Formula SAE Performance Enhancement VU FSAE Instrumentation Team – 12/13/2007

 Collegiate design competition  Small formula-style racing cars  1 year project time span 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation2

 610 cc max engine displacement  20 mm air intake  Independent 4 wheel suspension  Structural safety req’mts 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation3

 120 International teams  10 international competitions sponsored by Society of Automotive Engineers  1000 total points  Static events  Dynamic events 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation4

12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation5

12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation6

 FSAE Design Team  System validates engineering design decisions  FSAE Competition Team  System improves driver training/driver performance  System improves vehicle performance  Data Analysis Team  Data is easily accessible, interface is easy to use  FSAE Cost Team  Impact on cost report  Senior Design Team  Wants a system which is modular, easy to develop and implement 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation7

 Currently, performance tuning requirements developed from driver feedback  No quantitative performance measurements 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation8

 Need a system which can capture and store multiple data channels  Capable of operating on a FSAE racecar  Can withstand exposure to various weather conditions including hot, cold and rain 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation9

 Various sensors networked to an analog to digital converter  Digital converter will process data and store it in onboard memory  System will download data to laptop  GUI on laptop will display and analyze data 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation10

 Performance must be high enough that quantitative measurements can be made  Reliability another performance issue  Low cost enough to fit in FSAE team budget 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation11

 External Systems  Car components ▪ Suspension ▪ Engine ▪ Chassis  FSAE Competition ▪ Endurance Event ▪ Acceleration ▪ Skidpad  Environmental Systems  Vehicle Context ▪ EMI ▪ Vibration ▪ Heat  Weather ▪ Rain ▪ Hot Ambient Temp ▪ Cold Ambient Temp 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation12

 Based on contextual requirements  Divided into four categories  Measurables  Environmental  Operational  Interface 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation13

 Three categories  Required ▪ These contribute the most to analyzing and validating vehicle and driver performance.  Optional ▪ Not focused on driver performance. Future project potential?  Extraneous ▪ Do not contribute to understanding driver or vehicle performance, but could be measured.  System expandability  Optionals = future project potential 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation14

REQUIREDOPTIONALEXTRANEOUS Shock Position & VelocityTire TemperatureFuel Level Lateral & Longitudinal Accel.Ambient TemperatureFuel Consumption Rate Wheel SpeedWater TemperatureOil Level Engine RPMExhaust TemperatureCoolant Level Oil PressureOil TemperatureTire Pressure Throttle PositionWheel LoadRide Height Steering PositionChassis Slip Angle Brake Pressure 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation15

 Required 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation16 MeasuredResolutionSamplingDynamic Range SignalOn track (in)Hz (S/sec) Shock Position/Velocity ";Vmax = 400mm/sec Lat./Long. Accel6200+/- 4g Wheel Speed rpm max Engine RPM ,000 rpm Oil Pressure psi Throttle Position degree range Steering Position degree range Brake Pressure psi

 System must withstand normal operating conditions on FSAE racecar  Electro-magnetic Interference (EMI)  Water Exposure  Vibration  Temperature  Ambient ( deg F)  Local heat sources  Weight - <20 lbs  Size – 10”x12”x5” max envelope 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation17

 Triggering  Data Pre-filter  Data processing  Storage Capacity, 25MB (see next slide)  Data Transfer  Download all data < 1min, 0.4MB/sec  SAE stand alone compliance  Monitors and records only  Passive, no direct feedback to driver  Not needed for vehicle operation 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation18

 Storage capacity derivation from measureable requirements 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation19

12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation20

12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation21

Operational Requirements - Interface  Graphs  Gauge levels  Scatter plots  Channel history  FFT output  Channel reports  Section times  Real-time playback 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation22  The system must have various options to represent:

 The M SD Dash / Logger is a combined LCD Dash and High Performance Data Logger  Cable bracket, Harness probable need to be through MoTec to fit system  16 MB max, 8 MB stock  28 analog inputs and up to 4 digital inputs  Maximum logging rate 20 Kbytes per second  32 Bit microprocessor  Data analysis software  USB interface 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation23

 Advantages  Turn-key system is easy to setup and use  Great software user interface  High performance and proven product  Can receive support from MoTec for troubleshooting and equipment failure  Disadvantages  Cost – $4900, not including sensors  Cannot add sensors to data logger or modify interface if not predefined by MoTec 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation24

 DaVid is a video and data logging system  AIM does not make ECU, must purchase independently (third party)  8 MB stock  5 analog inputs  Maximum logging rate 50 Hz (Slow)  Data analysis software (Not as good as MoTec)  USB interface 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation25

 Advantages  Turn-key system is easy to setup and use  Average Software user interface  High performance and proven product  Can receive support from AIM for troubleshooting and equipment failure  Disadvantages  Cost – At least $2500, not including sensors  Few inputs, few predetermined sensor options and weak memory  Cannot add sensors to data logger or modify interface if not predefined by AIM 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation26

Discussion of Options – cRIO/custom  The National Instruments CompactRIO is a modular data input/logger/analysis system  64 MB DRAM available  Using the NI 9205 & 9215 modules:  16 bit resolution  36 measurable channels  Maximum logging rate 650k samples per second  Integrates with NI’s LabVIEW software  USB & Ethernet interface 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation27

 Advantages  Sensor choice is very open & not limited by NI  Extensive NI & LabVIEW support available  Cost – free for hardware & software (already provided by NI)  Meets or exceeds all quantitative systems reqs.  Modular system allows interchangeability and expandability as desired  Disadvantages  LabVIEW will require learning a new programming environment  Wiring harness will have to be fabricated separately

Choosing the cRIO Requirements  ~3,500 samples/sec  14 channels  25MB storage  0.4MB/s transfer rate  20 – 105 F  <20lbs  10”x12”x5” max Capabilities  650,000 samples/sec  36 channels  64MB onboard DRAM  USB: 1.5MB/s  -40 – 70 C  Change to as config. wt  7”x4.5”x3.5”  SAE Standalone compliant 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation29

12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation30 cRIO Block Diagram

On-board memory GUI Data Reduction GUI Interface RS232 CAT5

12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation32 MeasurementSensorBrand Part NumberCost Shock Position/Rate Linear Potentiometer Latitudinal and Longitudinal AccelerationAccelerometerCrossbow GP Series tri axis$315 Wheel SpeedProximity SensorOmega PRX n$85 Engine RPMDirect **Data can be taken directly from engine - Honda CBR600F4 Oil Pressure Pressure TransducerOmega PX32B1- 250GV Already own Throttle Position Rotary or String Pot Steering Position Rotary or String Pot Brake Pressure Pressure TransducerOmegaPX305-3KGI$285

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Operational Definition - FPGA  Custom hardware alterations  Custom Input/Outputs  Custom control hardware  Easy-to-use graphical development  Built-in interface functions integrated into cRIO 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation34

 Measurables  Bench test sensors – verify output accuracy  Operational  Visual Inspection  Operational successfulness  Interface  Visual Inspection 12/7/2007Vanderbilt University FSAE Instrumentation Project - Fall Semester Presentation35 V&V Methodology