MTS SWIFT 40 User Manual

be certain.

SWIFT® 40 Sensor Product Information

Spinning Wheel Integrated Force Transducer For Light Trucks

100-026-691 G

Trademark information MTS is a registered trademark of MTS Systems Corporation within the United

States. These trademarks may be protected in other countries. Microsoft is a registered trademark of Microsoft Corporation. All other

trademarks or service marks are property of their respective owners.

Publication information

MANUAL PART NUMBER PUBLICATION DATE

151956-00B B February 1999 100-026-691 A June 2000 100-026-691 B April 2001 100-026-691 C May 2005 100-026-691 D October 2005 100-026-691 E January 2006 100-026-691 F August 2008 100-026-691 G November 2008

Contents

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

Spinning Applications (Test Track) 16 Non-spinning Applications (Simulation Lab) 17 Construction 18

Design Features 22 Coordinate System 23 Specifications 25 Calibration 29 Transducer Interface 31

TI Front Panel 34

TI Rear Panel 41

TI Jumpers 42 Interfacing with RPC 43

Software Utilities 45

Introduction 46 TISTATUS - Transducer Interface Status 47 TIXFER - Transducer Interface Transfer 48 TISHUNT - Transducer Interface Shunt 51

Setting Up Shunt Calibration Reference Values 55 TISETZERO – Transducer Interface Set Zero Method 56 Error Messages 57

SWIFT 40 Sensors Contents

Shunt Error Status 58

Setting up the Transducer Interface 59

Select a Zero Method 60

Calibration File Elements 61 Zero Algorithms 62

Upload the Calibration File 64 Edit the Calibration File 65 Download the Calibration File 69

Installing the Transducer 71

Test Track Vehicle 72

Attaching SWIFT Components to the Vehicle 75 Attaching SWIFT and Wheel Assembly to the Vehicle 78 Installing the Transducer Interface Electronics 80 Setting up the SWIFT Sensor for Data Collection 82 Verifying the Quality of the Zero Procedure 91 Collecting Data 94

Road Simulator 96

Attaching SWIFT Components to the Fixturing 98 Zeroing the Transducer Interface 101

Communication Configurations 102 Cable Configurations 103

SWIFT TI to PC Host (9-pin) 103

SWIFT TI to PC Host (25-pin) 103

SWIFT TI to SWIFT TI 103

T ermination Jumper 104

Analyzing SWIFT Data 105

The Data 106 Fx Data (Longitudinal Force) 107 Fz Data (Vertical Force) 109 Mx Data (Overturning Moment) 110 My Data (Brake Moment) 113 Acceleration and Braking Events Example 114 Slalom Curve Driving Example 116

Contents

SWIFT 40 Sensors

Maintenance 117

Transducer 118

Transducer Interface 119

Cables 120

Troubleshooting 121

Assembly Drawings 135

Cable Drawings 136 SWIFT 40A Mechanical Drawings 151 SWIFT 40T Mechanical Drawings 155 Common Parts 161

SWIFT 40 Sensors Contents

Contents

SWIFT 40 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 inform ation.

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 40 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 40 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 40 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 40 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 op eration and preventive maintenance manuals. Controller and application software manuals are typically included on the software CD distribution disc(s).

SWIFT 40 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 40 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 40 Sensors Preface

Conventions

Preface

SWIFT 40 Sensors

Hardware Overview

Data

S40-25

Test Track

Laboratory Simulation

Overview The MTS Spinning Wheel Integrated Force Transducer (SWIFT

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 both on the test track and 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 and on a road simulator. It is available in various sizes and materials to fit various vehicle and loading requirements.

) is a light-

Contents Spinning Applications (Test Track) 16

Non-spinning Applications (Simulation Lab) 17 Construction 18

Design Features 22 Coordinate System 23 Specifications 25 Calibration 29 Transducer Interface 31

TI Front Panel 34

TI Rear Panel 41

TI Jumpers 42 Interfacing with RPC 43

SWIFT 40 Sensors Hardware Overview

Spinning Applications (Test Track)

Customer Supplied

12 Vdc Power Supply

Customer Supplied

Data Recorder

Transducer Interface

(TI)

Transducer Signals

Output

Signals

S40-26

Spinning Applications (Test Track)

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 located inside the vehicle or in the trunk..

Hardware Overview

Spinning Application (Test Track)

SWIFT 40 Sensors

Non-spinning Applications (Simulation Lab)

12 Vdc Power Supply

(with 4 connections)

Customer Supplied

Data Recorder

Transducer Interface

(TI)

Transducer Signals

Output

Signals

Communication

S40-27

Non-spinning Applications (Simulation Lab)

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.

Four of the six loads measured by the transducer directly correlate to the MTS Model 329 Road Simulator inputs: vertical force, longitudinal force, lateral force, and braking input.

The same transducers used to collect road data at the test track can be mounted directly in the wheel adapters of the MTS Model 329 Road Simulator. For durability testing, an aluminum SWIFT sensor can be used for iterations within the RPC process. The aluminum 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 40 Sensors Hardware Overview

Construction

S20-03

Transducer

Hub Adapter

Slip Ring

(with Encoder)

Modified

Wheel Rim

Slip Ring

Bracket (Spider)

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.

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

spins with the wheel. It does not spin on a road simulator. The transducer is available in two materials: aluminum for spinning applications where the priority is on light weight, and titanium for non-spinning applications, where the priority is on durability.

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.

Hardware Overview

SWIFT 40 Sensors

Construction

(Components exaggerated to show detail)

Slip

Ring

Slip Ring Bracket

(Spider)

Transducer

Interface

Cable

Anti-rotate Device

(Bend to fit vehicle)

Transducer

Customer-supplied

Attachment Bracket

Tire

Wheel Rim

Customer-supplied

Rim Adapter Flange

Hub

Adapter

Attach to

vehicle

suspension

S20-04

Hub adapter The hub adapter attaches to the inner diameter of the transducer, allowing you to

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

Components Set Up for Test Track

Slip ring bracket

(spider)

The slip ring bracket (also referred to as the “spider”) is used to attach 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

uses an optical encoder, integrated into the slip ring assembly, that counts off “ticks” to measure the angular position as the wheel rotates. It measures 2048 (512 plus quadrature) points per revolution (ppr) with a resolution of 0.18 degrees and an accuracy 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. The slip ring is not used for non-spinning applications.

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 optical encoder. Its secondary function is to prevent the cable from rotating with the wheel and becoming tangled or breaking.

The anti-rotate device is mainly used 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 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.

SWIFT 40 Sensors Hardware Overview

Construction

Wheel Well

A jarring motion will damage the slip ring

Allow enough clearance for all loading and suspension travel

S20-05

Connector Housing

Non-Spinning

Cable Assembly

Non-Spinning

Connector Bracket

S40-39

Spinning Slip Ring Bracket

Shunt A

Shunt B

Load

Accelerometer

(optional)

S40-40

Non-Spinning

Connector Bracket

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.

Non-spinning

connector housing or

connector bracket

The non-spinning connector housing or the non-spinning connector bracket (both shown below) provide a connection between the SWIFT and the TI electronics for non-spinning use. Both assemblies incorporate rugged connectors suitable for durability testing. The non-spinning connector housing can also include an optional connector with built-in, tri-axial accelerometers.

Hardware Overview

SWIFT 40 Sensors

Construction

Transducer Interface

(TI)

Additional

components

The TI conditions the power supply, and uses previously stored calibration values to convert the eight bridge outputs and the encoder signal to six non-rotating analog outputs (Fx, Fy, Fz, Mx, My, Mz) plus 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 shunt and transducer data cables, TI power cable, a SWIFT Transducer Interface Utilities disk, and the calibration file. MTS can also provide a 12 V DC power converter for use in the test laboratory.

SWIFT 40 Sensors Hardware Overview

Construction

Design Features

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

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.

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

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

As mentioned earlier, flexure isolation allows thermal expansion with minimal stresses.

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.

Hardware Overview

SWIFT 40 Sensors

Coordinate System

Transducer

Interface

Output signals

10 Volts

Angular Position

Bridge

Outputs

S20-06

+Mz

+Fz

+Fy

+My

+Mx

+Fx

Forces acting on outer ring

S20-07

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

Coordinate System

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).

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

SWIFT 40 Sensors Hardware Overview

Coordinate System

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) is positive out of the transducer

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”.

Hardware Overview

SWIFT 40 Sensors

Specifications

SWIFT 40 Transducer Performance

ARAMETER SPECIFICATION

Use

SWIFT 40 A (aluminum) for

SWIFT 40 T (titanium) for Maximum usable rpm Maximum speed fits rim size (usable range)

Maximum hub bolt circle diameter accommodates M12 or 1/2 inch studs

Input voltage required Input power required per transducer Output voltage ± full scale calibrated load

SAE J328 rated load capacity Standard Maximum Calibrated Load Rating‡

Longitudinal force (Fx)

Lateral force range (Fy)

Vertical force range (Fz)

Overturning moment (Mx)

Driving/braking moment (My)

Steering moment (Mz) Resolution (analog system) Noise level (peak-to-peak 0-500 Hz) Performance accuracy

Nonlinearity

Hysteresis

Modulation§

Cross talk Maximum operating temperature

Low level amplifiers

Transducer interface

12 kN (2,700 lbf) 22.7 kN (5,100 lbf)

±40 kN (±8,990 lbf) ±60 kN (±13,490 lbf) ±30 kN (±6,745 lbf) ±45 kN (±10,115 lbf) ±40 kN (±8,990 lbf) ±60 kN (±13,490 lbf)

±9 kN•m (±79,655 lbf•in) ±15 kN•m (±132,760 lbf•in)

±13 kN•m (±115,060 lbf•in) ±20 kN•m (±117,015 lbf•in)

±9 kN•m (±79,655 lbf•in) ±15 kN•m (±132,760 lbf•in)

Specifications

low weight, high sensitivity

high fatigue life, durability

2,200

240 kph (150 mph)

13–17 inch

170.5 mm (6.713 in)

10–17 VDC

30 W maximum (22 W typical)

†

±10 V

Aluminum Titanium

Infinite

20 N (4.5 lbf) 30 N (6.7 lbf)

1.0% full scale

0.5% full scale ≤3.0% reading

1.5% full scale

70°C (158°F) 50°C (122°F)

* A special flange configuration is required for a 13 inch wheel. Larger diameter rims can be used, providing

that overall clearance from brake calipers and suspension components is maintained. † Load impedance >1 kΩ; 0.01 µF (maximum) load capacitance. ‡ The actual calibrated range may be different based on individual customer requirements. Consult the

calibration range sheet that accompanies each transducer for the correct calibration range.

§ Typical value on most steel rims. Aluminum rims typically have slightly higher modulation, but at a lower

added weight. # Each SWIFT sensor is calibrated on an MTS calibration machine. MTS provides complete documentation

of calibration values for each SWIFT unit

SWIFT 40 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

33.7 mm 1.325 in 33.7 mm 1.325 in

0.0 mm 0.000 in 0.0 mm 0.000 in

816 kg·cm2279 lbm·in21260 kg·cm2431 lbm·in 1572 kg·cm2537 lbm·in22422 kg·cm2828 lbm·in 816 kg·cm2279 lbm·in21260 kg·cm2431 lbm·in

Hardware Overview

SWIFT 40 Sensors

Transducer Interface

ARAMETER SPECIFICATION

Physical

Height Width Depth Weight Rack Mounting Kit

Environmental

Ambient temperature Relative humidity

Power Requirements

Input voltage Supply current Fuse

31.75 mm (1.25 in)

431.8 mm (17 in)

215.9 mm (8.5 in.)

1.68 kg (3 lb 11.1 oz) Optional

0° C (32° F) to 50° C (122° F) 0 to 85%, non-condensing

10–17 V DC 2 A typical, 3 A maximum at 12 V DC 3 A fast-blow

Specifications

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 outpu t stable) Transducer cable length Shunt cable length Analog outputs

Voltage

12 µs (typical) 100 ft maximum 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 6 mA maximum 7 mVpp, DC - 500 Hz (typical)

15 mVpp, DC - 500 Hz (maximum)

Bandwidth (bridge input to main output)

–3 dB at 30.1 kHz (typical) 90 degree at 16.6 kHz (typical)

* 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 40 Sensors Hardware Overview

Specifications

Transducer Interface Communications

ARAMETER SPECIFICATION

Communications Channel # 1 (Remote Host Connections)

Baud rates Parity Stop bits Data bits Isolated RS-232/RS-485 interface power

supply Electrical interface

19,200 Kbits/s None 1 8 +5 V DC @ 200 mA maximum

Isolated RS-232 or RS-485 remote host connection Isolated RS-485 TI to TI connection

Maximum number of devices that can be part of a RS-485 multidrop chain

Maximum cable length

32 with RS-232 remote host 31 with RS-485 remote host

For RS-232 host:

50 ft from host to the first (nearest) TI, and 300 ft from the first TI to the last SWIFT TI in the RS-

485 multidrop chain

For RS-485 host:

300 ft from host to the last (furthest) TI in the RS-485 multidrop chain

* Includes all compatible devices, such as an MTS 407 Controll er. A maximum of only nine transducer

interfaces can be connected, because the addresses are limited to 1–9.

Hardware Overview

SWIFT 40 Sensors

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 located at the back of each TI box.

The calibration file is loaded into the TI non-volatile RAM 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.

SWIFT 40 Sensors Hardware Overview

Calibration

When you press the Shunt button, the associated Shunt LED lights. 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 LED on the front panel will go off (after several seconds). If any bridge fails to fall within the shunt tolerance range, the LED will blink, indicating that the shunt calibration has failed. See the chapter, “Troubleshooting”, for more information on dealing with shunt calibration failures.

ShuntTolerance=2 FX1ShuntDeltaRef=-3.91836 FX2ShuntDeltaRef=-3.91896 FY1ShuntDeltaRef=-3.92366 FY2ShuntDeltaRef=-3.91639 FY3ShuntDeltaRef=-3.91824 FY4ShuntDeltaRef=-3.92494 FZ1ShuntDeltaRef=-3.92282 FZ2ShuntDeltaRef=-3.92673 FX1ShuntDeltaMeas=-3.91854 FX2ShuntDeltaMeas=-3.9192 FY1ShuntDeltaMeas=-3.92412 FY2ShuntDeltaMeas=-3.91572 FY3ShuntDeltaMeas=-3.91815 FY4ShuntDeltaMeas=-3.92464 FZ1ShuntDeltaMeas=-3.9227 FZ2ShuntDeltaMeas=-3.92646

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 TIXFER program, from the transducer interface RAM to a computer or from a computer to the transducer interface RAM. Note that items marked ShuntDeltaMeas are uploaded from RAM, but not downloaded from the computer. (For more information on TIXFER, see the chapter, “Software Utilities.”

You can check the calibration of a transducer at any time by pressing the Shunt switch. 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).

If the current feedback values from a shunt calibration are outside the tolerance, the Shunt LED blinks to indicate a failure.

Hardware Overview

SWIFT 40 Sensors

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