MTS SWIFT 10 User Manual

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SWIFT® 10 ATV Sensor Product Information

Spinning Wheel Integrated Force Transducer

For Recreational and Small Vehicles

100-183-736 C

Trademark information MTS, SWIFT, TestStar, and TestWare are registered trademarks of MTS Systems

Corporation within the United States. These trademarks may be protected in other countries.

Microsoft, Windows, Windows for Workgroups, Windows 95, and Windows NT are registered trademarks of Microsoft Corporation. Apple and Macintosh are registered trademarks of Apple Computer, Inc. UNIX is a registered trademark of The Open Group. LabVIEW is a registered trademark of National Instruments Corporation.

Publication information

MANUAL PART NUMBER PUBLICATION DATE

100-183-736 A February 2008

100-183-736 B April 2008

100-183-736 C November 2008

Technical Support 7

How to Get Technical Support 7

Before You Contact MTS 7

If You Contact MTS by Phone 9

Problem Submittal Form in MTS Manuals 10

Preface 11

Before You Begin 11

Conventions 12

Documentation Conventions 12

Hardware Overview 15

Overview 16

Spinning Applications (Track or Road) 18

Non-spinning Applications (Laboratory) 19

Construction 20

Design Features 23

Coordinate System 24

Specifications 26

Calibration 30

Transducer Interface 32

TI Front Panel 35

TI Rear Panel 36

Interfacing with RPC 37

Software Utilities 39

Introduction 40

TI2STATUS - Transducer Interface Status 41

Description of TI2STATUS Indications 41

TI2XFER - Transducer Interface Transfer 43

TI2SHUNT - Transducer Interface Shunt 45

Setting Up Shunt Calibration Reference Values 48

Error Messages 49

SWIFT 10 ATV Sensors Contents

Setting up the Transducer Interface 51

USB driver installation 52

Select a Zero Method 54

Calibration File Elements 55

Upload the Calibration File 56

Edit the Calibration File 57

Download the Calibration File 60

Installing the Transducer 61

Hazard Icon 62

Road and Track Vehicles 63

Attaching SWIFT Components to the Vehicle 67

Attaching Anti-rotate Assemblies 70

Installing the Transducer Interface Electronics 74

Setting up the SWIFT Sensor for Data Collection 77

Verifying the Quality of the Zero Procedure 80

Collecting Data 82

Road Simulator 85

Attaching SWIFT Components to the Fixturing 88

Zeroing the Transducer Interface 92

Analyzing SWIFT Data 97

The Data 98

Fx Data (Longitudinal Force) 99

Fz Data (Vertical Force) 101

Mx Data (Overturning Moment) 102

My Data (Brake Moment) 105

Acceleration and Braking Events Example 107

Slalom Curve Driving Example 109

Maintenance 111

Transducer 112

Transducer Interface 114

Cables 115

Contents

SWIFT 10 ATV Sensors

Troubleshooting 117

Assembly Drawings 129

Cable Drawings 130

SWIFT 10 Mechanical Drawings 136

SWIFT 10 ATV Sensors Contents

Contents

SWIFT 10 ATV Sensors

Technical Support

How to Get Technical Support

Start with your

manuals

Technical support

methods

MTS web site

www.mts.com

E-mail techsupport@mts.com

Telephone MTS Call Center 800-328-2255

Fax 952-937-4515

Technical support

outside the U.S.

The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes MTS software, look for online help and README files that contain additional product information.

If you cannot find answers to your technical questions from these sources, you can use the internet, e-mail, telephone, or fax to contact MTS for assistance.

MTS provides a full range of support services after your system is installed. If you have any questions about a system or product, contact MTS in one of the following ways.

The MTS web site gives you access to our technical support staff by means of a Technical Support link:

www.mts.com > Contact MTS > Service & Technical Support

Weekdays 7:00 A.M. to 5:00 P.M., Central Time

Please include “Technical Support” in the subject line.

For technical support outside the United States, contact your local sales and service office. For a list of worldwide sales and service locations and contact information, use the Global MTS link at the MTS web site:

www.mts.com > Global MTS > (choose your region in the right-hand column) > (choose the location closest to you)

Before You Contact MTS

MTS can help you more efficiently if you have the following information available when you contact us for support.

Know your site

number and system

number

SWIFT 10 ATV Sensors Technical Support

The site number contains your company number and identifies your equipment type (material testing, simulation, and so forth). The number is usually written on a label on your MTS equipment before the system leaves MTS. If you do not have or do not know your MTS site number, contact your MTS sales engineer.

Example site number: 571167

When you have more than one MTS system, the system job number identifies which system you are calling about. You can find your job number in the papers sent to you when you ordered your system.

Example system number: US1.42460

Know information from

prior technical

If you have contacted MTS about this problem before, we can recall your file. You will need to tell us the:

assistance

• MTS notification number

• Name of the person who helped you

Identify the problem Describe the problem you are experiencing and know the answers to the

following questions:

• How long and how often has the problem been occurring?

• Can you reproduce the problem?

• Were any hardware or software changes made to the system before the

problem started?

• What are the model numbers of the suspect equipment?

• What model controller are you using (if applicable)?

• What test configuration are you using?

Know relevant

computer information

Know relevant

software information

If you are experiencing a computer problem, have the following information available:

• Manufacturer’s name and model number

• Operating software type and service patch information

• Amount of system memory

• Amount of free space on the hard drive in which the application resides

• Current status of hard-drive fragmentation

• Connection status to a corporate network

For software application problems, have the following information available:

• The software application’s name, version number, build number, and if

available, software patch number. This information is displayed briefly when you launch the application, and can typically be found in the “About” selection in the “Help” menu.

• It is also helpful if the names of other non-MTS applications that are

running on your computer, such as anti-virus software, screen savers, keyboard enhancers, print spoolers, and so forth are known and available.

Technical Support

SWIFT 10 ATV Sensors

If You Contact MTS by Phone

Your call will be registered by a Call Center agent if you are calling within the United States or Canada. Before connecting you with a technical support specialist, the agent will ask you for your site number, name, company, company address, and the phone number where you can normally be reached.

If you are calling about an issue that has already been assigned a notification number, please provide that number. You will be assigned a unique notification number about any new issue.

Identify system type To assist the Call Center agent with connecting you to the most qualified

technical support specialist available, identify your system as one of the following types:

• Electromechanical materials test system

• Hydromechanical materials test system

• Vehicle test system

• Vehicle component test system

• Aero test system

Be prepared to

troubleshoot

Write down relevant

information

After you call MTS logs and tracks all calls to ensure that you receive assistance and that action

Prepare yourself for troubleshooting while on the phone:

• Call from a telephone when you are close to the system so that you can try

implementing suggestions made over the phone.

• Have the original operating and application software media available.

• If you are not familiar with all aspects of the equipment operation, have an

experienced user nearby to assist you.

Prepare yourself in case we need to call you back:

• Remember to ask for the notification number.

• Record the name of the person who helped you.

• Write down any specific instructions to be followed, such as data recording

or performance monitoring.

is taken regarding your problem or request. If you have questions about the status of your problem or have additional information to report, please contact MTS again and provide your original notification number.

SWIFT 10 ATV Sensors Technical Support

Problem Submittal Form in MTS Manuals

Use the Problem Submittal Form to communicate problems you are experiencing with your MTS software, hardware, manuals, or service which have not been resolved to your satisfaction through the technical support process. This form includes check boxes that allow you to indicate the urgency of your problem and your expectation of an acceptable response time. We guarantee a timely response—your feedback is important to us.

The Problem Submittal Form can be accessed:

• In the back of many MTS manuals (postage paid form to be mailed to MTS)

• www.mts.com > Contact Us > Problem Submittal Form (electronic form to

be e-mailed to MTS)

Technical Support

SWIFT 10 ATV Sensors

Preface

Before You Begin

Safety first! Before you attempt to use your MTS product or system, read and understand the

Safety manual and any other safety information provided with your system. Improper installation, operation, or maintenance of MTS equipment in your test facility can result in hazardous conditions that can cause severe personal injury or death and damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue. It is very important that you remain aware of hazards that apply to your system.

Other MTS manuals In addition to this manual, you may receive additional MTS manuals in paper or

electronic form.

If you have purchased a test system, it may include an MTS System Documentation CD. This CD contains an electronic copy of the MTS manuals that pertain to your test system, including hydraulic and mechanical component manuals, assembly drawings and parts lists, and operation and preventive maintenance manuals. Controller and application software manuals are typically included on the software CD distribution disc(s).

SWIFT 10 ATV Sensors Preface

Conventions

DANGER

WARNING

CAUTION

Conventions

Documentation Conventions

The following paragraphs describe some of the conventions that are used in your MTS manuals.

Hazard conventions As necessary, hazard notices may be embedded in this manual. These notices

contain safety information that is specific to the task to be performed. Hazard notices immediately precede the step or procedure that may lead to an associated hazard. Read all hazard notices carefully and follow the directions that are given. Three different levels of hazard notices may appear in your manuals. Following are examples of all three levels.

Note For general safety information, see the safety information provided with

your system.

Danger notices indicate the presence of a hazard with a high level of risk which, if ignored, will result in death, severe personal injury, or substantial property damage.

Warning notices indicate the presence of a hazard with a medium level of risk which, if ignored, can result in death, severe personal injury, or substantial property damage.

Caution notices indicate the presence of a hazard with a low level of risk which, if ignored, could cause moderate or minor personal injury, equipment damage, or endanger test integrity.

Notes Notes provide additional information about operating your system or highlight

easily overlooked items. For example:

Note Resources that are put back on the hardware lists show up at the end of

the list.

Special terms The first occurrence of special terms is shown in italics.

Illustrations Illustrations appear in this manual to clarify text. It is important for you to be

aware that these illustrations are examples only and do not necessarily represent your actual system configuration, test application, or software.

Electronic manual

conventions

This manual is available as an electronic document in the Portable Document File (PDF) format. It can be viewed on any computer that has Adobe Acrobat Reader installed.

Preface

SWIFT 10 ATV Sensors

Conventions

Hypertext links The electronic document has many hypertext links displayed in a blue font. All

blue words in the body text, along with all contents entries and index page numbers, are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic.

SWIFT 10 ATV Sensors Preface

Conventions

Preface

SWIFT 10 ATV Sensors

Hardware Overview

Contents Overview 16

Spinning Applications (Track or Road) 18

Non-spinning Applications (Laboratory) 19

Construction 20

Design Features 23

Coordinate System 24

Specifications 26

Calibration 30

Transducer Interface 32

TI Front Panel 35

TI Rear Panel 36

Interfacing with RPC 37

SWIFT 10 ATV Sensors Hardware Overview

Overview

Data

S10-01

Track or Road

Laboratory Simulation

WARNING

Overview

The MTS Spinning Wheel Integrated Force Transducer (SWIFT®) sensor is a light-weight, easy-to-use transducer that enables you to conduct faster, less expensive data acquisition and road simulation testing.

The transducer is designed for use on the test track and public roads, as well as in the test laboratory. It attaches to the test vehicle or an MTS Series 329 Road Simulator using an adapter and a modified wheel rim.

You can achieve excellent data correlation using the same transducer and vehicle on the test track or public road and on a road simulator. It is available in various sizes and materials to fit various vehicle and loading requirements.

Hardware Overview

Driving a vehicle with SWIFT sensors mounted on it will change the handling characteristics of the vehicle.

Driving a vehicle configured in this way on public roads can pose unexpected dangers to pedestrians and other vehicle traffic.

Only authorized, licensed drivers, who are experienced driving a vehicle with SWIFT sensors mounted on it, should be allowed to operate the vehicle on public roads. Drive the vehicle with the SWIFT sensor attached on closed courses only until you have proper experience.

When driving the vehicle on public roads, you must conform to all local laws and regulations.

SWIFT 10 ATV Sensors

Overview

CAUTION

Parts replacement,

disassembly, and care

The SWIFT sensor assembly, Transducer Interface box, and the accessory components have no user serviceable parts. These components should not be disassembled other than as outlined in “Troubleshooting” beginning on page 117.

Do not disassemble the SWIFT sensor, Transducer Interface (TI) electronics, and accessory components.

The SWIFT sensor, TI electronics, and accessory components are not intended to be disassembled, other than as outlined in “Troubleshooting”.

Disassembling or tampering with these components may result in damage to the sensor, loss of watertight seal, and voiding of the warranty.

• The sensor assembly should be returned to MTS annually for recalibration

and inspection.

• Clean the sensor assembly after each use, as described in Maintenance

beginning on page 111, especially if it is exposed to corrosive or abrasive material, such as salt or sand.

• Read and follow all warnings and cautions affixed to the transducer and in

this manual especially those warnings and cautions that deal with installation, use, inspection and maintenance of the transducer.

The SWIFT sensor assembly should not:

• Be allowed to strike hard surfaces or objects while driving the vehicle.

• Be driven through grass or brush that is taller than the bottom edge of the

sensor.

• Be exposed to loads that exceed the full scale calibrated ranges. Refer to the

calibration sheets accompanying your transducers.

• Be used if the integrity of the sealed cover has been compromised or the

warning label has been removed.

• Be used if the sensor assembly shows indications of damage (such as dents

on the transducer or slip ring assembly, a bent anti-rotate assembly, etc.).

• Be used if any part of the assembly has been modified without explicit,

written authorization from MTS.

SWIFT 10 ATV Sensors Hardware Overview

Spinning Applications (Track or Road)

Customer Supplied

Power Supply

Customer Supplied

Data Recorder

Transducer

Interface (TI)

Transducer Signals

Output

Signals

S10-02

Spinning Applications (Track or Road)

The SWIFT sensor can be used for road load data acquisition (RLDA) applications:

• Durability

• Noise, Vibration and Harshness (NVH)

• Ride and Handling

• Tire Performance

The transducer is durable enough to withstand harsh road testing and data acquisition environments. The transducer is splash resistant and suitable for use in conditions where the test vehicle will encounter occasional standing or running water, or will be exposed to precipitation. However, it should not be submerged.

In a typical spinning application, the transducer is mounted on a modified rim of a tire on a test vehicle, as shown in the following figure. The Transducer Interface (TI), power supply, and data recorder can be securely mounted on a carriage rack. The TI box should be protected against environmental conditions (water and mud splashes and dust), and it should not be allowed to be immersed.

Hardware Overview

Spinning Application (Track or Road)

SWIFT 10 ATV Sensors

Non-spinning Applications (Laboratory)

Power Supply (with 4

connections)

Customer-Supplied

Test Control System

Transducer

Interface (TI)

Transducer Signals

Output

Signals

PC Communication

S10-03

Non-spinning Applications (Laboratory)

The SWIFT sensor can be fully integrated into the simulation process, since it is an optimal feedback transducer for use with MTS Remote Parameter Control

) software. The transducer takes data at points where fixturing inputs are

(RPC located rather than at traditional instrumentation points along the vehicle’s suspension. Using the SWIFT sensor saves you instrumentation time, and fewer iterations are required to achieve good simulation accuracy.

Measuring spindle loads allows engineers to generate generic road profiles. Generic road profiles are portable across various vehicle models, do not require new test track load measurements for each vehicle, and eliminate additional RLDA tasks.

Several of the six loads measured by the transducer directly correlate to the MTS Model 329 Road Simulator inputs.

The same transducers used to collect road data can be mounted directly in the wheel adapters of the MTS Model 329 Road Simulator. For durability testing, the SWIFT sensor can be used for iterations within the RPC process. The SWIFT sensor should then be removed for the durability cycles, to preserve its fatigue life. It can be replaced by an adapter plate, available from MTS, to duplicate the mass and center of gravity of the actual SWIFT sensor. If a SWIFT sensor is to be used during full durability tests, we suggest using the titanium model, which has a higher fatigue rating.

In a typical non-spinning application, a SWIFT sensor is mounted on a road simulation test fixture, as shown in the following figure.

Non-spinning Application (Laboratory Simulation)

SWIFT 10 ATV Sensors Hardware Overview

Construction

Slip Ring

Bracket

(with encoder)

Washer

Plate

Transducer

Modified Wheel Rim

Lug Nuts

Inner Hub

Adapter

S10-08

Construction

The SWIFT sensor has one-piece construction for outstanding fatigue life, low hysteresis, and high stiffness. Its compact package has a minimal effect on inertia calculations, and a minimal dynamic effect on the test vehicle.

The transducer can be used for developing conventional durability tests on the MTS Model 329 Road Simulator. Normally, the transducer is replaced with an equivalent wheel adapter after the simulation drive signals are developed and prior to the start of the test.

The SWIFT sensor includes several mechanical and electrical components.

Hardware Overview

Transducer The transducer attaches directly to a modified wheel rim. On the test track

vehicle, the transducer spins with the wheel. On a road simulator, the transducer attaches directly to an adapter plate on the 329 spindle housing. The slip ring can be used to accommodate the range of motion of the rear swing arm.The transducer is available in two materials.

The transducer’s unibody design means there are no multiple parts welded or screwed together.

The transducer has four beams with strain gages that measure six orthogonal outputs:

Fx—longitudinal force

Fy—lateral force

Fz—vertical force

Mx—overturning moment

My—acceleration and brake torque

Mz—steering moment

It has onboard conditioning and amplifiers to improve the signal-to-noise ratio.

SWIFT 10 ATV Sensors

Construction

Anti-Rotate

Assembly

Slip Ring

and Encoder

Slip Ring

Bracket

Alternate

Spindle Hub

Interface

(for hub piloted

spindle)

Coupling Teeth

Interface

Transducer

Interface

Cable

Washer

Plate

Transducer

Vehicle

Spindle Hub

Inner

Hub Adapter

Anti-Rotate

Mounting Bracket

(customer supplied)

S10-04

Inner hub adapter The inner hub adapter attaches to the inner diameter of the transducer and the

spindle face of the vehicle. The inner hub adapter enables you to maintain the original position of the tire on the vehicle (the tire will not protrude from the vehicle) while the transducer is attached to the vehicle.

Components Set Up for Test Track

Slip-ring bracket The slip-ring bracket attaches the slip ring to the transducer. It has internal wiring

that provides excitation power to the strain gage bridges and brings signals out from the transducer to the slip ring.

Encoder An encoder measures the angular position of the transducer. The SWIFT sensor

encoder is integrated into the slip ring assembly, and counts off “ticks” to measure the angular position as the wheel rotates. It measures 2048 (512 pulse quadrature) points per revolution (ppr) with a resolution of 0.18 degrees.

Slip ring The slip ring allows you to output the transducer bridge signals and angular

position to the TI. A transducer data cable attaches from the slip ring to the back panel of the TI.

Anti-rotate device The anti-rotate device is attached to the slip ring and the vehicle’s suspension (or

other non-rotating point). It is able to move up and down with the vehicle. Its primary function is to provide a fixed reference point for the angle sensor. Its secondary function is to prevent the cable from rotating with the wheel and becoming tangled or breaking.

The slip ring and anti-rotate device are used mainly for road data collection. Although it can also be used for short periods of time on a road simulator. MTS does not recommend this use. Due to the extreme fatigue loading characteristics

SWIFT 10 ATV Sensors Hardware Overview

of durability testing on road simulators, we suggest that you either remove the slip ring assembly before installing the vehicle on a road simulator, or use it only for iteration passes, then promptly remove it.

Construction

The anti-rotate device should be configured such that no loading occurs to the slip ring throughout all loading and suspension travel. This means that when you attach the anti-rotate device to the vehicle, you must consider all possible motion of the suspension. The anti-rotate device should not bump against the wheel well at any time; any jarring of the anti-rotate arm will damage the slip ring. For steering axles, the anti-rotate bracket must be mounted to part of the unsprung suspension that steers with the tire, such as the brake caliper. For additional antirotate device mounting recommendations, refer to the Anti-Rotate Customer/ User Assembly drawing at the back of this manual.

Transducer Interface

(TI)

Additional

components

The TI provides power to the transducer and uses previously stored calibration values to convert the raw transducer signals from the bridge outputs and the encoder to three force outputs (Fx, Fy, Fz), three moment outputs (Mx, My, Mz) and an angle output. The force and moment outputs have a value of 10 V full scale, unless a different full-scale output is requested by a customer. The angle output is a 0–5 V sawtooth output.

Additional components that are supplied with your SWIFT sensor include transducer data cables, TI power cable, a SWIFT Transducer Interface Utilities CD or disk, and the calibration file. MTS can also provide a 12 V DC power converter for use in the test laboratory.

Hardware Overview

SWIFT 10 ATV Sensors

Design Features

Flexure isolation The SWIFT sensor has a very stiff outer ring and flexured beam isolation which

Thermal stability The entire sensor is machined from a solid, specially forged billet of high

Construction

render it relatively insensitive to stiffness variations in matings with rims and road simulator fixtures.

Flexure isolation minimizes thermal expansion stresses. With flexure isolation, if the inner hub experiences thermal expansion the beams are allowed to expand out, resulting in lower compressive stress on the beams.

strength titanium or aluminum. The absence of bolted joints permits an efficient transfer of heat across the sensor structure, minimizing temperature differentials in the gaged area.

The transducer is designed to accommodate the high temperature environments that occur during severe driving and braking events. Individual temperature compensation of each strain gage bridge minimize temperature induced variations in accuracy. Since minimal electronics reside on the SWIFT sensor, it can easily tolerate high temperatures. The temperature rating for the SWIFT sensor is 125° C (257° F) at the spindle hub.

Temperature compensation is done on each bridge for better performance in transient or non-uniform temperature occurrences.

Low hysteresis The SWIFT sensor has very low hysteresis, since the sensing structure is

constructed with no bolted joints. Micro slippage in bolted joints contributes most of the hysteresis in highly stressed structures. Hysteresis errors due to micro-slip at joints can contribute to unresolvable compounding errors in coordinate transformation of the rotating sensor.

Low noise The SWIFT sensor uses a slip ring rather than telemetry for the transducer output

signals. On-board amplification of the transducer bridges minimizes any slip ring noise contribution.

Low cross talk The advanced design of the SWIFT sensor means that it has very low cross talk.

The alignment of the sensing element is precision machined. This alignment is critical to achieving minimum cross talk error between axes and minimum errors in coordinate transformation (from a rotating to a non rotating coordinate system). Any small amount of cross talk present is compensated by the TI.

Velocity information Angular output is available from the TI when it is used in the spinning mode with

the encoder. This angular output can be used to calculate wheel velocity. In nonspinning applications, accelerometers can be integrated into the transducer connector housing.

MTS does not supply any conditioning electronics for accelerometers. Ask your MTS consultant for more information about this option.

SWIFT 10 ATV Sensors Hardware Overview

Coordinate System

Transducer

Interface

Output signals

±10 Volts

Angular

Position

Bridge

Outputs

S10-10

Coordinate System

In the transducer, independent strain gage bridges measure forces and moments about three orthogonal axes. The signals are amplified to improve the signal-tonoise ratio. An encoder signal measures angular position, which is used to convert raw force and moment data from the rotating transducer to a vehiclebased coordinate system. The force, moment, and encoder information are sent to the transducer interface (TI).

The TI performs cross talk compensation and converts the rotating force and moment data to a vehicle coordinate system. The result is six forces and moments that are measured at the spindle: Fx, Fy, Fz, Mx, My, and Mz. A seventh (angular) output is available for tire uniformity information, angular position, or to determine wheel speed (depending on the data acquisition configuration).

Hardware Overview

SWIFT 10 ATV Sensors

Coordinate System

+Fz

+Mz

+Fx

+Fy

S10-09

Forces Acting on Rim-side of Transducer

Hub Adapter

Mounting Side

Rim Flange

Mounting Side

+Mx

+My

The coordinate system shown below was originally loaded into the TI settings by MTS. It uses the right-hand rule.

The SWIFT coordinate system is transducer-based, with the origin located at the center of the transducer. Positive loads are defined as applied to the outer ring of the transducer.

• Vertical force (Fz) is positive up.

• Lateral force (Fy) is positive out of the vehicle.

• Longitudinal force (Fx) follows the right-hand rule, consistent with Fz and

Fy described above.

You can change to the MTS Model 329 Road Simulator convention (lateral load into the vehicle is always positive) or to any coordinate system by changing the polarities in the calibration file. For instructions on how to change the coordinate system polarities, see the chapter, “Setting up the Transducer Interface”.

SWIFT 10 ATV Sensors Hardware Overview

Specifications

SWIFT 10 ATV Transducer Performance (part 1 of 2)

ARAMETER SPECIFICATION

Use

SWIFT 10 ATV (aluminum) for:

SWIFT 10 ATV (titanium) for:

Maximum usable rpm

Maximum speed

Shock resistance, each axis

Fits rim size (usable range)

Number of Lug nuts accommodated

Hub bolt circle diameter accommodate

Wheel stud size accommodated

Input voltage required

Input power required per transducer

Output voltage ± full scale calibrated load

SAE J328

Rated load capacity

Bending moment

Full scale calibrated ranges

Resolution

Performance accuracy

Nonlinearity

Hysteresis

Modulation

Cross talk

Maximum operating temperature

Assembly Weight – single wheel

Transducer

Aluminum hub adapter/spacer

Slip ring assembly

Modified aluminum rim

Lug nuts

Outer steel washer plate

Attached fasteners

Total

‡

low weight, high sensitivity, lower measured forces

1.45 kN•m (12 869 lbf•in)

Consult the calibration range sheet that accompanies each transducer

high fatigue life, longer durability, higher loads

2,200

250 kph (155 mph)

150 G

7-12 inch

All

9–30 V DC

7 Watts maximum (22 Watts typical)

†

±10 V

Aluminum

2.5 kN (550 lbf)

Titanium

4.2 kN (925 lbf)

4.76 kN•m (42117 lbf•in)

Infinite

1.0% full scale

0.50% full scale

≤5.0% reading

1.5% full scale

125°C (257°F

1.4 kg (3.0 lb)

0.5 kg (1.0 lb)

0.5 kg (1.1 lb)

2.4 kg (5.3 lb)

0.1 kg (0.2 lb)

0.2 kg (0.4 lb)

0.8 kg (1.8 lb)

5.8 kg (12.8 lb)

2.0 kg (4.5 lb)

0.5 kg (1.0 lb)

0.5 kg (1.1 lb)

2.4 kg (5.3 lb)

0.1 kg (0.2 lb)

0.2 kg (0.4 lb)

0.8 kg (1.8 lb)

6.5 kg (14.3 lb)

Hardware Overview

SWIFT 10 ATV Sensors

Specifications

SWIFT 10 ATV Transducer Performance (part 2 of 2)

ARAMETER SPECIFICATION

Output connector type

Auto shunt calibration

* Contact MTS for other rim sizes. Larger diameter rims can be used, provided that overall clearance from

brake calipers and suspension components is maintained. † Load impedance >1 k ‡ Half axle rated capacity per SAE J328.

§ Moment fatigue-rated for 100,000 cycles. # Each SWIFT sensor is calibrated on an MTS calibration machine. MTS provides complete documentation

of calibration values for each SWIFT unit ** Measured at the spindle hub.

Ω; 0.01 µF (maximum) load capacitance.

D-shell or BNC via adapter

On vehicle or laboratory test rig.

SWIFT 10 ATV Sensors Hardware Overview

Specifications

Transducer Center-of-Gravity

Transducer Center-of-Gravity and Inertia Specifications

ATERIAL

ALUMINUM TITANIUM

0.0 mm 0.000 in 0.0 mm 0.000 in

18.0 mm 0.710 in 18.0 mm 0.710 in

0.0 mm 0.000 in 0.0 mm 0.000 in

26 kg·cm29 lbm·in

50 kg·cm217 lbm·in280 kg·cm227 lbm·in

26 kg·cm29 lbm·in

42 kg·cm214 lbm·in

Transducer Interface (part 1 of 2)

ARAMETER SPECIFICATION

Physical

Height

Width

Depth

Weight

Rack Mounting Kit

28 mm (1.100 in)

213 mm (8.375 in)

171 mm (6.750 in.)

0.907 kg (30 oz)

Optional

Environmental

Ambient temperature

Relative humidity

Protection

Hardware Overview

0° C (32° F) to 50° C (122° F)

0 to 90%, non-condensing

IP64 (complete dust protection, projected water from all directions)

SWIFT 10 ATV Sensors

Transducer Interface (part 2 of 2)

ARAMETER SPECIFICATION

Power Requirements

Input voltage

Fuses

10–28 V DC

Internal thermal, self-resetting

Specifications

Power Consumption

4 Watts maximum without transducer or encoder

6 Watts typical with transducer and encoder at 12 V DC

Angular velocity

Encoder limit

Processing limit

Encoder resolution

2,200 rpm maximum

10,000 rpm maximum

2048 counts per revolution (512 pulses with quadrature)

Time delay (encoder tick to main output stable)

Transducer cable length

Analog outputs

Vol tag e

150 µs (typical)

100 ft maximum

±10 V range† (force and moment outputs) 0–5 V sawtooth (angle output)

Capacitive load

Current

Noise at output, with typical gains

0.01 µF maximum

2 mA maximum

7 mVpp, DC - 500 Hz (typical) 15 mVpp, DC - 500 Hz (maximum)

* Add 25.4 mm (1.0 in) for ground lugs. † Standard from MTS. Other full scale voltages can be evaluated and may be provided at special

request.

SWIFT 10 ATV Sensors Hardware Overview

Calibration

Each transducer is calibrated by MTS before shipment. The transducer and TI may be returned to MTS for repair and recalibration as required.

Calibration is performed at MTS on a special fixture that is capable of applying multiple loads to the transducer. During calibration, raw signals are measured. The calibration gains and cross talk compensation values are computed from this raw data. These gains are recorded in a calibration file.

A unique calibration file is supplied for each transducer. The serial number of the TI associated with the transducer is listed at the top of the calibration file. A label with the serial number of the TI box (and the SWIFT sensor with which it was originally calibrated) is attached to the back of each TI box.

The calibration file is loaded into the TI non-volatile memory by MTS before the transducer is shipped. A copy of the file is also provided on a diskette.

MTS verifies the calibration by applying loads to the transducer, measuring the main outputs and checking for accuracy. Final calibration reports are provided with each transducer.

Shunt calibration At the end of the calibration process, a shunt calibration is performed. During a

shunt calibration, a resistance is introduced into the bridge circuit. The difference between the shunted and unshunted voltage is the delta shunt reference value for each bridge. That value is saved in the calibration file, which is downloaded from a PC or laptop computer and stored in non-volatile memory in the TI.

At any time afterward, pressing the Shunt button on the front of the TI causes each of the strain gage bridges to be shunted in sequence, and the measured shunt voltage (delta shunt measured value ) is compared to the reference value.

An acceptable tolerance range is also loaded into the TI memory during system calibration. One tolerance value is used for all bridges. This value is loaded as a percentage of allowable deviation from the delta shunt values. For example, if the FX1 bridge has a shunt delta reference value of –3.93, and the tolerance is set at 2 (percent), the acceptable range for the measured value would be –3.85 to –4.01.

Hardware Overview

SWIFT 10 ATV Sensors

Calibration

When you press the Shunt button, the associated Shunt indicators toggle while the shunt is in progress. As the TI automatically switches through the series of bridges, it verifies that the outputs are within the accepted tolerance range. If all bridge shunt values fall within the tolerance range, the Shunt indicators on the front panel will go off (after several seconds). If any bridge fails the shunt test, the red, fail indicator lights, indicating that the shunt calibration has failed. The fail indicator remains lit until a shunt check passes or until you cycle power off and on. Use the TI2STATUS utility to get more detailed information about the shunt failure.

ShuntTolerance=2 FX1ShuntDeltaRef=-1.379 FX2ShuntDeltaRef=-1.386 FY1ShuntDeltaRef=-1.381 FY2ShuntDeltaRef=-1.378 FY3ShuntDeltaRef=-1.382 FY4ShuntDeltaRef=-1.381 FZ1ShuntDeltaRef=-1.380 FZ2ShuntDeltaRef=-1.380 FX1ShuntDeltaMeas=-1.378 FX2ShuntDeltaMeas=-1.386 FY1ShuntDeltaMeas=-1.380 FY2ShuntDeltaMeas=-1.379 FY3ShuntDeltaMeas=-1.382 FY4ShuntDeltaMeas=-1.382 FZ1ShuntDeltaMeas=-1.385 FZ2ShuntDeltaMeas=-1.382

Checking the

calibration

Example of Calibration File Shunt Data

The above example shows shunt data from the calibration file. This data may be transferred, using the TI2XFER program, from the transducer interface memory to a computer or from a computer to the transducer interface memory. Note that items marked ShuntDeltaMeas are uploaded from memory, but not downloaded from the computer.

For more information on TI2XFER, see the chapter, “Software Utilities”.

You can check the calibration of a transducer at any time by pressing the Shunt switch (described earlier). Subsequent shunt commands compare the current feedback values against those stored in the TI. You may set the tolerance values for each TI by editing the calibration file. See the chapter, “Setting up the Transducer Interface”, for instructions.

SWIFT 10 ATV Sensors Hardware Overview

Transducer Interface

Transducer

Interface

Output signals

(±10 Volts)

Angular

Position

Bridge

Outputs

Transducer bridge output

signals and encoder

angular position signal are

sent through slip ring

Transducer Interface

converts signals to non-

spinning vehicle coordinates,

applies calibration gains and

cross talk compensation

Force, moment, and

angle analog signals

are output from

Transducer Interface

Angle signal

(05 Volts)

S10-05

Transducer Interface

The TI performs cross talk compensation, transforms the loads from a rotating to a non-rotating coordinate system, and produces an analog output signal suitable for any data recorder.

Cross talk

compensation

Cross talk occurs when a force is applied to one axis, but a non-real force is measured on another axis. The SWIFT sensor design has very low inherent cross talk. The TI compensates for cross talk by subtracting cross talk values measured during calibration.

Signal conditioning The TI is specifically designed to be used for both spinning and non-spinning

applications. The TI performs signal conditioning and communications functions. The output from the TI is a high-level signal suitable for input into a multichannel data recorder or an MTS Automated Site Controller (ASC).

Hardware Overview

SWIFT 10 ATV Sensors

Transducer Interface

Fx1 Fx2 Fy1

Fy2 Fy3 Fy4 Fz1 Fz2

Fx Fy Fz Mx My

Geometric

Matrix

Zero and

Scaling

Cross

Coupling

Matrix

Rotational

Transformation

Inputs Outputs

Transducer Interface Functions

S50-011

The TI transforms eight inputs (amplified bridge signals) into three forces and three moments by the following process:

• Applying a zero offset and scaling the signals

• Using a geometric matrix to transform the signals into three forces and three

moments in the transducer reference frame

• Using a cross-coupling matrix calculation to scale and sum the individual

signals into each output

• In spinning applications, using a rotational transformation to put the forces

and moments into a stationary reference frame

The TI conditions the transducer signals, producing seven analog output signals proportional to the following values:

• Longitudinal force (Fx)

• Lateral force (Fy)

• Vertical force (Fz)

• Overturning moment (Mx)

• Driving/Braking moment (My)

• Steering moment (Mz)

• Angle output (θ)

Analog signals The force and moment signals are output from the TI in the form of ±10 V

scale analog signals. These signals can be used by most data acquisition systems.

The angle output is an analog voltage that is proportional to angular position. At 0° the output is 0 V. At 360°, the output is 5 V.

full

1. Standard from MTS. Other full-scale output voltages can be evaluated and may be

provided at special request.

SWIFT 10 ATV Sensors Hardware Overview

Transducer Interface

0 360°

0° 360°

Angle

Output

1 rev = 360°

S20-10

The angle output for a tire rotating at constant velocity can be represented by the following illustration:

Although you may not routinely use it, the angle output information is available for tasks such as tire uniformity testing and troubleshooting. You may also calculate angular velocity by measuring the frequency of the angle output signal.

If using the sawtooth angle output for analysis or computing velocity, care should be taken when setting the data acquisition to avoid filter-induced ringing or attenuation of the sawtooth output.

Communications The TI uses USB 2.0 for communication. The MTS supplied USB drivers must

be installed on each computer you connect to the TI.

Hardware Overview

SWIFT 10 ATV Sensors

TI Front Panel

Power button and Indicator and Fail Indicator

Shunt button and Indicators

Zero button and Indicators

J5 USB Connector

J4 I/O Connector

Transducer Interface

Transducer Interface Front Panel

Power button and

Indicator

Shunt button and

indicators

Zero button and

indicators

The power button turns power on and off. Pressing and holding the button turns on power and initializes the TI. During initialization, all indicators turn on momentarily. When initialization is complete, all indicators will turn off with the exception of the green Power indicator.

Pressing this button performs a shunt calibration (shunt cal) of the transducer. You do not need to hold the button in continuously, only until the Shunt indicators light up (indicating that the TI has started the shunt cal). The two indicators will alternately toggle on and off as the TI sequences through the shunt calibration of each bridge.

Before you perform a shunt cal, check that the appropriate shunt reference value and error tolerance have been downloaded (these values are normally loaded during system calibration, and are referred to as the shunt delta cal values).

A shunt calibration will determine the current delta values by measuring the bridges unshunted and shunted values, and then compare these values to the previously loaded calibration values.

If the measured values are outside of an acceptable tolerance the red status indicator under the Power indicator with light.

Note The state of the shunt cal check is cleared at power-up, so the shunt cal

should be performed when the system installation is in question.

The zero button is used to zero the transducer inputs. When you press the button, the TI executes the ZeroAlgorithm that you specify in the calibration file (see following illustration).

J5 USB connector The USB connector is a standard USB 2.0 type B connector for output to a laptop

or PC with the correct drivers installed.

J4 I/O connector Not used at this time.

SWIFT 10 ATV Sensors Hardware Overview

Transducer Interface

J3 Transducer Connector

J2 Output Connector

J1 Power Connector

TI Rear Panel

Transducer Interface Rear Panel

J1 Power connector Connect a power cable from the external power source.

J2 Output connector The J2 Output connector provides the conditioned sensor outputs that can be

connected to a data acquisition or test control system.

J3 Transducer

connector

Connect the data cable from the transducer slip ring to the Transducer Connector.

Hardware Overview

SWIFT 10 ATV Sensors

Interfacing with RPC

The SWIFT sensor is directly compatible with the MTS Remote Parameter Control (RPC) simulation software. The SWIFT system produces outputs that directly correspond to the uncoupled spindle forces that the MTS Model 329 Road Simulator applies to the vehicle. Traditional instrumentation techniques provide coupled suspension loads data. Using the SWIFT sensor, the RPC simulation software needs to apply less correction to obtain the road simulator drive signals. Fewer iterations are required to recreate the measured loads.

You must ensure that the full scale value for your data recorder and the MTS electronics match. MTS electronics are typically set at ±10 V full scale, while some data recorders are ±5 V full scale.

The SWIFT sensor is calibrated for ±10 V full scale. To recompute the TI gains for ±5 V full scale, a verification pass must be run or the calibration will not be traceable. Upon special request, MTS can evaluate and may provide calibration for ±5 V or other full scale voltages.

Interfacing with RPC

SWIFT 10 ATV Sensors Hardware Overview

Interfacing with RPC

Hardware Overview

SWIFT 10 ATV Sensors

Software Utilities

Contents Introduction 40

TI2STATUS - Transducer Interface Status 41

TI2XFER - Transducer Interface Transfer 43

TI2SHUNT - Transducer Interface Shunt 45

Setting Up Shunt Calibration Reference Values 48

Error Messages 49

SWIFT 10 ATV Sensors Software Utilities

Introduction

The SWIFT utility programs in this distribution are for Win32 Operating Systems (Windows 2000 and XP). They are designed to be run from the Command Prompt or MSDOS Shell. However, it is possible to create a shortcut to run the programs. If launched from a shortcut the application window may close immediately when the application terminates making it impossible to see any error messages. The Command Prompt application is usually found in Start–>Programs–>Accessories but the actual location depends on the version of your operating system.

To run a SWIFT utility program

• Copy it to your computer. For example, create the folder

the executables (*.exe) to that folder.

• Launch Command Prompt

• Change the working directory to where you copied the executables: cd bin.

This step can be eliminated if you set up the PATH environment variable to

include the directory where you copied the SWIFT utility executables.

• Type the name of a SWIFT utility program providing the necessary

command line arguments, for example: from the TI box. Then select the desired function, for example: to upload settings from the TI box. If no command line arguments are provided the program will display a simple help message. This is helpful if you forget the order of the command line arguments.

ti2xfer to transfer settings to or

C:\bin and drag

Choice 1

Software Utilities

1. You may want to change the layout properties for the Command Prompt window to display a larger area or to increase the screen buffer size. Within Command Prompt, select Properties and the Layout tab to modify the screen buffer size or window size.

2. In Windows 2000 and Windows XP, the environment variables can be changed at Start–>Settings–>Control Panel–>System. Click on the Advanced tab, and the Environment Variables button. The path is a system variable. Adding string will cause Command Prompt to search that directory for applications.

;c:\bin, or whatever directory name you used, to the end of the

SWIFT 10 ATV Sensors

TI2STATUS - Transducer Interface Status

This program gets status information from the SWIFT Transducer Interface (TI) when the TI has encountered a problem and the red failed indicator is lit. You can use this program to easily interpret the error. For certain errors this program may provide additional information.

Syntax ti2status

The following is an example of the ti2status command report:

Example

C:\bin>ti2status

SWIFT Mini TI status (Version 1.3)

Fatal error: NONE Boot Loader version: 1 FPGA version: 10 Firmware version: 24

Zero: Good

Fx1 Shunt: Good Fx2 Shunt: Good Fy1 Shunt: Good Fy2 Shunt: Good Fy3 Shunt: Good Fy4 Shunt: Good Fz1 Shunt: Good Fz2 Shunt: Good

Calibration data is: Good

Unit serial number: 02036413

Description of TI2STATUS Indications

Fatal Error: Provides an indication that the CPU is unable to run. The message indicates the

possible reason (see, “Error Messages,” on page 49 for a list of the possible errors).

Boot Loader version: The boot loader is a program that verifies that the main program is complete. The

version number is a reference for use by service personnel (see, “Error

Messages,” on page 49 for a list of the possible errors).

FPGA version: Identifies the version of the functions programmed in the field programmable

gate array. The version number is a reference for use by service personnel.

Firmware Version: Displays the version of the software installed in the TI. This software is stored in

flash memory and if needed can be upgraded in the field by an MTS service engineer.

SWIFT 10 ATV Sensors Software Utilities

TI2STATUS - Transducer Interface Status

Zero: Indicates whether the transducer zeroing was successful or not (see, “Error

Messages,” on page 49 for a list of the possible errors).

F## Shunt: Indicates the status of shunt test for each bridge (see, “Error Messages,” on page

49 for a list of the possible errors).

Calibration data is: Indicates the condition of the calibration data (see, “Error Messages,” on page 49

for a list of the possible errors).

Unit serial number: Displays the serial number of the TI box

Software Utilities

SWIFT 10 ATV Sensors

TI2XFER - Transducer Interface Transfer

This program is used to read the current settings in the TI and save them to the computer (upload) or write the values from a calibration file on the computer to a TI (download).

Syntax ti2xfer

Example The following is an example of the ti2xfer command:

C:\bin>ti2xfer

SWIFT Mini TI transfer (Version 1.0) Upload and download settings

0...Exit

1...Upload settings from TI box

2...Download settings to TI box

Choice? 1

Filename? sample.cal

0...Exit

1...Upload settings from TI box

2...Download settings to TI box

Choice? 0

File Format The file used with commands contains a header and version number, and a list of

parameters. Transducer calibrations can be uploaded and saved individually. If a test needs to be rerun at a later date but the original transducer is not available, another transducer can be used by downloading its calibration information.

The header must be the first thing in the file, and it must be in the form:

[SWIFT]

Following the header is a list of parameter settings. The syntax is:

ParamName=ParamValue

The following rules apply:

Tabs and spaces are allowed.

The parameters can occur in any order

Names are case insensitive. If a parameter name is not recognized, an error will be reported, and further processing will be stopped.

If an error causes the program to abort while downloading, any parameters prior to the error will have been successfully downloaded because parameters are downloaded as they are read.

SWIFT 10 ATV Sensors Software Utilities

TI2XFER - Transducer Interface Transfer

CAUTION

Make important files (such as those containing calibration data) read-only after uploading.

If not protected, important data may get overwritten.

Make important files read-only. Make backups of important data.

Check force and moment output signals after downloading new settings.

Downloading new settings may affect Transducer Interface outputs.

After downloading new settings, force and moment output signals should be monitored to check basic system operation.

More about TI2XFER

files

The calibration files created by TI2XFER are plain text files that can be read by Microsoft Notepad or WordPad (see the example calibration file on page 55). In general, use a common extension such as “.cal” to help identify the files, but that is not required. The settings files contain both configuration settings and calibration settings. As a general rule parameters that begin with K are calibration gains and should not be edited.

Whenever downloading settings, make sure the file is for the transducer connected to the SWIFT Transducer Interface. Usually the filename for the settings contains the serial number for the transducer. If settings for one transducer are used with another they will not be accurate. Because the TI is calibrated by itself, calibration settings for a given transducer can be used with any TI, however, some calibration methodologies require the transducer, cable and TI to be used as a calibration set (end-to-end calibration).

The serial number in the TI2XFER settings file is the serial number of the TI that the settings were first uploaded from.

The bridge and angle zero values will change whenever a zero is activated by pressing the TI front panel Zero button. Therefore, after a zero is performed the zero values uploaded will not match those downloaded.

Software Utilities

SWIFT 10 ATV Sensors

TI2SHUNT - Transducer Interface Shunt

This program is a utility with various functions related to shunts. The SWIFT system includes the ability to connect a shunt resistor across each of the resistive bridges in the transducer. This shunt function can be used as a simple verification that the SWIFT system is working normally. Shunt verification activates the shunts and compares the results to those recorded during calibration. While this does not guarantee the transducer is still in calibration, it provides some level of confidence it is working normally. If the shunt results differ significantly from those recorded during calibration the SWIFT system should be evaluated for possible problems.

Syntax ti2shunt

Example

C:\bin>ti2shunt

SWIFT Mini TI Shunt (Version 1.0)

0...Exit

1...Read current shunt status

2...Set the TI shunt tolerance

3...Scan inputs with shunts

4...Command a shunt cal

5...Set references to last measured

Enter choice: 1

The Shunt Main Menu options are described in the following paragraphs.

Option 0 Use this option to exit the program.

Option 1 Use this option to read the last measured shunt values, the reference values, and

the shunt status.

Note The shunt status is not maintained over power cycles, so it is only valid if

the shunt is executed after power is applied. Refer to, “Error Messages,” on page 49.

The following is typical of what is displayed when this selection is made:

Enter choice: 1

FX1 Ref: 0.854 Measured: 0.854 Status: Good FX2 Ref: 0.855 Measured: 0.855 Status: Good FY1 Ref: 0.857 Measured: 0.857 Status: Good FY2 Ref: 0.858 Measured: 0.857 Status: Good FY3 Ref: 0.856 Measured: 0.856 Status: Good FY4 Ref: 0.857 Measured: 0.856 Status: Good FZ1 Ref: 0.856 Measured: 0.856 Status: Good FZ2 Ref: 0.856 Measured: 0.855 Status: Good

SWIFT 10 ATV Sensors Software Utilities

TI2SHUNT - Transducer Interface Shunt

Option 2 Use this to set the shunt tolerance. When selected, the following is displayed:

Enter choice: 2

The current shunt tolerance is 2%

Enter new shunt tolerance in percent?

Option 3 Use this option to apply a shunt to each bridge individually, read the output of the

bridge, compare the result with the value stored in the Transducer Interface and display the difference each bridge. See the table on the next page. The shaded fields are the bridge being shunted. The actual sequence depends on the transducer wiring. Note that this option does not update the shunt measured values or error status.

Software Utilities

SWIFT 10 ATV Sensors

Enter choice: 3

Unshunted:

Shunted1: Differ1:

TI2SHUNT - Transducer Interface Shunt

FX1 FX2 FY1 FY2 FY3 FY4 FZ1 FZ2

0.00050 0.00042 0.00017 -0.00050 -0.00005 -0.00033 -0.00025 0.00000

0.85475 0.00008 -0.00017 -0.00050 0.00028 -0.00033 -0.00025 0.00000

0.85424 -0.00033 -0.00033 0.00000 0.00033 0.00000 0.00000 0.00000

Unshunted:

Shunted2: 0.00050 0.00042 0.85675 -0.00117 0.00028 -0.00000 0.00008 0.00000 Differ2: 0.00033 0.00033 0.85725 0.00100 -0.00033 0.00033 0.00000 0.00000

Unshunted:

Shunted3: 0.00050 0.00008 -0.00017 -0.00017 0.00062 -0.00000 Differ3: 0.00000 0.00000 -0.00033 0.00033 0.00067 0.00000

Unshunted:

Shunted4: 0.00050 0.00008 -0.00017 Differ4: 0.00033 0.00000 0.00033

Unshunted:

Shunted5: 0.00050 0.85557 -0.00017 -0.00050 -0.00005 -0.00033 0.00042 0.00000 Differ5: -0.00033 0.85582 0.00000 -0.00033 -0.00067 0.00000 0.00033 -0.00033

Unshunted:

Shunted6: -0.00017 0.00042 0.00017 -0.00017 Differ6: -0.00067 0.00033 0.00000 0.00033

Unshunted:

Shunted7: 0.00084 0.00008 0.00050 -0.00050 -0.00005 -0.00033 0.00008 Differ7: 0.00033 -0.00033 0.00067 0.00033 0.00000 0.00000 0.00000

0.00017 0.00008 -0.00050 -0.00117 0.00062 -0.00033 0.00008 0.00000

0.00050 0.00008 0.00017 -0.00050 -0.00005 -0.00000 0.00042 0.00000

0.85620 -0.00033

0.85579 -0.00033

0.00017 0.00008 -0.00050 -0.00084 -0.00005 -0.00000 0.00075 -0.00033

0.85747 -0.00005 -0.00033 0.00008 0.00000

0.85831 0.00000 -0.00033 -0.00067 0.00033

0.00084 -0.00025 -0.00017 -0.00017 0.00062 -0.00033 0.00008 0.00033

0.00050 0.00008 0.00017 -0.00050 -0.00038 -0.00000 0.00008 0.00033

0.85614 -0.00033 -0.00025 -0.00033

0.85653 -0.00033 -0.00033 -0.00067

0.00050 0.00042 -0.00017 -0.00084 -0.00005 -0.00033 0.00008 0.00000

0.85510

Unshunted:

Shunted8: -0.00017 0.00008 0.00017 -0.00050 0.00028 0.85610 0.00008 0.00000 Differ8: -0.00033 0.00000 0.00000 0.00033 0.00033

0.00017 0.00008 0.00017 -0.00084 -0.00005 -0.00000 0.00008 0.00067

0.85610 0.00000 -0.00067

Option 4 Use this option to command a Shunt Cal in the Transducer Interface. This is the

same as pressing the Shunt button on the front panel of the TI. A period is displayed on the screen for every change in the shunt state. This gives you a quick view of the progress.

Option 5 A valid shunt calibration should be performed prior to executing this command.

This option allows an easy means of setting the Shunt Calibration Reference values after calibration. After this option has executed, the file that was written can then be downloaded (using TI2XFER option 2). Downloading the file will set the Shunt Reference values to the last measured values, so that subsequent Shunt Calibrations should pass when the SWIFT system is setup properly, and fail when not setup properly.

Note This menu choice should only be used by qualified service personnel.

SWIFT 10 ATV Sensors Software Utilities

TI2SHUNT - Transducer Interface Shunt

Setting Up Shunt Calibration Reference Values

The ti2shunt utility provides all of the necessary functions for setting up a Transducer Interface with valid Shunt Cal Reference values.

Note This procedure should only be performed by qualified service personnel.

Before running the ti2shunt utility, connect the Transducer cable from the SWIFT TI to the SWIFT Transducer Assembly. Power up the SWIFT TI and wait for the red Fail indicator on the TI front panel to go out (this indicates that the TI is ready).

Note that it is not necessary to perform a System (Transducer) Zero prior to the Shunt Cal.

Procedure 1. Launch the ti2shunt utility.

2. Using Option 2, enter the desired shunt tolerance.

3. Using Option 4, command a shunt cal, and wait for it to complete. This causes the TI to apply and measure each shunt delta. These measured values will be written as the Cal Reference values. The Shunt indicator on the TI front panel should not blink (blinking indicates that the shunt cal verification failed).

4. Using Option 1, read the current shunt parameters. It is not necessary to save these to a file. Review the measured values and verify that they are correct.

5. Using Option 5, write the last shunt measurements to a parameter file. This sets up a file that contains the eight Set Shunt Cal Reference commands, with the last measured values as the values for the commands. This step does not download the values, but forces the generation of a shunt cal reference parameter file.

Write down the filename that is generated, as it will be required later.

6. Using TI2Xfer option 2 to download the shunt parameters from a file to the TI. Enter the filename used in Option 5 (Step 5). The tishunt utility then downloads the shunt cal reference values to the TI. These values are written into non-volatile memory within the TI, and are automatically restored whenever the TI is powered up.

7. Using Option 4, command another shunt cal, and wait for it to complete. This provides a verification, showing that the values downloaded are valid.

The Shunt indicators on the TI Front Panel should toggle indicating the shunt calibration is in process.

Software Utilities

SWIFT 10 ATV Sensors

Error Messages

When a SWIFT utility encounters an error, the red failed indicator on the TI front panel lights. Run the TI2STATUS program to identify the cause of the error.

Following is a list of possible error messages:

• Fatal Errors

Error Messages

NONE

Failed command port initialize

Failed I2C (integrated-integrated-circuit) initialize

Failed non-volatile memory initialize

Failed comput module initialize

Failed ADC (analog-to-digital converter) initialize

Failed DAC (digital-to-analog converter) initialize

Failed calibration multiplexer initialize

Failed while reading I2C

Failed timer initialize

Failed interrupt initialize

Failed encoder initialize

Failed zero module initialize

Failed shunt module initialize

Unrecognized failure code – This error could be due to hardware

failures or software bug.

• Boot Loader – The boot loader runs when you turn on power. This line

displays the version number if boot was successful.

Error, boot loader has not run – This occurs if the CPU is not running.

Error, the boot loader has not finished – Something prevented the CPU from completing booting the main program.

Error, the boot loader found a bad Flash CRC (cyclic redundancy check) – This error is likely due to a corrupted Flash program.

Computed CRC =

Flash CRC =

Error, unrecognized boot loader error code of: – Possibly corrupted

memory or communications or the version of TI2STATUS is not compatible with the firmware.

• Zero

Good – no problems detected

Bad Angle Offset – The change in angle was not 90°, ±2°.

Direction Change – The direction of 90° increments reversed.

SWIFT 10 ATV Sensors Software Utilities

Error Messages

• Shunt

Good – no problems were detected.

Reference Bad – The shunt reference is out of range.

Shunted Bad – A shunt value does not match the shunt reference.

Unshunted Bad – While shunting one bridge another bridge output

unexpectedly changed.

• Calibration Data is:

Good – No problems were detected.

Bad – The unit has not been calibrated or the calibration memory is

corrupted.

Software Utilities

SWIFT 10 ATV Sensors

Setting up the Transducer Interface

Overview Two different software configurations are used by the TI, depending on whether

you will be using the SWIFT sensor on the test track (typical for spinning application) or in the laboratory (typical for non-spinning or fixed application). Angular transformation is required on the test track only. If you are using the same transducer and TI for data collection on the test track and simulation testing in the laboratory, you must change the software configuration in the TI when you change testing modes.

Contents USB driver installation 52

Select a Zero Method 54

Calibration File Elements 55

Upload the Calibration File 56

Edit the Calibration File 57

Download the Calibration File 60

SWIFT 10 ATV Sensors Setting up the Transducer Interface

USB driver installation

Two USB 2.0 drivers must be installed to recognize the Transducer Interface. Perform the following procedure to install these drivers on a laptop or desktop computer that does not already have these drivers installed.

Important Do not allow Windows to search for or choose the drivers for you.

Always direct Windows to the path containing the Mini TI USB drivers.

1. Copy the Mini TI USB drivers from the Utilities CD provided to your hard drive.

2. Push and hold the Power button on the Mini TI. Release the button when the Power indicator lights.

All the indicators on the Mini TI will light briefly then go out leaving only the Power indicator lit.

3. Connect the USB cable between the computer and the Mini TI.

The Found New Hardware Wizard will launch. On the screen that displays, select the No, not this time radio button (see the next figure).

Setting up the Transducer Interface

SWIFT 10 ATV Sensors

USB driver installation

4. On the next window, select the Install from a list or specific location (Advanced) radio button.

5. If you copied the driver files from the CD to your hard drive, use the browser to direct the wizard to the location where you copied the files as shown in the next figure.

6. Click Next to install the loader for the MTS SWIFT TI Interface

7. When the installation is complete, click Finish on the window that displays.

8. Another Found New Hardware Wizard will display.

Repeat Steps 4 through 7 to install the MTS SWIFT TI Interface driver for the TI Interface.

9. Restart your computer to activate the new settings.

SWIFT 10 ATV Sensors Setting up the Transducer Interface

Select a Zero Method

Before you install a transducer and zero it, you must configure the transducer interface (TI) for the appropriate operating mode.

Equipment required You will need:

• A laptop computer (at test track) or desktop PC with Window 2000 or XP

operating system.

• A USB 2.0 communication cable with type A to type B connectors.

• SWIFT Transducer Interface Utilities diskette.

• Some experience with DOS commands and text editors.

Modes There are two separate modes for using the transducer interface. The mode you

choose depends on whether you will use the transducer in a spinning (test track) application (AngleMode = 0) or non-spinning (road simulator) application (AngleMode = 1).

If you are using the same transducer with a road simulator that you used previously on the test track, or vice versa you must download the proper calibration file and re-zero the transducer.

In either mode, the zero button on the front panel of the TI is used to zero the angle and balance the bridges.

What you need to do To change the angle mode used by the TI you will need to:

1. Copy the original calibration file from the CD or diskette that came with the transducer to the computer.

Note A separate calibration file was created at the factory for each transducer.

In the next steps, note the serial number of the transducer identified in the calibration file and the serial number of the TI box that the file was downloaded to. This information will be used later.

2. Edit the calibration file to select appropriate angle mode: 0 = spinning, 1 = non-spinning (fixed).

3. Download the modified calibration file from the computer to the TI box.

4. Repeat the process for all of the transducers.

These steps are described in detail in the following sections.

Setting up the Transducer Interface

SWIFT 10 ATV Sensors

Calibration File Elements

AngleMode=0 AngleOffset=2.10938 AngleFixed=0 EncoderSize=2048 FXPolarity=0 FYPolarity=0 FZPolarity=0 MXPolarity=1 MYPolarity=0 MZPolarity=1

ZFX1=-0.0249317 ZFX2=0.0181511 ZFY1=0.0692687 ZFY2=-0.275767 ZFY3=0.095961 ZFY4=-0.250816 ZFZ1=-0.042539 ZFZ2=0.00590447

FX1Channel=2 FX2Channel=6 FY1Channel=3 FY2Channel=5 FY3Channel=7 FY4Channel=1 FZ1Channel=4 FZ2Channel=0 InputRange=10.0 KFX1=0.497807 KFX2=0.497807 KFY1=0.478072 KFY2=0.478072 KFY3=0.478072 KFY4=0.478072 KFZ1=0.494473 KFZ2=0.494473 KMX=1.61575 KMYX=1.45028 KMYZ=1.45028 KMZ=1.56116 KFXFY=0.00366337 KFXFZ=-0.00238232

Polarity for each output

(0 = normal, 1 = inverted)

Angle Mode (0 = Spinning, 1 = Fixed)

Angle Offset

Fixed Angle

Bridge Zeroes

Do Not Modify

Calibration Gains

Do Not Modify

S10-33

Encoder Size

The following figure shows some elements of the calibration file:

Select a Zero Method

Typical Calibration File

Items you may edit • OutputPolarities—defines the polarities of the six outputs. Change these

• AngleMode—selects the mode used for determining the encoder sine and

only if your application requires different polarities from those identified on the transducer label.

cosine.

• AngleFixed—used for non-spinning applications.

• AngleOffset— used for spinning applications. Normally you do not need to

change this value.

• EncoderSize–defines the size of the encoder.

SWIFT 10 ATV Sensors Setting up the Transducer Interface

Upload the Calibration File

A unique calibration file was loaded into the TI memory by MTS before the transducer and transducer interface were shipped. Use the program TI2XFER to retrieve the calibration file.

1. Connect a USB cable from the laptop computer or PC to the TI.

Note Ensure the proper USB 2.0 drivers are installed on the laptop or PC.

Refer to, “USB driver installation,” on page 52, as necessary

2. Insert the SWIFT Transducer Interface Utilities CD or diskette into the laptop computer or PC.

3. Run the program TI2XFER.

4. Enter 1 at the prompt to upload the calibration file. (See the illustration below.)

5. Enter a file name.

6. Enter a description of the file.

You may enter the serial number of the transducer or descriptive words to help you identify the correct calibration file.

7. TI2XFER will prompt you when the file has uploaded.

SWIFT Mini TI transfer (Version 1.0) Upload and download settings

0...Exit

1...Upload settings from TI box

2...Download settings to TI box Choice? 1

Filename? sample.cal

0...Exit

1...Upload settings from TI box

2...Download settings to TI box Choice? 0

8. Enter 0 at the prompt to exit the program.

Setting up the Transducer Interface

SWIFT 10 ATV Sensors

Edit the Calibration File

CAUTION

Do not change any other items in the calibration file.

The calibration file contains offset values for all of the bridge outputs. Changing any of the items other than those listed in the following procedure will cause your calibration file to be incorrect.

Take care not to change any values except those listed in the following procedure. If your calibration file is incorrectly changed, reload the original file from the diskette provided by MTS.

1. Open the calibration file using a text editor.

Typically two calibration files are provided with each transducer: one for spinning applications and one for non-spinning (fixed) applications.

Edit the Calibration File

The spinning application files are usually names in the format <transducer serial number>s.cal.

The non-spinning (fixed) application files are usually names in the format <transducer serial number>f.cal.

SWIFT 10 ATV Sensors Setting up the Transducer Interface

Edit the Calibration File

S20-34

Front

Fz Up

Out

Aft

Fz Up

Fore

Out

S20-35

Front

Fy In

Fz Up

Fx Aft

Fore

Fz Up

S20-41

Front

Fx Aft

Fz Up

Aft

Out

Fz Up

Output Polarity Value

2. If necessary, edit the value for Polarity (see the table below).

The polarities that match the coordinate icon on the transducer are:

Fx=0 Fy=0 Fz=0 Mx=1 My=0 Mz=1

Example Output Polarities

Description

Direction of Positive output from load on tire when mounted on left hand side of the vehicle

Direction of Positive output from load on tire when mounted on right hand side of the vehicle

OutputPolarities = 0 Standard Setting from

MTS. Matches the axis orientation on the front cover of the SWIFT.

OutputPolarities = 1 Common setting to

alter the axis for-aft and in-out lateral axis

OutputPolarities (left side) = 1

OutputPolarities (right side) = 0

Common setting for vehicle coordinate matching between the two sides of the vehicle.

+Fx = fore

+Fy = out from car, left

+Fz = up

+Mx, +My+, +Mz = Right-hand rule about Force axis

+Fx = aft

+Fy= into car, right

+Fz = up

+Mx, +My, +Mz = Right-hand rule about Force axis

+Fx = aft

+Fy= into car, right

+Fz = up

+Mx, +My, +Mz = Right-hand rule about Force axis

+Fx = aft

+Fy = out from car, right

+Fz = up

+Mx, +My, +Mz = Righthand rule about Force axis

+Fx = fore

+Fy = into car, left

+Fz = up

+Mx, +My, +Mz = Righthand rule about Force axis

+Fx = aft

+Fy = out from car, right

+Fz = up

+Mx, +My, +Mz = Righthand rule about Force axis

3. Perform this step for spinning application. For non-spinning applications, skip to Step 4.

A. Verify the value for AngleMode.

Set the AngleMode=0

In this mode, the encoder pulses are summed in with the offset. At the end of the process the value in the TI internal memory and is used to perform the rotational transformation of the output signals.

Setting up the Transducer Interface

SWIFT 10 ATV Sensors

Edit the Calibration File

B. The AngleOffset value is used when you are operating in encoder

mode (spinning applications). This value is summed with the encoder output count. At the end of the process the value in the TI internal memory and used when the angle mode is set to 0 (encoder). Negative angles are converted to their positive equivalent so that the readback value range is 0–360°.

The AngleOffset value is calculated by the TI during the zero process. At the end of the process it is written to the calibration file.

There is no need to change this calculated value.

C. Verify that EncoderSize=2048.

4. Perform this step for non-spinning (fixed) applications. For spinning applications, skip to Step 5.

A. Verify the value for AngleMode.

Set the AngleMode=1

In this mode, the sine and cosine RAM address is fixed. The encoder is not used, nor is the encoder offset.

B. Edit the value for AngleFixed.

The AngleFixed value is used for non-spinning applications. This value addresses the sine and cosine in memory when the angle mode is set to 1 (fixed). Negative angles are converted to their positive equivalent so that the readback value range is 0–360°.

You may set the fixed angle value when you are operating in fixed angle mode (non-spinning applications) only if the transducer is rotated from its correct Fz–Fx orientation on the road simulator. For installations where the Fz-Fx orientation on the SWIFT cover(s) is aligned with gravity. The correct setting is:

AngleFixed=0

If the SWIFT is installed at an angle to the desired Fz–Fx output axis, set the AngleFixed value equal to the installed angle offset in degrees, with clockwise rotation positive.

For example: AngleFixed = 45.

5. Save the changes and exit the editor.

6. Download the calibration file to the appropriate TI box. See, “Download the

Calibration File,” on page 60.

SWIFT 10 ATV Sensors Setting up the Transducer Interface

Download the Calibration File

Use the program TI2XFER to download the modified calibration file to the TI.

1. Insert the CD or diskette into the laptop computer or PC.

2. Run the program TI2XFER.

3. Enter 2 at the prompt to download the calibration file.

4. Enter the name of the file you wish to download.

5. TI2XFER will prompt you when the file has successfully downloaded.

6. Enter 0 at the prompt to exit the program.

SWIFT Mini TI transfer (Version 1.0) Upload and download settings

0...Exit

1...Upload settings from TI box

2...Download settings to TI box Choice? 2

Filename? sample.cal

0...Exit

1...Upload settings from TI box

2...Download settings to TI box Choice? 0

Program completed

Setting up the Transducer Interface

SWIFT 10 ATV Sensors

Installing the Transducer

The SWIFT sensor can be installed on a vehicle at the test track or on an MTS Series 329 Road Simulator in the test laboratory.

Contents Hazard Icon 62

Road and Track Vehicles 63

Attaching SWIFT Components to the Vehicle 67

Attaching Anti-rotate Assemblies 70

Installing the Transducer Interface Electronics 74

Setting up the SWIFT Sensor for Data Collection 77

Verifying the Quality of the Zero Procedure 80

Collecting Data 82

Road Simulator 85

Attaching SWIFT Components to the Fixturing 88

Zeroing the Transducer Interface 92

SWIFT 10 ATV Sensors Installing the Transducer

Hazard Icon

The following hazard icon is part of the label affixed to the side of the SWIFT 10 ATV Sensor.

CON DESCRIPTION

Read the manuals. Become familiar with safety information. Also become familiar with operating and maintenance information

Installing the Transducer

SWIFT 10 ATV Sensors

Road and Track Vehicles

Equipment required This procedure can be performed by one person. To install the SWIFT 10 sensor,

you will need the following equipment:

• Inner hub adapter (see next figure)

• Modified rim (see next figure)

• Washer plate (see next figure)

• Anti-rotate assembly (including customer-supplied mounting arm)

• Small set of metric hex-head wrenches

• Tube bender for the restraint tube

• Tube cutter

• Metric socket head drive set (up to 10 mm) with extension

• Molykote g-n paste, 2.8 oz. tube (MTS part number 011-010-217)

• Nikal based anti-galling compound (MTS part number 011-354-902)

• Transducer mounting bolts (per transducer)

20 size M8 X 1.25 mm X 50 mm long

8 size M8 X 1.25 mm X 75 mm long

8 washers 17 mm O.D. X 8.4 mm I.D.

lug nuts and shim washers

• Slip ring jack screws (2): M5 X 0.5 mm

• Torque wrenches, capable of the following ranges:

19–38 N•m (14–28 lbf•ft)

95 N•m (70 lbf•ft)

• Cables (transducer and BNC, plus customer-supplied from transducer

interface to data recorder)

• Tie wraps

• Data recorder

• Power supply–12 V DC or suitable 12 V DC vehicle battery

1. Lengths shown are for reference only. Verify lengths for you specific rim and hub design.

2. Not all vehicles have alternators to maintain the charge to the vehicle battery if the battery is also used by the SWIFT sensor and the data acquisition system. Additional batteries and/or chargers may be necessary.

SWIFT 10 ATV Sensors Installing the Transducer

Road and Track Vehicles

Slip Ring

Bracket

(with encoder)

Washer

Plate

Transducer

Modified Wheel Rim

Lug Nuts

Inner Hub

Adapter

S10-08

Installation Components (outboard of rim shown)

Importance of bolts Bolts provide exceptional clamp force at the transducer to rim/spindle interface.

• Bolts on the inner hub secure the hub adapter to the SWIFT sensor.

• Bolts on the outer ring secure the SWIFT sensor to the wheel rim (or road

simulator spindle adapter).

Note Make sure all bolts are in place, are of the proper length, and fully

torqued during all tests. Correct use of bolts reduces the safety hazard and ensures optimal transducer performance.

Installing the Transducer

SWIFT 10 ATV Sensors

Road and Track Vehicles

CAUTION

Before you begin Observe the following safety conditions while you are attaching the SWIFT

sensor and components to the vehicle.

Do not pressure-wash the transducer or clean it with solvents.

Pressure-washing the transducer or cleaning it with solvents can damage it or degrade the silastic seal and may void the warranty.

Using strong cleaners or solvents can damage the RTV seal and may void the warranty.

Use only a soft sponge or brush with non-metal bristles and a gentle detergent (such as dish soap) to wash the transducer.

Do not use high-pressure air to clean debris from around the transducer connectors.

High-pressure air can damage the silastic seals and may void the warranty.

Use a brush with fine, non-metal bristles and low air-pressure [0.07 MPa (10 psi)] to clean debris from around the transducer connectors.

Do not lay the wheel down on top of the transducer without proper padding.

If the wheel is laid down with the transducer under it, the transducer could be scratched and the connectors damaged.

Always hold the wheel upright when the transducer is attached to it. If needed, have another person hold the wheel upright while you tighten the bolts, if laying the wheel down cannot be avoided, place the wheel on a layer of foam or a pad to protect the connectors.

SWIFT 10 ATV Sensors Installing the Transducer

Road and Track Vehicles

WARNING

CAUTION

Do not under-torque the lug nuts.

Lug nuts that are not properly tightened can become loose during testing. Loss of a wheel can cause damage to the test vehicle and transducer and result in serious injury, death, or property damage.

Always tighten the lug nuts to the torque rating recommended for the vehicle/ wheel. Recheck the torque daily and/or before each testing session.

Do not drop the slip-ring bracket.

Dropping the slip-ring bracket can damage the slip ring or a connector.

Always use care when you handle the slip-ring bracket.

Do not allow the mounting arm or anti-rotate arm to bump against any portion of the wheel or wheel well.

Any jarring of the mounting arm or anti-rotate arm will damage the slip ring and/or the encoder.

Position the mounting arm and anti-rotate assembly so that full suspension travel will not cause interference with the wheel well or any other part of the vehicle.

Installing the Transducer

SWIFT 10 ATV Sensors

Attaching SWIFT Components to the Vehicle

SWIFT 10 Fasteners

UANTITY FRONT AND REAR

Road and Track Vehicles

* The length of these fasteners is dependant on the thickness of the

rim flange and washer plate. The fastener length must ensure a minimum thread engagement of 12 mm (0.47 in) into the rim flange but must not protrude through the rim where it could interfere with vehicle brake calipers, uprights, rotors, etc.

† The length of these fasteners is dependant on the design of the

inner hub adapter. The fastener length must ensure a minimum thread engagement of 12 mm (0.47 in) but must not extend through the inner hub adapter such that it would interfere with or contact the spindle face.

‡ Lug nuts and washers will vary with vehicle and spindle

configuration.

M8 X 1.25 mm

Lug nuts and washers

†

‡

Material required:

• Molykote g-n paste (MTS part number 011-010-217).

• Nikal based anti-galling compound (MTS part number 011-354-902)

Procedure 1. Remove the current wheel from the test vehicle.

2. Clean all surfaces of the vehicle tire(s) and the modified rim(s). It is critical that all surfaces be free of stones, burrs, and grease. Wash with a mild detergent such as dish soap. Use an alcohol-based solvent to remove grease.

Important It is imperative that the mounting surfaces of the transducer be

protected from getting scratched. Any wheel components and work surfaces that might come in contact with the transducer must be clean, smooth, and free of debris

3. Mount the tire(s) on the modified rim(s).

4. Wipe the unpainted mating surfaces of the modified rim, the inner hub adapter, the transducer, the slip ring bracket assembly and the washer plate with a clean dry cloth.

Use cottons swabs or other soft tool to clean the coupling teeth on the inner hub adapter, transducer, and the slip ring bracket.

5. Attach the inner hub adapter to the vehicle spindle. Torque the lug nuts in a cross-pattern to the torque rating recommended by the wheel manufacturer.

SWIFT 10 ATV Sensors Installing the Transducer

Road and Track Vehicles

Vehicle

Spindle Hub

Inner Hub

Adapter

Lug Nuts

Modified Rim

Transducer

Washer

Plate

Slip Ring

Bracket

Slip Ring

S10-11

6. Use the twenty M8 fasteners to attach the transducer and washer plate to the modified wheel rim (see the previous table). Ensure the electrical connectors on the transducer face away from the rim. Hand tighten the bolts.

If environmental conditions warrant, coat each fastener with Birchwood Casey Sheath RB1 rust preventative (or equivalent).

Lubricate the threads and under the head of each fastener with Molykote g-n paste.

Installing the Transducer

Typical Wheel Assembly

7. Tighten the twenty M8 mounting bolts securing the transducer to the modified rim.

A. Following the outer bolt pattern sequence shown in the figure on page

69, torque the twenty M8 bolts (1 through 20) to the value for the first

increment shown in the table on page 69.

B. Repeat Step 7A for the final increment.

8. Mount the wheel assembly.

With the wheel assembly against the inner hub adapter, position the slip ring bracket, with the slip ring, against the transducer. Ensure the connectors between the slip ring bracket and the transducer engage properly.

SWIFT 10 ATV Sensors

Road and Track Vehicles

Inner Bolt

Pattern

Outer Bolt

Pattern

S10-12

D B

Jack Screw

Holes

Note If the jack screws used to remove the slip ring bracket are still in the slip

ring bracket, remove them before continuing.

Use the eight M8 fasteners provided to attach the slip ring bracket to the transducer and inner hub adapter. Hand tighten the bolts.

Lubricate the threads and under the head of each fastener with Molykote g-n paste.

Bolt Torque Sequence

9. Tighten the eight M8 mounting bolts securing the transducer and modified rim assembly to the inner hub adapter.

A. Following the inner bolt pattern sequence shown in the previous figure,

torque the eight M8 bolts (A through H) to the value for the first increment shown in the following table.

B. Repeat Step 9A for the second increment.

Note To minimize negative clamping effects, you must torque the bolts in the

sequence shown.

TORQUE INCREMENT M8 BOLT SIZE

1st Increment

Final Increment

19 N•m (14 lbf•ft)

38 N•m (28 lbf•ft)

SWIFT 10 ATV Sensors Installing the Transducer

Road and Track Vehicles

Attaching Anti-rotate Assemblies

1. Since the bracket is unique to each vehicle the anti-rotate bracket must be provided by the customer. The following are guidelines for manufacturing and locating the bracket. See the next two figures.

• The anti-rotate must move appropriately with the wheel of the vehicle

without relative motion between the wheel and the vehicle mounting position. Alignment must be maintained to ensure that there is no preload or forces on the slip ring due to suspension travel.

• The bracket must be stiff, preferably steel or stiff stainless steel tubing,

so as not to move or rotate when connected to an unsprung mass or spindle, which will allow the slip ring assembly to move with the tire as the vehicle is moving or testing.

• The bracket must be positioned so as not to hit the fender or other body

parts at the extreme end of the suspension travel.

• The bracket must maintain a minimum clearance from the tire so as not

to hit the tire when it is loaded and rotating.

2. For front wheel configurations (see the next figure):

A. Attach the anti-rotate bracket to an unsprung mass (such as the wheel

brake cylinder mount) which will move with the slip ring as the ATV is moving or testing. Existing fasteners may have to be adjusted for length.

Torque the fasteners as specified by the ATV manufacturer.

B. Secure the tubing, with the hinged anti-rotate bracket, in the anti-rotate

bracket.

C. Bend the tubing over the tire in the manner shown in the next figure

until the holes in the hinge assembly remain nearly lined up with the mounting holes in the slip ring when let go of the tube.

Note A large offset between the hinge assembly and the slip ring can cause a

constant side load on the slip ring that can shorten the life of the slip ring bearings.

D. Secure the hinge assembly to the slip ring using the two M4 fasteners

provided.

Before tightening the fasteners, check for obstructions. Load the suspension and turn the steering fully in both directions several times to ensure the tube does not contact any part of the wheel, suspension, or body. Make adjustment as necessary.

Installing the Transducer

Torque the two M4 fasteners in the slip ring to 3.2 N•m (2.4 lbf•ft).

Torque the eight 10-24 UNC fasteners in the anti-rotate bracket to 5.3 N•m (3.9 lbf•ft).

SWIFT 10 ATV Sensors

Road and Track Vehicles

Front Anti-rotate Bracket

This bracket will vary due

to different brake caliper

mounts and spindle design

Anti-rotate bracket to be attached

to unsprung mass or spindle

which will allow the slip ring

to move with the tire as

the ATV is moving or testing

Slip Ring/Encoder

Transducer

Output Cable

Anti-rotate and

Hinge Assembly

S10-13

M4 Fasteners (2)

E. Attach the transducer output cable to the slip ring encoder connector

and the J3 Transducer connector on the TI box.

Secure the cable along its length so that it will not become damaged during testing. (For example tape it to the anti-rotate tube to prevent it from getting caught in the tire tread.) Leave enough slack in the cable to allow for the full range of wheel travel (jounce and steer).

SWIFT 10 ATV Sensors Installing the Transducer

Example Front Anti-rotate Bracket Assembly (view from front)

3. For rear wheel configurations (see the next figure):

A. Attach the anti-rotate bracket in such a way that the end of the anti-

rotate arm is aligned with the pivot point of the swing arm and can pivot with the swing arm as the ATV jounces while moving or testing.

Torque the four 10-24 UNC fasteners provided to 5.3 N•m (3.9 lbf•ft).

Road and Track Vehicles

B. Align the bracket welded on one end of the tube with the mounting bolt

hole on the slip ring and the other end with the slot in the anti-rotate bracket.

Through experimentation, measure and bend the tube around the wheel and to the slot in the anti-rotate bracket while considering the following:

•Space must be allowed for flexing of the tire.

•The end of the tube should fit in the slot far enough to prevent it from

bouncing out when the ATV is moving. The end can extend through the slot as long as it does not contact any obstructions.

•With the bracket welded to the tube attached to the slip ring, the other

end of the tube should fit in the slot of the anti-rotate bracket midway from front to back.

•The end of the tube in the slot should not bind against the top and

bottom of the slot. Binding can cause a bending moment on the slip ring which can shorten the life of the slip ring bearings.

Before tightening the fasteners, check for binding or obstructions. While an assistant fully loads and unloads the suspension several times, check that the end of the tube in the slot does not contact the front or rear of the slot or bind against the top and bottom of the slot. Make adjustment as necessary.

C. Secure the bracket on the end of the tube to the slip ring.

Torque the two M4 fasteners in the slip ring to 3.2 N•m (2.4 lbf•ft).

Installing the Transducer

SWIFT 10 ATV Sensors

Road and Track Vehicles

Slip Ring/Encoder

Transducer

Output Cable

Anti-rotate

Assembly

ATV Foot Peg

Anti-rotate bracket to be attached

to the foot peg support bracket

which will allow the slip ring anti-rotate

to move with the tire as

the ATV is moving or testing

S10-14

M4 Fasteners (2)

D. Attach the transducer output cable to the slip ring encoder connector

and the J3 Transducer connector on the TI box.

Secure the cable along its length so that it will not become damage during testing. (For example tape it to the anti-rotate tube to prevent it from getting caught in the tire tread.) Leave enough slack in the cable to allow for the full range of wheel travel (jounce and steer).

SWIFT 10 ATV Sensors Installing the Transducer

Example Rear Anti-rotate Bracket Assembly (view from top)

Road and Track Vehicles

Installing the Transducer Interface Electronics

The Transducer Interface (TI) electronics should be securely fastened to the vehicle. The TI box is designed to withstand the accelerations associated with the body of a vehicle during rugged durability and typical data acquisition testing.

The TI box can be located anywhere on the vehicle that is convenient. However, it should be protected from impact and securely attached to the vehicle to prevent it from being dislodged during testing.

Considerations Consider the following guidelines when you fasten the TI box(es) to the vehicle:

• Mount the TI box in a position on the vehicle that is protected from impact

and high acceleration events.

• Do not expose the TI box to rain, snow, or other wet conditions.

• Multiple TI boxes may be rigidly attached to each other using optional

mounting straps.

• Place a thin foam or rubber material between TI boxes and any hard

mounting surface.

• Use ratcheting straps to provide a tight connection that will not loosen or

untie during testing.

• Do not use rubber cords to secure the TI box because they may stretch and

lose retention in the cord due to inertial forces.

Procedure 1. Connect the data cables from the TI to the data recorder.

There is a single cable assembly, with a D-type connector for connection from the J2 Output connector on the TI and seven BNC connectors to the data recorder. The BNC connectors correspond to the three forces, three moments, and angular position.

Note Make sure that there is no tension or strain in the cables or at the cable

and connector junction. There should be some slack in the cables to ensure that they are not pulled during testing.

2. Connect the TI to the power source (such as the vehicle battery).

The TI chassis is grounded through the power connection to the battery negative terminal. (See the following figures.)

Installing the Transducer

SWIFT 10 ATV Sensors

Road and Track Vehicles

12 Vdc

Transducer Interface

S10-25

Data Recorder

12 Vdc

Transducer Interface

S10-26

Data Recorder

Note Some data acquisition systems may introduce electrical noise spikes to

the battery and cabling. The TI electronics should always be used with the cleanest power supply possible. To reduce the likelihood of noise spikes from the data recorder, we suggest running the power cables in parallel, as shown in the following diagrams. If this does not remove the noise spikes, separate batteries may be required.

The data recorder should also be connected to the battery negative terminal. (See the following figures.)

Suggested Grounding for a single TI Box

Suggested Grounding for a Multiple TI Boxes

3. Secure the TI box so that it will not move during data collection.

Note If the TI box is not properly secured, it can dislodged from the ATV.

SWIFT 10 ATV Sensors Installing the Transducer

4. Cover the J4 I/O and J5 USB connectors to protect the connectors from contamination.

Road and Track Vehicles

5. Turn on the TI

Press and hold the Power switch until the indicator lights. All other indicators will light until initialization is complete and then turn off. Only the Power indicator should remain lit.

Installing the Transducer

SWIFT 10 ATV Sensors

Setting up the SWIFT Sensor for Data Collection

CAUTION

To ensure accurate data collection, complete this setup procedure daily before you begin testing.

The accuracy of the data that you collect depends on the ability of the SWIFT electronics to “zero out” the forces and angles present in an initial, unloaded state. During the Zero process, the TI box reads the transducer bridge values and compensates for any offsets so that the bridge output is 0 at 0.0 V. It also reads the current angle and compensates for any offset from the Z axis facing up.

You can ensure the success of the Zero procedure by taking these simple precautions:

Do not touch or bump the wheel while the transducer is zeroing (after you have pressed the Zero button).

Road and Track Vehicles

Touching or bumping the wheel will add loads to the transducer, resulting in an erroneous zero reading.

After pressing the Zero button, avoid all contact with the wheel until the transducer zeroing at the current angle is complete. If you suspect that the zero process is incorrect, begin again.

This zero method samples all eight input bridges at four 90° intervals (that is at 0°, 90°, 180°, and 270°). After the data is taken, all eight input channels are analyzed for signal offsets, and the X and Z input channels are analyzed to determine the angular zero point.

The following procedure assumes:

• The transducers have been properly installed on the vehicle and the TI boxes

have been connected to the transducers and a power source. See “Road and

Track Vehicles” beginning on page 63

• The calibration file for each transducer has been edited, as required, for the

angle mode and polarity, and the calibration files have been downloaded to the TI boxes. See “Edit the Calibration File” on page 57.

Zero the TI When you zero the TI, you want the vehicle to be fairly level and the transducer

to be as close to plumb as practical.

1. Raise the vehicle with a lift or with jacks until each wheel is off the road surface.

The vehicle should be raised in a level manner, such that the orientation of the anti-rotate bar is the same in the lifted position as it was in the grounded position

Note Perform the remainder of this procedure completely for one transducer/

TI box combination at a time.

SWIFT 10 ATV Sensors Installing the Transducer

Road and Track Vehicles

Axes Icon

S20-22

2. Rotate the tire one full revolution so that the encoder can find the zero index mark.

Note The encoder has a red dot on the mounting flange connected to the slip-

ring bracket and a black dot on the slip-ring connector housing where it interfaces with the mounting flange. These dots, when aligned next to each other, indicate the index mark is under the encoder sensor.

3. Rotate the tire, as necessary, until the Fz on the axes icon (see the next figure) printed on the transducer label is pointing up.

4. If not already assembled, attach the inclinometer to the level bracket using the two 6-32 UNC fasteners provided.

Apply Locktite 222 to the threads on the fasteners. Torque each fastener to 2 N•m (18 lbf•in).

5. Install the inclinometer/level bracket assembly on the transducer by inserting the dowel pins in the level bracket into the pin pilot holes provided in the transducer, as shown in the next figure.

The orientation of the inclinometer/level bracket assembly is determined by the orientation of the anti-rotate bracket.

Installing the Transducer

SWIFT 10 ATV Sensors

Road and Track Vehicles

Zero Button and Indicators

6. Adjust the tire rotation, as necessary, until the inclinometer reads 0.0°, ±0.1° (or 90.0°, ±0.1°) depending on the orientation of the inclinometer as shown in the previous figure.

7. Push the Zero button on the front of the TI box.

The Zero indicators will toggle during the zero process. When the Zero indicators turn off the process is complete for this angle.

8. Remove the level bracket/inclinometer assembly.

9. Repeat Step 5 through 8 three more times.

Before Step 5 of each iteration, rotate the tire 90°.

Always rotate the tire in the same direction. (That is, if the first rotation was clockwise, the succeeding rotations should also be clockwise.)

Note If the red Fail indicator lights a problem was detected during the zero

process. Try repeating the procedure. Use TI2STATUS for a more detailed explanation of the problem. If you continue to have an error, consult the chapter, “Troubleshooting,” on page 117.

SWIFT 10 ATV Sensors Installing the Transducer

Road and Track Vehicles

Shunt Button and Indicators

Verifying the Quality of the Zero Procedure

Perform the following consistency checks for each SWIFT sensor while the vehicle (or corner) is elevated.

1. Does Fz measure the approximate weight of the tire/rim assembly?

2. Is Fx small (less than 0.1% of the rated load)?

3. What is the variance in Fz (modulation) when the tire is slowly rotated? The typical value should be <100 N.

4. When the vehicle is on the ground, is the Fz reading approximately equal to the corner weight of the vehicle? (See, “Effect of Zero Reference on SWIFT

Output,” on page 81.)

5. Perform a shunt calibration on each transducer.

Press the Shunt button on the front of the TI box (see the next figure), or use the TI2SHUNT program.

The shunt indicators will toggle until the process completes. If the red failed indicator lights, the shunt calibration has failed.

Installing the Transducer

6. Verify that the outputs from the TI box matches those on the calibration report.

Use either the TI2SHUNT or TI2XFER program to look at the shunt values of the individual bridges.

The shunt calibration will fail if the measured shunt values are >2% (the shunt tolerance) of the reference values that were set at the factory. Typically, the shunt values will vary a maximum of 0.020-0.030 V from the reference values.

Refer to the chapter, “Troubleshooting”, for more information on dealing with shunt calibration failures.

SWIFT 10 ATV Sensors

Road and Track Vehicles

Effect of Zero

Reference on SWIFT

Output

When the SWIFT sensor is used in spinning applications, it is important that a correct absolute zero of each strain gage bridge is used to ensure the proper computation and transformation of the transducer outputs to a non-rotating vehicle coordinate system. An error in the absolute zero of each bridge will produce a one-time-per-revolution modulation error in the output signals. To achieve absolute zero of each bridge, the zeroing process must account for the tare weight acting on the transducer.

When the vehicle is lifted and the tire and wheel assembly are suspended, the mass of the tire, rim, outer diameter fasteners, and outer ring of the transducer are all reacted through the beams of the transducer. With gravity acting on this outer tire/rim assembly, the SWIFT sensor measures a vertical force pulling down on the transducer.

The SWIFT output cannot be zero, because it is not possible to set the vehicle on the ground precisely enough that the ground supports only the outer tire/rim weight.

As the vehicle is set completely on the ground, the output from the SWIFT sensor will read the corner weight of the vehicle from the reference point of the transducer. The output of the SWIFT sensor will be slightly less than the total corner weight of the vehicle, because the SWIFT sensor is inboard of the outer tire and rim assembly, and will therefore not measure the weight of the outer tire and rim assembly.

SWIFT 10 ATV Sensors Installing the Transducer

Road and Track Vehicles

Collecting Data

After you zero the TI, you are ready to collect data.

Note If you turn off power to the TI boxes, the zero values will remain valid, but

after power is restored, the wheels should be rotated at least one full revolution so that the encoder can detect the index pulse to properly convert the rotating coordinates to stationary coordinates. The transducer outputs will not be correct until this happens.

1. Spin the wheels twice to ensure that each TI can identify the index pulse.

Spinning the wheels after you have completed the zero process will ensure that each encoder is correctly referenced to the index pulse. Otherwise, the data collected during the first revolution will be flawed.

2. Remove the vehicle from the lift or jacks.

3. Secure the connector that attaches the signal cable to the top of the slip ring with high quality duct or electrical tape.

This will prevent dust, dirt, and water from entering the connector and causing wear on the pins and sockets.

4. Perform a final inspection of the SWIFT sensor and the electronics to ensure that everything is secure and that the TI boxes are on (see the note above).

After the zeroing procedure, the settings are stored in non-volatile memory in each TI box and will be retained when power is cycled. However, if the environment temperature changes significantly, or the anti-rotate is modified, rezeroing is recommended.

Note Rezeroing the transducer is good practice when thermal changes occur.

Rezeroing the transducer at conditions and temperatures closest to the test conditions will provide a more accurate zero and reduce thermal errors.

5. Turn on the data recorder.

6. Start data collection.

Important Before beginning data collection, read the cautions on the next

page.

Installing the Transducer

SWIFT 10 ATV Sensors

Road and Track Vehicles

CAUTION

WARNING

Do not allow the SWIFT assembly to bump into any hard surfaces or objects while you are driving the vehicle.

Bumping the SWIFT assembly into hard surfaces such as garage doors, ramps and railings, or objects such as rocks, stumps, and earth, will damage the anti-rotate device, cable, slip ring, slip ring bracket (spider), and transducer.

The SWIFT assembly will protrude approximately 102 mm (4 in) from the side of the vehicle. Remember to allow extra space on each side of the test vehicle when driving through areas with possible hazards.

Do not drive through tall grass and brush.

Driving through grass and brush that is higher than the bottom edge of the transducer can damage the cable and tear off the slip ring.

Avoid driving in any areas with tall grass and brush.

Driving a vehicle with SWIFT sensors mounted on it will change the handling characteristics of the vehicle.

Driving a vehicle configured in this way on public roads can pose unexpected dangers to pedestrians and other vehicle traffic.

When driving the vehicle on public roads, you must conform to all local laws and regulations.

SWIFT 10 ATV Sensors Installing the Transducer

Road and Track Vehicles

WARNING

Do not use the SWIFT sensor if it has been exposed to load cycles that exceed the full scale calibrated ranges listed on the calibration sheets provided with each transducer.

Excessive loading or load cycles could cause a fracture of the transducer, wheel rim, hub adapter, or fasteners and can result in serious injury, death or property damage.

Always be aware of the maximum full scale loads appropriate for your transducer. If the prescribed limit for any axis of the transducer has been exceeded, contact MTS for an evaluation and, if necessary, to arrange for the return of the transducer, with the recorded load cycles, to MTS for physical inspection and analysis of the load cycle history.

Installing the Transducer

SWIFT 10 ATV Sensors

Road Simulator

CAUTION

Before you begin There are two methods of using a SWIFT on a road simulator.

The traditional “non-spinning” or “fixed” mode relies on the orientation of the SWIFT during road simulator use maintaining the same orientation relative to the anti-rotate position used during road testing. The SWIFT outputs are given in set coordinates relative to the SWIFT sensor orientation, and no angular transformation is applied to the SWIFT outputs. This is the typical method of use for larger vehicles where the angle variations of the anti-rotate bar are negligible during road testing.

The second method uses the SWIFT in a “spinning” mode. While the SWIFT itself is not spinning, the outputs from the SWIFT are passed thru the rotational transformation processing in the TI box, and the actual angle of the SWIFT relative to the encoder anti-rotate is taken into account. This method is best when there are significant angle variations of the anti-rotate bar during use, as is common on many smaller, high deflection recreational vehicles.

Depending on which mode you are using, you must load the correct calibration file into the TI boxes. Two calibration files are provided with each TI box:

Road Simulator

• For fixed (non-spinning) mode the calibration file name is

serialnumberf.cal.

• For spinning mode the calibration file name is serialnumbers.cal.

Clean all surfaces. It is critical that all surfaces be free of stones, burrs, and grease.

Do not pressure-wash the transducer or clean it with solvents.

Pressure-washing the transducer or cleaning it with solvents can damage it or degrade the silastic seal and may void the warranty.

Using strong cleaners or solvents can damage the RTV seal and may void the warranty.

Use only a soft sponge or brush with non-metal bristles and a gentle detergent (such as dish soap) to wash the transducer.

SWIFT 10 ATV Sensors Installing the Transducer

Road Simulator

CAUTION

WARNING

Do not use high-pressure air to clean debris from around the transducer connectors.

High-pressure air can damage the silastic seals and may void the warranty.

Use a brush with fine, non-metal bristles and low air-pressure [0.07 MPa (10 psi)] to clean debris from around the transducer connectors.

Do not under-torque the lug nuts.

Lug nuts that are not properly tightened can become loose during testing. Loss of a wheel can cause damage to the test vehicle and transducer and result in serious injury, death, or property damage.

Always tighten the lug nuts to the torque rating recommended for the vehicle/ wheel. Recheck the torque daily and/or before each testing session.

Equipment required This procedure requires one person. To install the transducer, you will need the

following equipment:

• Spindle adapter spacers (see next figure)

• Adapters to 329 simulator

• Anti-rotate assembly (including customer-supplied mounting arm)

• Small set of metric hex-head wrenches

• Tube bender for the restraint tube

• Tube cutter

• Metric socket head drive set (up to 14 mm) with extension

• Molykote g-n paste, 2.8 oz. tube (MTS part number 011-010-217)

• Nikal based anti-galling compound (MTS part number 011-354-902)

• Transducer mounting bolts (per transducer)

20 size M8 X 1.25 mm X 50 mm long

Installing the Transducer

8 size M8 X 1.25 mm X 75 mm long

8 washers 17 mm O.D. X 8.4 mm I.D.

lug nuts and shim washers

1. Lengths shown are for reference only. Verify lengths for you specific rim and hub design.

SWIFT 10 ATV Sensors

Road Simulator

• Slip ring jack screws (2): M5 X 0.5 mm

• Torque wrenches, capable of the following ranges:

19–38 N•m (14–28 lbf•ft)

95 N•m (70 lbf•ft)

Slip ring extension assembly

Four size M12 X 1.75 mm X 30 mm long bolts

• Slip ring assembly fasteners

Four size M8 X 1.25 mm X 20 mm long bolts

• Torque wrenches, capable of the following ranges:

24–74 N•m (18–55 lbf•ft),

203–815 N•m (150-600 lbf•ft);

108–325 N•m (80–240 lbf •ft)

93 N•m (69 lbf•ft)

• Cables (transducer and BNC, plus customer-supplied from transducer

interface to data recorder)

• Tie wraps

• Data recorder

• Power supply–12 V DC or suitable 12 V DC vehicle battery

1. Not all vehicles have alternators to maintain the charge to the vehicle battery if the battery is also used by the SWIFT sensor and the data acquisition system. Additional batteries and/or chargers may be necessary.

SWIFT 10 ATV Sensors Installing the Transducer

Road Simulator

Attaching SWIFT Components to the Fixturing

SWIFT 10 Fasteners

UANTITY FRONT AND REAR

16 M10 X 1.50 X 30 mm long

* The length of these fasteners is dependant on the thickness of the

† The length of these fasteners is dependant on the design of the

‡ Lug nuts and washers will vary with vehicle and spindle

configuration.

M8 X 1.25 mm

Lug nuts and washers

†

‡

Material required:

• Molykote g-n paste (MTS part number 011-010-217).

• Nikal based anti-galling compound (MTS part number 011-354-902)

1. Clean all surfaces with a mild detergent, such as dish soap. It is critical that all surfaces be free of stones, burrs, and grease. Use an alcohol-based solvent to remove grease.

Installing the Transducer

Important It is imperative that the mounting surfaces of the transducer be

protected from getting scratched. Any wheel components and work surfaces that might come in contact with the transducer must be clean, smooth, and free of debris

2. Wipe the unpainted mating surfaces of the inner hub adapter, the transducer, the slip ring bracket assembly and the washer plate with a clean dry cloth.

Use cottons swabs or other soft tool to clean the coupling teeth on the inner hub adapter, transducer, and the slip ring bracket.

3. Attach the inner hub adapter to the vehicle spindle. Torque the lug nuts in a cross-pattern to the torque rating recommended by the wheel manufacturer.

SWIFT 10 ATV Sensors

Road Simulator

4. Position the vehicle in the test fixture.

The vehicle should be raised in a level manner, such that the orientation of the anti-rotate bar is the same in the lifted position as it was in the grounded position

Refer also to the instructions in your road simulator operation manual.

Adjust the fixture, as necessary, to allow the inner hub adapter to extend through the spindle housing.

Spindle Housing

Inner Hub

Adapter

M10 Fasteners

(16)

Transducer

Vehicle

Spindle Hub

Adapter Plate

M8 Fasteners

(20)

Washer Plate

5. Use the twenty M8 fasteners to attach the transducer and washer plate to the adapter plate. Ensure the electrical connectors on the transducer face outward. Hand tighten the bolts.

A. Lubricate the threads and under the head of each fastener with

Molykote g-n paste.

B. Following the outer bolt pattern sequence shown in the next figure,

torque the twenty M8 bolts (1 through 20) to the value for the first increment shown in the table on page 90.

C. Repeat Step 5B for the final increment.

6. Mount the slip ring bracket, with the slip ring installed, and the transducer and adapter plate assembly to the inner hub adapter.

Note For spinning mode application, before installing the slip ring bracket

locate the index mark on the slip-ring rotor and using a marker, transfer this mark to the slip ring bracket. After installing the slip ring bracket, transfer this mark to the adapter plate.

S10-34

SWIFT 10 ATV Sensors Installing the Transducer

Road Simulator

Inner Bolt

Pattern

Outer Bolt

Pattern

S10-12

D B

Jack Screw

Holes

A. With the transducer and adapter plate assembly against the inner hub

adapter, position the slip ring bracket, with the slip ring, against the transducer.

Ensure the connectors between the slip ring bracket and the transducer engage properly.

Note If the jack screws used to remove the slip ring bracket are still in the slip

ring bracket, remove them before continuing.

B. Use the eight M8 fasteners provided to attach the slip ring bracket to

the transducer and inner hub adapter. Hand tighten the bolts.

C. Lubricate the threads and under the head of each fastener with

Molykote g-n paste.

Bolt Torque Sequence

D. Following the inner bolt pattern sequence shown in the previous figure,

Note To minimize negative clamping effects, you must torque the bolts in the

Installing the Transducer

torque the eight M8 bolts (A through H) to the value for the first increment shown in the following table.

19 N•m (14 lbf•ft) 26 N•m (19 lbf•ft)

38 N•m (28 lbf•ft) 53 N•m (39 lbf•ft)

SWIFT 10 ATV Sensors

E. Repeat Step 6D for the second increment.

sequence shown in the figure above.

TORQUE INCREMENT M8 BOLT SIZE M10 BOLT SIZE

1st Increment

Final Increment

Road Simulator

7. Repeat steps 1 through 6 for each corner.

8. Attach a transducer output cable to the slip ring encoder connector and the J3 Transducer connector on each TI box.

Secure the cables to the anti-rotate assembly so that it will not become damaged during testing.

Be sure to leave enough slack for the full range of movement of the simulation fixture.

9. Connect the power source to the J1 Power connector on the TI.

10. Connect the data cable from the J2 Output connector on the TI to the data recorder or your test control system.

11. Before continuing with this procedure, proceed to, “Zeroing the Transducer

Interface,” on page 92 For fixed mode or For spinning mode as required.

12. After completing Step 11,

A. For spinning mode only: Rotate the adapter plate to align the index

mark (see the first note in Step 6) as close as practical with the slip ring connector while allowing the fasteners to be installed.

For fixed mode only: Rotate the adapter plate only enough to align the mounting holes.

B. Attach the adapter plate to the spindle housing using the sixteen M10

fasteners.

Lubricate the threads and under the head of each fastener with Molykote g-n paste.

C. Using a cross pattern, torque the sixteen M10 bolts to the value for the

first increment shown in the previous table.

D. Repeat Step 12C for the final increment.

E. For fixed mode only: Measure the angle, caused by rotating the adapter

plate to attach the fasteners, and update the AngleFixed value in the calibration file as described in to, “Zeroing the Transducer Interface,” on page 92 For fixed mode.

SWIFT 10 ATV Sensors Installing the Transducer

Road Simulator

Zeroing the Transducer Interface

For fixed mode For the non-spinning (fixed) zero method, use the TI2Xfer to download the fixed

calibration file (serialnumberf.ca)l to the appropriate TI box. The angle mode in the file should be:

AngleMode=1

Rotate the transducer such that the orientation labeling is consistent with the reference orientation. In most cases, this means rotating the transducer so the labels are upright.

If an additional angle correction is required after installation, you will need to measure the angle from zero, and then enter the new value for the AngleFixed in the TI calibration file (see earlier instructions, “Edit the Calibration File,” on page 57).

Zeroing the transducer in fixed mode can be performed before or after connecting the adapter plate to the spindle housing.

• Perform zero before

you want to zero the transducer without the effects of the vehicle load on the transducer.

With the transducer oriented as described above press Zero on the TI Box.Repeat for each transducer.

Return to the procedure, Attaching SWIFT Components to the Fixturing to complete the installation.

• Perform zero after

want to apply the vehicle load to the transducer before you zero the transducer.

Return to the procedure, Attaching SWIFT Components to the Fixturing to complete the installation.

With installation complete and the vehicle load on the transducers, press the Zero button on each TI Box.

connecting the adapter plate to the spindle housing if

connecting the adapter plate to the spindle housing if you

For spinning mode For the spinning zero method, use the TI2Xfer to download the spinning

calibration file (serialnumbers.cal) to the appropriate TI box. The angle mode in the file should be:

AngleMode=0

Installing the Transducer

1. Rotate the adapter plate with the transducer attached one full revolution so that the encoder can find the zero index mark.

SWIFT 10 ATV Sensors

Road Simulator

Axes Icon

S20-22

Note The encoder has a dot on the mounting flange connected to the slip-ring

bracket and another dot on the slip-ring connector housing where it interfaces with the mounting flange. These dots, when aligned next to each other, indicate the index mark is under the encoder sensor.

2. Rotate the adapter plate, as necessary, until the Fz on the axes icon (see the next figure) printed on the transducer label is pointing up.

3. If not already assembled, attach the inclinometer to the level bracket using the two 6-32 UNC fasteners provided.

Apply Locktite 222 to the threads on the fasteners. Torque each fastener to 2 N•m (18 lbf•in).

SWIFT 10 ATV Sensors Installing the Transducer

Road Simulator

Setup for Horizontal Anti-rotate

Bracket Configuration

Axes

Icon

S10-21

Digital Inclinometer

–in this position

should read 90°, ±0.1°

Level Bracket

Setup for Vertical Anti-rotate

Bracket Configuration

Digital Inclinometer

–in this position

should read 0°, ±0.1°

Level Bracket

Mounting Holes (4)

Adapter Plate

4. Install the inclinometer/level bracket assembly on the transducer by inserting the dowel pins in the level bracket into the pin pilot holes provided in the transducer, as shown in the next figure.

The orientation of the inclinometer/level bracket assembly is determined by the orientation of the anti-rotate bracket.

Installing the Transducer

SWIFT 10 ATV Sensors

Road Simulator

Zero Button and Indicators

5. Adjust the adapter plate, as necessary, until the inclinometer reads 0.0°, ±0.1° (or 90.0°, ±0.1° depending on the orientation of the inclinometer) as shown in the figure above.

6. Push the Zero button on the front of the TI box.

The Zero indicators will toggle during the zero process. When the Zero indicators turn off the process is complete for this angle.

7. Remove the level bracket/inclinometer assembly.

8. Repeat Step 5 through 8 three more times.

Before Step 5 of each iteration, rotate the adapter plate 90°.

Always rotate the adapter in the same direction. (That is, if the first rotation was clockwise, the succeeding rotations should also be clockwise.)

Note If the red Fail indicator lights a problem was detected during the zero

process. Try repeating the procedure. Use TI2STATUS for a more detailed explanation of the problem. If you continue to have an error, consult the chapter, “Troubleshooting,” on page 117.

9. Return to the procedure, Attaching SWIFT Components to the Fixturing

SWIFT 10 ATV Sensors Installing the Transducer

Road Simulator

Installing the Transducer

SWIFT 10 ATV Sensors

Analyzing SWIFT Data

Overview This chapter contains examples of data collected from SWIFT installations, and

explains how the data can be analyzed.

Contents The Data 98

Fx Data (Longitudinal Force) 99

Fz Data (Vertical Force) 101

Mx Data (Overturning Moment) 102

My Data (Brake Moment) 105

Acceleration and Braking Events Example 107

Slalom Curve Driving Example 109

SWIFT 10 ATV Sensors Analyzing SWIFT Data

The Data

The following figure shows handling data taken on a flat, winding surface, using a SWIFT sensor and SOMAT software. The driving speed was between 30 and 100 kph (18–62 mph).

Analyzing SWIFT Data

SWIFT 10 ATV Sensors

Fx Data (Longitudinal Force)

Mz+

Distance

Fx+

S50-016

Direction of Motion

Distance

Fx+

S50-015

Mz+

Direction of Motion

Fx Data (Longitudinal Force)

This figure shows the Fx (longitudinal force) data.

• The offset in Fx after zeroing the SWIFT sensor is due to frictional force

and rolling resistance on a flat road.

• There is a strong similarity between Fx and Mz, due to the SWIFT sensor

measurement characteristics. That is, the SWIFT sensor measures at the transducer centerline. As a result, any Fx load results in an additional Mz output:

Mz due to Fx loading = Fx load x Distance

SWIFT 10 ATV Sensors Analyzing SWIFT Data

Fx Data (Longitudinal Force)

Friction/Rolling resistance Offset Fx Offset=165N

Mz Offset due to Fx=28Nm

The following figure illustrates the relationship between Fx and Mz, for this test case, which had a 170 mm (6.7 inch) offset from the tire centerline to the SWIFT sensor centerline:

Fx = 165 N observed

Distance = 170 mm

Mz = Fx x Distance = 165 N x 170 mm = 28 N•m

Analyzing SWIFT Data

100

SWIFT 10 ATV Sensors

MTS SWIFT 10 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Technical Support

How to Get Technical Support

Before You Contact MTS

Identify the problem Describe the problem you are experiencing and know the answers to the

If You Contact MTS by Phone

Identify system type To assist the Call Center agent with connecting you to the most qualified

After you call MTS logs and tracks all calls to ensure that you receive assistance and that action

Problem Submittal Form in MTS Manuals

Preface

Before You Begin

Safety first! Before you attempt to use your MTS product or system, read and understand the

Other MTS manuals In addition to this manual, you may receive additional MTS manuals in paper or

Conventions

Documentation Conventions

Hazard conventions As necessary, hazard notices may be embedded in this manual. These notices

Notes Notes provide additional information about operating your system or highlight

Special terms The first occurrence of special terms is shown in italics.

Illustrations Illustrations appear in this manual to clarify text. It is important for you to be

Hypertext links The electronic document has many hypertext links displayed in a blue font. All

Hardware Overview

Contents Overview 16

Overview

Spinning Applications (Track or Road)

Non-spinning Applications (Laboratory)

Construction

Transducer

Slip Ring

Inner hub adapter The inner hub adapter attaches to the inner diameter of the transducer and the

Slip-ring bracket The slip-ring bracket attaches the slip ring to the transducer. It has internal wiring

Encoder An encoder measures the angular position of the transducer. The SWIFT sensor

Anti-rotate device The anti-rotate device is attached to the slip ring and the vehicle’s suspension (or

Design Features

Flexure isolation The SWIFT sensor has a very stiff outer ring and flexured beam isolation which

Thermal stability The entire sensor is machined from a solid, specially forged billet of high

Low hysteresis The SWIFT sensor has very low hysteresis, since the sensing structure is

Low noise The SWIFT sensor uses a slip ring rather than telemetry for the transducer output

Low cross talk The advanced design of the SWIFT sensor means that it has very low cross talk.

Velocity information Angular output is available from the TI when it is used in the spinning mode with

Coordinate System

Specifications

Calibration

Shunt calibration At the end of the calibration process, a shunt calibration is performed. During a

Transducer Interface

cross talk compensation

Signal conditioning The TI is specifically designed to be used for both spinning and non-spinning

Analog signals The force and moment signals are output from the TI in the form of ±10 V

Communications The TI uses USB 2.0 for communication. The MTS supplied USB drivers must

TI Front Panel

Shunt button and Indicators

Zero button and Indicators

J5 USB Connector

J4 I/O Connector

J3 Transducer Connector

J2 Output Connector

J1 Power Connector

TI Rear Panel

Interfacing with RPC

Software Utilities

Contents Introduction 40

Introduction

TI2STATUS - Transducer Interface Status

Syntax ti2status

Example

Description of TI2STATUS Indications

Fatal Error: Provides an indication that the CPU is unable to run. The message indicates the

Boot Loader version: The boot loader is a program that verifies that the main program is complete. The

FPGA version: Identifies the version of the functions programmed in the field programmable

Firmware Version: Displays the version of the software installed in the TI. This software is stored in

Zero: Indicates whether the transducer zeroing was successful or not (see, “Error

F## Shunt: Indicates the status of shunt test for each bridge (see, “Error Messages,” on page

Calibration data is: Indicates the condition of the calibration data (see, “Error Messages,” on page 49

Unit serial number: Displays the serial number of the TI box

TI2XFER - Transducer Interface Transfer

Syntax ti2xfer

Example The following is an example of the ti2xfer command: