1

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.

20Section Outline

● Proposed Solution

● Project Expense Breakdown

● Economic Analysis

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)

33High Level Gantt Chart

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

39

40EXTRA SLIDES

41

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

42

Expanded Gantt Chart