0 sae formula car data acquisition & display system ahmed albitarjohn gertie justin ibarrasean...
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SAE Formula Car
Data Acquisition & Display System
Ahmed Albitar John GertieJustin Ibarra Sean Lenz
Bradley University Electrical Engineering Department
Advisor: Professor Steven GutschlagOctober 2, 2014
2Agenda
● 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
3Section 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
4Competition Concept
● Formula SAE Competitiono Prototype car to be evaluated for productiono Designed for non-professional weekend
competitoro Car must be low in cost, reliable and easy to
maintaino Car’s marketability can be enhanced with
aesthetics
5Competition Awards
● Spirit of Excellenceo Top 10 with highest overall score
● Designo Top 3 with highest scores in design
6BU SAE Formula Car● BU MEs develop a new car annually● Design Goals
o Aesthetically pleasingo Economically viable o Race ready performance o User friendly for all levels
● ‘07-’10 Honda CBR600RR engine● Total budget of $10,000
7Current 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
8Current System Flaws
● Poor notification systemo Indicators are small, not always noticeable
Engine failure due to overheating● Display can’t be customized
o Drivers can’t adjust display to their likingo Gauges are small, can be difficult to see
● No display for crewo Only the driver monitors sensor data
9Client Goals for New System
● Multiple display modeso 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
10Client Needs for New System
● Wireless Data Transmissiono Sensor data monitored remotely
● Data Loggero Store data for future reviewo Useful for making vehicle adjustments or
diagnosing problems
11Past Efforts
● Past senior project groups have worked on the data acquisition system
● No past group has implemented the system on the formula car
12Section Outline
● System Objectives
● System Requirements
● Safety Requirements
● Construction Requirements
● Design Approach
● Additional research needed
● Testing
13System Objectives
● Data Acquisitiono Data readings include: Oil Pressure, Water
Temperature, Voltage, speedometer, tachometer
● Displayo Driver Displayo Remote Displayo Notification System
14System Requirements● Data Acquisition
o Accurately acquire data with a maximum of 5% error
o Ability to send data for displayo Store Data for review
● Wirelesso Accurate data transmissiono Range of 0.5 to 1 mile
● Displayo Accessible to driver’s touch screen and crew’s
computero safe
15Safety 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
16Construction Requirements
● Inside the cockpito Withstand temperatures of 40 to 120˚Fo 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˚Fo Withstand vibrations/forces of magnitude up to 8g
● Undercarriageo Withstand Temperatures of 40 to 250˚Fo Withstand vibrations/forces of magnitude up to 8G
17Design Approach
● Design alternatives● Evaluated design options using multiple
evaluation techniques
● Selected design best fit to client’s needs
● Interdisciplinary collaboration
18Additional Research needed
● Gemstudio will be usedo Program uses Gemscript
● This system will require collaboration with the mechanical engineering department
● Contingency plan
19Testing
● 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.
21Proposed Solution
● Standalone systemo Universal applicationo Can be moved to new car when necessary
● Electric sending unitso Keeps hot fluids away from drivero Better reliabilityo Less maintenance
22Proposed 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
23Proposed Solution
● Wireless transmissiono RF transceivers
● Remote displayo Shows critical value at all timeso Notification systemo Data logging capabilitieso Gauges appear in digital & analog form
24Project Expense Breakdown
Equipment Minimum Maximum
Software Programs $2000 $2600
Sensors $480 $600
Screen $175 $220
RF transceivers $130 $180
Table 1: Equipment price range
25Economic Analysis
● Project is feasible
● $3000 (minimum) estimated cost to complete projecto $2000 software programso Free for students
● $3700 (maximum) estimated cost to complete projecto $2600 software programs
26Economic Analysis (cont.)
● Estimated manufacturing cost (minimum) is $1000
● Estimated manufacturing cost (maximum) is $1100
● Estimated Retail is $1500
● Estimated Cost to implement is $200o Wiring, insulation, Packaging, etc
27Section Outline
● Societal & Environmental Impacts
● Division of Labor
● Milestones & Scheduling
● Summary & Conclusion
28
Societal & Environmental Impacts● Increase safety while operating vehicle
● Reduce catastrophic failures
● Minimize repair costs
● Help contain spills
29Division of Labor
● Amulet display for driver (Sean and Justin)o Display crucial car data
Multiple display modeso Warn driver if data exceeds threshold
Flash screeno Data sent via UART from microcontroller
30Division of Labor
● RF Communication (John & Ahmed)o Establish communication
Board to board Board to HyperTerminal Microcontroller to HyperTerminal
o Receive data from microcontrollero Send data packets to off track PCo Transmission range of 1 mile
31Division of Labor
● Labview GUI (Sean & Justin)o Receive data packets via RF o Data sent to computer using serial
communicationo Advanced display of crucial datao Alert crew if problem occurso Log data in spreadsheet
32Division of Labor
● HW/SW interfacingo 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)
34Milestones & Schedule
● Progress Presentation Nov. 25● Progress Presentation Feb. 24● Project Demonstration Mar. 31● Final Presentation Apr. 14● Final Report Apr. 30
35Summary
● Bradley ME dept. builds formula car o Current data acquisition system is inadequate
● ME’s expressed need for more advanced systemo Customizable multi-mode displayo Wireless data transmissiono Data logger
36Summary
● Proposed system will meet requestso Amulet for multi-mode displayo RF for wireless communicationo Data storage for later analysiso Alert driver and crew if problems occuro Reduce catastrophic failureso Reduce environmentally harmful spills
37Conclusion
● Universal application
● Cost to complete project is about $3000-$3700
● Projected finish: February 24, 2015
38References http://www.digikey.com/product-detail/en/AC4790-200A/AC4790-200A-ND/1844885 (AC4)http://www.wvshare.com/product/STK128-Premium.htmhttp://sine.ni.com/nips/cds/view/p/lang/en/nid/1385http://www.digikey.com/product-detail/en/STK-480272C/681-1016-ND/2001099?enterprise=44http://freesafesoft.com/discount/GEMstudio_Pro-32323639392d35-coupon-code.phphttp://www.automationdirect.com/adc/Shopping/Catalog/Process_Control_-a-_Measurement/Temperature_Sensors_-a-_Transmitters/Temperature_Transmitters_(Integral_Sensor)/TTD25N-20-0300F-Hhttp://students.sae.org/cds/formulaseries/fsae/2014mis_handbook.pdfhttp://students.sae.org/cds/formulaseries/fsae/fsaeprogram.pdfhttp://cegt401.bradley.edu/projects/2013-2014/FSAE/BRADLEYMOTORSPORTS.htmhttp://cegt401.bradley.edu/projects/2010-2011/FSAE/powertrain.html
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Equipment Minimum Maximum
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