmed to do a very wide variety of calculations and analysis tasks. For example, online processing with -Lab allows the test driver to check that all systems are functioning correctly while measuring is in progress.
-Graph Software
Caesars high-speed analysis software, -Graph, allows test data representation and offline analysis of the data recorded on disk. Even data files with many channels and Gigabytes of data can be seen and analyzed within a few seconds. Format converters for RPCIII, Matlab or other simulation or analysis software packages are also available from CAESAR. The calculation from unresolved into resolved signals is required because the rotating wheels have a rotating coordinate system, whereas global non-rotating street coordinates relative to the vehicle body are required. So, under normal conditions the following signals are acquired: 1. 2. 3. 4. 5. 6. 7. fx, unresolved fy, unresolved fz, unresolved mx, unresolved my, unresolved mz, unresolved Angle position, , of the wheel rotation
A Unified Approach
8. 9. Sin of the rotational angle Cos of the rotational angle The menu-controlled MAGIC software manages all information around typical road load recording requirements. It handles all settings of the MOPS, the definition of the channels to be transferred, monitored and recorded, the online display, and the file organization. The test administrator uses MAGIC to define the components of the car that are under test, which are instrumented with strain gages or accelerometers. The test administrator then selects the proving ground profiles to be used in the test, thus preparing the test sequences for the driver with profile name and the vehicle speed for the test run. The administrator can easily compose or modify the test layout. All this information is combined into a full testing program that is then executed by the driver.
10. RPM of the wheel (calculated from the sine and cosine) 11. Number of revolutions of the wheel The software then uses a series of formulas to r e solve and convert signal data for all axes to account for wheel rotation, wheel offset, and rolling radius.
MOPS-TIU MOPSThrough the use of CADA, the MOPS Transducer Interface Unit (MOPS-TIU) has become fully int egrated into the data acquisition system, providing for dynamic force, torque, and position communication between the wheel sensor and the data acquisition system. Using modern microprocessor technology, the MOPS system employs TIU signal conditioning modules that are much smaller, lighter, and much faster than previous units. A single half-sized 19-inch rack-mount unit provides signal conditioning for all four wheels and is fully integrated with on-board calculation capability. There is virtually no warm-up time required for the electronics. The TIU module consists of the power supplies and signal conditioning electronics that convert the WFT signals into equivalent signals referenced to the wheel axes. In addition to supporting the WFTs, the TIU can provide up to 96 channels for additional inputs in standard 8.5-inch or 19-inch rack mount type package. The TIU automatically and continuously adjusts the sin and cos signal to be symmetric to the ZERO line and to be max 1V. It also compensates signal offsets and gain of all strain gage-based signals when the CAL switch is activated by user control or by software when the data transfer is started beginning a new test record.
Shunt Cal While Vehicle is Rolling The setup history i kept in a spreadsheet file that s contains serial number and cal factors, which also are stored in a memory chip in the wheel, from the wheel electronics. The software sets the gain according to 6 axes information replicating and documenting the test with date and time of last calibration.
Online Data Screenshot Signals Zeroed During Test Drive All settings are stored in a protocol trace file and can be printed out later as corner loads, zero offsets, or shunt cal values. It provides for on-line calculation and recording of the resolved signals. It has the capability of storing all signals or subsets of the channels like resolved signals only. Data is available for evaluation and analysis immediately after recording is finished; areas with potential errors during the test run can be easily identified. Data can be directly transformed into various software formats such as nCodes DAC-format or MTS RPCIII format
A Unified Approach
track. One shows the profile of some pot holes as they were recorded and the second shows the behavior of the vehicle on a torsional track section.
Max/Min Evaluation Other methods of analysis can be defined and the online results displayed in a list similar to this example, such as max hysteresis loops of a rain flow analysis, or max frequency and amplitude of a vibration spectrum or distance, duration, deceleration and brake pressure from a brake test. By clicking on one of the fields in the display, the data of this channel i the corresponding road segment n will be displayed as a time history display. The analysis program -Graph is started and the corresponding data is displayed. -Graph is the fastest and most user-friendly analysis and report generating software package for road load data. The list of road segments is shown and dragging and dropping either other signals or other road segments into the graphics can arrange the display of the data. -Graph also offers format converters for a wide range of other software used for road load handling, fatigue analysis, such as nCode FATIMAS, or rig control, such as MTS RPC III, IST Rigsys, or Servotest SBF format. A MATLAB converter is also available. -Graph can be set in automatic mode to let you compose complex sequences of analysis, and graphic output routines that can run fully automated and provide a series of report plots without the time consuming interactive data handling of the operator. The plots can be laid out as presentation plots with graphics, bitmaps, text, tables and logos like the e xample shown below. New test data will just be activated and all analysis and displays are u pdated with the new data. The plot shows the three forces as time history plot and rain flow matrix plot and power spectrum of the vertical force in vehicle coordinates.
Data Report
Wheel Sensor under Test RS Technologies has a state-of-the-art facility and an experienced staff to provide complete diagnostic, repair, and calibration services for all makes of road load and torque wheels. All torque and force calibration services are accredited by A2LA according to ISO Guide 25 and traceable to NIST standards.
A Unified Approach
GENERAL WFT SPECIFICATIONS
Nonlinearity ........................................ 0.5% of rated output. Non-repeatability ............................. 0.25% of rated output. Hysteresis ........................................... 0.5% of rated output. Crosstalk ............................................................... 1% typical, 3% Full Scale, maximum. Excitation ..................................................................... 15 VDC Output (all axes) .......................... 5.00 vdc 0.2%, nominal. Temperature Range............................................-25 to 150 C Temperature Drift.................................................... 0.005%/C Angle Encoder .........................................Sine/cosine resolver Coordinates ......................................................SAE Standard. Resolution ................. Depends on resolution of electronics and capacity of sensor, generally > 10 Nt for force axes; > 1 Nm for moment axes. Bridge Resistance ................................. Fx & Fz 525 Ohms, Fy, Mx, My & Mz 1400 Ohms, nominal. Isolation Resistance ..................................... 2,000 M Ohms. Overload Capacity ................ 50% of Full Scale on all axes applied simultaneously, provided that the combined load on each axis does not exceed the overload rating for that axis. Natural Frequency .................................................... <300 Hz. Acceleration Tolerance ................................. Shock 50 Gs. Environmental .......................... Dust-proof, water resistant, short-term submersible, corrosion resistant Sampling Rate per Channel........................................... 6 kHz A/D Converter.................................................16 bit resolution, separate converter per channel Crosstalk Rotor Electronics.....................................>100 dB Linearity Rotor Electronics....................................... < 0.01% Analog Output ...............................................On wheel, 10 V, driven, 7pol. binder connector water-protected Temperature Channel.................... 8 bit resolution, 127 C, for control of the temperature in the wheel electronics Angle of Rotation ....................................Incremental sensor, 2048 pulses per rev, sin- and cos -values are transferred with time correction Controller....................................... Microprocessor controlled, settings are saved on EEPROM on rotor electronics, power on-download Remote Control Commands ........ Autozero per component separate shunt calibration, combined high pass setting for x- and z-components Data Transfer .........Infrared, axial, serial format, 1.28 Mbps Remote Control Signal Transfer ........................... Inductive, RS232-format, 9600 Baud Processor Unit .......................................x- and z-components by means of processor controlled calculation unit, direction of rotation is programmable Power Supply ..................................Separate power supplies 12 V/0.5 A per wheel Weight Rotor Electronics............................................1.15 kg Temperature Range ............................................-20 ... +80 C Water Protection..........................................According to IP67 Max. Driving Speed.............................260 km/h (161.5 mph) Synchronizer & Interface.....Per wheel 19-plug-in module, bus coupling via dual ported RAM Interface to MOPS
TELEMETRY SPECIFICATIONS
Amplifier...................................... 6 instrumentation amplifiers for full-bridge strain gages Sensitivity...............................Adjusted according to sensors Sensor Power Supply ..................................................... 10 V Shunt Calibration ..............50% full scale, remote controlled High Pass Filter .. x- and z-components, 0.5 Hz, switchable Aliasing Filter............................... 7-pol. Butterworth, 1.2 kHz Sample and Hold ................................................Simultaneous
ACCESSORY LIST
A complete set of accessories for mounting and setting up the system is available.
FX
60 K N (13.5 K LBF) 60 K N (13.5 K LBF) 30 K N (6.7 K LBF) 7.5 K N M (66 K LB -I N) 7.5 K N M (66 K LB -I N) 10 K N M (88 K LB -I N) 84
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RS Technologies World Headquarters Farmington Hills, Michigan USA More information on wheel force transducers is available from:
RS Technologies, Ltd. 24350 Indoplex Circle Farmington Hills, Michigan 48335 USA Telephone: 248-888-8260 FAX: 248-888-8266 Email: info@rstechltd.com www.rstechltd.com
CAESAR DatenSysteme GmbH Keltenring 16 82041 Oberhaching, Germany Telephone: +49-89-613049-0 Fax: +49-89-613049-97 Email: info@caesar-datensysteme.de www.caesar-datensysteme.de CAESAR DataSystems, Inc. 24350 Indoplex Circle Farmington Hills, Michigan 48335 USA Telephone: 248-888-8268 Fax: 248-888-8269 Email: info@caesar-datasystems.com www.caesar-datasystems.com
050412
061525-600