hot wheelz powertrainedge.rit.edu/edge/p15280/public/msd ii/documentation...powertrain cart 2. have...

HOT WHEELZ POWERTRAIN

TEST BENCH USER MANUAL

P15280

Maura Chmielowiec: ME Jennifer Smith: ME

Eric Paterno: ME Henry Lei: EE

Vladimir Kravljaca: EE Dixon Wong: EE

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Table of Contents ACRONYMS ....................................................................................................................................................................................... 2

SAFETY PROCEDURE .......................................................................................................................................................................... 2

SAFETY SYMBOLS ....................................................................................................................................................................................... 2 High Voltage ................................................................................................................................................................................................... 2 Emergency Stop Button .................................................................................................................................................................................. 2 Safety Glasses ................................................................................................................................................................................................. 2 Pinch Point ...................................................................................................................................................................................................... 2 Heavy Item ...................................................................................................................................................................................................... 3

GENERAL SAFETY GUIDELINES ...................................................................................................................................................................... 3

MECHANICAL SAFETY GUIDELINES ................................................................................................................................................................. 3

ELECTRICAL SAFETY GUIDELINES .................................................................................................................................................................... 3

MECHANICAL SYSTEMS ..................................................................................................................................................................... 4

MOUNTING THE MOTOR & MOVING THE POWERTRAIN CART ........................................................................................................................... 4

MOUNTING THE DYNAMOMETER SPROCKET ................................................................................................................................................... 9

CHAIN MOUNTING ................................................................................................................................................................................... 13

CHAIN TENSIONER SETUP .......................................................................................................................................................................... 16

ELECTRICAL SYSTEMS ...................................................................................................................................................................... 23

KGCOE DYNAMOMETER QUICK START GUIDE .............................................................................................................................................. 23

KGCOE DYNAMOMETER LOAD CELL CALIBRATION GUIDE .............................................................................................................................. 29

TEST BENCH SENSOR GUIDE ....................................................................................................................................................................... 35 Types of Sensors ........................................................................................................................................................................................... 35 Specification/Calibration .............................................................................................................................................................................. 35 Thermocouple Set-up on test bench.............................................................................................................................................................. 37 Testing functionality of the Sensors .............................................................................................................................................................. 38

ELECTRICAL OPERATIONS- HARDWARE ......................................................................................................................................................... 41 Setup & Power on Procedure ........................................................................................................................................................................ 41 Power off Procedure ..................................................................................................................................................................................... 46

SETTING UP THE CAMERA .......................................................................................................................................................................... 47

GRAPHICAL USER INTERFACE ...................................................................................................................................................................... 48 Setting up the GUI for the 1st Time ................................................................................................................................................................ 48 Manual Mode Description ............................................................................................................................................................................ 50 Automated Mode Description ....................................................................................................................................................................... 50 Emergency Stop-Non Responsive GUI When Test in Progress ....................................................................................................................... 52 Manual Mode Operation .............................................................................................................................................................................. 53 Automated Mode Operation ......................................................................................................................................................................... 53 Closing Procedure ......................................................................................................................................................................................... 54

APPENDIX ........................................................................................................................................................................................ 55

Appendix A: Viewing Collected Data ............................................................................................................................................................. 55 Appendix B: Verifying COM Port ................................................................................................................................................................... 56 Appendix C: Changing the Code .................................................................................................................................................................... 56 Appendix D: Downloading NI support for Matlab ......................................................................................................................................... 58 Appendix E: Visual Studio Premium 2012 Installation ................................................................................................................................... 77

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Acronyms DAQ: Data Acquisition

DUT: Device Under Test

GLV: Ground Low Voltage

GUI: Graphical User Interface

KGCOE: Kate Gleason College of Engineering

NI: National Instruments

USB :Universal Serial Bus

Safety Procedure

Safety Symbols The following symbols will be used throughout this manual and in other documentation related to the RIT Hot Wheelz Test

Bench. When you see a safety symbols, please take the necessary precautions to midget injuries.

High Voltage The following symbol indicates that high voltage is live and present. This means that nobody should be

working on or around the cart until the high voltage has been shut off by the emergency stop button.

Additionally, insulated tools should be used on the cart while batteries are connected to the system. NOTE:

Only highly trained members should be near the cart while voltage is live

Emergency Stop Button The following symbol indicates that all emergency stop buttons MUST be pressed, cutting all power to the

system, prior to performing the desired task OR when the cart is no longer in use and being transported. The

system SHOULD NEVER be left live while unattended.

Safety Glasses The following symbol indicates that safety glasses MUST be worn while performing the specified task.

Additionally, safety glasses should be worn at all times while working on or around the cart.

Pinch Point The following symbol indicates that there is a pinch point hazard which means extra caution should be

taken when working on or around this sub-system or your fingers or hands could be seriously injured

or even cut off. Be aware when you are working on a system with this hazard.

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Heavy Item The following symbol indicates that the object is heavy and requires two people to move or

lift the object. Injuries could occur from dropping the object if one person attempts to lift or

move it.

General Safety Guidelines Read ALL user guides before using or working with the test bench.

Never transport or operate the system alone. Two people should always be present in case of an accident and one

person needs to get help.

Proper Personal Protective Equipment must be warn when specified.

When approaching the test bench, ALWAYS check that the electrical system is off before working or testing the system.

The cart wheels should be locked at all times when not in transport. This will prevent the cart from moving around

while working on it.

Only work on ONE sub-system at a time (chain, motor, batteries, controller, sensors, power supplies, DAQ, or GUI).

There should never be more than 6 people in the dyno room at the same time.

All team members should leave the dynamometer room and the door should be locked before the dynamometer is

powered on.

Never perform a task you are unqualified to do. If you are unaware of how to do something always ask the safety

manager for assistant.

If you suspect something is broken or not working correctly, report it to the Chief Engineer, Project Manager, and Safety

Manager immediately.

Mechanical Safety Guidelines Never work on a mechanical sub-system while the electrical system is on or troubleshooting is occurring. All team

members should be focused on the same system.

Nobody should be between the dynamometer and the chain or idler system while it is in motion. Remain at least 6 feet

behind.

Be aware of the Pinch Points when working with or around the chain and sprockets.

Electrical Safety Guidelines All Estops must be down while attending to the system.

Never troubleshoot or test the electrical system if a mechanical system is being fixed or tested.

Never operate the system without proper connections, including lugs, Molex connectors, and quick disconnect

connectors.

Never touch live wires, especially with metal tools.

Understand how each electrical component functions and what it is capable of before troubleshooting.

Check that the system under test is operational before starting test

Check the systems battery voltages prior to beginning test

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Mechanical Systems

MOUNTING THE MOTOR & MOVING THE POWERTRAIN CART 30 Minute Assembly Time

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Safety:

STEP 1: ACQUIRE MATERIALS

1. Locate the following Equipment:

a. Motor Mount with Motor b. Powertrain Cart

2. Have the following tools/hardware ready:

a. Nuts and Bolts to Fasten the Motor you are Using

b. Sockets c. Ratchet

STEP 2: INITIAL PLACEMENT

1. Lift Motor Onto Powertrain Cart

a. Ensure that the two casters on the powertrain cart are locked, so that the cart doesn’t move

b. Two people must lift the motor onto the wooden platform in the front of the motor cart

c. Align the slots on the mount with the corresponding holes on top of the wooden platform

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STEP 3: FASTEN MOTOR TO

THE PLATFORM

1. Bolt Motor to Wooden Platform

a. When the motor mount holes/slot is aligned to the wooden platform, insert all 4 X 3/8” bolts through to the bottom of the wood

b. Fasten the 3/8” nuts to the bottom of the bolts

c. Using a Ratchet and a 9/16” Socket head, tighten the bolts so that the motor is secured to the cart

STEP 4: TRANSPORT

POWERTRAIN CART

1. Unlock the casters on the cart

2. Carefully maneuver the powertrain cart from your location into the dyno room

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3. Push the cart in, motor first until you are at the dyno as seen in the image to the left

NOTE: This is a two person operation, one person pushing the

cart while the other person ensuring that the cart will not hit anything

during transportation

STEP 5: MOVING THE

MOTOR MOUNT FROM THE

CART TO THE DYNO

1. Lock the Casters on the cart to ensure the cart is secured

2. Unfasten the Motor from the Cart

a. Using the 9/16” Socket and Ratchet remove the screws holding the motor to the cart

3. Lifting the motor to the dyno

a. Two people will lift the motor off the cart and

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place onto the dyno platform

NOTE: One person must pay attention so that the wires

STEP 6: MOUNTING THE

MOTOR TO THE DYNO

PLATFORM

1. Bolt the motor to the dyno platform

a. Using the proper fasteners for the motor you are using, bolt down the motor so that it is secured to the dyno table

NOTE: The motor will need to be adjusted side to side to align the chain properly so hand tightening

the motor at this point is acceptable

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MOUNTING THE DYNAMOMETER SPROCKET

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Safety:

Sprocket Face Plate

Sprocket Assembly

STEP 1: GATHER MATERIALS

1. Source the following components: a. Sprocket face plate b. Sprocket assembly

2. Source the following parts:

a. 5x 5/16” Hex head set screws

b. 10x 5/16” washers c. 5/16” T-handle Hex tool d. Adjustable wrench e. 30mm dynamometer

center screw and lock washer

STEP 2: ASSEMBLY

1. Assemble the gathered materials as shown in the drawing

a. Some 5/16” set screws may not easily pass through the holes in the sprocket assembly. If this happens, use the 5/16” T-handle Hex tool to screw them all the way through.

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STEP 3: MOUNTING

2. Position the assembly

a. Move the assembly to the dynamometer mount

b. Align the 5 5/16” set screws with the corresponding 5 tapped holes in the mount on the dynamometer

c. Carefully slide the assembly back onto the mount, ensuring that the holes are still aligned.

3. Securing the assembly

a. Use the 5/16” T-handle Hex tool and the “star” tightening pattern at left to tighten down the 5/16” set screws. This ensures even displacement of the screws and keeps the assembly plumb.

b. At each screw, tighten three turns before moving to the next screw in the pattern.

c. Repeat this process until all 5 sets of washers touch the dyno mount. Visually inspect the assembly to ensure it is

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plumb, and finish tightening the 5 screws.

d. Place the 30mm dynamometer center screw and lock washer in the center hole and hand-tighten as much as possible.

e. Use the adjustable wrench to finish tightening 30mm center screw.

f. The assembly may rotate; try to hold the sprocket in place to finish tightening. It is not critical for the screw to be super-tight

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CHAIN MOUNTING

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Safety:

Dynamometer Without Chain Installed

Dynamometer Sprocket

Pulling Chain Toward Motor

STEP 1: GATHER

MATERIALS

1. Source the following components:

a. Chain b. Alignment Bar (Machine

shop office)


a. Motor sprocket b. Motor shaft keyway c. Two mounting set screws

for motor sprocket d. Allen wrenches for motor

sprocket mounting set screws

STEP 2: POSITION CHAIN

1. Wrap the chain around the dynamometer sprocket as shown

2. Add the motor sprocket to the chain and slowly pull it back toward the motor shaft

3. Add keyway to slot in motor shaft

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Aligning Sprocket with Shaft Keyway

Using Hammer to Complete Initial Mounting

STEP 3: MOUNT MOTOR

SPROCKET

1. Rotate the chain to align the keyway slot in the motor sprocket with the keyway on the shaft

a. Once aligned, push the sprocket toward the motor so it remains in place

2. Use rubber hammer to tap sprocket the rest of the way on the shaft

3. Use the alignment bar to align the motor sprocket to the dynamometer sprocket (See Step 4 of Chain Tensioner Setup)

a. The chain shall be parallel to the motor mount edge.

4. Use the Allen wrenches to tighten the two motor sprocket set screws

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CHAIN TENSIONER SETUP

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Safety:

Initial Placement

STEP 1: GATHER

MATERIALS

1. Source the following components:

a. Chain Tensioner b. Alignment bar


a. 4x 3/8” Set Screws b. 8x 3/8” Washers c. 4x 3/8” Nuts d. 1x Allen wrench for 3/8”

hex head e. 2x 3/4” wrench f. 1x 1/2” wrench

STEP 2: INITIAL PLACEMENT

2. Slide the chain tensioner under the chain

a. Chain will rest next to the sprocket on the side closest to the dynamometer

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Alignment with Hole Pattern

Placing in 4x set screws with washers

STEP 3: SET UP FOR CHAIN

ALIGNMENT

1. Place the chain on the idler sprocket

a. Lift the chain, slide the chain tensioner toward the dynamometer, guide chain onto sprocket

2. Position the chain tensioner so that all four holes are visible in the slots

a. Proper positioning is 5 holes from the north of the room, 3 holes from the front edge of the table

3. Place a set screw with washer through each of the 4 holes

5 Holes

3 Holes

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Checking Alignment with Alignment Bar

STEP 4: ADJUST

ALIGNMENT

1. Position the alignment bar

a. Rest one end on the motor sprocket and hold the other end by the dynamometer sprocket

2. Check and adjust alignment

a. Proper alignment is indicated by the alignment bar being parallel to the motor mount

b. Slide the chain tensioner to adjust the lower alignment

c. Use rubber hammer to adjust the motor sprocket position

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Secure Aligned Chain Tensioner To Table

STEP 5: SECURE CHAIN

TENSIONER

1. Ensure chain tensioner has not moved since the previous step

2. Tighten chain tensioner to table

a. Slide a washer and hand-tighten a nut onto the bottom each of the 4 3/8” set screws

b. Hold the bottom nut with a 1/2” wrench while tightening the set screw with the Allen wrench.

c. After tightening, push on the chain tensioner in a direction parallel to the slots to ensure it is secure.

FRONT

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Adjusting and Checking Chain Tension

STEP 6: ADJUSTING

TENSION

1. Move the idler sprocket shaft up to increase chain tension

2. Use the alignment bar to check chain tension

a. Lightly tighten the idler sprocket shaft to fix it in place

b. Rest one end on the motor sprocket and hold the other end by the dynamometer sprocket, touching the chain on both sides.

c. Use your hand to displace the chain upward in the center of the upper span until it cannot move upward any more

d. Proper tension is reached when the perpendicular distance from the alignment bar to the displaced chain (at the location displaced) is 1/2”

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Locking Idler Sprocket in Place

e. If the proper distance is not met, loosen the idler sprocket shaft and repeat this process

STEP 7: LOCKING TENSION

1. Use the two 3/4" wrenches to tighten the idler sprocket shaft

a. Keep the right wrench vertical and tighten the left wrench three full revolutions

STEP 8: FINAL INSPECTION

1. Check chain tension to ensure it has not changed

2. Check all nuts and screws to ensure tightness

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Electrical Systems

KGCOE DYNAMOMETER QUICK START GUIDE This quick start guide was written by the P15280 senior design team to assist any team working with the dynamometer and to provide clarification on anything that may not be up to date in the official Dyn-Loc IV user manual and quick start manual. The

manufacturer’s documentation can be found at the links below. User Manual- http://www.dynesystems.com/PDFs/Dyn-LocIV_User_Manual.pdf Quick Start Guide- http://www.dynesystems.com/PDFs/Dyn-Loc-IV-QSG.pdf Overview of the environment The dynamometer system is split into two rooms, a test room and a controls room. The picture below shows the test room complete with the dynamometer and auxiliary cooling solutions. There is an access port in the wall at the right for controls and data acquisition cabling and is connected to the equipment bay in the controls room. The electric motor or engine to be tested, DUT, is mounted to a rigid platform and coupled to the dynamometer input shaft with a chain and idler system. The regenerated power from the dyno is fed back into the building’s power bus.

Pictured below is the controls room equipment bay. The Dyn-Loc IV controller on the top rack as well as the PC is available for use by anyone in KGCOE. Additional instrumentation shown is dedicated for Formula SAE only use.

http://www.dynesystems.com/PDFs/Dyn-LocIV_User_Manual.pdf

http://www.dynesystems.com/PDFs/Dyn-Loc-IV-QSG.pdf

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Steps to operate the Dyno without a DUT 1. Before operating the dyno, make sure the circuit breaker in the test room is ON. The picture below shows the circuit breaker labeled Dyno Motor Power in the test room. If the dyno is turned on while the breaker is OFF, you will need to reset the breaker located in the basement by switching it off for 30 seconds. (Please refer to the section below How to Reset Basement Circuit Breaker for additional information.) It is important to vacate the test room and close the door before operating the system.

2. There are two ways to operate the Dyn-Loc IV controller. To control it manually, refer to the picture and instructions below.

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A. (REFER TO GREEN rectangle) First, make sure the controller is set on MASTER mode by depressing the MASTER push button and observing that the switch indicator is lit. B. (REFER TO ORANGE rectangle) Set it to RPM or TORQUE mode as desired. Change the RPM/TORQUE switches to the desired speed or force and hit the ACTIVE button to use either the top or bottom switch settings. The switch should be fixed so the light comes on when it is supposed to. C. (REFER TO PURPLE rectangle) Depress the Auto Zero switch while the dyno is off for measurement accuracy. Set the LAC to the desired acceleration rate for the dyno to reach the desired RPM/TORQUE. D. (REFER TO RED) Press DYNE ON to start the dyno. 3. To control the Dyne Controller remotely, use an application program such as RealTerm. Open the program and select the port tab. Set the baud rate to 19200 and set the port to COM2. Finally click change to connect to the Dyn-Loc.

To communicate with the controller select the Send tab. On the left there is a text field where the user can enter desired commands and click Send ASCII to send the command. The Dyn-Loc should reply with a “\” as an acknowledgement. Each sent command should end with carriage return and newline characters, \r\n.

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To test the operation of the dyno use the following commands. Procedure Command

1. Set controller to computer mode MD COMP\r\n

2. Set controller to RPM mode MD RPM\r\n

2. Set linear acceleration rate LAC 100\r\n

3. Set the RPM set point SP 1000\r\n

4. Turn the Dyn-Loc on MD DON\r\n

5. Get speed, torque and power data, confirm 1000RPM

AD\r\n

6. Set RPM set point to 0 SP 0\r\n

7. Turn Dyn-Loc off MD DOFF \r\n

4. At the completion of testing, turn off the dyno and the main circuit breaker (mentioned in step 1). Remove all test hardware so the system is ready for the next user. Problems and discrepancies with official Manual and Quick Start Guide.

According to the manual, the set baud rate for the Dyn-Loc IV controller can be found through the different combination of switches as seen in the picture below. Since switches 1, 2 and 3 are on, the baud rate should be 256k, however this is inaccurate. The baud rate to connect with the controller is 19200.

According to the manual, the H20 terminal and I.L. terminal has to be wired together for the DYNE ON light to stay on as shown in the picture below. Please note that this is NOT required for operation.

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How to Reset Basement Breaker 1. Obtain basement key from Rob Kraynik, Jan Maneti or any other machine shop personnel from the machine shop office. If you are new to the shop, ask for assistance before entering the basement. 2. The picture below shows the entrance to the basement, next to the entrance of the ME Machine Shop located at GLE-2430.

3. At the bottom of the stairs, turn walk past the locked gate shown in the picture below.

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4. At the end of the basement, enter the room in the picture below.

5. You will see many circuit breakers. The one you are in interested in resetting to the right labeled Dyno Master Power Switch. Refer to the picture below. As mentioned at the beginning of this guide, switch off the breaker for 30 seconds before switching it back on.

6. On your way out, lock the gate and return the key to machine shop office.

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KGCOE DYNAMOMETER LOAD CELL CALIBRATION GUIDE This quick start guide was written by the P15280 senior design team to assist any team working with the dynamometer and to

provide clarification on how to calibrate the load cell.

BEFORE CALIBRATING THE LOAD CELL, MAKE SURE

All systems are powered off

User can carry at least 50lbs of weight Steps for Load Cell Calibration (When done correctly, process takes ~5 minutes)

1. Please refer to the diagrams below.

Make sure:

Dyne-controller is on MASTER and TORQUE MODE (Fig 1)

ACTIVE light on (Fig 1)

Also, please make sure the dynamometer power switch is off (Fig 2) as well as the power for DUT (Device under

test) to prevent any possible injuries of the dyno operating when user is in the room.

Fig 1: Dyne controller

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Fig 2: Dyne Power Switch

2. Fig 3 below shows the weights used to calibrate the load cell. We will only be using the two 50lb plates and one 20 lb

plate.

Fig 3: Weights

3. With no weight on the calibration bar, press auto-zero on the dyne-tower in control room.

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Fig 4: Auto Zero on Dyne Controller

4. Fig 5 below shows the weight holder used to hold the weights on the calibration bar. Fig 6 shows how the weight

holder is installed onto the calibration bar. Follow Fig 7 to place the three weights onto the weight holder.

Fig 5: Placing weights on with weight holder

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Fig 6: Installment of weight holder on calibration bar

Fig 7: Using Weight holder to place 3 weights (2 50lbs 1 20lbs) onto calibration bar

5. Referring to Fig 8 below, input torque into the tower (3611). We are using 3611 because the calibration bar is 3ft long

with 120 lbs of weight. 3*120 = 360 plus extra for offset.

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Fig 8: Inputting Torque on dyne controller

6. Referring to Fig 9 below, press the auto span button on the dyne controller.

Fig 9: Auto Span on Dyne controller

7. Refer to Fig 10 below, after auto spanning, change settings back to 0000. The load cell is successfully calibrated.

3611

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Fig 10: Setting back to 0000

8. Remove weight from calibration bar and place it back to the corner of the floor where you found it (Fig 3) as well as

the weight holder (Fig 5).

0000

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TEST BENCH SENSOR GUIDE

Types of Sensors 2: K-type thermocouples

o Sense temperature of AC motor and DC battery

1: CR5310-600 DC Voltage Transducer

o Monitor DC voltage of batteries of up to 600Vdc

1: CR4511-500 AC Voltage Transducer

o Monitor AC voltage of motor of up to 500Vac

2: Honeywell CSLA2EL Current transducer

o Monitor AC current of motor and DC current of batteries of up to 500A AC/DC

Specification/Calibration Sensor Analog/Digital

Output Senses Power

Supply Needed

Output range Calibration

CR5310-600 Analog DC voltage 24V 0-5Vdc Vin=120Vout

CR4511-500 Analog AC voltage 24V 0-10Vdc Vin=50Vout

CSLA2EL Analog AC/DC current

10V Depends on supply voltage

Current=(Vout-5)/(4.3*10^-3)

K-thermocouple Analog Temperature N/A Read by program

Read by Program

Where

Vout is the voltage outputted by sensor

Vin is the voltage that is monitored

Please note that Vin for AC voltage is RMS value and is equal to Vpp/(2*radical(2)).

The section below shows the pin layout and specifications for each sensor used in this project.

1. CR4511-500 (AC voltage transducer)

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2. CR5310-600 (DC voltage transducer)

3. CSLA2EL (AC/DC current transducer)

Pin schematic is not available. There are three pins, (+) for positive power supply, (-) for ground and (o) for output.

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Thermocouple Set-up on test bench **Please refer to hardware section of Electrical Operation Manual for detailed information in setting up voltage and

current sensor on the test bench

There are two thermocouples used in this project to monitor temperature of the motor and battery. Below are pictures of

their position for test bench purpose. **Please note that for better accuracy, thermocouples with a shorter rod should be

used. Also, the location of the thermocouple may vary, depending on the motor used. The motor shown in the picture is an

old DC motor, for the AC motor to be used by Hot Wheelz, please check with manufacturer to see which location is most vital

for temperature monitoring. The same goes for the batteries.

The pictures below show the NI DAQ (left) used for processing the analog output data from the sensors. The module shown on

the right is used to connect the leads of the thermocouple. Please note that the program is currently set to process

thermocouple data in ports 0 and 2 of the module. If additional thermocouples are used for future purposes, be sure to turn

on acquisition from the other ports in the software code.

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Testing functionality of the Sensors The section below talks about the verification of the sensors before placing onto the test bench. For step by step procedures of

the tests, please refer to P15280 Test Plan documentation. The section below talks about the results from testing sensors used

in this project. Please refer to pin information mentioned in section above to correctly connect each sensor.

A. AC voltage transducer test

For the AC voltage transducer, 24Vdc is applied as the power supply between pins (5) and (6). AC voltage is applied to pins (1) and (3). Output result can be read from pins (8) and (6). The table below shows the output DC voltage from the sensor as the result of the various AC voltages applied. The sensitivity equation calibration Vin=50Vout is applied to the result to find the actual AC voltage of the system, where Vout is the voltage output by sensor and calculated Vout is the output we expect from the sensor for the input voltage applied. For additional clarification, Vpp refers to the value from AC power supply. To convert it to Vin, use the formula Vin = Vpp/(2*radical(2)). As can be seen, the sensor is more accurate as higher voltages are applied. (Please note that this is only application for when an AC motor is used, otherwise, use setup/calibration from the DC voltage transducer).

B. DC voltage transducer test

For the DC voltage transducer, the setup is identical to AC voltage transducer. The sensitivity equation is Vin=120Vout. Like the

AC voltage transducer, the readings are more accurate as higher voltages are applied.

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C. Current Sensor test

The photo above contains the setup for testing the current transducers. 8 Vdc is supplied to power the sensor (Test bench will

use Vdd as 10Vdc) through (+) and (-) pin. Different input voltages are applied and connected to the 10W resistor (to generate

different currents) and through the current sensor. The current received by the sensor is amplified by the amount of loops (N).

In this case there are 20 loops. The output is hooked up to a multimeter through the (o) pin and reads as

Vdd/2+4.3mV*N*current. Referring to the results table below, the error ranged from 0-10%.

Please note that the test uses 20 loops since the sensor senses up to 500A and has trouble measuring low amperage. Also, a

10W resistor is used since Power = Voltage * Current and normal 0.5W resistors from EE labs will easily burn up.

C. Thermocouple test

The picture below contains the setup for testing thermocouples. Two thermocouples are hooked up to the data acquisition

modules. The cooking thermometer shown is used to verify the output. Ice is applied to the bowl of water until the temperature

reached ~0 degrees Celsius. The temperature is captured at 5 different points and can be seen in the table above, the error

ranges from 0 to 1.4 degrees Celsius between the two thermocouple outputs and the cooking thermometer.

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Troubleshooting/Additional Tips

Current Transducer Pins are very fragile, as they are exposed and are connecting directly to the circuit board. Take extra

care when connecting/disconnecting connectors around pins and try to limit possible sources of vibration to the pins

during testing.

K-type thermocouples used in this project are connected to a long metal rod which senses temperature. For more

accurate measurements, source a shorter rod so that the sense area is smaller and more precise.

Voltage transducers used in this project have warranty from manufacturer until September 2016. This warranty covers

the cost of troubleshooting and mailing fee from the manufacturer back to you.

Make sure voltage transducers have a regulated power supply. For some reason, the power supply from 3rd floor EE

Electronics labs managed to burn the supply fuse a couple of times.

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ELECTRICAL OPERATIONS- HARDWARE This section covers the hardware portion of the electrical systems on the test bench. Readers reading this guide should

familiarize themselves with all the figures in this guide and read the complete guide prior to installation.

Figure 1 – Diagram of Electrical System

Setup & Power on Procedure 1. Prior to taking the bench to into the dyno room:

a. Remove the key from the key switch in the DUT. This is dependent on the DUT (device under test) and please

consult with others if unsure where the key-switch is located (most likely it will look familiar to a regular lock

with a slot for a key).

b. Check the battery voltages of the testing unit. The GLV voltage should be at 12 or above, and the tractive

system voltage should be at 72 V or above. Figure 2 and Figure 3 below captures the GLV and tractive system

voltage probe points. The black box denotes where the black probe should go and the red box denotes where

the red probe should go. The actual Formula hybrid electrical system will have different voltage probe points

and ratings. DO NOT OPERATE IF THE VOLTAGES ARE NOT MET.

Control Room Dyno Room

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Figure 2 – GLV Battery

Figure 3 – Tractive system battery

c. When the NI DAQ power (labeled 1. DAQ Power in Figure 1) is plugged into the wall (main power, AC 110V,

etc.), turn on the DAQ. The Ready and Active lights should light up or flash. A picture of the DAQ is in Figure 4.

Turn off and unplug the DAQ after checking.

d. Similarly, when the electronic enclosure box (labeled 2. Sensor Power in Figure 1) is plugged into the wall, the

green LED that’s outside of the black enclosure lights up. A picture of the box is in Figure 5. Unplug the cord

after checking.

e. Disconnect the Analog Voltage Throttle connection from the DAQ, per Figure 1.

Figure 4 – Picture of DAQ

Figure 5 – Picture of electronic enclosure box

2. Place the DAQ and the electronic enclosure in their respective spots on the cart if they are not already. A picture of

where they should be is in Figure 6. The electronic box should be situated on a metallic mount on the back plate with

Velcro, and the DAQ should be in the corner of the cart.

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Figure 6 – Locations of electronic enclosure and DAQ

3. Upon arrival to the dyno,

a. For safety, activate ALL E-Stop (on the testing unit, the dyno, etc.). Activate means that the E-stops are pressed,

and the Dyno power switch is off. Please consult others if unsure where the E-stops are located or if they are

activated or deactivated.

Figure 7 – Dyno power switch in its off position

b. Obtain a welder rod and proceed to bend a hook at the end, or obtain a measuring tape and tape. These will

be used to feed harnesses and cables from the dyno room to the control room.

c. Feed the USB cable through the wall (from the dyno room to control room).

d. Feed the connector labeled E-Stop Harness Control through the wall as well. The connector will be located at

the end of a very long harness with grey sleeve.

e. Wait till all mechanical installations are done.

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4. Power the DAQ and electronic enclosure by plugging the wall-plugs into the wall.

a. Ensuring the Analog Voltage Throttle is still disconnected, plug the DAQ Power and Sensor Power into the wall,

turn on the DAQ.

b. Then using Figure 1, connect all remaining connectors by matching the names on them. If the names don’t

match, do not plug them in!

i. The connectors are keyed, with matching wire colors (black-black, red-red).

c. The RS232 cable goes between the Dyn-Loc controller (Figure 10)’s serial port (which is located on the back

and there should be a cable plugged into it already) and the only light-blue connector on the back of the

desktop. User may have to unplug connector captured in Figure 9 from another desktop (record the location,

and note that the connector will have masking tape with the word comp on it). Connect the two connectors in

Figure 8 and Figure 9. Ensure to return the connector in Figure 9 to its original location once testing is done

d. The USB cable can be connected directly to the desktop.

Figure 8 – picture of light-blue connector on the back of the

desktop

Figure 9 – picture of the other end of the RS232 cable

that’s connected to the back of the dyno-controller

Figure 10 – front of dyn-loc controller (dyno controller)

5. Inspection

a. Visually inspect that there is no unconnected connectors on the cart. If there are, please consult others prior

to proceeding.

b. Visually inspect that both current sensors have wires through the opening.

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Figure 11 – Current Sensor on Left and Voltage Sensor on Right

c. Visually inspect that that the AC voltage sensor is connected to an AC voltage source (i.e. the actual

Hotwheelz competition motor), and the DC Voltage sensor is connected to a DC voltage source (i.e. battery

terminals or the go-kart DC motor).

d. Refer to the Sensor Guide for installation of the thermal couples.

6. Safety off procedure

a. Ensure the mechanical installations are done, and no one is near the moving components of the cart.

b. Activate the key switch on the testing unit.

c. Deactivate (lift up) the control-room E-stop, which should already be installed and connected to a harness in

step 4b.

d. Turn key switch on and off to ensure the contactor is functioning (indicated by the clicking noise when

turned)

e. Leave the key switch on the ON position (to the right), then activate and deactivate the control-room E-stop,

while another person is in the dyno-room. Ensure the contactor is functioning (again by the clicking noise).

f. Connect the analog voltage throttle if it isn’t connected already.

g. Ensure the GUI is not running.

h. Double check to ensure no one is near moving components of the cart.

i. Lift up the testing unit’s main E-stop.

i. Now the DUT is HOT

j. Lift up the main dyno-switch in the dyno-room.

i. Now the Dyno is HOT

k. Exit the dyno room.

Figure 12 – Picture of E-Stop in its deactivated (lifted) position

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Power off Procedure Steps 1, 3 and 5 must be done prior to ANY mechanical modifications to the system.

1. Activate (press) E-stop in control room (captured in Figure 13).

2. Ensure the GUI is off. Please refer to the GUI user manual if unsure if it’s shut off.

3. After entering the dyno room, activate emergency stop on the device under test (the big red button on the cart).

Please consult others if unsure of the location of the e-stop.

4. Turn key in key switch to off position, remove key.

a. Now the DUT is off.

5. Turn off dyno switch, which is captured in Figure 7.

a. Now the dyno is off.

6. Unplug the Analog Voltage Throttle connection from the DAQ.

7. Turn off and unplug the DAQ.

8. Unplug the sensor power cord from main power.

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SETTING UP THE CAMERA

To open up the Camera:

Step 1: On the desktop, locate the webcam icon and double click

Step 2: A pop up window will open, select Quick Launch

Step 3: With the help of a team member, position camera in the dyno room to look at both the motor and dyno sprocket

Step 4: Position the pop up window in the bottom left corner of the screen

Set up complete

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GRAPHICAL USER INTERFACE

Setting up the GUI for the 1st Time

To set up application File:

Step 1: In the Files provided find the folder titled GUI src

Step 2: Open the folder GUI src

Step 3: Open the folder titled Hot Wheelz Test Bench

Step 4: Open the folder titled Hot Wheelz Test Bench (within the previous Hot Wheelz Test Bench folder)

Step 5: Open the Bin folder

Step 6: Open the Debug folder

Step 7: Right click on the file titled Hot Wheelz Test Bench.exe and press copy

Step 8: Paste to the desktop

To set up MATLAB script files (used by GUI)

Step 1: In the Files provided find the folder titled HotWheelz_GUI and right click on it

Step 2: Press copy

Step 3: Go to the desktop and paste it there

Set up complete

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Figure 1: Screen Capture of Graphical User Interface

Description of GUI Functionality

There are two modes – Manual Mode and Automated Mode. In Manual Mode the user is able to vary the throttle

position, linear acceleration rate (LAC), and RPM of the dyno in real time. In Automated mode the user is able to apply

a simulation profile with predetermined test parameters and execute them with the click of a button.

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Manual Mode Description

Throttle Position Slider

This slider is able to vary the voltage applied to the controller, which results in the Hot Wheelz motor spinning.

When manual mode is started, the default value outputted is 0.5 V, because this is the minimum required by

the controller to get the Hot Wheelz motor to spin. The first three ticks of the slider are the dead zone – these

correspond to an output of 0.5 V. Each additional tick after the third adds 0.25 V to the throttle voltage. The

maximum voltage output is limited to 5 V.

RPM Text Box and Buttons

The RPM text box allows the user to set the angular velocity at which the dyno motor will spin. The dyno control

system operates by speed control and when the RPM is set, it should be seen when applied no matter what

the Hot Wheelz motor throttle position is set to. The RPM value is input as an integer. The minimum value is

100 and the max is 999.

The apply button takes the value inputted into the text field and sends the set point to the dyno controller. The

user can repeatedly send new set points by entering a value and clicking apply.

LAC

The LAC is the linear acceleration rate of the dyno. For example, if the angular velocity is set to 100rpm and

the LAC is set to 39 and a new set point of 178 rpm is applied, it will take two seconds to make the transition

because the units of the LAC are RPM/sec. The minimum value is 39 and the maximum is 539. The default

value is set to 39 (first tick). Each additional tick adds 50 to the LAC. The LAC will only be applied after the user

lets go of the mouse.

Automated Mode Description

When Automated Mode is selected, the Simulation Profile text box will be enabled. The format of the simulation profile is best

described through an example profile. The profile must be at least one lines for it to function correctly. The example profile can

be seen below.

100 500 100 005

050 200 039 010

025 150 100 007

025 200 100 005

- The Throttle Position, RPM, Linear Acceleration Rate, and Duration are inputted in order.

- The format is XXX_XXX_XXX_XXX. The values are separated by a single space.

- The first XXX represents the Throttle Position, expressed as a percentage (010-100).

- The second XXX represents the dyno RMP (100-999).

- The third XXX represents the Linear Acceleration Rate (LAC) (039-539).

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- The fourth XXX represents the duration the above parameters are applied for (005-999).

- Ensure that at least one line is filled and there are no empty lines at the bottom.

- Each integer value must take up 3 spaces, for example, 5 must be written as 005.

Once the start button is clicked, the GUI will check the inputted values and if they are within range the Automated Mode will

begin, else a message box will be displayed indicating an error. There can be no empty lines for the profile to pass inspection.

The user must confirm that the text cursor is located to the right of the last duration value before starting or an error will be

displayed.

When the test begins, the Hot Wheelz and dyno motors will be brought up to speed before applying the first simulation profile.

As the duration of each profile expires the GUI will apply the next profile in line and will continue to do so until the last one has

expired. The dyno control system operates by speed control and when the RPM is set, it should be seen when applied no matter

what the Hot Wheelz motor throttle position is set to. After the execution of the last profile, the Hot Wheelz motor and dyno

will come to a stop, a test complete message will be shown, and the serial communication between the dyno controller and GUI

will be closed.

Start Button

When clicking this button it is expected that the equipment is set up and the user is ready to begin the test. Clicking the

start button will make the GUI connect to the dyno through RS232 communication. If the interlock status bar is red,

clicking start will force a message box to be displayed indicating that the interlock needs to be reset. The test will be

able to begin given that the interlock status bar is green.

Stop Button

By clicking the stop button the user forces the dyno and Hot Wheelz motors to stop spinning, i.e. the “dyno off”

command is sent to the dyno controller as well as a voltage of 0 V is set for the throttle. Additionally, the serial port

between the GUI and dyno controller is closed.

Reset Button

This button must be pressed whenever the user wants to begin a test and the interlock status bar is red. The interlock

status bar becomes red when one of the E-Stops is activated. Activating any of the E-Stops will cause both the dyno and

Hot Wheelz motors to come to a complete stop. Once the E-Stops are reset the user will be able to hit the Reset Button

to clear the fault and begin the test.

Test Progress Text Box

This text box will display any relevant information the user might want to be aware of. Such as whether or not the serial

connection was able to be made.

Before Opening GUI

1. Confirm that all other systems are ready.

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2. Verify that the USB-to-Serial connecter is plugged into the correct USB port (see Appendix B) and that the computer

and dyno controller are connected.

3. Confirm that the DAQ is turned on and plugged into the computer.

4. Confirm that the Hot Wheelz motor spins in the clock wise direction (when looking at the dyno from the entrance).

6. Confirm that the folder titled HotWheelz_GUI is located on the desktop.

7. Do not start GUI if the above requirements are not met.

Emergency Stop-Non Responsive GUI When Test in Progress

The user is able to activate the E-Stop switches at any point while the GUI is open. Activating causes a test in progress to come

to a stop and the Hot Wheelz motor and dyno motor are brought to a complete stop.

There may arise a situation where the computer freezes and the GUI is not responsive. In the event this occurs the E-Stop

switch is connected to the Hot Wheelz system directly as well as through software. Activating the E-Stop in the case of

application freeze will still stop the Hot Wheelz motor; however the dyno motor will remain active. To bring the dyno motor to

a stop the user must interact with the manual controls of the dyno controller. Refer to the steps below to manually stop the

dyno motor.

Step 1: Hit the MASTER Button

Step 2: Hit the DYNE OFF button

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Manual Mode Operation

Double click Hot Wheelz Test Bench.exe icon on the desktop to open the GUI, be patient, it may take some time to open up.

Step 1: Select the Manual radio button located at the top left of GUI.

Step 2: Ensure that the Interlock Status bar is green.

If red – Ensure all E-Stops are in the up position and that the NI-DAQ is on and hit the reset button

Step 3: Hit the start button

- GUI will attempt to connect to dyno controller.

- 0.5 V will be applied to the throttle, i.e. the minimum amount required for the Hot Wheelz motor

to begin spinning.

- Dyno motor will limit the RPM to 150 by default

- MATLAB window will begin to display sensor data.

Step 4: Vary the Throttle or dyno angular velocity

The load can be adjusted in two ways:

1. Keep the dyno angular velocity constant and vary the throttle position

2. Keep the throttle position constant and vary the dyno angular velocity

Step 5: When complete hit the Stop button

- Dyno and Hot Wheelz motor will come to a stop

- GUI will close serial connection with dyno controller

Step 6: View and Delete the MATLAB CSV file (see Appendix A)

Automated Mode Operation

Step 1: Select the Automated radio button located at the top left of GUI.

- The simulation profile text field will be enabled

Step 2: Input a simulation profile

- The Throttle Position, RPM , Linear Acceleration Rate, and Duration are inputted

- Input each value by a space. ex. XXX XXX XXX XXX

- The first XXX represents the Throttle Position, expressed as a percentage (000-100)

- The second XXX represents the dyno RMP (100-999)

- The third XXX represents the Linear Acceleration Rate (LAC) (039-500)

- The fourth XXX represents the duration the above parameters are applied for

- Each value is separated by a space

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- Ensure that at least 5 lines are filled in and there are no empty lines at the bottom

Step 3: Ensure that the Interlock Status bar is green.

If red – Ensure all E-Stops are in the up position and that the NI-DAQ is on and hit the reset button

Step 4: Hit the Start Button

- The simulation profile will be inspected to ensure the values inputted are within range and in the correct

format

- GUI will attempt to connect to dyno controller

- 0.5 V will be applied to the throttle, i.e. the minimum amount required for the Hot Wheelz motor to

begin spinning

- MATLAB window will begin to display sensor data

- The profile will be applied and stepped through

- Once the last profile has completed the test will stop and the Hot Wheelz motor and dyno will come to a

stop.

Step 5: View and Delete the MATLAB CSV file (see Appendix A)

Closing Procedure

The current setup of the GUI does not close completely as the user hits the X in the upper right. Although the MATLAB and

GUI windows disappear additional steps need to be performed to ensure proper shutdown.

Step 1: Click the X at the top right of the GUI, The GUI and MATLAB window should close

Step 2: Start the task manager by pressing the ctr + alt + delete buttons at the same time

Step 3: Once the task manager is displayed select the processes tab

Step 4: Find MATLAB.exe under the Image Name column, select it and hit the End Process button

Step 5: A window will appear, hit the End Process button

Step 6: Find Hot Wheelz Test Bench.exe under the Image Name column, select it and hit the End Process Button

Step 7: A window will appear, hit the End Process button

Step 8: Close the Task Manager. Procedure complete.

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Appendix

Appendix A: Viewing Collected Data

*Note: In order for the GUI to operate properly, the folder titled HotWheelz_GUI must be located on the desktop and must

contain the sub directory titled Matlab_Files, which contains the necessary MATLAB scrips required for data collection and

graphing.

Every time the user hits the start button and data is collected, a file titled shape_metrics.csv will be created within the

Matlab_Files directory.

After a test is completed, this file will need to be deleted (or relocated) in order to prevent another test to append more data

to it.

To view the data:

Step 1: Navigate to the desktop

Step 2: Open the folder titled HotWheelz_GUI

Step 3: Open the folder titled Matlab_Files

Step 4: Open the file titled shape_metrics.csv using excel (depending on the amount of data points acquired it may

need to be opened in MATLAB)

The format is as follows

Column 1: Time

Column 2: Unscaled DC Current

Column 3: Unscaled AC Voltage

Column 4: Unscaled AC Current

Column 5: E-Stop Voltage

Column 6: Unscaled DC Voltage

Column 7: Thermocouple 0 (in Fahrenheit)

Column 8: Thermocouple 1 (in Fahrenheit)

Column 9: Torque (in ft-lbs)

Column 10: Angular Velocity (in RPM)

To delete file: Right click on file and select delete. It will automatically be regenerated the next time a test is performed.

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Appendix B: Verifying COM Port

In order for the GUI to properly connect to the dyno controller, the USB-to-Serial adapter must be plugged into the USB port

which corresponds to COM 4. To verify, follow the procedure below.

Step 1: Click the Windows Start button in the lower left part of the window

Step 2: Type Device Manager in the search bar

Step 3: Select Device Manager shown in the results

Step 4: Expand the Ports (COM & LPT) tab, you should see “Prolific USB-to Serial Comm Port (COM4)” present

If “Prolific USB-to Serial Comm Port” is present but the COM number isn’t 4, remove the USB to serial adapter from the USB

port and plug it into a different one. Repeat steps 1-4 to check whether or not the correct the adapter is plugged into the

correct USB port. Repeat process until “Prolific USB-to Serial Comm Port (COM4)” is present.

Appendix C: Changing the Code

Step 1: Open the folder titled GUI src

Step 2: Open the folder Hot Wheelz Test Bench

Step 3: Open the folder Hot Wheelz Test Bench

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Step 4: Open up the project by opening Hot Wheelz Test Bench.csproj

Step 5: When Microsoft Visual Studio opens, open the file titled Form1 – The code will be displayed

*Read the comments and understand the code before making any changes.

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Appendix D: Downloading NI support for Matlab Download NI support for Matlab

Go to http://www.mathworks.com/hardware-support/nidaqmx.html

Click get support package

http://www.mathworks.com/hardware-support/nidaqmx.html

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Navigate to the downloads directory and open the file titled nidaqmx

MATLAB will begin to open

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The MATLAB window will appear as shown

If the installer doesn’t open on its own, open the file titled nidaqmx.mlpkginstall located on the left side of the screen

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The Following will appear

Click Next

The following will be displayed

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Click Log In

The following will be displayed. If you do not have an account. Go ahead and create one. Enter your user name and password

into the text fields and click Log In.

The following will be displayed. Hit I accept and click Next.

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Hit next again.

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Hit Install.

The following will be displayed.

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After the above gets to 100% the following will appear

Click Next

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Select custom and hit next

Open the Application Development Support

Scroll to the .NET Framework Files. Click on the X for each and click Install this feature to a local drive and click Next.

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The Following will appear. Click Next.

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Click I accept the License Agreement and hit Next.

Click Next again.

The install will begin as shown below.

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After Installation is complete the following window is shown. Click Next.

This message will be shown. Follow Instructions. After clicking ok, allow the install to wrap up before restarting.

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Install complete. Press Finish to finalize.

Now Close everything and restart computer.

Once the computer has been restarted you will need to download the updated NI-DAQmx 15.1.1 software by using the same

settings in NI-DAQmx 9.7 instructions above. A copy of the installer can be provided in the downloads folder.

To complete the MATLAB configuration you will have to replace the session.m file within the MATLAB directory.

Navigate to My Computer.

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Open Windows (C:)

Open Program Files

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Open MATLAB

Open R2014b

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Open toolbox

Open daq

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Open daq

Open +daq

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Navigate to the provided session.m file and copy the file into this folder. Click Copy and Replace.

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The following window pops up. Click Continue.

Next copy the provided folder titled HotWheelz_GUI to the desktop. The MATLAB setup is now complete.

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Appendix E: Visual Studio Premium 2012 Installation

Obtain a copy of Visual Studio Premium 2012 (x86)

Launch the installer. This may be done differently depending on your source. For this example, the installer is located in the

downloads directory.

Open the file named vs_premium. The installer will begin to open.

The following window will be displayed. Select I agree to the License terms and conditions and click Next

Click Install.

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The Following window will be shown.

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When install is complete the following window will be shown. Click Launch.

Select Don’t show this message again and hit Run program.

Choose Visual C# Development Settings and hit Start Visual Studio.

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Install is complete.

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