1. 0 SAE Formula Car Data Acquisition & Display System Ahmed AlbitarJohn Gertie Justin IbarraSean Lenz Bradley University Electrical Engineering Department Advisor: Professor Steven Gutschlag October 2, 2014

2. 1 Agenda ● Background Information ● Project Requirements and Objectives ● Design Approach ● Method of Solution ● Economic Analysis ● Societal and Environmental impact ● Schedule and Division of Labor ● Summary and Conclusion

3. 2 Section Outline ●Background ○ Competition Concept ○ Competition Awards ○ BU SAE Formula Car ■ Current System ■ Current System Flaws ■ Client Goals for New System ■ Client Needs for New System ○ Past Efforts

4. 3 Competition Concept ● Formula SAE Competition o Prototype car to be evaluated for production o Designed for non-professional weekend competitor o Car must be low in cost, reliable and easy to maintain o Car’s marketability can be enhanced with aesthetics

5. 4 Competition Awards ● Spirit of Excellence o Top 10 with highest overall score ● Design o Top 3 with highest scores in design

6. 5 BU SAE Formula Car ● BU MEs develop a new car annually ● Design Goals o Aesthetically pleasing o Economically viable o Race ready performance o User friendly for all levels ● ‘07-’10 Honda CBR600RR engine ● Total budget of $10,000

7. 6 Current System ● Mychron 3 (Discontinued) ● Features  tachometer  data log(30 min limit)  Single temp. sensor (EGT, CHT, H20)  Lap time  3.3”x2.0” Display ● $825

8. 7 Current System Flaws ● Poor notification system o Indicators are small, not always noticeable  Engine failure due to overheating ● Display can’t be customized o Drivers can’t adjust display to their liking o Gauges are small, can be difficult to see ● No display for crew o Only the driver monitors sensor data

9. 8 Client Goals for New System ● Multiple display modes o Driver can select more appropriate display o Better visibility of sensor data when racing o All inclusive data display for practice o Demo display for judging

10. 9 Client Needs for New System ● Wireless Data Transmission o Sensor data monitored remotely ● Data Logger o Store data for future review o Useful for making vehicle adjustments or diagnosing problems

11. 10 Past Efforts ● Past senior project groups have worked on the data acquisition system ● No past group has implemented the system on the formula car

12. 11 Section Outline ● System Objectives ● System Requirements ● Safety Requirements ● Construction Requirements ● Design Approach ● Additional research needed ● Testing

13. 12 System Objectives ● Data Acquisition o Data readings include: Oil Pressure, Water Temperature, Voltage, speedometer, tachometer ● Display o Driver Display o Remote Display o Notification System

14. 13 System Requirements ● Data Acquisition o Accurately acquire data with a maximum of 5% error o Ability to send data for display o Store Data for review ● Wireless o Accurate data transmission o Range of 0.5 to 1 mile ● Display o Accessible to driver’s touch screen and crew’s computer o safe

15. 14 Safety Requirements ● No loose parts ● No exposed wiring ● Does not interfere with driver performance ● Is not a fire hazard ● Does not pose threat in case of accident

16. 15 Construction Requirements ● Inside the cockpit o Withstand temperatures of 40 to 120˚F o Withstand vibrations/forces of a lateral magnitude 0 to 2G and forward of 5g ● Inside the engine bay o Withstand temperatures of 40 to 250˚F o Withstand vibrations/forces of magnitude up to 8g ● Undercarriage o Withstand Temperatures of 40 to 250˚F o Withstand vibrations/forces of magnitude up to 8G

17. 16 Design Approach ● Design alternatives ● Evaluated design options using multiple evaluation techniques ● Selected design best fit to client’s needs ● Interdisciplinary collaboration

18. 17 Additional Research needed ● Gemstudio will be used o Program uses Gemscript ● This system will require collaboration with the mechanical engineering department ● Contingency plan

19. 18 Testing ● All software testing will be done at Bradley University in the electrical engineering labs. ● Hardware testing will also be done at Bradley University in the mechanical engineering labs.

20. 19 Section Outline ● Proposed Solution ● Project Expense Breakdown ● Economic Analysis

21. 20 Proposed Solution ● Standalone system o Universal application o Can be moved to new car when necessary ● Electric sending units o Keeps hot fluids away from driver o Better reliability o Less maintenance

22. 21 Proposed Solution ● Touchscreen o Mounted on dash, in front of driver o Guages appear in digital & analog form o Demo, practice, and race modes o Independent sensor data refresh rates o Aggressive notification system

23. 22 Proposed Solution ● Wireless transmission o RF transceivers ● Remote display o Shows critical value at all times o Notification system o Data logging capabilities o Gauges appear in digital & analog form

24. 23 Project Expense Breakdown EquipmentMinimumMaximum Software Programs$2000$2600 Sensors$480$600 Screen$175$220 RF transceivers$130$180 Table 1: Equipment price range

25. 24 Economic Analysis ● Project is feasible ● $3000 (minimum) estimated cost to complete project o $2000 software programs o Free for students ● $3700 (maximum) estimated cost to complete project o $2600 software programs

26. 25 Economic Analysis (cont.) ● Estimated manufacturing cost (minimum) is $1000 ● Estimated manufacturing cost (maximum) is $1100 ● Estimated Retail is $1500 ● Estimated Cost to implement is $200 o Wiring, insulation, Packaging, etc

27. 26 Section Outline ● Societal & Environmental Impacts ● Division of Labor ● Milestones & Scheduling ● Summary & Conclusion

28. 27 Societal & Environmental Impacts ● Increase safety while operating vehicle ● Reduce catastrophic failures ● Minimize repair costs ● Help contain spills

29. 28 Division of Labor ● Amulet display for driver (Sean and Justin) o Display crucial car data  Multiple display modes o Warn driver if data exceeds threshold  Flash screen o Data sent via UART from microcontroller

30. 29 Division of Labor ● RF Communication (John & Ahmed) o Establish communication  Board to board  Board to HyperTerminal  Microcontroller to HyperTerminal o Receive data from microcontroller o Send data packets to off track PC o Transmission range of 1 mile

31. 30 Division of Labor ● Labview GUI (Sean & Justin) o Receive data packets via RF o Data sent to computer using serial communication o Advanced display of crucial data o Alert crew if problem occurs o Log data in spreadsheet

32. 31 Division of Labor ● HW/SW interfacing o Connect to microcontroller  RF transmitter (John & Ahmed)  Amulet LCD (Sean & Justin)  Sensors (John & Ahmed) ● Test with simulated data (Sean & Justin) ● Install on car (John & Justin) ● System testing on vehicle (Sean & Ahmed)

33. 32 High Level Gantt Chart

34. 33 Milestones & Schedule ● Progress Presentation Nov. 25 ● Progress PresentationFeb. 24 ● Project DemonstrationMar. 31 ● Final PresentationApr. 14 ● Final ReportApr. 30

35. 34 Summary ● Bradley ME dept. builds formula car o Current data acquisition system is inadequate ● ME’s expressed need for more advanced system o Customizable multi-mode display o Wireless data transmission o Data logger

36. 35 Summary ● Proposed system will meet requests o Amulet for multi-mode display o RF for wireless communication o Data storage for later analysis o Alert driver and crew if problems occur o Reduce catastrophic failures o Reduce environmentally harmful spills

37. 36 Conclusion ● Universal application ● Cost to complete project is about $3000-$3700 ● Projected finish: February 24, 2015

38. 37 References http://www.digikey.com/product-detail/en/AC4790-200A/AC4790-200A-ND/1844885http://www.digikey.com/product-detail/en/AC4790-200A/AC4790-200A-ND/1844885 (AC4) http://www.wvshare.com/product/STK128-Premium.htm http://sine.ni.com/nips/cds/view/p/lang/en/nid/1385 http://www.digikey.com/product-detail/en/STK-480272C/681-1016-ND/2001099?enterprise=44 http://freesafesoft.com/discount/GEMstudio_Pro-32323639392d35-coupon-code.php http://www.automationdirect.com/adc/Shopping/Catalog/Process_Control_-a-_Measurement/Temperature_Sensors_-a- _Transmitters/Temperature_Transmitters_(Integral_Sensor)/TTD25N-20-0300F-H http://students.sae.org/cds/formulaseries/fsae/2014mis_handbook.pdf http://students.sae.org/cds/formulaseries/fsae/fsaeprogram.pdf http://cegt401.bradley.edu/projects/2013-2014/FSAE/BRADLEYMOTORSPORTS.htm http://cegt401.bradley.edu/projects/2010-2011/FSAE/powertrain.html

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40. 39 EXTRA SLIDES

41. 40 EquipmentMinimumMaximum Screen$175$220 Wireless transmission$130$180 Microcontroller$40$60 Temperature sensor$120$150 Pressure sensor$120$150 RPM sensor$120$150 Vehicle speed sensor$120$150 Software ( touchscreen )$500$700 Software ( microcontroller )$500$700 Software ( remote display )$1000$1200 Total$2825$3660 Table 2: Full Equipment Expenses

42. 41 Expanded Gantt Chart