Data Acquisition Systemq y

Jody J. Nelson, Sr. Advisor, Energy Storage Technologies

Outline

• Data acquisition system (DAS) will be provided to every Team 

• Every Team must have DAS installed – Requirement• Objectives and system overview for competition• Description of hardware being provided• Introduction of the DAS vendor• Sensors – appropriate sensors to estimate MPGe and 

emissions will be provided

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• Website

What is a Data Acquisition System (DAS)?

ll l h l h l dA DAS allows you to sample physical vehicle parameters and analyze them

Ph i l t i l dPhysical parameters include:

• Voltages (12 V battery, HV battery, on‐board power supplies)

C t (HV d t ti t d /d t )• Currents (HV dc, traction motor, dc/dc converter)

• Temperatures (motor, traction inverter temperature, cabin temperature)p )

• Speeds (engine rpm, traction motor rpm, vehicle)

• Fluid flow

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• Pressure

What is a Data Acquisition System (DAS)?

Components of a DAS include:

• Sensors and signal conditioning; converting g g; gphysical parameters to electrical signals

• Analog‐to‐digital (A/D) converters convertingAnalog to digital (A/D) converters converting conditioned sensor signals to digital values

• Some means to acquire the data and then• Some means to acquire the data and then display, analyze and/or record the data

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End User:• On‐board display

DAS Example

Physical Source

Sensor + Circuitry A/D

On board display• Storage• DAS SW• Diagnostic SWCAN

+ ‐12 V 0‐5 V 11001001010…

• CAN

0 18

0.25 4.7550

Physical Voltage Range

Scaled Voltage

[V]

[V]

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Failed Sensor Reading

Preferred DAS Arrangement

On vehicle – provided by Teams

+ ‐12 V 0‐5 V 11001001010…

PhysicalSensor + Circuitry

A/DEnd UserPhysical 

Sourcey End User

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Acceptable DAS Arrangement

On vehicle – provided by Teams

+ ‐12 V 0‐5 V 11001001010…

PhysicalSensor + Circuitry

A/DEnd UserPhysical 

SourceCircuitry End User

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CAN is a standard serial bus with multiple masters and is used for

Controller Area Network (CAN)

CAN is a standard serial bus with multiple masters and is used for interconnecting all electronic control units (ECU) of a vehicle

• ISO 11898 provides specifications on CAN• ISO 11898 provides specifications on CAN• ISO 15765 is the legislated OBD‐compliant specification on 

diagnostics using CAN

Note: As of 2008, all vehicles sold in the United States are required to have CAN and to meet ISO 15765‐4 (Road vehicles ‐‐ Diagnostics on 

ll k ( ) fController Area Networks (CAN) ‐‐ Part 4: Requirements for emissions‐related systems)

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If you have a combustion engine, be aware of OBD and California Air Resources Board (CARB) requirements

Objectives of DAS

• Provide Teams with capability of troubleshooting vehicle

• Provide data for the educational website, sponsored by the DOEp y• Displaying vehicle position, approximate MPGe, 

approximate emissions

• Allow for policing Teams during competition events

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Overall System Overview

Vehicle Receiving

On‐Board ModemData Acquisition System

Vehicle Interface DAS OBM Receiving 

SystemWebsite

•Data Logger•Analog I/O•CAN Interface

•Cellular Modem

•Analog or •CAN

•Cellular Provider

LES

•Book of Record•DataCAN Interface

•Power Supply•GPS Receiver•NVM

CAN or •Analog & CAN

Data Processing•Data Formatting•Database

Provided by Progressive Insurance Automotive X PRIZE

Scheduled to be shipped the end of February

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Scheduled to be shipped the end of February

Provided System OverviewVehicle Data NetworkAn instruction Vehicle Data Network

J1708 CAN 2.0B6x Analog

(16 bit)6x Analog

(16 bit)

An instruction manual and limited phone support will 

6x Analog(12 bit)

4x Digital

MT 30

USBThumb Drive

RS-232(Service Tool)

be provided

MT-30Telematics Product RS-232

(Serial Device)

Vehicle P

2x Frequency

2x High Side Drivers

Power

GSM/GPRS850/900/1800/1900

OPTION

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Wireless Networks

850/900/1800/1900

STANDARD

Q d B d GSM/ S O i l

DAS: MT‐30 from Morey Corporation

• Quad‐Band GSM/ Satcom Optional• GPS• uCLinux OS• 32 bit Core/32M/32M• 32‐bit Core/32M/32M• USB 1.1 Host, 2x RS232• RTC/HW Watchdog• (4) Digital inputs(4) Digital inputs• (6) Analog (10/12bit) inputs• (2) Frequency inputs• (12) Analog (16bit) input optional ( ) g ( ) p p• 2 HSD outputs• CAN J1939• IP67

Use Case: 

• Designed for Automotive Environments

• Optional Multi‐Mode Wireless Communications

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• 12/24V • Multiple Sensors and Vehicle Interface 

OBM: GPS and cellular antenna

( )3.9 x 2.6 x 0.8 in. (100 mm x 66 mm x 21 mm)

0.35 oz. (151 g)

< 25 mA@ 5V< 25 mA @ 5V

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Custom Cable Harness Made for Each Vehicle

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An Introduction to the Morey Corporation

Emad S. Isaac, Chief Technical Officer, Morey Corp.

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We make

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Ruggedized Electronics

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Commercial

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Industrial

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Construction

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Agricultural

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Military

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Displays

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Controllers

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Telematics

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When I say “Ruggedized”

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What I mean

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≠≠

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Given the cost of theGiven the cost of the equipmentequ p e t

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wouldn’t it have beenwouldn t it have been better

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if the vehicle itself called forif the vehicle itself called for help the instant it happened? 

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> Message from Unit ID: [U-157]

> Help!> I've fallen, and I can’t get up

> end transmission

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What if the whole thing couldWhat if the whole thing could have been prevented?have been prevented?

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Telematics

Telemetry + Informatics

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“The potential for collection, aggregation and storage of pertinentaggregation, and storage of pertinent data, that can be digested locally, or post‐processed remotely.”

‐ E.S. Isaac

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One Size Does Not Fit All

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General Vehicle Signals

No. Signal Name Description Range Unit

1 Accel_Pos Accelerator pedal position 0 ‐ 100 %2 Brake_Pos Brake pedal position 0 ‐ 100 %3 VS Veh Vehicle speed as provided by vehicle 0 ‐ 200 mph_ p p y p4 EM_RPM Traction motor speed 0 ‐ 15,000 rpm5 EM_pwr Traction motor power 0 ‐ 225 kW6 HVBat_V HV traction battery voltage 0 ‐ 600 V7 HVBat_I HV traction battery current (‐1000) ‐ 1000 A8 HVBat_SOC HV traction battery State of Charge 0 ‐ 100 %9 HVBat_Temp HV traction battery temperature (maximum) (‐20) ‐ 60 C10 EM_Temp Electric motor temperature (maximum) (‐20) ‐ 200 C11 PE_Temp Power electronics temperature (maximum) (‐20) ‐ 150 C12 E RPM E i d 0 700012 Eng_RPM Engine speed 0 ‐ 7000 rpm13 Eng_pwr Indicated engine power 0 ‐ 225 kW14 Eng_Temp Engine oil temperature 0 ‐ 120 C15 Fuel_Lev Fuel level (sensor in vehicle removable tank or pressure sensor for gaseous fuels) 0 ‐ 100 %16 Fuel Flow Fuel injector flow rate 0 ‐ 200 lb/h

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16 Fuel_Flow Fuel injector flow rate  0   200 lb/h

SensorsSensors are a critical aspect to the quality of the dataSensors are a critical aspect to the quality of the data

Two important parameters are for the calculations of MPGe and emissions. Five powertrains need to be considered (distance is required on all powertrains):

(a) ICE – Gasoline (including HEV): (d) HEV/PHEV:i. Fuel flow sensor

(b) ICE – Diesel (including HEV):

i. MAF + O2 sensors or ECM based 

i. HV dc current sensor

ii. HV dc voltage sensor

iii. + appropriate ICE fuel flow

(c) BEV:

i. HV dc current sensor

sensor from (a) or (b)

iv. SOC

(e) CNG:

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ii. HV dc voltage sensor

iii. SOCi. Pressure sensor

ii. Temperature sensor

Sensors – Fuel Flow Sensor

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Sensors – MAF + O2

d l d• Needs regulated excitation power & signal conditioning 

• Need to weld fit into exhaustNeed to weld fit into exhaustwith a desired 0.5 meter straight section h d/b hi d MAF tahead/behind MAF to reduce turbulence

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Sensors – HV Current and VoltageOff‐the‐shelf EVision:Off the shelf EVision:• Instantaneous voltage (V), 

current (A), and power (W)C t it (Ah)• Current capacity (Ah), energy (kWh), SOC (%), and temperature (C)

Many other solutions available: 

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Sensors – Transponder

To be provided to Teams; type is still under discussionunder discussion

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Summary

T ill b id d i h h M DAS i h l• Teams will be provided with the Morey DAS with external antenna

• Provided DAS must be installed in all vehicles

• Scheduled to be shipped the end of February, 2010

• Teams will be provided phone assistance, if needed, for installing the Morey DAS system properly

• The DAS must be fully operating by the time of the Shakedown event andThe DAS must be fully operating by the time of the Shakedown event and will be tested during vehicle inspections

• Teams will be provided with appropriate sensor for determining MPGe and emissions; additionally Teams will be provided transpondersemissions; additionally, Teams will be provided transponders

• Teams must complete the DAS questionnaire and provide feedback on their vehicle communication system and existing sensors – critical for the proper design of the DAS; follow‐up questions may be required

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design of the DAS; follow up questions may be required