SWIFT® 50 GLP Sensor Installation Instructions

SWIFT® 50 GLP Sensor
Installation Instructions
Spinning Wheel Integrated Force Transducer
For Medium and Heavy Trucks
100-176-179 A
m
Copyright information
Trademark information
© 2007 MTS Systems Corporation. All rights reserved.
MTS, SWIFT, TestStar, and TestWare are registered trademarks of MTS Systems Corporation.
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Computer, Inc. UNIX is a registered trademark of The Open Group.
LabVIEW is a registered trademark of National Instruments Corporation.
Proprietary information
Contact information
Publication information
This manual, and the software it describes, are both copyrighted, with all rights reserved. Under the
copyright laws, neither this manual nor the software may be copied, in whole or part, without
written consent of MTS Systems Corporation, except in the normal use of the software or to make
a backup copy of the software. The same proprietary and copyright notices must be affixed to any
permitted copies as are made for others, whether or not sold, but all of the material purchased (with
all backup copies) may be sold, given, or loaned to another person. Under the law, copying includes
translating into another language or format. This software may be used on any computer, but extra
copies cannot be made for that purpose.
MTS Systems Corporation
14000 Technology Drive
Eden Prairie, Minnesota 55344-2290 USA
Toll Free Phone: 800-328-2255 (within the U.S. or Canada)
Phone: 952-937-4000 (outside the U.S. or Canada)
Fax: 952-937-4515
E-mail: info@mts.com
http://www.mts.com
Manual Part Number
Publication Date
Original English 100-176-179 A
January 2007
Content
Preface 5
About This Manual
6
Conventions
7
Contacting MTS
8
What to Expect When You Call
Customer Feedback
9
11
Hardware Overview 13
Overview
14
Spinning Applications (Track or Road)
16
Non-spinning Applications (Laboratory)
Construction
17
18
Coordinate System
Specifications
21
23
Installing the Transducer 27
Hazard Icons
28
Road and Track Vehicles
29
Attaching SWIFT Components to the Vehicle
33
Attaching SWIFT and Wheel Assembly to the Vehicle
Installing the Transducer Interface Electronics
Setting up the SWIFT Sensor for Data Collection
Verifying the Quality of the Zero Procedure
Collecting Data
Road Simulator
36
43
45
55
57
59
Attaching SWIFT Components to the Fixturing
Zeroing the Transducer Interface
Communication Configurations
Cable Configurations
65
66
67
SWIFT TI to PC Host (9-pin)
SWIFT TI to PC Host (25-pin)
SWIFT TI to SWIFT TI
Termination Jumper
SWIFT 50 GLP Sensors
61
67
67
67
68
3
4
SWIFT 50 GLP Sensors
Preface
Safety first!
Before you attempt to use your transducer, read and understand all safety
information. Safety information specific to the SWIFT sensor can be found
throughout the manual. General safety information for MTS products and test
systems can be found in the yellow Safety manual (MTS part number 100-003805).
Improper installation, operation, or maintenance of the wheel force transducer
can result in hazardous conditions that can cause personal injury or death, and
damage to your equipment. It is very important that you remain aware of hazards
that apply to your system.
Contents
About This Manual
6
Conventions
7
Contacting MTS
8
What to Expect When You Call
Customer Feedback
SWIFT 50 GLP Sensors Installation
9
11
Preface
5
About This Manual
About This Manual
This Product manual is part of a set of documentation that you will use to learn
about, operate, and maintain the SWIFT sensor. If you are using the SWIFT
sensor with a road simulator, refer to the Operation manual for your road
simulator system for all information relevant to the operation of that test system.
Summary
These chapters are included in this manual:
“Hardware Overview”, introduces you to the mechanical and electrical
components of the SWIFT sensor, lists pertinent specifications, and briefly
describes their functions. It also describes the control concepts used by the
transducer.
“Installing the Transducer”, contains installation procedures for road data
acquisition and laboratory testing using a road simulator.
6
Preface
SWIFT 50 GLP Sensors Installation
About This Manual
Conventions
The following paragraphs describe some of the conventions that are used in your
MTS manuals.
Hazard conventions
Hazard notices are embedded in this manual and 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.
DANGER
DANGER indicates the presence of a hazard with a high risk which, if not avoided, will
result in death or serious injury, or substantial property damage.
WARNING
WARNING indicates the presence of a hazard with a medium level of risk which, if not
avoided, could result in death, serious injury, or substantial property damage.
CAUTION
CAUTION indicates the presence of a hazard with a low level of risk which if not
avoided could result in minor or moderate injury, or cause minor equipment damage, or
endanger test integrity.
Other conventions
Notes
Other conventions used in your manuals are described below:
Notes provide additional information about operating your system or highlight
easily overlooked items. For example:
Note
Important notes
Using multiple instances of the scope (on multiple stations) can slow
system response time.
Important notes provide information critical to operating your system, but not so
critical that it involves injury or equipment. Important notes should be read. For
example:
Important
Control names
Cross references in
online media
Text you have to type
Illustrations
In the Level Units list, selecting the scientific notation display
feature may result in the loss of original level values. If your
selection moves the original level value beyond four digits,
the original value will be lost.
References to items shown in windows, including window names, window
controls, menu names, and menu commands are shown in bold font style.
References to controls on equipment, including keyboards, control panels, and
consoles are also shown in bold font style.
Cross references in online media are blue in color and utilize hypertext links. To
move to the reference source, position the cursor over the cross reference and
click. In addition, you may use other online navigational aids to go back or
forward within the document.
Characters needing to be typed are shown in bold, sans serif style.
Illustrations appear in this manual to clarify text. It is important for you to
remember that these illustrations are examples only and do not necessarily
represent your actual system configuration or application.
SWIFT 50 GLP Sensors Installation
Preface
7
Contacting MTS
Contacting MTS
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.
Note
Address
If you need technical support, review the following pages for information
about what to expect when you contact us.
MTS Systems Corporation
14000 Technology Drive
Eden Prairie, Minnesota USA 55344-2290
Telephone
In the United States and
Canada
General information:
952-937-4000
Weekdays 7:30 A.M. to 5:00 P.M.,
Central Time
Technical support or spare parts:
HELPLine 800-328-2255
Weekdays 7:00 A.M. to 6:00 P.M.,
Central Time
Outside the U.S. or
Canada
Fax
Contact your local service center.
800-925-5205 (within the U.S. or Canada)
952-937-4515 (outside the U.S. or Canada)
Please include an MTS contact name if possible.
Internet
8
Preface
E-mail: info@mts.com
Internet home page: http://www.mts.com
SWIFT 50 GLP Sensors Installation
Contacting MTS
What to Expect When You Call
Before you call
Know your site number
and system number
MTS can help you more efficiently if you have pertinent information about your
test system available when you call.
You will be asked for your site number and system number.
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 an MTS site number or do not know your site number, you should contact
your MTS sales engineer.
Example site number:
C84166-W01
When you have more than one MTS system, the system (or 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 (job) number:
Know information from
prior technical
assistance
Identify the problem
Know relevant
computer information
US1.12345
If you have called regarding this problem before, we can recall your file. You will
need to tell us the:
•
MTS work order number
•
Name of the person who helped you
Describe the problem you are experiencing and know the answers to the
following questions:
•
How long 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 and serial numbers of the suspect equipment?
If you are experiencing a computer problem, have the following information
available:
•
Manufacturer’s name and model number
•
Amount of system memory
•
Network information (type and version level)
SWIFT 50 GLP Sensors Installation
Preface
9
Contacting MTS
Know relevant
software information
Be prepared to
troubleshoot
While on the phone
Write down relevant
information
After you call
10
Preface
If you are experiencing a software problem, have the following information
available:
•
Operating software information (type and version level)
•
MTS application software information (name and version level)
•
Names of other software that are running on your computer, such as screen
savers, keyboard enhancers, print drivers, and so forth
Prepare yourself for troubleshooting while on the phone:
•
Call from a telephone close to the system so that you can try implementing
suggestions made over the phone.
•
Have the original operating and application software disks available.
•
If you are not familiar with all aspects of the equipment operation, have an
experienced user nearby to assist you.
Your call will be registered by a HELPLine agent if you are calling within the
United States or Canada. In addition to asking for your site number, the agent
may also ask to verify your name, company, company address, and the phone
number where you can normally be reached.
Prepare yourself in case we need to call you back:
•
Remember to ask for the work order 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.
MTS logs and tracks all calls to ensure that you receive assistance and that action
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.
SWIFT 50 GLP Sensors Installation
Contacting MTS
Customer Feedback
We want to hear from you! MTS is continually striving to improve our products,
including the system manuals. Please take the time to mail, fax, or e-mail your
feedback to MTS.
The Customer Quality
Request
MTS manuals include a Customer Quality Request (CQR) form located in the
back of the manual.
Use this form to forward complaints or suggestions for improving manuals,
products, or service. This form includes check boxes that allow you to select
when you expect us to respond to your input. We guarantee a timely response—
your feedback is important to us.
SWIFT 50 GLP Sensors Installation
Preface
11
Contacting MTS
12
Preface
SWIFT 50 GLP Sensors Installation
Hardware Overview
Contents
Overview
14
Spinning Applications (Track or Road)
Non-spinning Applications (Laboratory)
Construction
SWIFT 50 GLP Sensors Installation
17
18
Coordinate System
Specifications
16
21
23
Hardware Overview
13
Overview
Overview
The MTS Spinning Wheel Integrated Force Transducer (SWIFT®) sensor is a
light-weight, easy-to-use transducer that enables you to conduct faster, less
expensive data acquisition and road simulation testing.
The transducer is designed for use on the test track and public roads, as well as,
in the test laboratory. It attaches to the test vehicle or an MTS Series 329 Road
Simulator using an adapter and a modified wheel rim.
You can achieve excellent data correlation using the same transducer and vehicle
on the test track or public road and on a road simulator. It is available in various
sizes and materials to fit various vehicle and loading requirements.
Data
Track or Road
WARNING
Laboratory Simulation
S50-001
Driving a vehicle with SWIFT sensors mounted on it will change the
handling characteristics of the vehicle.
Driving a vehicle configured in this way on public roads can pose
unexpected dangers to pedestrians and other vehicle traffic.
Only authorized, licensed drivers, who are experienced driving a vehicle with
SWIFT sensors mounted on it, should be allowed to operate the vehicle on public
roads. Drive the vehicle with the SWIFT sensor attached on closed courses only
until you have proper experience.
14
Hardware Overview
SWIFT 50 GLP Sensors Installation
Overview
Parts Replacement,
Disassembly, and Care
CAUTION
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” in the SWIFT 50 GLP
Sensor Product Information manual (MTS part number 100-162-722).
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” in
the SWIFT 50 GLP Sensor Product Information manual (MTS part number
100-162-722).
Disassembling or tampering with these components may result in damage to the
sensor, loss of watertight seal, and voiding of the warranty.
The SWIFT sensor
assembly should not:
•
The sensor assembly should be returned to MTS annually for recalibration
and inspection.
•
Clean the sensor assembly after each use, as described in Maintenance in the
SWIFT 50 GLP Sensor Product Information manual (MTS part number
100-162-722), 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.
•
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 23.
•
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 50 GLP Sensors Installation
Hardware Overview
15
Spinning Applications (Track or Road)
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..
Customer Supplied
Data Recorder
Output
Signals
Transducer Interface
(TI)
Transducer Signals
Customer Supplied
Power Supply
S50-002
Spinning Application (Track or Road)
16
Hardware Overview
SWIFT 50 GLP Sensors Installation
Non-spinning Applications (Laboratory)
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. For durability testing, a
stainless steel SWIFT sensor can be used for iterations within the RPC process.
The stainless steel 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.
Customer-Supplied
Test Control System
Output
Signals
Transducer Interface
(TI)
Transducer Signals
Power Supply (with 4
connections)
PC Communication
S50-003
Non-spinning Application (Laboratory Simulation)
SWIFT 50 GLP Sensors Installation
Hardware Overview
17
Construction
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.
Modified
Wheel Rim
(front wheel)
Spindle Adapter
Spacer
Slip Ring
Bracket
(with encoder)
Rim-to-Transducer
Assembly Fasteners
Transducer
Lug Nuts and
Shim Washers (10)
Transducer
Spacer-to-Transducer
Fasteners
S50-008
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 is available in two materials: titanium, for spinning applications,
where the priority is light weight, and stainless steel, for non-spinning
applications, where the priority is maximum load capacity and 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.
18
Hardware Overview
SWIFT 50 GLP Sensors Installation
Construction
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.
Anti-Rotate
Mounting Bracket
(customer supplied)
Anti-Rotate
Mounting Bracket
(customer supplied)
Anti-Rotate
Assembly
Tire
Tire
Spindle
Adapter
Spacer
Transducer
Interface
Cable
Slip Ring
Slip-Ring
Bracket
Slip-Ring
Extension
Bracket
SWIFT 50
Transducer
Dual Rim Configuration
Anti-Rotate
Assembly
Tire
Spindle
Adapter
Spacer
Transducer
Interface
Cable
Slip Ring
Slip Ring
Bracket
SWIFT 50
Transducer
Front Rim Configuration
S50-004a
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
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 50 GLP Sensors Installation
Hardware Overview
19
Construction
The anti-rotate device should be configured such that no loading occurs to the
slip ring throughout all loading and suspension travel. This means that when you
attach the anti-rotate device to the vehicle, you must consider all possible motion
of the suspension. The anti-rotate device should not bump against the wheel well
at any time; any jarring of the anti-rotate arm will damage the slip ring. For
steering axles, the anti-rotate bracket must be mounted to part of the unsprung
suspension that steers with the tire, such as the brake caliper. For additional antirotate device mounting recommendations, refer to the Anti-Rotate Customer/
User Assembly drawing at the back of the SWIFT 50 GLP Sensor Product
Information manual (MTS part number 100-162-722).
20
Transducer Interface
(TI)
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
Additional components that are supplied with your SWIFT sensor include shunt
and 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 50 GLP Sensors Installation
Coordinate System
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).
Output signals
±10 Volts
Fx
Bridge
Outputs
Fy
Transducer
Interface
Fz
Mx
My
Mz
Angular
Position
S50-010
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.
+Fz
+Mz
+Mx
+Fx
+My
Rim Flange
Mounting Side
+Fy
Hub Adapter
Mounting Side
Forces Acting on Rim-side of Transducer
SWIFT 50 GLP Sensors Installation
S50-009
Hardware Overview
21
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 “Setting up the Transducer Interface” in the SWIFT 50
GLP Sensor Product Information manual (MTS part number 100-162-722).
22
Hardware Overview
SWIFT 50 GLP Sensors Installation
Specifications
Specifications
SWIFT 50 GLP Transducer Performance (part 1 of 2)
Parameter
Specification
SWIFT 50 GLP S (stainless steel) for
high fatigue life, durability
SWIFT 50 GLP T (titanium) for
low weight, high sensitivity
Use
Maximum usable rpm
2,200
Maximum speed
200 kph (125 mph)
Fits rim size (usable range)
Maximum hub bolt circle diameter
accommodates M22 studs
Input voltage required
Input power required per transducer
22.5–24.5 inch*
335 mm (13.189 in)
10–17 V DC or 18–34 V DC†
30 W maximum (22 W typical)
Output voltage ± full scale calibrated load
SAE J267
±10 V ‡
Stainless Steel
capacity§
Titanium
64.50 kN (14,500 lbf)
44.48 kN (10,000 lbf)
55.8 kN•m (494,075 lbf•in)
38.5 kN•m (340,740 lbf•in)
Longitudinal force (Fx)
±220 kN (±49,458 lbf)
±150 kN (±33,721 lbf)
Lateral force range (Fy)
±100 kN (±22,481 lbf)
±60 kN (±13,489 lbf)
Rated load
Bending
moment#
Full scale calibrated ranges**
Vertical force range (Fz)
±220 kN (±49,458 lbf)
±150 kN (±33,721 lbf)
Overturning moment (Mx)
±50 kN•m (±442,537 lbf•in)
±37 kN•m (±327,478 lbf•in)
Driving/braking moment (My)
±50 kN•m (±442,537 lbf•in)
±40 kN•m (±354,030 lbf•in)
Steering moment (Mz)
±50 kN•m (±442,537 lbf•in)
±37 kN•m (±327,478 lbf•in)
Resolution (analog system)
Noise level (peak-to-peak 0-500 Hz)
Infinite
40 N (9.0 lbf)
30 N (6.7 lbf)
Performance accuracy
Nonlinearity
1.0% full scale
Hysteresis
0.75% full scale
Modulation††
≤5.0% reading
Cross talk‡‡
1.5% full scale
SWIFT 50 GLP Sensors Installation
Hardware Overview
23
Specifications
SWIFT 50 GLP Transducer Performance (part 2 of 2)
Parameter
Specification
Maximum operating temperature
*
†
‡
§
#
**
††
‡‡
24
Low level amplifiers
70°C (158°F)
Transducer interface
50°C (122°F)
Contact MTS for other rim sizes.Larger diameter rims can be used, provided that overall clearance from
brake calipers and suspension components is maintained.
Specified at time of purchase.
Load impedance >1 kΩ; 0.01 µF (maximum) load capacitance.
Half axle rated capacity per SAE 267.
Seen on the transducer for 100,000 cycles.
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. Stainless steel 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
Hardware Overview
SWIFT 50 GLP Sensors Installation
Specifications
Transducer Interface
Parameter
Specification
Physical
Height
31.75 mm (1.25 in)
Width
431.8 mm (17 in)
Depth
215.9 mm (8.5 in.)*
Weight
1.68 kg (3 lb 11.1 oz)
Rack Mounting Kit
Optional
Environmental
Ambient temperature
0° C (32° F) to 50° C (122° F)
Relative humidity
0 to 85%, non-condensing
Power Requirements
Input voltage
10–17 V DC or 18–34 V DC†
Supply current
2 A typical, 3 A maximum at 12 V DC
Fuse
3 A fast-blow
Angular velocity
Encoder limit
2,200 rpm maximum
Processing limit
10,000 rpm maximum
Encoder resolution
2048 counts per revolution
(512 pulses with quadrature)
Time delay (encoder tick to main output stable)
12 µs (typical)
Transducer cable length
100 ft maximum
Shunt cable length
100 ft maximum
Analog outputs
Voltage
±10 V range‡ (force and moment outputs)
0–5 V sawtooth (angle output)
Capacitive load
0.01 µF maximum
Current
6 mA maximum
Noise at output, with typical gains
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.
† Specified at time of purchase.
‡ Standard from MTS. Other full scale voltages can be evaluated and may be provided at special
request.
SWIFT 50 GLP Sensors Installation
Hardware Overview
25
Specifications
Transducer Interface Communications
Parameter
Specification
Communications Channel # 1
(Remote Host Connections)
Baud rates
19,200 Kbits/s
Parity
None
Stop bits
1
Data bits
8
Isolated RS-232/RS-485 interface power
supply
+5 V DC @ 200 mA maximum
Electrical interface
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
32 with RS-232 remote host*
31 with RS-485 remote host
Maximum cable length
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 RS485 multidrop chain
For RS-485 host:
*
26
300 ft from host to the last (furthest) TI in the RS-485
multidrop chain
Includes all compatible devices, such as an MTS 407 Controller. A maximum of only nine transducer
interfaces can be connected, because the addresses are limited to 1–9.
Hardware Overview
SWIFT 50 GLP Sensors Installation
Installing the Transducer
The SWIFT sensor can be installed on a vehicle at the test track or on an MTS
Series 329 Road Simulator in the test laboratory.
Contents
Hazard Icons
28
Road and Track Vehicles
29
Attaching SWIFT Components to the Vehicle
33
Installing the Transducer Interface Electronics
43
Setting up the SWIFT Sensor for Data Collection
Verifying the Quality of the Zero Procedure
Collecting Data
Road Simulator
55
57
59
Attaching SWIFT Components to the Fixturing
Zeroing the Transducer Interface
Communication Configurations
Cable Configurations
SWIFT 50 GLP Sensors Installation
45
61
65
66
67
Installing the Transducer
27
Hazard Icons
Hazard Icons
The following hazard icon is part of the label affixed to the side of the SWIFT 50
GLP Sensor.
Read, understand, and
follow the instructions
in the manual
S50-48
28
Installing the Transducer
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
Road and Track Vehicles
Equipment required
This procedure requires two people. To install the SWIFT 50 GLPS or SWIFT 50
GLPT sensor, you will need the following equipment:
•
Spindle adapter spacers (see next figure)
•
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 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)
For dual rims
16 size M16 X 1.5 mm
8 size M10 X 1.5 mm
4 size M5 X 0.5 mm
lug nuts and shim washers
For front rims
16 size M16 X 1.5 mm
8 size M10 X 1.5 mm
4 size M5 X 0.5 mm
lug nuts and shim washers
•
For dual rims
Slip ring extension assembly
Four size M12 X 1.75 mm X 30 mm long bolts
•
Slip ring assembly fasteners
Four size M8 X 1.25 mm X 20 mm long bolts
•
Torque wrenches, capable of the following ranges:
2.3–23 N•m (20–200 lbf•in)
24–74 N•m (18–55 lbf•ft),
203–815 N•m (150-600 lbf•ft);
108–325 N•m (80–240 lbf •ft)
93 N•m (69 lbf•ft)
•
Cables (transducer and BNC, plus customer-supplied from transducer
interface to data recorder)
•
Tie wraps
•
Data recorder
•
Power supply–12 V DC or optionally 24 V DC1 (for example, a truck
battery)
1 If 24 Vdc compatible electronics was ordered at time of purchase.
SWIFT 50 GLP Sensors Installation
Installing the Transducer
29
Road and Track Vehicles
Modified
Wheel Rim
(front wheel)
Spindle Adapter
Spacer
Slip Ring
Bracket
(with encoder)
Rim-to-Transducer
Assembly Fasteners
Spacer-to-Transducer
Fasteners
Transducer
Lug Nuts and
Shim Washers (10)
S50-008
Installation Components (Test Track–Front)
Rim-to-Transducer
Assembly Fasteners
Modified
Wheel Rim
(dual wheel)
Slip Ring
Bracket
(with encoder)
Slip Ring
Extension
Bracket
Spindle
Adapter
Spacer
Transducer
Lug Nuts and
Shim Washers (10)
Spacer-to-Transducer
Fasteners
S50-013
Installation Components (Test Track–Duals)
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
30
Installing the Transducer
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.
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
Before you begin
CAUTION
Observe the following safety conditions while you are attaching the SWIFT
sensor and components to the vehicle.
Do not pressure-wash the transducer or clean it with solvents.
Pressure-washing the transducer or cleaning it with solvents can damage it
or degrade the silastic seal and may void the warranty.
Using strong cleaners or solvents can damage the RTV seal and may void
the warranty.
Use only a soft sponge or brush with non-metal bristles and a gentle detergent
(such as dish soap) to wash the transducer.
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.
CAUTION
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.
WARNING
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.
CAUTION
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.
SWIFT 50 GLP Sensors Installation
Installing the Transducer
31
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.
32
Installing the Transducer
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
Attaching SWIFT Components to the Vehicle
SWIFT 50 GLP Fasteners
Front Rim
Dual Rims
M16 X 1.5 mm*
M16 X 1.5 mm*
M10 X 1.5 mm†
M10 X 1.5 mm†
M5 X 0.8 mm‡
M5 X 0.8 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 must ensure a minimum thread
engagement of 37 mm (1.46 in) but must not exceed 43 mm (1.69 in).
† The length of these fasteners is dependant on the thickness of the rim
flange. The fastener length must ensure a minimum thread
engagement of 28 mm (1.10 in) but must not exceed 34 mm (1.33 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 function of the customer wheel
geometry.
§ The standard lug nuts provided have a thread size of M22 X 1.50 mm.
Other thread sizes can be ordered at customer request.
Material required:
Procedure
•
Molykote g-n paste (MTS part number 011-010-217).
•
Nikal based anti-galling compound (MTS part number 011-354-902)
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. Attach the spindle adapter spacer to the rim side of the transducer (see the
next figure) using the four M5 fasteners provided (see the previous table).
Ensure the pilot surface of the spindle adapter spacer is facing the
transducer.
Lubricate the threads and under the head of each fastener with Molykote g-n
paste and torque to 6.5 N•m (4.8 lbf-ft).
SWIFT 50 GLP Sensors Installation
Installing the Transducer
33
Road and Track Vehicles
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.
Connector Side
Modified
Lug Nuts
Transducer
Hub Side
Spindle
Adapter
Spacer
1 through 10 = M22
(modified lug nuts)
Front Rim
Modified
Lug Nuts
Transducer
Hub Side
M5 Threaded
Holes (4)
Spindle
Adapter
Spacer
A through H = M10 bolts
1 through 16 = M16 bolts
Rim and Hub Mount Side
S50-006
Dual Rim
Bolt Torque Sequence
34
Installing the Transducer
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
6. Tighten the M10 mounting bolts.
A.
Following the sequence shown in the previous figure, torque the eight
M10 bolts (A through H) to the value for the first increment shown in
the following table.
B.
Repeat Step 6A for the second increment.
C.
Repeat Step 6A for the final torque.
7. Tighten the M16 mounting bolts.
A.
Following the sequence shown in the previous figure, torque the
sixteen M16 bolts (1 through 16) 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.
Note
To minimize negative clamping effects, you must torque the bolts in the
sequence shown.
Bolt Size
SWIFT 50 GLP Sensors Installation
Torque Increment
M10
M16
1st Increment
24 N•m (18 lbf•ft)
108 N•m (80 lbf•ft)
2nd Increment
48 N•m (36 lbf•ft)
317 N•m (160 lbf•ft)
Final Torque
74 N•m (55 lbf•ft)
325 N•m (240 lbf•ft)
Installing the Transducer
35
Road and Track Vehicles
Attaching SWIFT and Wheel Assembly to the Vehicle
1. Before installing the SWIFT and wheel assembly, attach the anti-rotate
bracket to the vehicle.
Since the bracket is unique to each vehicle the anti-rotate bracket must be
provided by the customer. The following are guidelines for manufacturing
and locating the bracket. See the next two figures.
•
The bracket must be stiff, preferably steel or stiff stainless steel tubing,
so as not to move or rotate when connected to an unsprung mass or
spindle which will allow the slip ring assembly to move with the tire as
the vehicle is moving or testing.
•
The bracket must be positioned so as not to hit the fender 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.
Anti-Rotate Bracket
(customer supplied)
Anti-Rotate
Assembly
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.
Cable
Conduit
Bracket
Slip Ring
Slip-Ring
Bracket
Transducer
Front Wheel Slip Ring and Anti-Rotate Assembly
36
Installing the Transducer
S50-44
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
If the anti-rotate bracket is
fender or trailer-mounted, it
must be in a vertical orientation
so that when the vehicle
jounces the anti-rotate arm does
not rotate and cause errors in
the data or bend the rod.
Ensure bracket will not hit
body parts during vehicle
testing or jouncing.
The anti-rotate arm must be
long enough to accommodate
vehicle jounce.
Anti-Rotate
Assembly
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 desireable).
Cable
Conduit
Bracket
If the arm is mounted to the fender
or trailer, the assembly must have
a close-fitting hole that will
accommodate the suspension
jounce travel.
Slip Ring
Slip-Ring
Extension
Bracket
The bracket can be attached to
the brake caliper if wheel hub
assembly is equipped with disc
braking system.
Transducer
S50-45
Dual Wheel Slip Ring and Anti-Rotate Assembly
2. Attach the wheel/transducer to the test vehicle.
CAUTION
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 203 N•m (150 lbf•ft) increments, in the sequence
shown in the next figure to the torque rating recommended for the wheel.
Important
SWIFT 50 GLP Sensors Installation
Do not exceed a torque of 815 N•m (600 lbf•ft).
Installing the Transducer
37
Road and Track Vehicles
Transducer
9
1
Modified
Lug Nuts (10)
7
6
3
4
5
8
2
10
S50-41
3. If necessary, assemble the cable conduit brackets and hinge base with antirotate 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.
Install the cable conduit bracket onto the slip ring and secure the left
side with the four M5 X 0.8 mm fasteners.
Lubricate the fasteners with Molykote g-n paste and torque to 6.5 N•m
(56 lbf•in).
38
Installing the Transducer
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
Tie-wrap Cable to
Anti-rotate Tube
(as required
to secure)
Cable Conduit
Bracket
Cable
Tie-wrap
Cable to
Conduit
Bracket
Wrap Connector
and Cable
with Butyl Rubber
Shrink Tape
Hinge Coupling
and Tube
(Rotated 90°)
M5 X 0.8 mm
Fasteners (4)
Slip Ring
Hinge
Base
M5 X 0.8 mm
Fasteners (4)
S50-46
D.
Align the hinge base to the holes on the right side of the conduit cable
bracket and slip ring. Rotate the hinge coupling and tube 90° to access
the top hole.
Secure the hinge base with the four M5 X 0.8 mm fasteners.
Lubricate the fasteners with Molykote g-n paste and torque to 6.5 N•m
(56 lbf•in).
E.
Rotate the anti-rotate tube parallel to the cable conduit bracket.
Secure the cable to the cable conduit bracket using tie-wraps through
the holes in the bracket.
Use tie-wraps to also secure the cable to the anti-rotate tube.
4. 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.
Note
B.
SWIFT 50 GLP Sensors Installation
The slip-ring bracket fits over the 9-pin connectors on the front of the
transducer at the locations labeled Board A and Board B. The slip-ring
bracket is similarly labeled to prevent connecting it the wrong way.
Use care when installing the slip-ring bracket. The 9-pin 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.
Lubricate the threads and under the bolt heads of the four M8 X 1.25
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 27 N•m (20 lbf•ft).
Installing the Transducer
39
Road and Track Vehicles
C.
Make sure that the covers on the shunt connectors are in place and
secure.
Press the covers over the shunt connector. Secure the covers by
tightening the two SST 10-32 UNF screws (one for each cover), using
an M4 or 5/32 inch hex key wrench, to 3.8 N•m (2.8 ft-lbf).
Anti-Rotate Bracket
(customer supplied)
Anti-Rotate
Assembly
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.
Cable
Conduit
Bracket
Slip Ring
Slip-Ring
Bracket
Transducer
Front Wheel Slip Ring and Anti-Rotate Assembly
S50-44
5. 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 to the top plate using the M5 X 10
mm long fasteners provided (2 fasteners each).
Orient the short side of the dovetail on the connector toward the center
of the top plate.
Lubricate each fastener with Molykote g-n paste and torque each to 6.5
N•m (58 lbf•in).
C.
Place the top plate, with extensions attached, over the standoffs.
Orient the top plate such that the Board A extension (see the labeling
on the top plate) is aligned with the Board A connector on the
transducer.
Note
40
Installing the Transducer
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.
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
Cable
Cable
Conduit
Bracket
Anti-rotate
Hinge
Assembly
Tube
M12 Bolts (4)
and Washers
Extension
Brackets (4)
Standoffs (4)
Hinge
Slip-Ring
Bracket
M8 Bolts (4)
Slip
Ring
M12 Threaded
Studs (4)
Top Plate
S50-40
D.
Secure the top plate to the standoffs 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, conduit bracket, 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 9-pin connectors on the top plate at
the locations labeled Board A and Board B. The slip-ring bracket is
similarly labeled to prevent connecting it the wrong way.
SWIFT 50 GLP Sensors Installation
Installing the Transducer
41
Road and Track Vehicles
Note
Use care when installing the slip-ring bracket. The 9-pin 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 four M8 X 1.25
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 27 N•m (20 lbf•ft).
G.
Make sure that the covers on the shunt connectors are in place and
secure.
Press the covers over the shunt connector. Secure the covers by
tightening the two SST 10-32 UNF screws (one for each cover), using
an M4 or 5/32 inch hex key wrench, to 3.8 N•m (2.8 ft-lbf).
6. Secure the cable along the restraint tube, as necessary, to prevent it from
rubbing against the tire.
7. 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
42
Installing the Transducer
Be sure to leave enough slack in the cable to allow for the full
range of wheel travel (jounce and steer) so the cable does not
become stretched or damaged during testing.
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
Installing the Transducer Interface Electronics
The Transducer Interface (TI) electronics should be securely fastened to the
vehicle in a protected location. The TI box is designed to withstand the
accelerations associated with the body of a vehicle during rugged durability and
typical data acquisition testing.
The TI box can be located anywhere in the vehicle that is convenient. However,
if the TI is able to bounce around during data collection, it can bump against
another piece of equipment, pushing in the Zero button. If the Zero button is
pushed, you will lose all of the data.
Considerations
Procedure
Suitable locations for the TI box include the vehicle trunk, flatbed, interior floor,
or rear seat. Consider the following guidelines when you fasten the TI box(es) to
the vehicle:
•
Mount the TI box in a position on or in the vehicle that is protected from
impact and high acceleration events.
•
Do not expose the TI box to rain, snow, or other wet conditions.
•
Orient the TI box horizontally.
•
Multiple TI boxes may be rigidly attached to each other using optional
mounting straps.
•
Place a thin foam or rubber material between TI boxes and any hard
mounting surface.
•
Use ratcheting straps to provide a tight connection that will not loosen or
untie during testing.
•
Do not use rubber cords to secure the TI box because they may stretch and
lose retention in the cord due to inertial forces.
1. Connect the data cables from the TI to the data recorder.
There is a single cable assembly, with a D-type connector for connection
from the J4 Output connector on the TI and seven BNC connectors to the
data recorder. The BNC connectors correspond to the three forces, three
moments, and angular position.
Note
Make sure that there is no tension or strain in the cables or at the cable
and connector junction. There should be some slack in the cables to
ensure that they are not pulled during testing.
2. Connect the TI and the data recorder to the power source (such as the
vehicle battery).
Note
SWIFT 50 GLP Sensors Installation
Some data acquisition systems may introduce electrical noise spikes to
the battery and cabling. The TI electronics should always be used with
the cleanest power supply possible. To reduce the likelihood of noise
spikes from the data recorder, we suggest running the power cables in
parallel, as shown in the following diagrams. If this does not remove the
noise spikes, separate batteries may be required.
Installing the Transducer
43
Road and Track Vehicles
3. Ground the TI and data recorder to the vehicle frame. (See the following
figures.)
Ground to
vehicle frame
Data Recorder
12 Vdc
Transducer Interface
S50-025
Suggested Grounding for a single TI Box
Ground to
vehicle frame
Data Recorder
12 Vdc
Transducer Interface
Transducer Interface
Transducer Interface
Transducer Interface
S50-026
Suggested Grounding for a Multiple TI Boxes
4. Secure the TI box so that it will not move during data collection.
Note
If the TI box is not properly secured, it can bump against another piece of
equipment or a hard surface, pushing in the Zero button. If the Zero
button is pushed, you will lose all of the data.
5. Verify that the shunt contacts are covered.
Make sure that the covers on the shunt connectors are in place and that the
thumb screws are tight.
6. Turn on the TI and let it warm up for 15-20 minutes before you zero the
strain gage bridges.
44
Installing the Transducer
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
Setting up the SWIFT Sensor for Data Collection
To ensure accurate data collection, complete this setup procedure daily before
you begin testing.
The accuracy of the data that you collect depends on the ability of the SWIFT
electronics to “zero out” the forces and angles present in an initial, unloaded
state. During the Zero process, the TI box reads the transducer bridge values and
compensates for any offsets so that the bridge output is 0 at 0.0 V. It also reads
the current angle and compensates for any offset from the Z axis facing up.
You can ensure the success of the Zero procedure by taking these simple
precautions:
CAUTION
Do not introduce extraneous forces or excessive accelerations into the
wheel while rotating it during the Zero process.
Any forces applied to the wheel, tire, rim, spider, or outer portion of the
transducer will cause a Bridge Zero error.
Make sure to apply only a gentle force at a steady rate to the inner hub while
rotating it.
CAUTION
Do not touch or bump the wheel while the transducer is zeroing.
Touching or bumping the wheel will add loads to the transducer, resulting in
an erroneous zero reading.
Avoid all contact with the wheel while the transducer is zeroing. If you suspect that
the zero process is incorrect, begin again.
Considerations for
rotating a tire
When using a zero method that collects zero data while the sensor is rotating (i.e.,
algorithm 1 or 3), you must be careful to minimize the forces that are induced in
the transducer’s bridges.
When using one of these zero methods, never rotate the tire directly, or by
grabbing the outer diameter of the transducer. This will introduce forces into the
transducer bridges that will result in a bad zero process and unreliable data.
•
Rotate the tire at an even rate to avoid accelerations on the transducer.
•
For positive-lock differentials, turn the other tire on the axle to cause the
desired rotation in the transducer you are zeroing.
•
If you must touch the transducer to rotate the tire, carefully rotate the tire by
touching only the inner diameter of the transducer.
SWIFT 50 GLP Sensors Installation
Installing the Transducer
45
Road and Track Vehicles
Choosing a Zero
method
Preferred method—Zero Algorithm 4 is the preferred method for configuring
the calibration file for spinning applications:
ZeroAlgorithm=4
AngleMode=0
This zero method samples all eight input bridges at two positions. After the data
is taken, all eight input channels are analyzed for signal offsets, and bridge zeroes
and angle zeroes are set in the TI.
Alternate methods—Zero Algorithm 1 and 3 are alternate methods for
configuring the calibration file:
ZeroAlgorithm=1
AngleMode=0
Zero Algorithm 1 samples all eight input bridges on every encoder tick, for one
complete revolution. After the data is taken, all eight input channels are analyzed
for signal offsets, and bridge zeroes are set in the TI. The angle offset is then
recorded in a separate step.
ZeroAlgorithm=3
AngleMode=0
Zero Algorithm 3 may be more convenient for some test setups. However, you
must take care when using it, because it is susceptible to two types of errors:
•
Noise spikes from power. These can be minimized by following the
grounding suggestions illustrated earlier in this chapter.
•
Extraneous loads. Be very careful to rotate the wheel only by touching the
inner hub of the transducer or by engaging the axle (for some vehicles, this
means putting the vehicle in Park) and rotating the opposite wheel.
Because the SWIFT sensor measures loads applied to the outer edge of the
transducer, you should never touch the outer edge while you are spinning
the wheel. The rotation speed should be smooth, in order to avoid applying
inertial braking moments to the transducer.
This zero method samples all eight input bridges on every encoder tick, for one
complete revolution. After the data is taken, all eight input channels are analyzed
for signal offsets, and the X and Z input channels are analyzed to determine the
angular zero point.
46
Installing the Transducer
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
[SWIFT]
Name=Fixed Template
SerialNum=1234567
Normalization=1
InputSwitches=255
OutputPolarities=40
ZeroAlgorithm=4
AngleMode=0
AngleOffset=0
AngleFixed=0
EncoderSize=1
ZFX1=0.0
ZFX2=0.0
ZFY1=0.0
ZFY2=0.0
ZFY3=0.0
ZFY4=0.0
ZFZ1=0.0
ZFZ2=0.0
0
1
2
3
4
0
1
Zero Algorithm
Non-spinning mode
Spinning mode (uses a digital
inclinometer for angle zero and
spinning the tire for the bridge zero
process
Not used
Spinning mode (uses spinning the
tire for both angle and bridge
processes)
Spinning mode (use a digital
inclinometer to define two positions
90° apart for the bridge zero and
angle zero processes.
Angle Mode
Spinning mode (obtains angle from
the encoder)
Fixed angle mode (used for test rigs
in the lab)
KFX1=0.241363
KFX2=0.241363
KFY1=0.458709
KFY2=0.458709
KFY3=0.458709
KFY4=0.458709
KFZ1=0.241346
KFZ2=0.241346
KMX=2.173
KMYX=4.454
KMYZ=4.454
KMZ=2.14267
KFXFY=0.000262752
KFXFZ= 0 000486382
S50-38
Example of a .cal file
If Zero Algorithm=4
When you zero the TI, you want the vehicle to be fairly level and the transducer
to be as close to plumb as practical.
1. Install the SWIFT sensor(s) and data collection equipment on the vehicle.
2. Connect all cables and turn on the power to the TI boxes.
3. Let the TI boxes and transducers warm up for 15-20 minutes.
4. Run the TISTATUS program to compare the supply voltages to the
reference voltages.
Type: TIstatus <port#> <box#>
If the supply voltages vary more than 0.5 V from the reference voltages,
there is a power supply problem that must be resolved before you can
continue.
SWIFT 50 GLP Sensors Installation
Installing the Transducer
47
Road and Track Vehicles
5. Verify that the calibration file is set up correctly for your testing application.
A.
Download the spinning calibration file (xxxxxs.cal) to the computer
from the MTS Disk that corresponds to the serial number of the
transducer that you are setting up.
B.
If necessary, modify the zero algorithm and angle mode to fit the
application/use requirements as described in, “Edit the Calibration
File,” in the SWIFT 50 GLP Sensor Product Information manual (MTS
part number 100-162-722).
C.
The EncoderSize parameter should be omitted or set to EncoderSize=1
D.
Download the calibration file to the TI box.
Note
If it becomes necessary to change the zero algorithm or angle mode
after downloading the file to the TI, you can do so by using the
TISETZERO utility, as described in, “TISETZERO – Transducer Interface
Set Zero Method,” in the SWIFT 50 GLP Sensor Product Information
manual (MTS part number 100-162-722).
6. Elevate the vehicle with a lift, raise each corner with a jack.
7. Perform the zero procedure on each corner of the vehicle.
Use a digital inclinometer to zero the angle and strain gage bridges on the
transducer.
A.
Note
B.
Rotate the tire one full revolution so that the encoder can find the zero
index mark.
The encoder has a red dot on the mounting flange connected to the slipring bracket and a black dot on the slip-ring connector housing where it
interfaces with the mounting flange. These dots, when aligned next to
each other, indicate the index mark is under the encoder sensor.
Rotate the tire, as necessary, until the Fz on the axes icon (see the next
figure) printed on the transducer label is pointing up.
Axes Icon
C.
S20-22
If not already assembled, attach the inclinometer to the level bracket
using the two 6-32 UNC fasteners provided.
Apply Locktite 222 to the threads on the fasteners. Torque each
fastener to 2 N•m (18 lbf•in).
D.
Note
48
Installing the Transducer
Insert the dowel pins on the level bracket into the pin pilot holes
provided in the top or bottom of the transducer, as shown in the next
figure (the transducer is shown without the conduit bracket).
If the cable conduit bracket interferes with the mounting of the digital
inclinometer, use the bottom mounting location shown.
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
Digital Inclinometer
–in this position
should read 0°, ±0.1°
Level Bracket
Mounting Screws
Axes
Icon
Digital Inclinometer
–in this position
should read 0°, ±0.1°
S50-20
E.
Rotate the tire until the inclinometer reads 0.0°, ±0.1°.
F.
Push the Bridge Zero button on the front of the TI box. The LED will
turn on for a few seconds, then start blinking rapidly. The Angle Zero
indicator will start blinking slowly.
Bridge Zero
Switch and Indicator
S20-21
Angle Zero
Switch and Indicator
G.
Rotate the tire in either direction until the inclinometer reads 90°,
±0.1°.
Rotate
Transducer
+ or –90°
Digital Inclinometer
–in this position
should read 90°, ±0.1°
Digital Inclinometer
–in this position
should read 90°, ±0.1°
Level Bracket
S50-23
SWIFT 50 GLP Sensors Installation
Installing the Transducer
49
Road and Track Vehicles
H.
Note
If Zero Algorithm=1
Push the Angle Zero button on the front of the TI box. The Angle Zero
indicator will light for a few seconds, then both the Bridge Zero and
Angle Zero indicators should turn off.
If the red Fail indicator lights momentarily and the Bridge Zero and
Angle Zero indicators end up blinking slowly, problems were detected
with the zero. Try repeating the procedure. Use TISTATUS for a more
detailed explanation of the problem. If you continue to have an error,
consult the chapter, “Troubleshooting,” in the SWIFT 50 GLP Sensor
Product Information manual (MTS part number 100-162-722).
I.
Rotate the transducer slightly to update the rotational transformation.
At this point the TI should be reading absolute forces in the vehicle
coordinate system.
J.
Perform, “Verifying the Quality of the Zero Procedure,” on page 55.
K.
Look at your data acquisition system to verify that the SWIFT sensor is
gathering data.
When you zero the TI, you want the vehicle to be fairly level and the transducer
to be as close to plumb as practical.
1. Install the SWIFT sensor(s) and data collection equipment on the vehicle.
2. Connect all cables and turn on the power to the TI boxes.
3. Let the TI boxes and transducers warm up for 15-20 minutes.
4. Run the TISTATUS program to compare the supply voltages to the
reference voltages.
Type: TIstatus <port#> <box#>
If the supply voltages vary more than 0.5 V from the reference voltages,
there is a power supply problem that must be resolved before you can
continue.
5. Verify that the calibration file is set up correctly for your testing application.
A.
Download the spinning calibration file (xxxxxs.cal) to the computer
from the MTS Disk that corresponds to the serial number of the
transducer that you are setting up.
B.
If necessary, modify the zero algorithm and angle mode to fit the
application/use requirements as described in, “Edit the Calibration
File,” in the SWIFT 50 GLP Sensor Product Information manual (MTS
part number 100-162-722).
C.
The EncoderSize parameter should be omitted or set to EncoderSize=1
D.
Download the calibration file to the TI box.
Note
50
Installing the Transducer
If it becomes necessary to change the zero algorithm or angle mode
after downloading the file to the TI, you can do so by using the
TISETZERO utility, as described in, “TISETZERO – Transducer Interface
Set Zero Method,” in the SWIFT 50 GLP Sensor Product Information
manual (MTS part number 100-162-722).
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
6. Put the vehicle on a lift or jack up the corner of the vehicle on which the
SWIFT sensor is mounted.
Important
Place wheel chocks under the wheels on the ground or
otherwise restrain the vehicle to prevent it from moving.
7. Push the Bridge Zero button. Only the Bridge Zero indicator will light.
8. Rotate the tire 1 1/4 to 2 revolutions, until the Bridge Zero indicator starts
flashing. Follow the guidelines in, “Considerations for rotating a tire,” on
page 45.
If the Bridge Zero indicator continues to slowly flash after 2 minutes, or if
the red Fail indicator flashes, there is an error in the zero process. Run
TISTATUS to find out more information. Repeat Steps A and B. If you
continue to have an error, consult the chapter, “Troubleshooting,” in the
SWIFT 50 GLP Sensor Product Information manual (MTS part number
100-162-722).
9. Perform the Angle Zero procedure.
Use a digital inclinometer to zero the angle on the transducer, then rotate the
tire to zero the strain gage bridges.
A.
Note
B.
Rotate the tire one full revolution so that the encoder will pass the zero
index mark at least once.
The encoder has a red dot on the mounting flange connected to the slipring bracket and a black dot on the slip-ring connector housing where it
interfaces with the mounting flange. These dots, when aligned next to
each other, indicate the index mark is under the encoder sensor.
Rotate the tire as necessary, until the Fz on the axes icon (see the next
figure) printed on the transducer label is pointing up
Axes Icon
C.
S20-22
If not already assembled, attach the inclinometer to the level bracket
using the two 6-32 UNC fasteners provided.
Apply Locktite 222 to the threads on the fasteners. Torque each
fastener to 2 N•m (18 lbf•in).
D.
Note
SWIFT 50 GLP Sensors Installation
Insert the dowel pins on the level bracket into the pin pilot holes
provided in the top or bottom of the transducer, as shown in the next
figure (the transducer is shown without the conduit bracket).
If the cable conduit bracket interferes with the mounting of the digital
inclinometer, use the bottom mounting location shown.
Installing the Transducer
51
Road and Track Vehicles
Level Bracket
Digital Inclinometer
–in this position
should read 0°, ±0.1°
Mounting Screws
Axes
Icon
Digital Inclinometer
–in this position
should read 0°, ±0.1°
S50-20
E.
Rotate the tire until the inclinometer reads 0.0°, ±0.1°.
F.
Push the Angle Zero button on the front of the TI box. The Angle Zero
indicator will turn on for a few seconds, then turn off indicating that the
Angle Zero procedure is complete.
10. After completing the Bridge and Angle Zero procedures, rotate the wheel
one full revolution clockwise.
This allows the electronics to locate the index pulse for the encoder.
Note
The wheel must rotate one-half revolution in the same direction and then
pass over the encoder index point before data collection is started.
11. Perform, “Verifying the Quality of the Zero Procedure,” on page 55.
12. Look at your data acquisition system to verify that the SWIFT sensor is
gathering data.
52
Installing the Transducer
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
If Zero Algorithm=3
When you zero the TI, you want the vehicle to be fairly level and the transducer
to be as close to plumb as practical.
1. Install the SWIFT sensor(s) and data collection equipment on the vehicle.
2. Connect all cables and turn on the power to the TI boxes.
3. Let the TI boxes and transducers warm up for 15–20 minutes.
4. Run the TISTATUS program to compare the supply voltages to the
reference voltages.
Type: TIstatus <port#> <box#>
If the supply voltages vary more than 0.5 V from the reference voltages,
there is a power supply problem that must be resolved before you can
continue.
5. Verify that the calibration file is set up correctly for your testing application.
A.
Download the calibration file (xxxxx.cal) to the computer from the
MTS Disk that corresponds to the serial number of the transducer that
you are setting up.
B.
If necessary, modify the zero algorithm and angle mode to fit the
application/use requirements as described in, “Edit the Calibration
File,” in the SWIFT 50 GLP Sensor Product Information manual (MTS
part number 100-162-722).
C.
The EncoderSize parameter should be omitted or set to
EncoderSize=1.
D.
Download the calibration file to the TI box.
Note
If it becomes necessary to change the zero algorithm or angle mode
after downloading the file to the TI, you can do so by using the
TISETZERO utility, as described in, “TISETZERO – Transducer Interface
Set Zero Method,” in the SWIFT 50 GLP Sensor Product Information
manual (MTS part number 100-162-722).
6. Elevate the vehicle with a lift, or raise each corner with a jack.
7. Perform the zero procedure on each corner of the vehicle. Both the angle
and bridge zeros are computed by rotating the tire.
A.
Push either the Angle Zero or Bridge Zero button on the front of the
TI box. Both indicators will light.
Bridge Zero
Switch and Indicator
Angle Zero
Switch and Indicator
B.
SWIFT 50 GLP Sensors Installation
S20-21
Rotate the tire 1 1/4 to 2 revolutions, until both the Angle Zero and the
Bridge Zero indicators start flashing. Follow the guidelines in,
“Considerations for rotating a tire,” on page 45.
Installing the Transducer
53
Road and Track Vehicles
The indicators will flash at a rapid rate for several seconds, then turn
off, indicating the procedure is complete.
C.
If the both indicators continue to slowly flash after 2 minutes, or if the
red Fail indicator flashes, there is an error in the zero process. Run
TISTATUS to find out more information. Repeat Steps A and B. If you
continue to have an error, consult the chapter, “Troubleshooting,” in the
SWIFT 50 GLP Sensor Product Information manual (MTS part
number 100-162-722).
D.
After completing the Bridge and Angle Zero procedure, rotate the
wheel one full revolution clockwise.
This allows the electronics to locate the index pulse for the encoder.
54
Installing the Transducer
E.
Perform, “Verifying the Quality of the Zero Procedure,” on page 55.
F.
Look at your data acquisition system to verify that the SWIFT sensor is
gathering data.
SWIFT 50 GLP Sensors Installation
Road and Track Vehicles
Verifying the Quality of the Zero Procedure
Perform the following consistency checks for each SWIFT sensor while the
vehicle (or corner) is elevated.
1. Does Fz measure the approximate weight of the tire/rim assembly?
2. Is Fx small (less than 0.1% of the rated load)?
3. What is the variance in Fz (modulation) when the tire is slowly rotated?
4. When the vehicle is on the ground, is the Fz reading approximately equal to
the corner weight of the vehicle, minus the tare weight? (See, “Effect of
Zero Reference on SWIFT Output,” on page 56.)
Acceptable Variations for Fx, Fz Readings
Transducer Model
Max Rated Load
(Fx, Fz)
Fx Reading
with Vehicle Lifted
Fz Modulation
with Vehicle Lifted
SWIFT 50 GLPS
(stainless steel)
220 kN
0.1% (220 N)
0.2% (±220–440 N)
SWIFT 50 GLPT
(Titanium)
150 kN
0.1% (150 N)
0.2% (±150–300 N)
5. Perform a shunt calibration on each transducer.
A.
Elevate the vehicle on a lift, or jack up each corner.
B.
Connect the shunt calibration cables from the Shunt A, Shunt B
connectors on the front of the transducer to the Shunt A, Shunt B
connectors on the back of the TI box (see the next figure).
C.
Connect the signal cable from the slip ring to the Slip Ring connector
on the back of the TI box.
D.
Press the Shunt button on the front of the TI box, or use option 5 in the
TISHUNT program.
The shunt indicator will light continuously for 30–45 seconds. If the
indicator continues to flash after shunt calibration is complete, the
shunt calibration has failed.
SWIFT 50 GLP Sensors Installation
Installing the Transducer
55
Road and Track Vehicles
Connect to
Data Acquisition
System
Board A
Shunt B
Shunt A
Board B
S50-24
Connect the shunt calibration cables
6. Verify that the outputs from the TI box matches those on the calibration
report.
Use either the TISHUNT or TIXFER program to look at the shunt values of
the individual bridges.
The shunt calibration will fail if the measured shunt values are >2% of the
reference values that were set at the factory. Typically, the shunt values will
vary a maximum of 0.020-0.030 V from the reference values.
For more information on dealing with shunt calibration failures, refeer to
“Troubleshooting” in the SWIFT 50 GLP Sensor Product Information
manual (MTS part number 100-162-722).
Effect of Zero
Reference on SWIFT
Output
When the SWIFT sensor is used in spinning applications, it is important that a
correct absolute zero of each strain gage bridge is used to ensure the proper
computation and transformation of the transducer outputs to a non-rotating
vehicle coordinate system. An error in the absolute zero of each bridge will
produce a one-time-per-revolution modulation error in the output signals. To
achieve absolute zero of each bridge, the zeroing process must account for the
tare weight acting on the transducer.
When the vehicle is lifted and the tire and wheel assembly are suspended, the
mass of the tire, rim, outer diameter fasteners, and outer ring of the transducer are
all reacted through the beams of the transducer. With gravity acting on this outer
tire/rim assembly, the SWIFT sensor measures a vertical force pulling down on
the transducer.
The SWIFT output cannot be zero, because it is not possible to set the vehicle on
the ground precisely enough that the ground supports only the outer tire/rim
weight.
As the vehicle is set completely on the ground, the output from the SWIFT sensor
will read the corner weight of the vehicle from the reference point of the
transducer. The output of the SWIFT sensor will be slightly less than the total
corner weight of the vehicle, because the SWIFT sensor is inboard of the outer
tire and rim assembly, and will therefore not measure the weight of the outer tire
and rim assembly.
56
Installing the Transducer
SWIFT 50 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 according to the guidelines in, “Considerations for
rotating a tire,” on page 45.
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 high quality duct or electrical tape.
This will prevent dust, dirt, and water from entering the connector and
causing wear on the pins and sockets.
4. Verify that the shunt contacts are covered.
Make sure that the covers on the shunt connectors are in place and that the
thumb screws are tight.
5. 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), you must 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.
6. Turn on the data recorder.
7. Start data collection.
Important
SWIFT 50 GLP Sensors Installation
Before beginning data collection, read the cautions on the
next page.
Installing the Transducer
57
Road and Track Vehicles
CAUTION
Do not allow the SWIFT assembly to bump into any hard surfaces or objects
while you are driving the vehicle.
Bumping the SWIFT assembly into hard surfaces such as garage doors,
ramps and railings, or objects such as rocks, stumps, and earth, will
damage the anti-rotate device, cable, slip ring, slip ring bracket (spider), and
transducer.
The SWIFT assembly will protrude approximately 102 mm (4 in) from the side of
the vehicle. Remember to allow extra space on each side of the test vehicle when
driving through areas with possible hazards.
CAUTION
Do not drive through tall grass and brush.
Driving through grass and brush that is higher than the bottom edge of the
transducer can damage the cable and tear off the slip ring.
Avoid driving in any areas with tall grass and brush.
WARNING
Driving a vehicle with SWIFT sensors mounted on it will change the
handling characteristics of the vehicle.
Driving a vehicle configured in this way on public roads can pose
unexpected dangers to pedestrians and other vehicle traffic.
Only authorized, licensed drivers, who are experienced driving a vehicle with
SWIFT sensors mounted on it, should be allowed to operate the vehicle on public
roads. Drive the vehicle with the SWIFT sensor attached on closed courses only
until you have proper experience.
WARNING
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
23.
Excessive loading or load cycles could cause a fracture of the transducer,
wheel rim, hub adapter, or fasteners and can result in serious injury, death
or property damage.
Always be aware of the maximum full scale loads appropriate for your transducer.
If the prescribed limit for any axis of the transducer has been exceeded, contact
MTS for an evaluation and, if necessary, to arrange for the return of the
transducer with the recorded load cycles to MTS for physical inspection and
analysis of the load cycle history.
58
Installing the Transducer
SWIFT 50 GLP Sensors Installation
Road Simulator
Road Simulator
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.
CAUTION
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.
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.
WARNING
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.
SWIFT 50 GLP Sensors Installation
Installing the Transducer
59
Road Simulator
Equipment required
This procedure requires one person. To install the transducer, you will need the
following equipment:
•
Spindle adapter spacers (see next figure)
•
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)
For dual rims
16 size M16 X 1.5 mm
8 size M10 X 1.5 mm
4 size M5 X 0.8 mm
lug nuts and shim washers
For front rims
16 size M16 X 1.5 mm
8 size M10 X 1.5 mm
4 size M5 X 0.8 mm
lug nuts and shim washers
•
For dual rims
Slip ring extension assembly
Four size M12 X 1.75 mm X 30 mm long bolts
•
Slip ring assembly fasteners
Four size M8 X 1.25 mm X 20 mm long bolts
•
Torque wrenches, capable of the following ranges:
24–74 N•m (18–55 lbf•ft),
203–815 N•m (150-600 lbf•ft);
108–325 N•m (80–240 lbf •ft)
93 N•m (69 lbf•ft)
•
Cables (transducer and BNC, plus customer-supplied from transducer
interface to data recorder)
•
Tie wraps
•
Data recorder
•
Power supply–12 V DC or optionally 24 V DC1 power supply
1 If 24 Vdc compatible electronics was ordered at time of purchase.
60
Installing the Transducer
SWIFT 50 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, “Edit
the Calibration File,” in the SWIFT 50 GLP Sensor Product Information
manual (MTS part number 100-162-722).
SWIFT 50 GLP Fasteners
Front Rim
Dual Rims
M16 X 1.5 mm*
M16 X 1.5 mm*
M10 X 1.5 mm†
M10 X 1.5 mm†
M5 X 0.8 mm‡
M5 X 0.8 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 must ensure a minimum thread
engagement of 37 mm (1.46 in) but must not exceed 43 mm (1.69 in).
† The length of these fasteners is dependant on the thickness of the rim
flange. The fastener length must ensure a minimum thread
engagement of 28 mm (1.10 in) but must not exceed 34 mm (1.33 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 function of the customer wheel
geometry.
§ The standard lug nuts provided have a thread size of M22 X 1.50 mm.
Other thread sizes can be ordered at customer request.
Material required:
•
Molykote g-n paste (MTS part number 011-010-217).
•
Nikal based anti-galling compound (MTS part number 011-354-902)
1. Clean all surfaces with a mild detergent such as dish soap. It is critical that
all surfaces be free of stones, burrs, and grease.
2. Attach the spindle adapter spacer to the rim side of the transducer (see the
next figure) using the four M5 fasteners provided (see the previous table).
Ensure the pilot surface of the spindle adapter spacer is facing the
transducer.
Lubricate the threads and under the head of each fastener with Molykote g-n
paste and torque to 6.5 N•m (4.8 lbf-ft).
SWIFT 50 GLP Sensors Installation
Installing the Transducer
61
Road Simulator
3. Tighten the M10 mounting bolts.
A.
Following the sequence shown in the previous figure, torque the eight
M10 bolts (A through H) 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 M16 mounting bolts.
A.
Following the sequence shown in the previous figure, torque the
sixteen M16 bolts (1 through 16) 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.
Note
To minimize negative clamping effects, you must torque the bolts in the
sequence shown.
Bolt Size
Torque Increment
M10
M16
1st Increment
24 N•m (18 lbf•ft)
108 N•m (80 lbf•ft)
2nd Increment
48 N•m (36 lbf•ft)
317 N•m (160 lbf•ft)
Final Torque
74 N•m (55 lbf•ft)
325 N•m (240 lbf•ft)
5. Bolt the transducer/hub adapter to the road simulator fixture using the
modified lug nuts and shim washers provided.
CAUTION
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.
(Refer to the documentation provided with the road simulator.)
Tighten the lug nuts in 203 N•m (150 lbf•ft) increments, in the sequence
shown in the next figure to the torque rating recommended for the wheel.
Important
Do not exceed a torque of 815 N•m (600 lbf•ft).
6. Repeat steps 1 through 5 for each corner.
62
Installing the Transducer
SWIFT 50 GLP Sensors Installation
Road Simulator
Connector Side
1 through 10 = M22
(modified lug nuts)
M5 Threaded
Holes (4)
A through H = M10 bolts
1 through 16 = M16 bolts
329 Simulator and Hub Mount Side
S50-47
Bolt Torque Sequence
7. Install the vehicle on the road simulator.
Refer to the instructions in your road simulator operation manual.
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.
SWIFT 50 GLP Sensors Installation
A.
Connect the cable from the Load connector on the connector housing,
or from the slip-ring connector, to the transducer connector on the slipring daughter board of the TI box(es).
B.
If used, connect the cable from the Accel connector on the connector
housing to your data acquisition device.
C.
Connect the cables from the Shunt A and Shunt B connectors on the
connector housing or the slip-ring bracket to the Shunt A and Shunt B
connectors on the TI box(es)
Installing the Transducer
63
Road Simulator
D.
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 (12 V DC or optional 24 V DC) to the TI.
You may need to first convert from 120 or 240 V AC to 12 V DC or 24 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.
64
Installing the Transducer
SWIFT 50 GLP Sensors Installation
Road Simulator
Zeroing the Transducer Interface
Non-spinning method
For the non-spinning zero method, the calibration file should be configured:
ZeroAlgorithm=0
AngleMode=1
These settings are maintained over power cycles, so once a system mode is set
up, there is no need to re-enter them.
This system zero method samples all eight input bridges at the time the zero
buttons are pressed.
1. Press the Bridge Zero button.
When the Bridge Zero button is pressed, the Zero indicator lights, and the
TI starts to zero out the input bridges.
2. The Bridge Zero indicator starts blinking (at about 4 Hz rate).
The input bridges are zeroed by adjusting the internal bridge zero DAC,
until the measured bridge signal is as close to zero as possible. This is
performed for all eight bridges, and the results are saved in non-volatile
RAM. These values are then restored for subsequent power-ups. This zero
method will zero out any existing offsets seen at the inputs to the TI.
3. The Zero indicator turns off when a successful zero process is finished.
At this point, the new bridge and angle zeroes are loaded into the transducer.
Note
SWIFT 50 GLP Sensors Installation
The transducer should be installed in such a position 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 AngleFixed in
the TI calibration file (see, “Edit the Calibration File,” in the SWIFT 50
GLP Sensor Product Information manual (MTS part number 100-162722).
Installing the Transducer
65
Communication Configurations
Communication Configurations
Communication between a SWIFT TI and a remote host is based on a master/
slave communications protocol. Each SWIFT TI has a unique address from 01 to
09. The address 00 is reserved for broadcast messages, which go out to all boxes.
To send a message to a particular SWIFT TI, the host must address that particular
SWIFT TI by number.
Note
A leading 0 is required in the communications protocol.
A remote host can be connected to a daisy-chain of SWIFT TIs through either an
RS-232 or an RS-485 cable. The host is connected to one controller, which
constitutes one end of the chain. A multidrop RS-485 cable connects the rest of
the chain of controllers. The last controller in the chain requires a termination
jumper plug (MTS part number 510743-01) to terminate the multidrop RS-485
transmit/receive lines for Communications Channel 1.
RS-232 host
The following figure shows an RS-232 host connected to an RS-485 chain of
SWIFT TIs. This configuration allows up to nine SWIFT TIs on the RS-485
multidrop chain.
50 ft
maximum
300 ft
maximum
Host
SWIFT TI
Comm
In
J2
Comm
Out
J3
SWIFT TI
Comm
In
J2
Comm
Out
J3
SWIFT TI
Comm
In
J2
Comm
Out
J3
SWIFT TI
Comm
In
J2
Comm
Out
J3
RS-232
RS-485 Chain
(Up to 9 SWIFT TIs)
Cable
(MTS p/n 510742-XX)
RS-485 host
Last Controller
Terminated with
Jumper Plug
(MTS p/n 510743-01)
S50-028
The following figure shows an RS-485 host connected to an RS-485 chain of
SWIFT TIs. This configuration allows up to nine SWIFT TIs on the RS-485
multidrop chain.
50 ft
maximum
300 ft
maximum
Host
SWIFT TI
Comm
In
J2
Comm
Out
J3
SWIFT TI
Comm
In
J2
Comm
Out
J3
SWIFT TI
Comm
In
J2
RS-485 Chain
(Up to 9 SWIFT TIs)
66
Installing the Transducer
Comm
Out
J3
SWIFT TI
Comm
In
J2
Comm
Out
Cable
(MTS p/n 510742-XX)
J3
Last Controller
Terminated with
Jumper Plug
(MTS p/n 510743-01)
S50-029
SWIFT 50 GLP Sensors Installation
Cable Configurations
Cable Configurations
SWIFT TI to PC Host (9-pin)
The following cable (MTS p/n 510741-XX) is used to connect a SWIFT TI to a
PC with a 9-pin serial port, for RS-232 communication.
P2
RJ-45
To COMM IN
of SWIFT TI
GND
5
MODE
6
D-9S
Twisted
Shielded
Pairs
5
GND
TX 7
2
RX
RX 8
3
TX
To Host
RS-232 Port
SWIFT TI to PC Host (25-pin)
The following cable (MTS p/n 510740-XX) is used to connect a SWIFT TI to a
PC with a 25-pin serial port, for RS-232 communication.
P2
RJ-45
To COMM IN
of SWIFT TI
GND
5
MODE
6
D-25S
Twisted
Shielded
Pairs
7
GND
TX 7
3
RX
RX 8
2
TX
To Host
RS-232 Port
SWIFT TI to SWIFT TI
The following cable (MTS p/n 510742-XX) is used to connect one SWIFT TI to
another, for RS-485 communication.
P3
To COMM OUT
of SWIFT TI
Twisted
Shielded
Pairs
P2
+TX
1
–TX
2
2
–TX
+RX
3
3
+RX
–RX
4
4
–RX
GND
5
5
GND
SWIFT 50 GLP Sensors Installation
1
+TX
To COMM IN
of SWIFT TI
Installing the Transducer
67
Cable Configurations
Termination Jumper
The following jumper plug (MTS p/n 510743-01) is used to terminate a chain of
SWIFT TIs using multidrop RS-485 communication. It plugs into connector
COMM OUT of the last SWIFT TI in the communications chain.
Termination Jumper
(MTS p/n 510743-01)
+TX 1
–TX 2
To COMM OUT
of SWIFT TI
Module
+RX 3
4
5
+TERMINATE 6
–TERMINATE 7
TERMINATE 8
68
Installing the Transducer
SWIFT 50 GLP Sensors Installation
m
MTS Systems Corporation
14000 Technology Drive
Eden Prairie, Minnesota 55344-2290 USA
Toll Free Phone: 800-328-2255
(within the U.S. or Canada)
Phone: 952-937-4000
(outside the U.S. or Canada)
Fax: 952-937-4515
E-mail: info@mts.com
http://www.mts.com
ISO 9001 Certified QMS

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