MTS SWIFT 45 User Manual

Download

be certain.

SWIFT® 45 GLP Sensor Product Information

Spinning Wheel Integrated Force Transducer For Medium Trucks

100-214-138 A

Trademark information MTS, SWIFT, T estStar, TestWare, MTS Remote Parameter Control, and RPC are

registered trademarks of MTS Systems Corporation within the United States. These trademarks may be protected in other countries.

Microsoft, Windows, Wi ndows 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. All other trademarks or service marks are property of their respective owners.

Proprietary information Software use and license is governed by MTS’s End User License Agreement

which defines all rights retained by MTS and granted to the End User. All Software is proprietary, confidential, and owned by MTS Systems Corporation and cannot be copied, reproduced, disassembled, decompiled, reverse engineered, or distributed without express written consent of MTS.

Software validation and

verification

Publication information

MTS software is developed using established quality practices in accordance with the requirements detailed in the ISO 9001 standards. Because MTSauthored software is delivered in binary format, it is not user accessible. This software will not change over time. Many releases are written to be backwards compatible, creating another form of verification.

The status and validity of MTS’s operating software is also checked during system verification and routine calibration of MTS hardware. These controlled calibration processes compare the final test results after statistical analysis against the predicted response of the calibration standards. With these established methods, MTS assures its customers that MTS products meet MTS’s exacting quality standards when initially installed and will continue to perform as intended over time.

MANUAL PART NUMBER PUBLICATION DATE

100-214-138 A June 2009

Contents

Technical Support 5

Preface 9

Conventions 10

Hardware Overview 13

Overview 14 Spinning Applications (Track or Road) 16 Non-Spinning Applications (Laboratory) 17 Construction 18

Design Features 21 Coordinate System 22 Specifications 24 Calibration 28

Installation 31

Hazard Icons 32 Road and Track Vehicles 33

Attaching SWIFT Components to the Vehicle 38

Attaching SWIFT and Wheel Assembly to the Vehicle 41

Collecting Data 48 Road Simulator 51

Attaching SWIFT Components to the Fixturing 54

Analyzing SWIFT Data 59

The Data 60 Fx Data (Longitudinal Force) 61 Fz Data (Vertical Force) 63 Mx Data (Overturning Moment) 64 My Data (Brake Moment) 67 Acceleration and Braking Events Example 68 Slalom Curve Driving Example 70

SWIFT® 45 GLP Sensors

Contents

Maintenance 71

Transducer 72 Cables 73

Troubleshooting 75

Assembly Drawings 79

Cable Drawings 80 SWIFT 45 GLP Mechanical Drawings 85

Contents

SWIFT® 45 GLP Sensors

Technical Support

How to Get Technical Support

Start with your

manuals

Technical support

methods

The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes 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 Technical Support in one of the following ways.

www.mts.com The web site provides access to our technical support staff by means of an

onlineform:

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

E-mail tech.support@mts.com

Telephone MTS Call Center 800-328-2255

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

Fax 952-937-4515

Please include “Technical Support” in the subject line.

Outside the U.S. 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:

Before You Contact MTS

Know your site

number and system

number

SWIFT® 45 GLP Sensors

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

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

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

Example site number: 571167

When you have more than one MTS system, the system job number identifies your system. You can find your job number in your order pape rwork.

Example system number: US1.42460

Technical Support

Know information from

prior technical

If you have contacted MTS about this problem before, we can recall your file based on the:

assistance

• MTS notification number

• Name of the person who helped you

Identify the problem Describe the problem and know the answers to the following questions:

• How long and how often has the problem occurred?

• Can you reproduce the problem?

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

problem started?

• What are the equipment model numbers?

• What is the controller model (if applicable)?

• What is the system configuration?

Know relevant

computer information

Know relevant

software information

For 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 where 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 can typically be found in the About selection in the Help menu.

• The names of other applications on your computer, such as:

– Anti-virus software – Screen savers – Keyboard enhancers – Print spoolers

Technical Support

– Messaging applications

SWIFT® 45 GLP Sensors

If You Contact MTS by Phone

A Call Center agent registers your call before connecting you with a technical support specialist. The agent asks you for your:

• Site number

• Name

• Company name

• Company address

• Phone number where you can be reached

If your issue has a notification number, please provide that number. A new issue will be assigned a unique notification number.

Identify system type To enable the Call Center agent to connect you with the most qualified technical

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

• Electromechanical material test system

• Hydromechanical material test system

• Vehicle test system

• Vehicle component 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 for your

• Aero test system

Prepare to perform troubleshooting while on the phone:

• Call from a telephone close to the system so that you can implement

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.

In case Technical Support must call you:

• Verify the notification number.

• Record the name of the person who helped you.

• Write down any specific instructions.

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

SWIFT® 45 GLP Sensors

Technical Support

Problem Submittal Form in MTS Manuals

Use the Problem Submittal Form to communicate problems with your software, hardware, manuals, or service that are not resolved to your satisfaction through the technical support process. The 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 respon se—your feedback is important to us.

Access the Problem Submittal Form:

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

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

form to be e-mailed to MTS)

Technical Support

SWIFT® 45 GLP Sensors

Preface

Before You Begin

Safety first! Before you 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 can result in hazardous conditions that can cause severe personal injury or death, or 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 manuals in paper or

electronic form. You may also receive an MTS System Documentation CD. It contains an

electronic copy of the manuals that pertain to your test system, such as:

• Hydraulic and mechanical component manuals

• Assembly drawings

• Parts lists

• Operation manual

• Preventive maintenance manual

Controller and application software manuals are typically included on the software CD distribution disc(s).

SWIFT® 45 GLP 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 Hazard notices may be embedded in this manual. These notices contain safety

information that is specific to the activity 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 all directions and recommendations. 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 or equipment damage, or could 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. They 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® 45 GLP 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

45 GLP Sensors

Preface

Conventions

Preface

SWIFT® 45 GLP Sensors

Hardware Overview

Contents Overview 14

Spinning Applications (Track or Road) 16 Non-Spinning Applications (Laborator y) 17 Construction 18

Design Features 21 Coordinate System 22 Specifications 24 Calibration 28

SWIFT® 45 GLP Sensors

Hardware Overview

Overview

S45-001

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 several sizes and materials to fit various vehicle and loading requirements.

Parts replacement,

disassembly, and care

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.

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

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 75.

Hardware Overview

SWIFT® 45 GLP Sensors

Overview

CAUTION

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 71, 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 bumped into 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, as listed in

“Specifications” on page 24.

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

warning labels removed.

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

bent slip ring bracket arms, a bent anti-rotate assembly, etc.).

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

written authorization from MTS.

SWIFT

45 GLP Sensors

Hardware Overview

Spinning Applications (Track or Road)

S45-002

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 located inside the vehicle or in the trunk.

Hardware Overview

Spinning Application (Track or Road)

SWIFT® 45 GLP Sensors

Non-Spinning Applications (Laboratory)

S45-003

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 (RPC) software. The transducer takes data at points where fixturing inputs are 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 can be mounted directly in the wheel adapters of the MTS Model 329 Road Simulator. 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.

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

45 GLP Sensors

Hardware Overview

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

vehicle, it spins with the wheel. It does not spin on a road simulator. 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® 45 GLP Sensors

Construction

Anti-Rotate Mounting Bracket (customer supplied)

Anti-Rotate Assembly

Spindle Adapter Spacer

Transducer Interface Cable

Slip-Ring Bracket

Slip-Ring Extension

Bracket SWIFT 45 Transducer

Slip-Ring

Dual Rim Conguration

Front Rim Conguration

Anti-Rotate Mounting Bracket (customer supplied)

Anti-Rotate Assembly

Spindle Adapter Spacer

Transducer Interface Cable

Slip-Ring Bracket

SWIFT 45 Transducer

Slip-Ring

Tire

Spindle adapter spacer The spindle adapter spacer 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 spindle adapter spacer 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. In addition, the spindle adapter spacer helps minimize brake heat from being transferred to the transducer.

Components Set Up for Test Track

Slip-ring bracket The slip-ring bracket 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

SWIFT

45 GLP Sensors

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.

Hardware Overview

Construction

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.

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 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 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 or 24 V DC power converter for use in the test laboratory.

Hardware Overview

SWIFT® 45 GLP Sensors

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 outward sensor is machined from a solid, specially forged billet of

high strength 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 minimizes temperature-induced variations in accuracy. The temperature rating for the SWIFT sensor is 125° C (257° F) at the spindle hub.

Construction

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). Linear cross talk 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

45 GLP Sensors

Hardware Overview

Coordinate System

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).

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.

Hardware Overview

SWIFT® 45 GLP Sensors

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”.

SWIFT

45 GLP Sensors

Hardware Overview

Specifications

MEASURED VALUE UNITS TITANIUM

SWIFT 45T (MT)

Max Calibrated Load Ratings

Fx lb (kN) 26,977 120

Fy lb (kN) 10,791 48

Fz lb (kN) 26,977 120

Mx in-lb (kN-m) 247,820 28

My in-lb (kN-m) 265,522 30

Mz in-lb (kN-m) 247,820 28

Noise Level peak to peak (0-500Hz) N8

Maximum usable RPM RPM 2200

Maximum Speed (15 in. rolling radius) mph (kph) 150 240

Max Operating Temperature (measured at the spindle hub)

Shock Resistance, Each Axis G50

SWIFT Environmental Protection Rating IP67

Input Voltage Required VDC 10-28

Input Power Required Per Transducer W6

Output Voltage at Full Scale Calibrated Load V±10

SAE J267 Half Axle Rating lb 8000

SAE Bending Moment Seen on Cell in-lb (kN-m) 206,000 23.3

°F (°C) 257 125

Hardware Overview

SWIFT® 45 GLP Sensors

Specifications

Accuracy

Force

Moment

Hysteresis

Force

Moment

Crosstalk

Force → Force

Force → Moment

Moment → Force

Moment → Moment

Assembly Weight Information

Transducer lb (kg) 23.6 10.7

Washer Plates lb (kg) 9.0 4.1

Slip Ring Assembly lb (kg) 2.0 0.9

% FS 1

% FS 0.5

% FS 1

% FS 1.5

% FS 0.5

HD Steel 19.5x6.75 Modified Rim lb (kg) 92.2 41.8

Modified Lug Nuts (qty. 10) lb (kg) 3.0 1.4

Attached Fast en er lb (kg) 6.8 3.1

Total Weight lb (kg) 136.6 62.0

Reference Weight of Standard Unmodified

19.5 X 6.75 X 5.5 Rim and Lug Nuts lb (kg) 61.0 27.7

Differential Weight lb (kg) 75.0 34.0

SWIFT

45 GLP Sensors

Hardware Overview

Specifications

Minimum Rim Size inch 17.5

Typical Lug Nut Bolt Circle Accommodated mm 165 to 225; 8x275

(8x275 pattern accepts 20mm Studs)

Output Connector Type BNC

Auto Shunt Calibration Internal Shunts

Notes:

• Based on loads at center of transducer.

• Each SWIFT 45 sensor will be calibrated on an MTS calibration machine. MTS provides complete

documentation of calibration values for each serial number SWIFT unit. Unique calibration values are stored electronically and transferred to the transducer interface unit (TI box) shipped with each SWIFT 45.

• Periodic recalibration services can be provided by MTS.

• Rim design is provided by MTS and tested to SAE J267 criteria.

• Proper rim design is essential for optimum performance.

• For applications involving non-listed wheel sizes, contact your MTS application engineer.

• Reference rim weights based on 19.5x6.75 truck rim with 5.5" offset, 10 hole 225mm bolt circle.

Single wheel configuration.

Hardware Overview

SWIFT® 45 GLP Sensors

Trans ducer Center-of-Gravity

North American Transducer Center-of-Gravity and Inertia Specifications

ITANIUM

Specifications

0.0 mm 0.0 in.

26.7 mm 1.05 in.

0.0 mm 0.0 in.

1404 kg·cm2480 lbm·in 2759 kg·cm2943 lbm·in 1404 kg·cm2480 lbm·in

SWIFT

45 GLP 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 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.

Hardware Overview

SWIFT® 45 GLP Sensors

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 and error light turns on, indicating that the shunt calibration has failed. For more information on dealing with shunt calibration failures, see the chapter, “Troubleshooting.”

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 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 T ransducer Interface”, for instructions.

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

SWIFT

45 GLP Sensors

Hardware Overview

Calibration

Hardware Overview

SWIFT® 45 GLP Sensors

Installation

Contents Hazard Icons 32

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.

Road and Track Vehicles 33

Attaching SWIFT Components to the Vehicle 38 Attaching SWIFT and Wheel Assembly to the Vehicle 41 Collecting Data 48

Road Simulator 51

Attaching SWIFT Components to the Fixturing 54

SWIFT® 45 GLP Sensors

Installation

Hazard Icons

Read, understand, and

follow the instructions

in the manual

The following hazard icon is part of the label affixed to the side of the SWIFT 45 GLP Sensor.

Installation

SWIFT® 45 GLP Sensors

Road and Track Vehicles

Equipment required This procedure requires two people. To install the SWIFT 45 GLP sensor, you

will need the following equipment:

• Hub adapter

• Modified rim (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 17 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)

– M20 x 1.5 mm (quantity 8) – M12 x 1.75 mm (quantity 8; length is dependant on the thickness of the

rim flange)

– M12 x 1.75 mm (quantity 32; length is dependant on the thickness of

the spindle adapter spacer)

– lug nuts, shim washers, and washer plates

• For dual rims

– M20 x 1.5 mm (quantity 8) – M12 x 1.75 mm (quantity 8; length is dependant on the thickness of the

rim flange)

– M12 x 1.75 mm (quantity 32; length is dependant on the thickness of

the spindle adapter spacer) – lug nuts, shim washers, and washer plates – slip ring extension assembly – M12 x 1.75 mm x 30 mm long bolts (quantity 4)

• Slip ring assembly fasteners

SWIFT

45 GLP Sensors

– M5 x0.8 mm bolts (quantity 8)

• Torque wrenches, capable of the following ranges:

– 2.3–23 N·m (20–200 lbf·in) – 24–74 N·m (18–55 lbf·ft),

Installation

Road and Track Vehicles

– 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 wr aps

• Data recorder

• Power supply–10 to 28 V DC

Installation

Installation Components (Test Track–Front)

SWIFT® 45 GLP Sensors

Installation Components (Test Track–Duals)

CAUTION

Road and Track Vehicles

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 and fully torqued during all tests. Correct

use of bolts reduces the safety hazard and ensures optimal transducer performance.

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

sensor and components to the vehicle.

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

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

Do not pressure-wash the transducer or clean it with solvents. Use only a soft sponge or brush with non-metal bristles and a gentle detergent (such as dish soap) to wash the transducer.

SWIFT

45 GLP Sensors

Installation

Road and Track Vehicles

CAUTION

WARNING

CAUTION

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.

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.

Installation

SWIFT® 45 GLP Sensors

Road and Track Vehicles

CAUTION

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.

SWIFT

45 GLP Sensors

Installation

Road and Track Vehicles

Attaching SWIFT Components to the Vehicle

SWIFT 45 GLP

Fasteners

M20 X 1.5 mm

M12 X 1.75 mm

M12 X 1.75 mm MTS modified lug nuts and shim washers

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

flange. The fastener length should ensure a minimum thread engagement of 30 mm (1.18 in).

† The length of these fasteners is dependant on the thickness of the rim

flange. The fastener length should ensure a minimum thread engagement of 18 mm (0.71 in).

‡ These fasteners secure the spindle adapter spacer to the transducer.

The length of these fasteners is dependant on the thickness of the spindle adapter spacer which is a functio n of the customer wheel geometry. The fastener length should ensure a minimum thread engagement of 18 mm (0.71 in).

†

‡

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. Use a mild detergent such as dish soap.

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.

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

3. Wipe the unpainted mating surfaces of the modified rim, the spindle adapter spacer and the transducer with a clean dry cloth.

4. Generally it is easier to attach the SWIFT sensor to the hub adapter first. Attach the hub adapter to the SWIFT sensor using the 32 M12 x 1.75 mm fasteners provided. Be sure to use the supplied 4-hole washer plates.

Ensure the pilot surface of the hub adapter spacer is facing the transducer. Lubricate the threads and under the head of each fastener with Molykote g-n

paste and torque to 32.5 N·m (24 lbf-ft). They will be tightened to final torque later.

Installation

SWIFT® 45 GLP Sensors

Road and Track Vehicles

Modified lug nuts

Transducer

Spindle adapter spacer

8 M12 rim fasteners A-H

8 M20 rim fasteners 1-8

32 M12 hub fasteners 1-32

5. Attach the transducer to the modified wheel rim using the fasteners provided (see the previous table). 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.

Bolt Torque Sequence

6. Tighten the M12 mounting bolts. A. Following the sequence shown in the previous figure, torq ue the eigh t

M12 bolts (A through H) to the value for the first increment shown in the following table.

B. Repeat Step 6A for the second increment.

SWIFT

45 GLP Sensors

Installation

Road and Track Vehicles

C. Repeat Step 6A for the final torque.

7. Tighten the M20 mounting bolts. A. Following the sequence shown in the previous figure, torq ue the eigh t

M20 bolts (1 through 8) to the value for the first increment shown in

the following table. B. Repeat Step 7A for the second increment. C. Repeat Step 7A for the final torque.

8. Refer to Step 4. Finish tightening the 32 hub adapter bolts. A. Following the sequence shown in the previous figure, torq ue the 32

M12 bolts (1 through 32) to the value for the first increment shown in

the following table. B. Repeat Step 8A for the second increment. C. Repeat Step 8A for the final torque.

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

sequence shown.

BOLT SIZE

TORQUE INCREMENT M12 M20

1st Increment 32.5 N·m (24 lbf·ft) 168.1 N·m (124 lbf·ft) 2nd Increment 65 N·m (48 lbf·ft) 336.2 N·m (248 lbf·ft) Final Torque 97.6 N·m (72 lbf·ft) 501.6 N·m (370 lbf·ft)

Installation

SWIFT® 45 GLP Sensors

Road and Track Vehicles

Anti-rotate assembly

Cable conduit bracket

Slip ring

Slip ring bracket

Transducer

Anti-rotate bracket (customer supplied)

For front or steering axles, anti-rotate arm must be mounted to a part of the unsprung suspension that steers with the tire, such as the brake caliper.

Attaching SWIFT and Wheel Assembly to the Vehicle

1. Before installing the SWIFT and wheel assembly, attach the anti-rotate bracket (customer supplied) to the vehicle.

Because 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 bracket must be stiff, preferably steel or 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 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.

SWIFT

45 GLP Sensors

Installation

Road and Track Vehicles

CAUTION

Ensure bracket will not hit body parts during vehicle testing or suspension travel.

For dual or nonsteering axles, the anti-rotate arm must be mounted to the unsprung mass or suspension, or possibly the fender or trailer (less desirable).

If the arm is mounted to the fender or trailer, the assembly must have a close-tting hole that will accommodate the suspension travel.

The bracket can be attached to the brake caliper if the wheel hub assembly is equipped with a disc braking system.

Anti-Rotate Mounting Bracket (customer supplied)

Tire

Dual Wheel Slip Ring and Anti Rotate Assembly

If the anti-rotate bracket is fender or trailer-mounted, it must be in a vertical orientation so that when suspension travel occurs, the anti-rotate are does not rotate and cause errors in the data or bend the rod.

The anti-rotate arm must be long enough to accommodate vehicle suspension travel.

Anti-Rotate Assembly

Spindle Adapter Spacer

Transducer Interface Cable

Slip-Ring

Slip-Ring Bracket

Slip-Ring Extension Bracket

SWIFT 45 Transducer

2. Attach the wheel/transducer to the test vehicle.

Installing the lug bolts directly against the transducer face, without the antigalling compound and the shim washers, can cause galling of the transducer face.

Galling of the transducer face can result in uneven torquing (and possible over-torquing) of the lug bolts.

To prevent galling, always use the shim washers provided. Always lubricate the bolts and shim washers as described below.

Lubricate the lug bolt threads, under the bolt head, and both faces of the shim washers with the Nikal based anti-galling compound.

Tighten the lug nuts in three increments up to the specified torque, in the sequence shown in the next figure to the torque rating recommended for the wheel.

Important Do not exceed maximum specified lug-nut torque.

Installation

SWIFT® 45 GLP Sensors

Road and Track Vehicles

3. If necessary, assemble the hinge base with anti-rotate tube onto the slip ring. See the next figure.

Note Typically this step is only required for new slip rings. After the assembly

is complete, there should be no need to disassemble it except if a component becomes damaged.

A. Connect the cable to the slip ring. B. Wrap the slip-ring connector and cable connector with butyl rubber

shrink tape (MTS part number 100-175-781 or equivalent). Cut approximately 150 mm (6 in) of tape from the roll. Remove the backing from the tape. Stretch the tape until it is approximately 1/2 of its original width. Begin by putting two wraps of tape tightly around the slip ring

connector and cable connector. Continue wrapping up the connector and cable approximately 150 mm

(6 in). Overlap the tape by approximately 1/2 of its width.

C. Measure, making bends as necessary, and cut the aluminum tube to

size. MTS provides an extra long tube with a hinge welded at one end. After

fitting the tube to your test vehicle, cut off the excess length. D. Tap the end of the aluminum tube 5/16-18 UNC X 1.00 inch deep. E. Insert the low-head cap screw through the delrin ball. F. Insert the aluminum tube into the steel sleeve.

SWIFT

45 GLP Sensors

Installation

Road and Track Vehicles

G. Tighten the screws that attach the hinge joint to the slip ring assembly.

4. Attach the transducer output cable to the slip ring encoder connector and the Slip Ring D-connector on the rear of the TI.

5. Secure the cable along its length so that ot will not become damaged during data collection. (For example, tape it to the external mirror.)

Be sure to leave enough slack in the cable to allow for the full range of suspension travel.

Installation

SWIFT® 45 GLP Sensors

Road and Track Vehicles

Anti-rotate assembly

Cable conduit bracket

Slip ring

Slip ring bracket

Transducer

Anti-rotate bracket (customer supplied)

For front or steering axles, anti-rotate arm must be mounted to a part of the unsprung suspension that steers with the tire, such as the brake caliper.

6. For front rim configurations (see the next figure): Attach the slip-ring bracket with the slip ring, conduit bracket, and restraint tube to the transducer.

A. The slip-ring bracket fits over the circular connectors on the front of

the transducer at the four locations. The slip-ring bracket is similarly labeled to prevent connecting it the wrong way.

Note Use care when installing the slip-ring bracket. The circular connectors

are keyed. The slip-ring bracket should be fitted on straight (without bending or angling it) to make sure it engages all four connectors simultaneously and evenly.

B. Lubricate the threads and under the bolt heads of the eight

M5 X 0.8 mm bolts with Molykote g-n paste. Insert them through the mounting hole in the slip-ring bracket and thread them into the transducer. Torque each to 6.8 N·m (5 lbf·ft).

SWIFT

45 GLP Sensors

7. For dual rim configurations (see the next figure): Attach the extension assembly and slip-ring bracket with slip ring to the transducer.

A. Thread the standoffs, with the M12 threaded studs, into the four M12

threaded holes in the face of the transducer. Lubricate the threads on each threaded stud with Molykote g-n paste

and torque to 93 N·m (69 lbf·ft). B. Attach the four extension brackets. C. Place the top plate, with extensions attached, over the standoffs.

Orient the top plate such that the Board 1 extension (see the labeling

on the top plate) is aligned with the Board 1 connector on the

transducer.

Installation

Road and Track Vehicles

Note Use care when installing the top plate and extensions. The 9-pin

connectors are keyed. The top plate and extensions should be fitted on straight (without bending or angling it) to make sure they engage the four connectors simultaneously and evenly.

Installation

D. Secure the top plate to the st andoffs using the four M12 bolts and

washers. Lubricate the threads with Molykote g-n paste and torque to 93 N·m

(69 lbf·ft).

E. Install the slip-ring bracket with the slip ring and restraint tube.

Slide the restraint tube through the hole in the anti-rotate bracket (installed earlier) as far as necessary to align the slip-ring bracket to the connectors on the top plate.

The slip-ring bracket fits over the circular connectors on the top plate at the locations labeled Board 1. The slip-ring bracket is similarly labeled to prevent connecting it the wrong way.

SWIFT® 45 GLP Sensors

Road and Track Vehicles

Note Use care when installing the slip-ring bracket. The circular connectors

are keyed. The slip-ring bracket should be fitted on straight (without bending or angling it) to make sure it engages both connectors simultaneously and evenly.

F. Lubricate the threads and under the bolt heads of the eight

M5 X 0.8 mm bolts with Molykote g-n paste. Insert them through the

mounting holes in the slip-ring bracket and thread them into the

transducer. Torque them to 6.8 N·m (5 lbf·ft).

8. Secure the cable along the restraint tube, as necessary, to prevent it from rubbing against the tire.

9. Secure the cable along the remainder of its length so that it will not become damaged during data collection. (For example, tape it to the fender or frame.)

Important Be sure to leave enough slack in the cable to allow for the full

range of wheel travel so the cable does not become stretched or damaged during testing.

SWIFT

45 GLP Sensors

Installation

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

the encoder will need to find the index pulse to properly convert the rotating coordinates to stationary coordinates. The transducer outputs will not be correct until this happens.

To reset the encoder, roll the vehicle either forward or backward so that the tire completes at least one revolution. This can be accomplished while driving to the test area, or if the vehicle is on a lift in the garage area, rotate the tire manually.

1. Spin the wheel twice to ensure that the encoder tick is correct. Spinning the wheel after you have completed the zero process will ensure

that the 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 butyl rubber shrink 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 the TI is on.

The zero data is saved at the end of each completed procedure. If the TI is off, the zero data will not be lost. However, due to thermal conditions that could affect your data, if the TI is powered off for an extended period of time (such as over night), repeat the zero process.

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.

Installation

SWIFT® 45 GLP Sensors

Road and Track Vehicles

CAUTION

WARNING

The SWIFT assembly will protrude approximately 130 mm (5 in) from the side of the vehicle.

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

Do not allow the SWIFT assembly to bump into any hard surfaces or objects while you are driving the vehicle. Remember to allow extra space on each side of the test vehicle when driving through areas with possible hazards.

Tall grass and brush can damage the sensor components. 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.

SWIFT

45 GLP Sensors

Installation

Road and Track Vehicles

WARNING

The SWIFT sensor can be exposed to load cycles that exceed the full scale calibrated ranges listed in, “Specifications,” on page 24.

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.

Do not use the SWIFT sensor if it has been exposed to load cycles that exceed the full scale calibrated ranges listed in, “Specifications,” on page 24. 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. If necessary, arrange for the return of the transducer with the recorded load cycles to MTS for physical inspection and analysis of the load cycle history.

Installation

SWIFT® 45 GLP Sensors

Road Simulator

CAUTION

WARNING

Before you begin Angular correction is required on the test track only. If you are using the same

transducer(s) for non-spinning simulation testing you must load the correct software into the TI.

The SWIFT sensor must be attached to the test fixture before the vehicle is mounted.

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.

Road Simulator

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 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.

SWIFT

45 GLP Sensors

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

Installation

Road Simulator

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

following equipment:

• Hub adapter

• Adapter 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)

– M20 x 1.5 mm (quantity 8) – M12 x 1.75 mm (quantity 8; length is dependant on the thickness of the

rim flange)

– M12 x 1.75 mm (quantity 32; length is dependant on the thickness of

the spindle adapter spacer)

– lug nuts, shim washers, and washer plates

• For dual rims

– M20 x 1.5 mm (quantity 8) – M12 x 1.75 mm (quantity 8; length is dependant on the thickness of the

rim flange)

– M12 x 1.75 mm (quantity 32; length is dependant on the thickness of

the spindle adapter spacer) – lug nuts, shim washers, and washer plates – slip ring extension assembly – M12 x 1.75 mm x 30 mm long bolts (quantity 4)

• Slip ring assembly fasteners

– M5 x0.8 mm bolts (quantity 8)

• Torque wrenches, capable of the following ranges:

Installation

– 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)

SWIFT® 45 GLP Sensors

Road Simulator

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

interface to data recorder)

• Tie wr aps

• Data recorder

• Power supply–10 to 28 V DC

SWIFT

45 GLP Sensors

Installation

Road Simulator

Attaching SWIFT Components to the Fixturing

Note Install the transducer in so that the orientation labeling is consistent with

the reference orientation. In most cases, this means installing it 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 a new offset value for the AngleOffset in the TI calibration file (see earlier instructions, “Edit the Calibration File,” on page 66).

SWIFT 45 GLP

Fasteners

M20 X 1.5 mm

M12 X 1.75 mm

M12 X 1.75 mm MTS modified lug nuts and shim washers

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

flange. The fastener length should ensure a minimum thread engagement of 30 mm (1.18 in).

† The length of these fasteners is dependant on the thickness of the rim

flange. The fastener length should ensure a minimum thread engagement of 18 mm (0.71 in).

‡ These fasteners secure the spindle adapter spacer to the transducer.

†

‡

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. Clean all surfaces with a mild detergent such as dish soap. It is critical that

all surfaces be free of stones, burrs, and 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.

Installation

2. Ensure the pilot surface of the hub adapter spacer is facing the transducer. Lubricate the threads and under the head of each fastener with Molykote g-n

paste and torque to 32.5 N·m (24 lbf-ft). They will be tightened to final torque later.

SWIFT® 45 GLP Sensors

Road Simulator

3. Tighten the 32 hub adapter bolts. A. Following the sequence shown in the following figure, torque the 32

M12 bolts (1 through 32) to the value for the first increment shown in

the following table. B. Repeat Step 3A for the second increment. C. Repeat Step 3A for the final torque.

4. Tighten the M12 mounting bolts. A. Following the sequence shown in the following figure, torque the eight

M12 bolts (A through H) to the value for the first increment shown in

the following table. B. Repeat Step 4A for the second increment. C. Repeat Step 4A for the final torque.

5. Tighten the M20 mounting bolts to the rim simulator. A. Following the sequence shown in the following figure, torque the eight

M20 bolts (1 through 8) to the value for the first increment shown in

the following table. B. Repeat Step 5A for the second increment. C. Repeat Step 5A for the final torque.

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

sequence shown.

OLT SIZE

TORQUE INCREMENT M12 M20

1st Increment 32.5 N·m (24 lbf·ft) 168.1 N·m (124 lbf·ft) 2nd Increment 65 N·m (48 lbf·ft) 336.2 N·m (248 lbf·ft) Final Torque 97.6 N·m (72 lbf·ft) 501.6 N·m (370 lbf·ft)

6. Bolt the transducer/hub adapter to the road simulator fixture using the modified lug nuts and shim washers provided.

SWIFT

45 GLP Sensors

Installation

Road Simulator

CAUTION

8 M12 rim fasteners A-H

8 M20 rim fasteners 1-8

32 M12 hub fasteners 1-32

Installing the lug bolts directly against the transducer face, without the antigalling compound and the shim washers, can cause galling of the transducer face.

Galling of the transducer face can result in uneven torquing (and possible over-torquing) of the lug bolts.

To prevent galling, always use the shim washers provided. Always lubricate the bolts and shim washers as described below.

Lubricate the lug bolt threads, under the bolt head, and both faces of the shim washers with the Nikal based anti-galling compound.

Tighten the lug nuts in three increments up to the specified torque, in the sequence shown in the next figure to the torque rating recommended for the wheel.

Important Do not exceed maximum specified lug-nut torque.

OLT SIZE

TORQUE INCREMENT M12 M20

1st Increment 32.5 N·m (24 lbf·ft) 168.1 N·m (124 lbf·ft) 2nd Increment 65 N·m (48 lbf·ft) 336.2 N·m (248 lbf·ft) Final Torque 97.6 N·m (72 lbf·ft) 501.6 N·m (370 lbf·ft)

Installation

Bolt Torque Sequence

7. Install the vehicle on the road simulator. Refer to the instructions in your road simulator operation manual.

SWIFT® 45 GLP Sensors

Road Simulator

8. Attach the connector housing (or the slip ring bracket and slip ring) to each transducer.

9. Attach the appropriate cables from the connector housing or one cable from the slip ring to the TI or data acquisition.

A. Secure the cables to the lateral strut of the road simulator 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.

10. Connect the power supply to the TI. You might need to first convert from 120 or 240 V AC to 10–28 V DC.

11. Connect the six data cables from the TI to the data recorder or your test control system.

There is one cable per channel of data from the TI to the data recorder.

SWIFT

45 GLP Sensors

Installation

Road Simulator

Installation

SWIFT® 45 GLP 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 60

Fx Data (Longitudinal Force) 61 Fz Data (Vertical Force) 63 Mx Data (Overturning Moment) 64 My Data (Brake Moment) 67 Acceleration and Braking Events Example 68 Slalom Curve Driving Example 70

SWIFT® 45 GLP 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® 45 GLP 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

45 GLP 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

SWIFT® 45 GLP Sensors

Fz Data (Vertical Force)

The offset force in the Z direction is the combined weight of the car, equipment, and driver at that corner.

5.2 kN = 530 kg (force) = 1169 lb for this vehicle at static loading.

Fz Data (Vertical Force)

SWIFT

45 GLP Sensors

Analyzing SWIFT Data

Mx Data (Overturning Moment)

S50-018

Distance Y

Distance Z

S50-017

Distance Z

Distance Y

Mx Data (Overturning Moment)

The moment Mx is the resultant of the forces Fz and Fy, and their respective distances to the center of the SWIFT sensor.

After zeroing the SWIFT sensor, with the wheel off the ground, there will always be a small moment Mx present. This is due to the offset of the tire assembly center of gravity from the SWIFT sensor centerline.

Analyzing SWIFT Data

SWIFT® 45 GLP Sensors

Mx Data (Overturning Moment)

Channel 4 Mx Data The following figure shows the relationship between Mx, Fz, and Fy, during a

cornering event. Fz decreases as the vertical force is shifted to the opposite wheel. Fy, the lateral force, increases to prevent side slip resulting in an increase in the overturning moment, Mx.

Mx = Fy x Distance Z +

Fz x Distance Y

After zeroing the SWIFT sensor with the wheel off the ground, a moment Mx will still be present, as the following figure shows.

1. Actual polarities depend upon how the polarity for each signal is set in the TI. (See “OutputPolarities” in, “Setting up the Transducer Interface.”)

SWIFT

45 GLP Sensors

Analyzing SWIFT Data

Mx Data (Overturning Moment)

Mx offset with

the wheel off

the ground

Mx offset with

the wheel off

the ground

Mx (wheel off ground) = Fz (active weight of the tire and rim outside the transducer) x Distance (CG to SWIFT sensor centerline)

Analyzing SWIFT Data

SWIFT® 45 GLP Sensors

My Data (Brake Moment)

S50-020

Distance Y

Distance Z

S50-019

Distance Y

The moment My should show strong similarities with the force Fx and is calculated by the SWIFT sensor using the distance Z.

My Data (Brake Moment)

∝ Fx x Distance Z

The relationship between Fx and My is shown in the following time history plot:

SWIFT

45 GLP Sensors

Analyzing SWIFT Data

Acceleration and Braking Events Example

Acceleration and Braking Events

-2000

-1500

-1000

-500

500

1000

1500

2000

0 2 4 6 8 10 12 14

time in seconds

Output - Lbs

-15000

-10000

-5000

5000

10000

15000

Output- In-Lbs

Fx (trac t i ve force) - Lbs Fy ( l ateral force) - Lbs Fz (nor m a l force) - Lbs

My (wheel torque) - In-Lbs Mz (aligni ng torque) -In-Lbs

Acceleration and Braking Events Example

Shown below is actual road data taken with the MTS SWIFT Sensor, located at the front passenger side of a mid-size passenger vehicle. Data shown is postprocessed to translate the forces and moments from the center of the transducer to the center of the tire.

Mx (overturning mom e nt) - I

The outputs from this acceleration and braking event are shown above. It should be noted that output fluctuations are primarily due to actual road surface irregularities.

Time 0 to 3.8 seconds: The car is at rest, with the brakes applied; no motion. The vertical force of the vehicle on this wheel is noted as slightly over 1000 lb.

Time 3.8 to 4.3 seconds: The brake pedal is released with the transmission engaged. Note the forces generated from the slight drive torque of the idle in this automatic transmission vehicle.

Time 4.3 to 6 seconds: Acceleration begins and transient forces and moments are shown.

Fx: Slightly less than 1000 lb of tractive force is reacting at the tire patch. Fy: Minimal Fy force is noted as the steering angle is maintained roughly

straight. Slight variations are noted with steering angle and vehicle suspension toe-in geometry effects.

Fz: The normal force is the result of weight transfer from the front wheel to the rear of the vehicle, and the anti-squat forces present in this front wheel drive vehicle.

Mx: The Mx output noted is corrected to give the overturning moment at the

Analyzing SWIFT Data

center of the tire. Minimal Mx moments are generated during these acceleration and braking events.

My: The acceleration torque of roughly 12000 in directly measured.

·lb acting on the vehicle is

SWIFT® 45 GLP Sensors

Acceleration and Braking Events Example

Mz: The Mz output noted is corrected to give the aligning moment at the center of the tire. Minimal Mz moments are generated during these straight line acceleration and braking events.

Time 6 to 10 seconds: During the relatively steady state acceleration of the vehicle, note the forces recorded.

Fz: Approximately 100 lb of the weight of the vehicle can be seen transferring from each front wheel to the rear of the vehicle during steady state acceleration.

Time 10 to 13 seconds: During the braking, many of the acceleration forces and moments described above are reversed.

SWIFT

45 GLP Sensors

Analyzing SWIFT Data

Slalom Curve Driving Example

Slalom Curve Driving

-2000

-1500

-1000

-500

500

1000

1500

2000

0 2 4 6 8 10 12 14

tim e i n se conds

Output - Lbs

-8000

-6000

-4000

-2000

2000

4000

6000

8000

Output- In-Lbs

Fx (t ractive force) - Lbs Fy ( l ateral force) - Lbs Fz (normal force) - Lbs

My (wh eel torque) - In-L bs Mz (ali gni ng t orque ) -In-Lbs

Slalom Curve Driving Example

Shown below is actual road data taken with the MTS SWIFT Sensor, located at the front passenger side of a mid-size passenger vehicle. Data shown is corrected to translate the forces and moments from the center of the transducer to the center of the tire.

Mx (overturning mom ent ) - In

The outputs from slalom (side to side steering) curve driving can be noted in the graph above:

Time 4 to 12 seconds shows the steering maneuvers. All other times show straight driving on an average road surface.

Fx: The tractive force remains relatively constant since no acceleration nor deceleration is occurring during these driving maneuvers.

Fy: The lateral force can be seen alternating from positive to negative with an amplitude of roughly 500 lb force as the vehicle changes directions with steering maneuvers.

Fz: The side to side weight distribution of the vehicle during these steering maneuvers can be noted in the vertical force outputs. The stationary vertical force of slightly over 1000 lb as noted above is seen to vary by nearly 400 lb.

Mx: The Mx output noted is corrected to give the overturning moment at the center of the tire, primarily caused by the lateral force Fy at the rolling radius of the tire.

My: There is little acceleration or brake torque applied during the steering maneuvers, as noted in the My output.

Mz: The aligning moments generated from the steering maneuvers can be noted to be in the order of 1000 in

·lb for this particular test.

Analyzing SWIFT Data

SWIFT® 45 GLP Sensors

Maintenance

Overview This chapter contains scheduling guidelines and detailed instructions for

performing preventive maintenance. Preventive maintenance is a set of routine procedures that allow you to extend the operating life of your transducer and the transducer interface electronics. You can prevent excessive wear or possible component failure through regular inspections and simple procedures.

The information provided in this chapter is a recommendation only. The actual time intervals will depend on the operating conditions at your facility.

Maintenance Schedule

CTIVITY CUSTOMER PREVENTIVE MAINTENANCE CONTACT MTS

CALENDAR TIME AS REQUIRED 1 DAY 1 WEEK 1 MONTH 1 YEAR SUGGESTED

Clean and Inspect Transducer X Inspect electrical cables X Calibrate the Transducer X

Contents Transducer 72

Cables 73

SWIFT® 45 GLP Sensors

Maintenance

Transducer

CAUTION

The transducer requires a minimum amount of maintenance.

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.

As required 1. Inspect the transducer daily and/or after each testing session for any cracks

that may indicate fatigue, or physical damage that may indicate the transducer has struck a hard surface or object. If the buildup of debris prevents adequate inspection, perform Steps 2 and 3 as necessary, then repeat this step.

Do not use a transducer if you determine that there are indications of fatigue or other damage. Contact MTS.

2. Clean the transducer of debris after each testing session. Carefully remove any debris (such as dust or gravel) that may be on the

transducer. If necessary use low-pressure-air (see the caution above).Do not use a screwdriver or other rigid tool to pry out the debris. Prying may damage the transducer.

3. Hand wash the transducer after each testing session (especially if the transducer was exposed to corrosive and abrasive materials, such as salt or sand) with a gentle detergent, such as dish soap, and a soft sponge or brush with non-metal bristles. Be very careful when cleaning around areas where RTV is used to seal the transducer so as not to break the seal.

Maintenance

4. Inspect the label affixed to the side of the transducer. Replace the label if it becomes loose, has been lost or is unreadable.

SWIFT® 45 GLP Sensors

Cables

Monthly Inspect all electrical cables monthly, or after every 160 hours of operation.

Always turn off the electrical power before you disconnect, repair, or replace a cable.

1. Check the condition of the cables for cuts, exposed wires, or other types of damage, loose connectors, and cracked or worn cable covers. Tighten any loose connectors. Replace any cracked or worn cables.

2. Ensure that cable connectors are securely plugged into their respective receptacles.

3. Ensure that all cables have appropriate strain relief devices installed.

4. Protect cables from being stepped on. In the test lab, elevate and cover all cables to protect them from exposure to spilled hydraulic fluid.

5. Ensure that all cables are supported every 1.2 m (4 ft). Cables should also be supported near a motion joint.

6. Check that path ways of moving cables are clear of obstructions. Prevent cables from moving or rubbing against sharp corners.

SWIFT® 45 GLP Sensors

Maintenance

SWIFT® 45 GLP Sensors

Troubleshooting

CAUTION

This chapter covers basic set-up related troubleshooting tips. Please read this section to investigate problems that you observe. In many cases, these problems will be setup related and can be corrected as described in this section.

Important In the event that these troubleshooting tips indicate that there is a

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 outl ined in this section.

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

component failure, or the correction tips do not correct the problem, contact MTS.

SWIFT® 45 GLP Sensors

Troubleshooting

Troubleshooting Guide (part 1 of 3)

YMPTOM POSSIBLE CAUSES SOLUTION

Spinning Application: Vehicle Coordinate System Outputs have unusual or incorrect waveform shapes to them.

A one-time-per-revolution of tire signal appears while the vehicle is driving straight on a flat surface. Mean level of the FZ output is roughly equal to the weight of the vehicle on that corner.

A two-time-per-revolution of tire signal is showing up when the vehicle is driving straight on a flat surface.

Temperature Effects: The SWIFT transducer is temperature compensated to reduce temperature induced errors, but any significant changes in temperature will induce zero shifts. In the spinning application, these bridge zero shifts will result in a one-time-per rev modulation error. For best results, zeroing should occur at the conditions closest to those of the test conditions.

Incorrect Bridge Zero: An incorrect bridge zero, in the spinning application, will result in a one-time-per-rev modulation error. See “Zero Offset” earlier in this Troubleshooting Guide.

Gain settings: Verify that the TI electronics calibration file gain settings have not been modified. Using the TIXFER utility, upload the current TI settings and compare them to the original gain setting on the disk provided.

Bridge Failure: If a single bridge is failing due to overstress, overload induced crack, and so on, the results could appear as this type of output. To verify that this is the cause, use the TIXFER utility to upload the current TI settings after a zeroing procedure, and record all bridge zeros. Load the transducer for several cycles, without inducing heat (drive vehicle for a few cycles but do not use excessive brake heating). Rezero the TI electronics. Use TIXFER to upload the new zero values. Compare them to the previously recorded zero values. These values should not change by more than 0.01 to 0.03 for two zeroes done at the same conditions, on the same transducer. If the changes are much larger, remove the transducer from vehicle and contact MTS.

Troubleshooting

SWIFT® 45 GLP Sensors

Troubleshooting Guide (part 2 of 3)

YMPTOM POSSIBLE CAUSES SOLUTION

Spinning Application: Vehicle Coordinate System Outputs have unusual or incorrect waveform shapes to them. (Continued)

A one-time-per-revolution of tire signal appears while the vehicle is driving straight on a flat surface. Mean level of the FZ output is roughly equal to the weight of the vehicle on that corner.

A two-time-per-revolution of tire signal is showing up when the vehicle is driving straight on a flat surface.

Incorrect Bridge Zero: An incorrect bridge zero, in the spinning application, will result in a one-time-per-rev modulation error. See “Zero Offset” earlier in this Troubleshooting Guide.

SWIFT® 45 GLP Sensors

Troubleshooting

Troubleshooting Guide (part 3 of 3)

YMPTOM POSSIBLE CAUSES SOLUTION

Spinning Application: Vehicle Coordinate System Outputs have unusual or incorrect waveform shapes to them. (Continued)

Angular Output

A four-time-per-revolution of tire signal is showing up when the vehicle is driving straight on a flat surface.

There is no angular output while the transducer and slip ring are spinning.

Wheel force transducers often have a modulation error with a cyclic frequency equal to the number of beams on the transducer. The SWIFT transducer has four beams, and will inherently have some level of four times per revolution modulation. This level will vary from ±0.5% to as high as ±5% of the equivalent radial load.

For example, a 4000 N mean level vertical Fz load (and negligible Fx loading) will result in a ±20 N to ±200 N error on the vertical Fz and Fx channels.

The magnitude of this modulation error is based on the geometries and stiffnesses of the components in the assembly.

A SWIFT 45 on a steel rim will have lower modulation than a SWIFT 45 on a very lightweight stainless steel rim. The trade-offs between lower added mass, load capacity requirements, and desired modulation should all be considered in choosing components for the wheel force transducer assembly.

Check that all power and signal cables are connected, and that the antirotate device is securely attached. The angular output should be 0 to 5 V sawtooth output per revolution of the tire.

Check that the encoder output is present. The angle output signal from the TI should be a 0 to 5 volt sawtooth output while the transducer is spinning at a constant velocity.

If this signal is not present, check that the slip ring/encoder assembly has not been damaged. If you suspect encoder damage, swap the slip ring assembly with a known functioning unit to verify it. If the slip ring/encoder assembly is damaged, call MTS or replace it with a spare slip ring assembly.

Troubleshooting

SWIFT® 45 GLP Sensors

Assembly Drawings

This chapter contains the assembly drawings and parts lists relevant to the SWIFT 45 GLP transducers.

Contents Cable Drawings 80

SWIFT 45 GLP Mechanical Drawings 85

SWIFT® 45 GLP Sensors

Assembly Drawings

Cable Drawings

ART NUMBER CABLE DESCRIPTION

Cable Drawings

572029-XX 572129-XX 572143-XX 100-179-353

Cable Assy - SWIFT Mini Transducer Interface Cable Assy - SWIFT Mini TI, Power w/PT Cable Assy - SWIFT Mini TI Power w/lug Cable Assy - SWIFT mini TI, Monitor

Assembly Drawings

SWIFT® 45 GLP Sensors

SWIFT 45 GLP Mechanical Drawings

SWIFT 50 GLPS Mechanical Drawings

ART NUMBER PART DESCRIPTION

700-004-835 700-002-218 700-002-219 700-004-834 100-213-964 700-004-846 700-004-754 700-004-853 700-004-837 100-204-920 100-204-921 545211-XX

REFERENCE DIMENSION ASSY-SWIFT 45 DISK RIM (FRT) CUSTOMER DIMENSIONAL DWG. DISK RIM (REAR) CUSTOMER DIMENSIONAL DWG BOLT TORQUE SEQUENCE-REFERENCE, SWIFT 45 ANTI-ROTATE ASSY-CUSTOMER/USER, SWIFT 45 ANTI-ROTATE BRACKET-REFERENCE, SWIFT 45 LEVEL ASSY-REFERENCE,SWIFT 45 TRANSDUCER EXTENSION ASSY-REFERENCE, SWIFT 45 ADAPTER-REFERENCE, HUB, INNER, SWIFT 45 PLATE-WASHER, OUTER HUB, SWIFT 45 PLATE-WASHER, INNER HUB, SWIFT 45 SCREW-MODIFIED, (SOCKET HEAD)-SW

SWIFT

45 GLP Sensors

Assembly Drawings

EAM 1

B LOCATION

USE SERIAL NUMBER

S REFERENCE TO

A LOCATE BEAM 1

REVISIONS

DESCRIPTION

ECN NO

DATE

LETTER

DRAWN

WITH DIGITAL LEVEL CENTERED

N SLIP RING LEVEL PLATE, THE

O LEVEL SHOULD READ 0 BEAM 1 IS LOCATED AT VERTICAL ZERO

LEVEL BRACKET (P/N 100-211-570)

WHEN

MATERIAL DESCRIPTION

-----

MATERIAL SIZE

-----

FINISH

-----

THREAD DEPTHS ARE TO MIN FULL TH DS DRILL DEPTHS ARE TO FULL DIA REMOVE BURRS AND SHARP EDGES

DO NOT SCALE PRINT

MTS SYSTEMS CORPORATION

UNLESS OTHERWISE SPECIFIED

DEN PRAIRIE, MINNESOTA U.S.A.

MASK

SCALE

1/2

MACHINED SURFACES

180

.XXX HOLE SIZE TOLERANCE

0.000

TO .750

+.010/-.002

GENERAL

TOLERANCES

THIRD ANGLE PROJ

.XX

.XXX

OVER .750

TO 1.500

+.015/-.003

TITLE

2ANGLE

1/4

LEVEL ASSEMBLY-REFERENCE,

.03

NEXT LEVEL

.010

PRODUCT CODE

SOURCE/REF DR

HE INFORMATION AND DESIGN(S)

T DISCLOSED HEREIN ARE CONFIDENTIAL AND THE PROPERTY OF MTS SYSTEMS CORPORATION AND MAY NOT BE USED, REPRODUCED OR DISCLOSED IN ANY FORM EXCEPT AS GRANTED IN WRITING BY MTS SYSTEMS CORPORATION. THIS RESTRICTION EXCLUDES INFORMATION THAT IS IN THE PUBLIC DOMAIN OR WAS LEGITIMATELY IN THE PRIOR POSSESSION OF THE RECIPIENT.

DRAWN

3-26-09 -

AWING

PROPRIETARY DATA

ENGR

HECK

DJO

DATE

DATEDATE

3-09 -

SWIFT 45 TRANSDUCER

NUMBER

SIZE

700-004-754

SHEET OF

MFG

DATE

REV

STANDOFF W/EXTERNAL

INTERNAL M12 X 1.75MM

THREADED ENDS (4)

SWIFT 45 TRANSDUCER

DRAWN

REVISIONS

DESCRIPTION

DATE

ECN NO

LETTER

TOP ADAPTER PLATE

12 X 1.75MM SOCKET HEAD

M SCREW W/FLAT WASHER (8)

CONNECTOR EXTENSION LEG (4)

5 X .8MM SOCKET HEAD CAPSCREWS (8)

SSEMBLY NOTES:

ATTACH STANDOFFS TO SWIFT 45 TRANSDUCER. APPLY MOLYKOTE GN PASTE TO

M12 X 1.75MM THREADED STUD AND USING A 27MM SOCKET, TORQUE STANDOFF TO 69 FT-LB (93 N-M).

ATTACH CONNECTOR EXTENSION LEGS TO TOP PLATE. ALIGN EACH LEG, SO THAT

THE KEYWAYS ARE ORIENTED AS SHOWN ON SHEET 2.

APPLY MOLYKOTE GN PASTE AND TORQUE M5 X .8MM SOCKET HEAD CAPSCREWS

TO 58 IN-LB (6.5 N-M).

ATTACH TOP PLATE TO STANDOFFS, WHILE ALSO PROPERLY ENGAGING CONNECTORS

TO THEIR RESPECTIVE MATING CONNECTOR ON SWIFT TRANSDUCER.

APPLY MOLYKOTE GN PASTE AND TORQUE M12 X 1.75MM SOCKET HEAD CAPSCREWS

TO 69 FT-LB (93 N-M).

ATTACH SLIP RING ASSEMBLY TO EXTENSION ASSY, USING M5 X .8MM SOCKET HEAD

CAPSCREWS, AT THE LOCATIONS SHOWN ON SHEET 2.

AWING

PROPRIETARY DATA

ENGR

HECK

BAO

RLJ

SIZE

DATE

DATEDATE

6-09 -

NUMBER

700-004-853

SHEET OF

MFG

DATE

REV

MATERIAL DESCRIPTION

-----

MATERIAL SIZE

-----

FINISH

-----

THREAD DEPTHS ARE TO MIN FULL TH DS DRILL DEPTHS ARE TO FULL DIA REMOVE BURRS AND SHARP EDGES

DO NOT SCALE PRINT

MTS SYSTEMS CORPORATION

UNLESS OTHERWISE SPECIFIED

DEN PRAIRIE, MINNESOTA U.S.A.

MASK

SCALE

NONE

MACHINED SURFACES

180

.XXX HOLE SIZE TOLERANCE

0.000

TO .750

+.010/-.002

GENERAL

TOLERANCES

THIRD ANGLE PROJ

.XX

.XXX

OVER .750

TO 1.500

+.015/-.003

TITLE

2ANGLE

1/4

.03

NEXT LEVEL

.010

PRODUCT CODE

SOURCE/REF DR

HE INFORMATION AND DESIGN(S)

DRAWN

6-1-09 -

EXT ASSY-REFERENCE,

UST/USER, SWIFT 45

WIDE KEYWAY

M5 X .8MM HOLE (8),

OR ATTACHMENT OF

F SLIP RING ASSEMBLY

REVISIONS

DESCRIPTION

ECN NO

DRAWN

DATE

LETTER

WIDE KEYWAY

MATERIAL DESCRIPTION

-----

MATERIAL SIZE

---

FINISH

-----

THREAD DEPTHS ARE TO MIN FULL TH DS DRILL DEPTHS ARE TO FULL DIA REMOVE BURRS AND SHARP EDGES

DO NOT SCALE PRINT

MTS SYSTEMS CORPORATION

DEN PRAIRIE, MINNESOTA U.S.A.

UNLESS OTHERWISE SPECIFIED

MASK

SCALE

NONE

MACHINED SURFACES

180

THIRD ANGLE

PROJ

.XXX HOLE SIZE TOLERANCE

0.000

TO .750

+.010/-.002

GENERAL

TOLERANCES

.XX

.XXX

OVER .750

TO 1.500

+.015/-.003

TITLE

2ANGLE

1/4

.03

NEXT LEVEL

.010

PRODUCT CODE

SOURCE/REF DR

HE INFORMATION AND DESIGN(S)

DRAWN

6-1-09 -

EXT ASSY-REFERENCE,

CUST/USER, SWIFT 45

AWING

PROPRIETARY DATA

ENGR

HECK

RLJ

SIZE

DATE

DATEDATE

6-09 -

NUMBER

700-004-853

SHEET OF

MFG

DATE

REV

MTS SWIFT 45 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Technical Support

How to Get Technical Support

Before You Contact MTS

If You Contact MTS by Phone

Problem Submittal Form in MTS Manuals

Preface

Before You Begin

Conventions

Documentation Conventions

Hardware Overview

Overview

Spinning Applications (Track or Road)

Non-Spinning Applications (Laboratory)

Construction

Design Features

Coordinate System

Specifications

Calibration

Installation

Hazard Icons

Road and Track Vehicles

Attaching SWIFT Components to the Vehicle

Attaching SWIFT and Wheel Assembly to the Vehicle

Collecting Data

Road Simulator

Attaching SWIFT Components to the Fixturing

Analyzing SWIFT Data

The Data

Fx Data (Longitudinal Force)

Fz Data (Vertical Force)

Mx Data (Overturning Moment)

My Data (Brake Moment)

Acceleration and Braking Events Example

Slalom Curve Driving Example

Maintenance

Transducer

Cables

Troubleshooting

Assembly Drawings

Cable Drawings

SWIFT 45 GLP Mechanical Drawings