Data Acquisition

Frank A. Whiton
GM Milford Proving Ground
by
Frank Whiton
Frank Whiton – GM Development
Engineer
• Crew Chief – GrandAM Cobalt & Camaro
• Lead Engineer – GM ‘Race vehicle engineering’
• Development Engineer – HPVO High
Performance Vehicle Operations
• Hybrid integration Battery & EGHR
• Measurement Engineer “Data Guy”
• Raced GT3, GT1, S2000 & Cobalt Rally
 Data logger function
• A physical parameter is converted by a sensor
to an electric signal captured and stored by
the data logger in a digital format.
• Data logger inputs are in the form of:
– Voltage – single ended or differential - press,
temp, position
– Voltage pulse/Frequency – RPM, wheel pulses,
injector pulses
– CAN, Ethernet, serial linked to other modules
• Analysis & post processing recorded data
Basic setup

Ground loop
Goal of data acquisition
• Gather information to make informed
Engineering decisions based on data
• Provide driver performance feed back during
the Race/event
– Lap times, split times ‘ref pre runs or theoretical’
• Provide the driver alarms when critical
parameters are exceeded “health check’
– Over temp, low oil press, excessive displacement
etc.
Development of Data acquisition
system - FSAE development testing
Define duty cycle
FSAE Dynamic events – Practice area

Design a test plan – group input

Vehicle health Driver

Powertrain Brake Cooling
monitoring Performance

Select a Data acquisition system to meet

testing needs

Select sensors to meet testing

requirement

Design wiring and sensor installation

Duty Cycle ‘Vehicle Dynamic Events’
• Focus in on what events are important and
rate by most value in winning!
– Acceleration event
– Skid-Pad event
– Autocross
– Fuel Economy
– Endurance
– Braking
– Practice events – need planned test setup
 Test Plan Design “w/all development engineers”
Purpose of test: Driving at 100% performance simulated SAE dynamic events in K-Mart parking lot
“Duty Cycle” . Determine vehicle operating parameters and performance .
Goals: “what do you want to accomplish”
• Vehicle health check performance – “need to warn driver?”
– Engine, transmission & diff. running temperature, Brake lining & fluid temps
– Engine oil starvation – pressure drop outs
• Drivers performance
– Lap time comparison, Driving line vs slip time
– Braking rate & gear selsction
– % time at full Throttle, steering wheel angle input rate
• Vehicle performance –
– Shock position , spring & bar tuning options , Understeer / oversteer, Grip levels – vector
acceleration
– Engine power levels , Spark advance
– Gear ratio selection - Tractive effort optimized for track
– Brake energy – cooling options
– Cooling - Radiator shrouding options
• Build a matrix of test events to run – “Follow the agreed plan or not everyone will get
their data” Analysis provides as many answers as it does questions -Try not to do
what-if testing you will get off track!
Start with a basic setup

• Vehicle speed
• Engine RPM
• Acceleration lat & long
• Engine & Trans temperatures
• Throttle position
• Steering wheel angle
• Most engineers start data logging with basic channels then extend step
by step as they gain experience
Channel list from development
plan, with logger input listed
Recording parameters using RaceTechnology DL1 MK2 and Dash3
Channel Sample
number Source Description Units Rate Owner Event req
1 GPS Vehicle speed kph 100 hz all all
2 CAN - Freq 1 LF wheel speed - optional wheel sensor kph 100 hz Tim/Jay 2
3 CAN - Freq 2 RF wheel speed - optional wheel sensor kph 100 hz Tim/Jay 2
4 CAN - Freq 3 LR wheel speed - optional wheel sensor kph 100 hz Tim/Jay 2
5 CAN - Freq 4 RR wheel speed - optional wheel sensor kph 100 hz Tim/Jay 2
6 Logger Lateral & longitudinal acc - internal to logger g 100 hz all
7 Logger Brake on-off g 100 hz all
8 Analog 1 Brake lining temp LF inner C 100 hz Jay 2-a*
9 Analog 2 Oil Pressure - kPa 50 hz Brian 2-a*
10 Analog 3 Coolant temp C 1 hz Rex 2-a*
11 Analog 4 Trans sump temp C 1 hz Rex 2-a*
12 Analog 5 Steering wheel angle deg 100 hz Tim 2-a*
13 Analog 6 Throttle position - optional CAN % 100 hz Tim 2-a*
14 Analog 7
15 Analog 8
16 Cam sensor Engine RPM - coil trigger - optional CAN RPM 100 hz All
17 Logger calc Grip indicator = vector acc [lat & long acc combined] g 100 hz Greg
18 User defined Ft wheel slip = GPS speed/wheel speed % Tim
19 Logger calc Engine power - Logger cal from acc [F=ma] HP Luke
20 User defined Brake energy - F=ma & work=F*distance kJ Jay
21 User defined Understeer = turn rad - steer angle Tim
Note: 2 a* - 1 If temps have not stabilized
 Data Logger Selection
Remember when you choose a system you are getting
into a long term relationship so spend time looking
at various units.
• Start by looking at demo software
– Is the software intuitive?
– Does it perform onboard or pre-processing of data
– Look at example plots to get an idea of plot formats
– Math channel capability
– Filtering
• Spend some time talking to mfg. Reps and users
before committing to a system
Data logger selection cont

• Number of input channels and type

– Voltage, single ended, differential, frequency, counter, event,
outputs.

• Operating voltage
– 9 to 32 Volts
• Note: some loggers lock up when voltage drops < rated.
• Regulated supply voltage to power sensors
– Typically 5 or 10 volt – most production sensors
require 5 V Regulated excitation!
Data Logger inputs/outputs

• Voltage – single ended or differential

• Frequency counter/totalize - pulse inputs
• Event state hi/low
• CAN/serial network inputs – Data from
vehicle control modules or add in modules
• Outputs
– Warning light, RS232, control i.e. fan
Why did I choose this one?
Real time - health check & active driver performance
• Alarms – upper and lower warning display of any variable
• Programmable alarm lights to warn driver plus display message
• Sector time - Lap time - Delta sector time - Delta lap time - Lap counter
• Predictive lap time - calculation based on your current completed sectors
in this lap – and displays a prediction of what lap time will be. This
prediction is based upon the assumption that you will complete all of the
remaining sectors in the same time that it took you during your best lap
• Shift lights programmable for ea. gear left
• Math channel calculations displays real time
• 5 display screen set ups
Hardware
• Built in GPS, 3 axis accelerometer.
• 5 Volt regulated supply – for sensor supply
• 8 - 0 to 12 Volt inputs
• 4 - frequency inputs & Engine RPM input
• up to 100 Hz sample rate
• 2MB Removable memory card
Software !!
• Multiple GPS variable calculations
• Analysis software easy to use w/multiple
page post analysis pages
• Math channel post processing Brake on-off
• Software developed for vehicle race analysis
• auto start/stop options
• Histograms, performance analysis, xy plotting,
GPS mapping, predictive analysis
• Predictive Lap simulation
• Calculated corner radius
Summary
Define duty cycle
FSAE Dynamic events – Practice area

Design a test plan – group input

Vehicle health Driver

Powertrain Brake Cooling
monitoring Performance

Select a Data acquisition system to meet

testing requirement

Select sensors to meet testing

requirement

Design wiring and sensor installation

 Vehicle Health Monitor
Sensor list
• Engine coolant temperature
– Upper alarm set = 112C
• Engine oil pressure
– Under predicted line “Dash program-if,then,else”
• Transmission oil temperature –
– Upper Alarm = 150C
• Diff oil temperature
– Upper Alarm = 150C
Sensor selection
• Engine coolant – Thermister “GM# 21015106 Saturn”
– 1/8 NPT w/5V reg supply range = -40 to 150C

• Trans Temp – Thermister “GM# 8678854”

– 1/8 NPT w/5V reg supply range = -40 to 150C
• Exhaust Temp– K-type
– Omega engineering & Race Technology amp
• Oil Pressure – Capacitive “GM# 12574403 or 12574309”
– ¼ NPT w/5V regulated supply, low cost & robust
– 10 to 90 PSI Range

• Throttle Position – Connect to TPS sensor

Wiring diagram

Ground loop
• Thermister Temperature Sensor Wiring
1991 – 2001 Saturn w/1.9 $11.99
GM pressure transducer scaling GM# 12574309 & 12574403

Pressure PSI = 32*Vout-16

 Red = below min Press

Oil PSI

Math Binary event

Channels =if(oilPSI<minPSI,1,0)

minPSI=if(RPM<=2320,(0.0300*(RPM+150)-20),(0.0072*(RPM+250)+44.66-10))
Analysis Resource
• Analysis Techniques for race car data acquisition
– http://www.sae.org/images/books/toc_pdfs/R367.pdf
• Buddy Fey Race Engineer blog
– http://buddyfey.blogspot.com/2009/06/recommended-
reading.html
• The Competition Car Data Logging Manual
– http://www.amazon.com/Competition-Data-Logging-Manual-
Speedpro/dp/184584162X
Sensor summary

• The level of sensor required is dependent on

your post processing requirement.
– Racing requires robust sensors typically a
production based sensor is the better choice.
• Calibrating the sensor in the range of interest will
increase the accuracy of production sensors.
– Development testing typically require higher
accuracy, thermal range and frequency response
than the production sensor will provide.
Results from calibration of a
production sensor with 2% full
scale error = 0.24%
 Test Days
The goal is to come back with data not excuses.

• Pre-run check list

– Clear the memory card of previously recorded data.
– Power up the logger
– Take a quick look to insure all sensors are alive.
– Re zero sensors and perform necessary calibration.
– Record a zero/cal file – short run with zero accels, baseline
ride heights, known sensor values. This will help sort out
data offsets in post processing.
– Start the logger or set up for auto start, don’t give the
driver this responsibility they are too busy.
Real Time Software Example
 End of Presentation
Additional support info to follow
• In the racing environment production based sensors
provide good durability at a lower cost than
instrumentation grade sensors.

PRODUCTION BASED SENSOR

Pros Cons
Robust Less accurate
Low cost Drift w/temp
sealed connectors Lower operating temp
High level output Low response time
Low frequency
 Technical specifications for Prod and
Instrumentation grade sensor
• Type High-level Low-level
• Full scale output 4.5Vdc 10mVdc
• Supply voltage 5V regulated 5V regulated
• Sensitivity 32mV/psig .1mV/psig
• Accuracy ± 1.5% ± 0.1%
• Temp range -40C to 135C -55C to 273C
• Compensated -20C to 85C -20C to 232C
• Proof press 2 x rated 2 x rated
• Response time 10ms – 100Hz 3µs - 380kHz
Trans/Diff temp sensor
GM# 8678854 1/8 NPT w/5Vsupply
High end race logger 16bit 2wire CAN
200 channels
GPS logger standard variables
ECU
Data Logger Specifications

• Max sample rate or throughput

– Fixed rate 100Hz or 35,000Hz w/100 channels max
• 35,000/50ch=700Hz max ea. or 35,000 Hz w/100ch = 350 HZ max
8
• Bit Resolution example: 8 bit = 2 = 256
– 8 bit = 256 : 12 bit = 4096 : 16 bit = 65,636
• 0 to 100PSI with 0 to 1 volt output w/ 8bit resolution on a 5 volt channel
- 500 psi /256 =1.95 PSI resolution

• Impedance
– Resistance to ground ex. >10M ohms DC
• Note: Some loggers impedance drops when the logger is not powered on.
Logger as a Voltmeter

• Voltmeter with multiple channels

– Differential inputs
• Uses a separate ground - reads positive and neg.
voltages
– Single ended
• All channels use the same ground reference – only
reads positive voltages
Voltage Channels
• Voltage channels
• Pressure
• Temperature
• Acceleration
• Yaw
• Travel/displacement
• Event on/off
• Force
• Torque
• Angle of twist
• Strain
Frequency Channels
• Frequency inputs
• Frequency Hz – typically < 500 Hz
– Frequency - Time between pulses
 Flow
 Rpm
 Speed mph

• Counter – Pulses in a given time period

– Totalize or frequency event
– Frequency – pulses in a given time period > 500 Hz
 Fuel used
 Distance traveled
 Total on/off time
CAN data list
What can be Monitored and/or Recorded?
The vast majority of the parameters measured today using existing analog channels are available on the CAN bus.
Vehicle Speed, RPM, Throttle position, Steering Wheel Angle, Engine Coolant Temp., Brake apply, Accelerations, Engine Torque,
Pedal Position, Requested and Delivered Torque, Vehicle Speed, Gear State etc.
Key Diagnostic parameters such as Mass Air flow, Absolute Manifold Pressure, Cam Phasors, Air/ Fuel Ratios, Transmission
Torques, Turbine Torques, etc.
Logger Summary:
• The logger stores data in digital format
• Accepts voltage, frequency, and event inputs
• CAN to vehicle bus
• Instrumentation amp options
• Built in sensors
• Onboard processing
• Application specific post analysis software – Track mapping,
track splits
 Establish Testing Goals
• State what you plan to accomplish i.e.
• The purpose of testing at PIR raceway:
1. Develop spring/shock package for optimum
performance.
2. Monitor critical engine parameters during
calibration development-Powertrain
3. Determine transmission duty cycle for PIR
4. Establish component operating temps –trans,
eng coolant and eng oil
5. Build track profile for Bosch LapSim w/lap times
Build the channel list from the
Goals
• As a team build a Christmas list of channels
from your goal list.
• List key info: vehicle parameter, requestor,
sensor location, special plots, etc.
 Mechanize Christmas list
• The requestor is the owner of the channel who will define post
processing requirements and the value of the data.
• Assign sample min. rate to ea. Sensor
• List sensor location and requirement
• Define post processing requirement
– Build data post processing plot format requirement xy, time history,
histograms, calculated channels etc.
– Assign ea. channel to a plot
• Define the value of the channel
– Assign priority to ea. sensor
• 1 = stop test and repair sensor
• 2 = repair sensor during next break
• 3 = need only 10 minutes of data or ref. data “log sheet”
– Revisit channel list to eliminate non value added data
Post processing - restate goals
• Develop spring/shock package for optimum
performance.
• Log sheet lap or times w/spring rates, bar setup and shock
settings – channel 8
• Monitor critical engine parameters during calibration
development-Powertrain
• Time history – channels 6,9,15 -21
• sort O2 >95% tps w/ spark & coolant temp – channels 6,18,19
• Engine Power & Torque w/tps>95% – channels 9,12,13
• Determine transmission duty cycle for PIR
• Time in gear for one lap – channels 5,9,12,13
• Diff input torque and Revolutions count - one lap – channels
9,12,13
 Production vs Instrumentation grade
Pressure sensor
Production pressure transducer Kulite brake pressure sensor
Parallel plate capacitive-single ended Silicone four arm bridge - differential
Define logger specs from the
Christmas list
• 21 channels of data 6 analog, 6 GMLAN, 3 frequency,
6 internal/analog and 3 math
• 5 V regulated supply
• 100 Hz max sample rate
• Need to quickly review engine data before next run
• Need CSV or MatLab data conversion format
• Track mapping capable w/lap times
• In the racing environment production based sensors
provide good durability at a lower cost than
instrumentation grade sensors.

PRODUCTION BASED SENSOR

Pros Cons
Robust Less accurate
Low cost Drift w/temp
sealed connectors Lower operating temp
High level output Low response time
Low frequency
 Technical specifications for Prod and
Instrumentation grade sensor
• Type High-level Low-level
• Full scale output 4.5Vdc 10mVdc
• Supply voltage 5V regulated 5V regulated
• Sensitivity 32mV/psig .1mV/psig
• Accuracy ± 1.5% ± 0.1%
• Temp range -40C to 135C -55C to 273C
• Compensated -20C to 85C -20C to 232C
• Proof press 2 x rated 2 x rated
• Response time 10ms – 100Hz 3µs - 380kHz
 Re-calibration of a production sensor
can increase accuracy
Post processing the Data
 Post processing

• Set up post
processing Plots.
• Provides a quick
viewing of critical
parameters.
 Driver support analysis
•Vehicle speed vs time slip rate %
•Time slip rate % shows where the driver
lost and gained speed compared to the
fast lap/sector
•Time slip rate % is speed comparison at
each point on the track
Finding a faster line – 0.2 sec gain
Deutsch
Terminals Solder vs Crimp

• With crimp terminals you will never have a cold

solder joint
• Crimp terminals allow the wire to flex at the
terminal
• Solder creates a solid connection at the terminal
limiting cable flexing
Crimp terminal
 Vehicle Wiring Options
• Permanently wiring into the vehicle
– Building a wiring harness for the vehicle creates a more
robust set up, but can limit versatility, depending on
logger capability.
– Allows minimum harness weight.
• Building a breakout box.
– Provides a central point to connect sensors.
– More versatile when various setups are required or for
new vehicle set ups.
Connectors

• Must be sealed if exposed to the elements

• Production connectors typically have a 1 life
duty cycle of 15 times so use only when
needed
Copyright © 2011 Frank A. Whiton.
All rights reserved.