50 IEEE TRANSACTIONS ON IECI February

PROGRAMING VEHICLE TESTING USING MAGNETIC TAPE

V. C. VANDERBILT, JR.* and C. L. ZIMMER*, Senior Member, IEEE

Summary-The selection of the program we believed that our industry would not for some
memory medium, the encoding problems, and time use enough tape equipment to allow an eco-
use of program information will be discussed. nomical specialized design. Therefore, we chose
Emphasis is on a frequency multiplexed FM to use the equipment available to the broadcast
system. A stable subcarrier oscillator which industry as our standard. This decision dictated
can be remotely tuned with simple passive ele- the signal encoding methods and number of data
ments, a unique circuit of signal use, and closed- channels.
loop error detection will be discussed. We chose frequency-modulated audio signals
as our intelligence encoding means. This pro-
vides a digital type signal for accurately averag-
HyTReSS 11 ing over a sampling period (simple frequency
counter) and yet an analog signal is easily
available. The various high, low and band-pass
The question of whether to make a simulated filters that are commercially available make the
field test or not can cause a good argument at number of available information channels some-
almost any time. From this it is implied that what arbitrary. HyTReSS II utilizes four frequency
there are many answers to the question, all of channels. These channels are contained below
which are logical under a set of conditions. 8600 cps and require a 3-3/4 inch per second tape
Once accepting this logic one must conclude speed from most commerical tape decks. See
that one method of test simulation will fit only Fig. 1.
a certain set of circumstances. We have used
the simple direct approach. We record the con-
HyTReSS I utilized a method of signal recording
that eliminated the need for accurate line fre-
ditions as they vary during a field test, then use quency control. This was accomplished by multi-
this for the laboratory simulation program. We frequency by the FM signal to be
believe this to be the easiest method of develop- plying line
recorded. As the line frequency varied, the wave-
ing the program. This method does away with length as recorded on the tape was constant since
much of the need to analyze the field data to de- the tape speed was proportional to line frequency
termine the extremes of the test or the statistics also. HyTReSS II utilizes a portable recorder
thereof. which has an internal speed servo. The speed
Most consumer goods are accepted by the field accuracy of the servo as we modify it is 0.1 per
test, therefore why be concerned with the statistics cent for 3-3/4 inch-second. This same tape re-
of field data in an effort to make laboratory testing corder has an optional cross-track recorder head
organized in a somewhat more orderly fashion. which can record a constant or synchronizing
This is particularly so, since field operation is signal on the same 1/4-inch track without disturb-
frequently so random. We answered these ques- ing the normal channel. On playback this signal
tions for our company's test work by building
the Hyway Test Recorder and Simulator System
(HyTRess I). HyTReSS II is now used by us and F-M BANDS OF RECORDER SYSTEM
many others to test internal combustion engines
for the evaluation of oil consumption, the life
testing engine components, the accumulation of
deposits in combustion chambers, etc.
We found magnetic tape offered the desired
accuracy needed for the recording medium and
yet was an inexpensive reusable storage medium
2 3 K K
200 2K 3K 4K 5K BK 9KIOK
6K 7K
200 2000 2550 3450 3995 5405 625 8450
with wide flexibility as to signal handling. Also, CYCLES PER SECOND

* Perfect Circle Corp., Hagerstown, Ind. Fig. 1.

1964 VANDERBILT AND ZIMMER: VEHICLE TESTING USING MAGNETIC TAPE
(a)
Fig. 2. (b)
can be used to control the tape speed or some
other device for synchronization with the tape
recorder. The playback equipment which we use
is a standard playback deck with capability for
14-inch reels and automatic reversing.
Our theoretical knowledge of FM multichannel
recording was verified experimentally early in
our work. The mixed frequencies must be rela-
tively pure sine waves or harmonics of lower
frequency channels appear in higher frequency
channels. This situation required either pre -
recording filtering or veryvpure sine wave
oscillators. The Resistance to Frequency tuned
Transducer (ReFreTran) is such a pure sine
51
wave oscillator. These units were developed to
provide our output with a linear relation of re -
sistance change to frequency. They can be re -
motely tuned by a passive resistance element.
Fig. 2(a) is a photo of three such units on the
front seat of an auto. This, together with the
temperature probes and tach generator, is the
equipment needed to make a field recording. The
particular grouping shown is necessary to record
manifold air pressure (frequency band 4700 + 15
per cent), oil temperature (frequency 7350 + 15
per cent), coolant temperature (frequency 3000 +
15 per cent), and engine rpm (frequency 200 - 2000
cps). The box on the lower right is the mixer and
rpm preamplifier. Thus, Fig. 2(a) depicts our
mobile data laboratory.
ReFreTran OSCILLATOR
The ReFreTran Oscillator can be represented
by the block diagram in Fig. 3. Two feedback
loops are used, the oscillating frequency being de -
termined by the notch network in the negative loop.
The oscillator operates at the point of minimum
negative feedback, the notch frequency. The gain
of the positive loop is automatically controlled to
hold amplitude within the linear range of the ac-
tive components. Thus low distortion is achieved.
To make the oscillator useful as a transducer, the
notch filter must be tuned by the variable to be
measured.
If a "bridged T" is assembled using inductance
and resistance as in Fig. 4, it can be shown that a
notch occurs at w 2 =
R2
LL .
If L2 = KL1,
I R
w . Thus, if the two resistances are
/: LI
varied in unison, the frequency is a linear function
of resistance. Linearity can be achieved in prac-
tice and is limited only by phase shifts in amplifier
components at the upper and lower ends of the
amplifier pass band. Values of K from 6 to 20 have
proved satisfactory.
The output from the ReFreTran is encoded for
direct recording on magnetic tape. No other spe-
cial instrumentation is needed to record this out-
put. Thus many ordinary tape recorders can be
used; however, tape-speed accuracy must be con-
sidered in relation to the over-all accuracy
required.
Frequency of the ReFreTran is dependent only
upon passive components and calibration is not
based on voltage references. Operation for six
month periods without attention is typical.
52 IEEE TRANSACTIONS ON IECI
Fig. 3.
Fig. 4.
Fig. 5.
Other notch networks can be used with the
oscillator for special applications. One special
configuration for use with semiconductor strain
gages is shown in Fig. 5. Consider Ri,2,3,4 to
be two voltage dividers. The network is tuned as
the tap on one divider is moved up and the other
is moved down. It is reasonably immune to
variation of the total divider resistance. Thus,
if. two of the gages are in tension and two in com-
pression, a strain to frequency transducer is
obtained. Temperature variations affect pri-
marily the total divider resistance and cause
little zero shift of the transducer.
SIGNAL COMPARISON
Signal comparison between the command and
the feedback signal is a very critical part of any
servo system.
February
T,2-
..;Il
TI PERMOD OF LINE VCLTAGE
Fig. 6.
The error detection or comparison of two
frequencies, command and feedback, is in the
simplest form a comparison of two dc voltages
which have been derived from the two frequencies.
However, if each frequency to dc analog conver-
sion is not performed exactly the same for each
signal, an apparent error will exist and cause a
real error.
Some designers use an FM discriminator on
the command signal only. In these systems the
feedback signal needs to be calibrated regularly
since it is subject to drift with time. One bad
experience with such a system causes a serious
lack of confidence by project engineers who do
not understand these problems.
Digital techniques can be used to program an
engine; however, those1 that have done this,
utilize an FM encoded signal derived from
voltage controlled oscillators. The dc supply
together with the oscillators make such systems
also subject to drift as mentioned previously.
The solution to the frequency comparison
problem in the HyTReSS has been by means of
a unique circuit. We call the circuit a Fre-
quency Comparator Circuit with Suppressed
Carrier Output (FCC-SCO). At null it is free
of drift.
Fig. 6 is a partial block diagram of the fre-
quency comparator circuit. The synchronous
switch causes first the tape signal, then the
feedback signal to be placed on a line alternately
and synchronously with the line voltage. Thus,
the tape signal is placed on the output terminals
when the line is positive with respect to ground.
When the line is negative, the feedback signal is
on the output line. This is represented by the
small graph following the synchronous switch
block. The next block is a frequency measuring
circuit which develops a dc voltage proportional
to the frequency of the input signal. Since this
signal may consist of a half period of high-
1 W. Leonhard and S. Waller, "Digitale Programmrege-
lung fur Prufstande der Kraftfahrzeugindustrie," re-
print from Siemens-Z., vol. 35, pp. 234-236, April
1961.
1964 VANDERBILT AND ZIMMER: VEHICLE TESTING USING MAGNETIC TAPE 53

APE SIGNAL -'S TCH---

S4NAL ITE SWITCH

FEEDBGCK SINAL
SIGNAL AFTER FIEQ. MEASURN CIRJIT
TAPE SIGNAL -SWfT-H
FEEDBACK SIAL
T- fERIOD OF LlK VOLTAGE . I , T
SIGNAL AFTER FlE. NEASING aIUT
Fig. 7.
frequency signal followed by one of low frequency, in collector voltage or operating point shift with
the dc output will vary with time and have the
same period as the line. Fig. 7 is a representation reasons mentioned earlier. Power amplifier
of two conditions; in one, the tape signal has a
higher frequency than the feedback
other the opposite is true. Note that the signal,
after the dc conversion, contains a 60-cycle com-
ponent, which changes phase 180° when the tape
and feedback signals reverse frequency relation-
ship. Also, the amplitude of the
component is proportional to the magnitude of
the difference in frequency.
At the null point when the frequency of each
input is the same, the line frequency signal van-
ishes in the output, and is not affected with fre-
quency to dc conversion drifts with time. The
error signal developed is the type of signal
needed to control a two-phase induction motor
with a high resistance armature.
FCC-SCO
A block diagram and a schematic of one chan-
nel of FCC-SCO are shown in Figs. 8 and 9. The
limiters QIOI and Q201 Fig. prevent
of
loading of the synchronous switch that would
allow spillover of one signal into the sample
period of the other. The emitters of switch tran-
sistors Q102 and Q202 are driven in push-pull
with the line-frequency square
Q203 so that they are alternately conducting and
cutoff. The combined outputs of Q102 and Q202
appear across the common load resistor R610.
The dc levels of the two transistors are balanced
by R605.
The sampled signal is amplified by Q301 to a
level that will insure reliable triggering of multi-
vibrator Q302 -Q303. This amplifier must be
T T
Fig. 8.
SIGNAL AFTER SNIACH
capable of passing a line-frequency square wave
in order to properly handle the sampled signals.
The multivibrator duplicates with a square
wave each cycle of the sampled signal. Its out-
put waveform is required to be of constant slope
and constant amplitude only from one 1/120-
second sampling period to the next. Slow changes
temperature have no effect on the system for
stage Q304 prevents loading of the multivibrator
signal; in the and furnishes sufficient drive for the frequency
measuring circuit.
The frequency to dc conversion is accomplished
by C401, the two diodes and the low-pass section
R402 - C402. C401 meters a uniform amount of
line frequency charge for each cycle of multivibrator output.
These pulses of charge are stored by C402 and are
allowed to bleed off through R402 to yield a voltage
proportional to frequency. If the input frequencies
are not identical, this voltage contains a line fre-
quency component.
At this point in the circuit the desired signal
(line frequency) is small compared to the noise
(input frequencies and switching transients). The
remainder of the circuitry provides gain and sup-
presses noise. The 60-cycle tuned circuit is for
noise suppression rather than for lag compensa-
tion although lag compensation can be inserted
here. Lead compensation is normally used in the
servo power amplifier.
The current delivered to the control winding of
9 over- the two phase motor must have a 90° phase rela-
tionship to that of the reference winding. The
method by which the control signal is generated,
plus low-pass filtering of the control signal in-
troduces phase shift. Adjustment of the phase
wave by Q103 and may be done at the synchronous switch by shifting
the phase of the line-frequency square wave (see
Fig. 8) or in the error amplifier by shifting the
control signal itself. Both methods have been
used with equal success. Of course, shifting the
line-frequency square wave affects all channels
switched by it, while the phase of one signal may
be altered independently if done in the error
amplifier.
54 IEEE TRANSACTIONS ON IECI February

I 1 R6AO
RED TEST JACK RA%65 s 2.2K

Rios RIOS R til

) 4.7K
Rl05 C102 ; 47K
^ IOOK
P06K. R102 6.2K 25u
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in RI01 47
RN1I SOUARE
1601 IR1i3 DO >RIOT
6s.6K
33K WAVE
IN No.I
RI
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~~~~~~~~~~~~~~~~~~~~~R310
~~~~~~~~~~~~~~~~~~~2.2K
R1

R311 2.tK
C101

25I YELLOW TEST JACK .R305 R306 6.2KO

IOOK 0302 R3l2

R301 0.2u.0 6.2K

27K 0302 0303

~~030 1
0301 15K
GREEN TEST JACK R303.
0-5t
COMm. IN
R206
R206 OK

Rtm ~~~0202 020 IOOK 303 3.36 156

6- 202

BA 47K 'SQUARE25.
R603 R604
66
2 102 P"2 476
6207
2
209
33K 33KNO
WAVE IN-

02, C060 C603 R201

0201
O.ts5.f- 0.11t 4.7K 6203 7

A. K
_z v.

100 FDIK. LIM. 300 MULTI. 500 60 AMP

ALL TRANSISTORS 2N324 EXCEPT Q102, 0103, 0202, 0203 WHICH ARE 2N321 200 COMM. LIM. 400 DIFF. 600 CII S

It2 VOLTS

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~0.253.0
l R6315 BLUE TEST
l l lrT l ] ] < lLACK TEST JACK
0304 R06307 .
63 Ki66 68K K RK513
0~~~~~4010402 6402
0304IlOOK
0403
0304
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0503
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6
66K L
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39K65 1J 5u. 0
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0.5 -A
R 6502 0.25.0 396 0SINA
CONTRO
27K 6503 6505609 C507
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2.2 I.56 0.5,uf.
47 4L1
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C502 2.5

R 5O506-i
33K

Fig. 9.

SERVO SYSTEM The rise times for various step input functions
are shown on the response curves of Figs. 10 and
The four individual control systems are all 12.
class-one servo systems. All cause a continuous
change in the actuator for any error signal.
Some stabilization is necessary to attain the TEST USES
response shown. Simple lead network compensa-
tion in the form of a twin T-notch filter has been The simulator equipment has been used in our
found adequate. The rpm servo system contains laboratory to determine oil economies of ring
a class 0 speed servo, in both absorb and drive. combinations under proving ground conditions.
In this control loop, a finite correction action is The best combination is selected and recom-
taken for a given error signal. The simulator mended to our customers. In these cases, the
system then closes around the entire system customer has allowed us to record his proving
with a class-one servo. The shift from drive to ground cycles. The correlation between the
absorb and back is accomplished automatically customer's proving ground results and the
by the dynamometer control system. It is thus simulated tests has been remarkable. One
possible to simulate long downhill coasting. combination indicated a simulator-controlled
The MAP system closes on the manifold pres- dynamometer oil economy of 830 miles per
sure and is independent of throttle setting or quart against the customer's proving ground
variation during changes of the engine on the average of 875 miles per quart. In another
dynamometer. case, the oil economy determined in an engine
1964 VANDERBILT AND ZIMMER: VEHICLE TESTING USING MAGNETIC TAPE 55

.1;
-.;

,- -7S
7-.

Fig. 10-Step function response of over-all MAP system.

Fig. 13-Rpm response to a command signal recorded
on the highway.
aw2uiu -C. 77-
iumzvnzz ir
--7- X z[iiX
r T
r7i ""7

l' .' - L I 1 'If

Fig. 11-Response of over-all MAP system to a com-

mand signal recorded on the highway.
Fig. 14-Command and response curves for the over-
all rpm channel. (Ward-Leonard controlled
dc dynamometer.)

C*Cilaz.L-D

7f,.rsr0to14c9roxr Ftf^Z Ic
C-w low4rw
- >r r _--i + Df

tS&cl7i L_ _ X

CID
\ t L V9vz

L__ -0

(t~~~~) C~~~v)
~ ~
~ ~ ~ ~ ~ ~ -rrMAY _-Z A1
\ oX 1 "Sor --c,oofrOATIVA
W *Se (

_
rO.rvx

Fig. 12-Step function response of rpm system.

(Automatic drive-absorb Eddy current
dynamometer.)
Fig. 15.
56 IEEE TRANSACTIONS ON IECI February
again for arbitrary schedules but where con-
(7)
trol system dynamics must be watched more
NI/F~~~~~~~~~~~~~~ closely.
/~~~~~
_7- _

SYSTEM AND COMPONENT ACCURACIES

jZECOrD ~ 2EQCOJ//EOCY°° Controlled variable accuracy using the

z^cx~~~~r1Te
\
( V) HyTReSS is limited by the magnitude of the
tape-speed errors. If these could be elimi-
o orwex!
-"EStQ. COIM? nated over-all system accuracies of 0.1 per
cent and better could be attainable. Tape-speed
inaccuracies produce controlled variable inac-
curacies which are inversely proportional to the
frequency bandwidth used. Thus the use of a
Fig. 16. narrow bandwidth causes greater error in the
controlled variable because of tape-speed vari-
"014 On /x
cowroo. ations than does use of a wider band.
When careful attention to tape transport
operative details is provided, over-all system
O ME
Po
accuracies of better than 1/2 per cent have
been attained.
/ One might assume from the foregoing that
accuracy of the controlled variable could be
c i1PVI I. no better than the tape speed. This is not so
if one allows the controlled variable to be
divided into subdivisions. Each subdivision
is located by another channel to an accuracy
fo a vi of better than 1/2 a subdivision. Thus, the
ultimate accuracy of the controlled variable
is the tape accuracy divided by the number of
which
also
wasD the_custo mrs p0rovingground subdivisions. Or, to put it another way, the
single-channel tape control system accuracy
momete test iniaed60 ilspr3aln applies to one subdivision interval.
Such a system using the Frequency Com-
parator Circuit has been developed by the
Electronics Division of Perfect Circle
Corporation and is called Perfect Circle
whihe
alsonwas
the custindependentvaom sprou Position Control or p 2. The accuracies
of this system are somewhat arbitrary since
theoretically one can add on many coarse
channels using the same basic ideas. How-
for. Fig. indicates ad thoeperlgation ever, equipment complexity does somewhat
when the main independent variable is a simple limit such systems. Systems with accuracies
position. Fig. 17 is used in the laboratory of one part in 1.2 x 105 are contemplated.