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Advanced Data Acquisition System for Formula Racing Car at Bradley University

The Electrical Engineering Department at Bradley University has developed an advanced data acquisition system for the SAE Formula Car to improve performance and prevent failures. The system monitors key data values, features an aggressive notification system, touch screen display, and wireless data transmission. Detailed division of labor, project requirements, sensor specifications, and test results are provided to highlight the system's design and functionality.

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Advanced Data Acquisition System for Formula Racing Car at Bradley University

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  1. 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 2

  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. 3

  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 4

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

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

  7. Division of Labor • Ahmed • 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 7

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

  9. Project Non-functional Requirements 9

  10. Project Functional Requirements 10

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

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

  13. Pressure and Temperature Sensor Circuitry 13

  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 14

  15. Temperature Sensor • ProSense TTD25N-20-0300F-H • Analog output: 4 to 20mA • Operating Voltage: 10 to 30VDC • Temperature range: 0-300 F • ¼ NPT • Cable : CD12L-0B-020-A0 15

  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 16

  17. RPM and Velocity Sensor • Supply Voltage: 4.5 - 24 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 17

  18. Temperature Sensor Result • Maximum 5% error • T = m × Io +k • m = 10418.75 • k = -59.48C • Linear Sensor • V = Io × Rf (Rf=250 ohms) T= temperature m = slope k = Temperature offset 18

  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 19

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

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

  22. Subsystem Block Diagrams Water Temp Input Amulet Touchscreen Home Page Oil Pressure Input MPH Input Demo Mode Aerocomm AC4790 RPM Input Race Mode Practice Mode Batt. Voltage Input Aerocomm AC4790 22 ATmega128 ATmega128

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

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

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

  26. Amulet Display Results • Aesthetics • Navigation • Widgets • Microcontroller communication 26

  27. Home Page 27

  28. Practice Mode 28

  29. Demo Mode 29

  30. Demo Mode 30

  31. Race mode 31

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

  33. Subsystem Block Diagram Water Temp Input Oil Pressure Input MPH Input RPM Input Aerocomm AC4790 LabVIEW Display Batt. Voltage Input ATmega128 Aerocomm AC4790 33

  34. Project Functional Requirements 34

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

  36. Wireless Transmission Testing • Board to board • Board to HyperTerminal • Microcontroller to HyperTerminal 36

  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 37

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

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

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

  41. Functional Requirements & Specifications FunctionalRequirements 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 looseor exposed wires Displayreal time data 41

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

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

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

  45. Amulet LCD • Serial Protocol • 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 45

  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 46

  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 Variable Address (High nibble) Variable Address (Low nibble) Variable Value (High nibble) Variable Value (Low nibble) Op-code Figure 1 – Transmit protocol for a byte variable. 47

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

  49. 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 Laptop (LabVIEW Display) Instrument I/O Assistant Aerocomm Transceiver Display Data Save Data 49

  50. Front Panel 50

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