1. Advisor : Professor Steven Gutschlag Ahmed Albitar John Gertie
Bradley University Electrical Engineering Department SAE Formula Car Data Acquisition & Display System
April 9, 2015
Advisor : Professor Steven Gutschlag
Ahmed Albitar John Gertie
Justin Ibarra Sean Lenz

2. Agenda Problem statement Background System block diagram
Division of labor
Project non-functional requirements
Project functional requirements
Discussion of individual contributions
System test results
Summary & conclusion

3. Problem Statement
Every year the Mechanical Engineering department at Bradley University designs and constructs a formula racing car. Past performances have proven to be inconsistent due to engine failures and structural breakdowns. To improve future performance, an advanced data acquisition system will be employed to indicate problems before a failure occurs. Unlike the existing system, data will be monitored by both the driver and the crew. A touch screen mounted in the vehicle will display data and warning signals to the driver. The same data will also be transmitted to a computer, where it will be recorded for diagnostic evaluations. Multiple indicators will be used to warn the driver and crew if data readings exceed a safe limit.This system will provide the necessary information to optimize the formula cars performance, giving Bradley’s mechanical engineering department an edge over the competition.

4. Problem Description Acquire 5 Key data values from SAE Formula Car
RPM
Speed
Oil Pressure
Water Temperature
Battery Voltage
Aggressive Notification system to alert driver if data exceeds threshold values
Multi-mode touch screen display
Wireless transmission of data to off-track computer
Data Logger

5. Background Design goals '07-'10 Honda CBR600RR engine
Aesthetically pleasing
Economically viable
Race ready performance
User friendly for all levels
'07-'10 Honda CBR600RR engine
Total budget of $10,000
Add what previous groups have accomplished.

6. System Block Diagram 5V Power Supply Amulet LCD Microcontroller
(ATmega128)
Amulet LCD
UART
Sensors
Wireless Transceiver
Laptop
(LabVIEW GUI)
UART
RS-232
Change rs-232 to UART

7. Division of Labor Ahmed Justin Justin & John Sean
Sensor selection & interfacing
Justin
Amulet display
Justin & John
Interface microcontroller with HyperTerminal
Test microcontroller with simulated sensor data
Interface microcontroller with LabVIEW
Sean
Prepared LabVIEW to receive wireless data
Interface microcontroller with Amulet
Setup external power supplies for the microcontroller, Amulet, and Op-Amps
Update for whole project. Add Amulet stuff.

8. System Block Diagram Sean 5V Power Supply Ahmed Microcontroller
(ATmega128)
Amulet LCD
UART
John & Justin
Sean
Sensors
UART
Wireless Transceiver
Laptop
(LabVIEW GUI)
RS-232

9. Project Non-functional Requirements

10. Project Functional Requirements

11. Ahmed's Agenda Subsystem block diagram
Pressure and Temperature Sensor Circuitry
Project functional requirement and specification
Sensors
Test result

12. Subsystem Block Diagram
Engine
12V
Temperature Sensor
ATmega128
Pressure Sensor
RPM Sensor
Velocity Sensor
Voltage Measurement

13. Pressure and Temperature Sensor Circuitry

14. Functional Requirements and specification
12 volts from the car's battery
Water temperature measured by a temperature sensor
Oil pressure measured by a pressure sensor
Velocity and RPM measured by a speed sensor
Data acquisition maximum error of 5%
Sensors compatible with engine

15. Temperature Sensor ProSense TTD25N-20-0300F-H Analog output: 4 to 20mA
Operating Voltage: 10 to 30VDC
Temperature range: F
¼ NPT
Cable : CD12L-0B-020-A0
Remove price

16. Pressure Sensor ProSense PTD25-20-0100H Analog output: 4 to 20mA
Operating Voltage: 9.6 to 32VDC
PSI range: 0 to 100
¼ NPT
Cable : CD12L-0B-020-C0
Remove price

17. RPM and Velocity Sensor
Supply Voltage: V DC
Supply Current: 10 mA
Output Signal: Pulse 0-50 V
Maximum output current: 20 mA
Sensing distance: From 0.5 to 2 mm
Maximum operating Frequency: 100KHz
Add maximum operating frequency

18. Temperature Sensor Result
Maximum 5% error
T = m × Io +k
m =
k = C
Linear Sensor
V = Io × Rf (Rf=250 ohms)
T= temperature
m = slope
k = Temperature offset
Graphs
Indicate units

19. Pressure Sensor Result
Maximum 5% error
P = m × Io +k
m = 6250
k = -25 C
Linear Sensor
V = Io × Rf (Rf=250 ohms)
P = Pressure
m = slope
k = pressure offset
Add units

20. RPM Sensor Result Maximum 5% error F = Frequency
RPM = F(cycle/sec) (60sec/1min) (1rev/2cycles)
Linear Sensor

21. Justin’s Agenda Subsystem block diagrams
Project functional requirements
Hardware and software used
Amulet touch screen
Subsystem test results
Wireless transmission

22. Subsystem Block Diagrams
Water Temp Input
Amulet Touchscreen
Home Page
Oil Pressure Input
Demo Mode
MPH Input
Aerocomm AC4790
Practice Mode
Race Mode
RPM Input
Batt. Voltage Input
ATmega128
As discussed I worked on both the amulet display and the wireless communication. Go over my block diagram. Go over John’sand mine block diagram. However, formy portion of the presentation I will just be discussing the touchscreen display and be handing off the wireless communication portion of the project to john to discuss.
ATmega128
Aerocomm AC4790

23. Project Functional Requirements
Data acquisition sends data for display
Display accessible to driver
Specification
Data can viewed on the touchscreen
Can be easily seen by driver without posing as a distraction from driving
Amulet touchscreen functional requirements

24. Hardware and Software Used
Amulet touchscreen
Laptop
Atmega128
Software
Gemstudio
Atmel Studio

25. Amulet Touchscreen Pseudo data used for demo mode
Aggressive warning system
Demo mode sweep
Navigation between modes

26. Amulet Display Results
Aesthetics
Navigation
Widgets
Microcontroller communication
Aesthetically pleasing – I made a home, demo, practice, and race mode visually appealing. This was done for both the judges of the competition the formula car will be in and the driver. While the amulet visually appealing it is also well organized so the driver can easily read the values that need to be seen while racing.
The different modes can also be easily navigated through. Each mode can be returned to the home page and then a new mode can be chosen
The widgets were programmed the to sweep from the maximum and minimum value in the demo mode
These widgets then flashed red when hazardous values were reached to alert driver
While flashing red everything else on the screen disappeared so the driver can easily focus on the hazardous value
The practice and race mode were then set up to receive data from the microcontroller. After I initially set the modes up sean continued with the testing and debugging which he will later discuss.

27. Home Page
Here is the homepage. As you can see it has three different buttons each going to it’s specified mode

28. Practice Mode
In the practice mode all data that is collected is displayed and our aggressive notification system is still being used

29. Demo Mode
Here we have a picture of the demo mode. As you can see there are now pseudo values assigned to each widget that is representing the sensors value. When this page is viewed in real-time the values are sweeping from their maximum value to their minimum value. Next up is a picture of the demo mode with our aggressive notification system in full effect

30. Demo Mode
Here you can see the hazardous value is red and all other values on the screen have disappeared. This hazardous value is flashing between red and white when viewed real-time to alert the driver as effectively as possible

31. Race mode
Lastly, here is a screenshot of the race mode. As of right now this is the same as the practice mode since all values displayed in the practice mode are necessary for the driver to see. However, if more sensors were to be added that the driver didn’t need to see while racing this page would stay the same and those sensor values would be added to the practice mode. I will now be leaving the floor to my colleague john to discuss our portion of the wireless communication

32. John's Agenda Subsystem block diagram Project functional requirements
Hardware & software used
Wireless transmission testing
Testing with simulated data
Interfacing with LabView
Subsystem test results

33. Subsystem Block Diagram
Water Temp Input
Oil Pressure Input
MPH Input
RPM Input
Aerocomm AC4790
LabVIEW Display
Batt. Voltage Input
ATmega128
Aerocomm AC4790
Mention that Aerocomm is wireless transmission

34. Project Functional Requirements

35. Hardware & Software Used
Atmega128
Aerocomm AC4790
Laptop
Software
Atmel Studio
HyperTerminal
LabVIEW

36. Wireless Transmission Testing
Board to board
Board to HyperTerminal
Microcontroller to HyperTerminal
Fill empty slide space

37. Testing with Simulated Data
Linear Output
Oil Pressure, Water Temperature, Battery Voltage
Simulated with Power Supply
Pulse Output
Tachometer, Speedometer
Simulated with the Wave Generator
include sampling rates

38. Interfacing with LabView
Communication Protocol
Universal Asynchronous Receiver/Transmitter(UART)
Transmission Type
Ascii
Sent using packets
more discussion of packets

39. Subsystem Test Results
Wireless communication established
Microcontroller communication with HyperTerminal
Data displayed is current
Values displayed in ascii equivalent

40. Sean’s Agenda Functional requirements Subsystem block diagram
Equipment used
Interface Amulet with microcontroller
Prepare LabVIEW to display wireless data
Results

41. Functional Requirements & Specifications
Display data to driver and pit crew
Touchscreen display
Store data for review
UART communication
Does not interfere with driver performance
5 V power supply
No loose or exposed wires
Display real time data

42. Subsystem Block Diagram
5V Power Supply
Microcontroller
(ATmega128)
Amulet LCD
UART
Data From Wireless Transceiver
Laptop
(LabVIEW GUI)
RS-232

43. Hardware & Software Equipment Software Amulet LCD
ATmega128 (microcontroller)
DC/DC converter (±5 𝑉 , ±15 [𝑉])
Level shifter (+5 [V] to +3.3 [V])
Laptop
Oscilloscope
GemStudio Pro (Amulet display software)
Atmel Studio 6.1 (microcontroller software)
LabVIEW 2014

44. Amulet Subsystem Bl0ck Diagram
5V Power Supply
Microcontroller
Put Sensor Data in Array to Transmit
Send Data Array
Amulet Touchscreen
UART
100 ms interrupt

45. Amulet LCD Serial Protocol Microcontroller is master Amulet is slave
UART
Ascii
9600 bps baud rate
Transmit specific protocol to access variables
Microcontroller is master
Initializes communication
Amulet is slave
Full Protocol- Responds only if Amulet receives valid message
Add slide to prove that 9600 baud is fast enough.

46. Amulet LCD Internal RAM (IR) is memory on the Amulet.
256 byte variables
256 word variables (word = 2 bytes)
Can receive 14 different command messages from microcontroller
Can access internal RAM on Amulet
Changing and copying variables
Jump to different pages on display
Draw pixel, line, or box

47. Amulet Serial Communication Flow Chart
Op-code = Tells Amulet what type of variable is being accessed (byte or word)
Address = The variables location on the RAM of the Amulet LCD
Value = The data to be displayed on the Amulet LCD
Op-code
Variable Address
(High nibble)
Variable Address
(Low nibble)
Variable Value
(High nibble)
Variable Value
(Low nibble)
Figure 1 – Transmit protocol for a byte variable.

48. LabVIEW Subsystem Bl0ck Diagram
Put Sensor Data in Transmission Array
Send Array Data
LabVIEW
I/O Assistant
(Parse Data)
LabVIEW
Gauge Display
RS-232
100 ms interrupt
Log Data

49. Instrument I/O Assistant
LabVIEW Display
Serial Protocol
RS-232
Ascii
9600 bps baud rate
Transmit packets of data
Instrument I/O Assistant
Front Panel vs. Block Diagram
Connect blocks to data type and viewing method
Aerocomm
Transceiver
Laptop
(LabVIEW Display)
Instrument I/O Assistant
Display Data
Save Data
Technically EIA-232 but everyone refers to standard as RS-232.

50. Front Panel

51. Serial Communication Setup

52. Block Diagram

54. Subsystem Results
Successful interface between ATmega128 and Amulet LCD
Data sent and displayed on the Amulet LCD
Successful interface between Aerocomm Transceiver and LabVIEW GUI
Data sent, displayed, and stored on the LabVIEW GUI

55. System Test Results
Display data to driver with aggressive notification system
Race, demo, and practice modes
Wirelessly send data to pit crew’s laptop to be displayed on LabVIEW
Data logged via LabVIEW
Sensor’s acquire data with max error under 5%

56. Summary & Conclusion
BU ME’s require more advanced notification system for driver
Requires data logging, multiple display modes, and wireless transmission
System is functional
Requires installation and further testing

57. Sources
Q_final_report.pdf
2.pdf

58. Appendix

59. Initialization

60. ISR

61. .C/.h files

62. to_ascii

63. Amulet Ascii Transmit Protocol Example
Microcontroller
Set Byte Variable
Amulet Response
Microcontroller
Set Word Variable
Amulet Response
Figure 2 – Serial communication flow chart

64. Amulet Protocol Ascii
Example: microcontroller sets internal RAM (IR) word variable to specific value (0x02C9)
Figure 3 – Serial communication flow chart

65. UART Transmit 1V per division 0.5ms per division
Transmission contains:
{0x00, 0xD6, 0x31}

68. Maximum data log time Limited by max rows in excel
Max rows about 1 million
Log data every 100 [ms]
Max time = 27.8 hours
0.1 [sec/row] *1.2E6 [rows] = 100,000 sec
100,000 [sec] /60 [sec/min] /60 [min/hr] = 27.8 hrs

69. Max Transmission Rate with 9600 bps Baud Rate
1 bit sending time:
1/9600 = 104 us
Assume 16 byte packet
8 bits + 1 start_bit + 1 stop_bit = 10 bits/byte_sent
104 [us/bit] * 10 [bits/byte] * 16 [bytes/packet] = 16.6 [ms/packet]

70. Research Amulet serial communication protocol
LabVIEW Instrument I/O Assistant
Troubleshooting errors
Eliminate???