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Copyright information Trademark information © 2008 MTS Systems Corporation. All rights reserved. MTS, SWIFT, RPC, Remote Parameter Control, TestStar, and TestWare are registered trademarks of MTS Systems Corporation within the United States. These trademarks may be protected in other countries. Microsoft, Windows, Windows for Workgroups, Windows 95, and Windows NT are registered trademarks of Microsoft Corporation. Apple and Macintosh are registered trademarks of Apple Computer, Inc.
Contents Technical Support 5 How to Get Technical Support Before You Contact MTS 5 5 If You Contact MTS by Phone 7 Problem Submittal Form in MTS Manuals 8 Preface 9 Before You Begin Conventions 9 10 Documentation Conventions 10 Hardware Overview 13 Overview 14 Spinning Applications (Track or Road) 16 Non-Spinning Applications (Laboratory) Construction 18 Design Features 21 Coordinate System Specifications Calibration 17 22 24 27 Transducer Interface 29 TI Front Panel 32 TI Rear
Setting up the Transducer Interface 47 USB Driver Installation Select a Zero Method 48 50 Calibration File Elements Upload the Calibration File Edit the Calibration File 51 52 53 Download the Calibration File 56 Installing the Transducer 57 Hazard Icon 58 Road and Track Vehicles 59 Attaching SWIFT Components to the Wheel 62 Installing the Transducer Interface Electronics 72 Setting up the SWIFT Sensor for Data Collection Verifying the Quality of the Zero Procedure Collecting Data Road Simula
Technical Support How to Get Technical Support Start with your manuals The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes MTS software, look for online help and README files that contain additional product information. If you cannot find answers to your technical questions from these sources, you can use the internet, e-mail, telephone, or fax to contact MTS for assistance. Technical support methods MTS web site www.mts.
Know information from prior technical assistance Identify the problem Know relevant computer information Know relevant software information 6 Technical Support If you have contacted MTS about this problem before, we can recall your file.
If You Contact MTS by Phone Your call will be registered by a Call Center agent if you are calling within the United States or Canada. Before connecting you with a technical support specialist, the agent will ask you for your site number, name, company, company address, and the phone number where you can normally be reached. If you are calling about an issue that has already been assigned a notification number, please provide that number.
Problem Submittal Form in MTS Manuals Use the Problem Submittal Form to communicate problems you are experiencing with your MTS software, hardware, manuals, or service which have not been resolved to your satisfaction through the technical support process. This form includes check boxes that allow you to indicate the urgency of your problem and your expectation of an acceptable response time. We guarantee a timely response—your feedback is important to us.
Preface Before You Begin Safety first! Before you attempt to use your MTS product or system, read and understand the Safety manual and any other safety information provided with your system. Improper installation, operation, or maintenance of MTS equipment in your test facility can result in hazardous conditions that can cause severe personal injury or death and damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue.
Conventions Conventions Documentation Conventions The following paragraphs describe some of the conventions that are used in your MTS manuals. Hazard conventions As necessary, hazard notices may be embedded in this manual. These notices contain safety information that is specific to the task to be performed. Hazard notices immediately precede the step or procedure that may lead to an associated hazard. Read all hazard notices carefully and follow the directions that are given.
Conventions Hypertext links SWIFT 10 MC Sensors The electronic document has many hypertext links displayed in a blue font. All blue words in the body text, along with all contents entries and index page numbers, are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic.
Conventions 12 Preface SWIFT 10 MC Sensors
Hardware Overview Contents Overview 14 Spinning Applications (Track or Road) Non-Spinning Applications (Laboratory) Construction Coordinate System Specifications 21 22 24 27 Transducer Interface 29 TI Front Panel 32 TI Rear Panel 33 Interfacing with RPC SWIFT 10 MC Sensors 17 18 Design Features Calibration 16 34 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.
Overview CAUTION The SWIFT sensor, TI electronics, and accessory components are not intended to be disassembled, other than as outlined in “Troubleshooting”. Disassembling or tampering with these components may result in damage to the sensor, loss of watertight seal, and voiding of the warranty. Do not disassemble the SWIFT sensor, Transducer Interface (TI) electronics, and accessory components.
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.
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.
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.
Construction Inner hub adapters The inner hub adapters attach to either side of the inner diameter of the transducer assembly. The inner hub adapters enable you to maintain the original position of the tire, brakes, and sprocket on the vehicle, while the centerline of transducer assembly is attached along the centerline of the wheel.
Construction When the right-side inner hub adapter is attached to the transducer assembly, the slip-ring outputs the transducer bridge signals and angular position to the TI. Internal wiring provides excitation power to the strain gage bridges and brings signals out from the transducer to the slip ring. A transducer data cable attaches from the slip ring cable connector to the back panel of the TI.
Construction Design Features Flexure isolation The SWIFT sensor has a very stiff outer ring and flexured beam isolation which render it relatively insensitive to stiffness variations in matings with rims and road simulator fixtures. Flexure isolation minimizes thermal expansion stresses. With flexure isolation, if the inner hub experiences thermal expansion the beams are allowed to expand out, resulting in lower compressive stress on the beams.
Coordinate System Coordinate System In the transducer, independent strain gage bridges measure forces and moments about three orthogonal axes. The signals are amplified to improve the signal-tonoise ratio. An encoder signal measures angular position, which is used to convert raw force and moment data from the rotating transducer to a vehiclebased coordinate system. The force, moment, and encoder information are sent to the transducer interface (TI).
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. • Longitudinal force (Fx) follows the right-hand rule, consistent with Fz as described above. You can change to the MTS Model 329 Road Simulator convention or to any coordinate system by changing the polarities in the calibration file.
Specifications Specifications SWIFT 10 MC Transducer Performance PARAMETER SPECIFICATION Use SWIFT 10 MC (aluminum) for high fatigue life, durability SWIFT 10 MC (titanium) for low weight, high sensitivity Maximum usable rpm 2,200 Maximum speed 250 kph (155 mph) Shock resistance, each axis 150 G Fits rim size (usable range) 7-12 inch* Input voltage required Input power required per transducer 10–28 V DC 7 Watts maximum (22 Watts typical) Output voltage ± full scale calibrated load SAE J328
Specifications Transducer Center-of-Gravity Transducer Center-of-Gravity and Inertia Specifications MATERIAL ALUMINUM TITANIUM Xcg 0.0 mm 0.000 in 0.0 mm 0.000 in Ycg 18.0 mm 0.710 in 18.0 mm 0.710 in Zcg 0.0 mm 0.000 in 0.0 mm 0.
Specifications Transducer Interface PARAMETER SPECIFICATION Physical Height 28 mm (1.100 in) Width 213 mm (8.375 in) Depth 171 mm (6.750 in.)* Weight 0.
Calibration Calibration Each transducer is calibrated by MTS before shipment. The transducer and TI may be returned to MTS for repair and recalibration as required. Calibration is performed at MTS on a special fixture that is capable of applying multiple loads to the transducer. During calibration, raw signals are measured. The calibration gains and cross talk compensation values are computed from this raw data. These gains are recorded in a calibration file.
Calibration When you press the Shunt button, the associated Shunt indicators toggle while the shunt is in progress. As the TI automatically switches through the series of bridges, it verifies that the outputs are within the accepted tolerance range. If all bridge shunt values fall within the tolerance range, the Shunt indicators on the front panel will go off (after several seconds). If any bridge fails the shunt test, the red, fail indicator lights, indicating that the shunt calibration has failed.
Transducer Interface Transducer Interface The TI performs cross talk compensation, transforms the loads from a rotating to a non-rotating coordinate system, and produces an analog output signal suitable for any data recorder.
Transducer Interface The TI transforms four inputs (amplified bridge signals) into two forces and one moment by the following process: • Applying a zero offset and scaling the signals • Using a geometric matrix to transform the signals into two forces and one moment in the transducer reference frame • Using a cross-coupling matrix calculation to scale and sum the individual signals into each output • In spinning applications, using a rotational transformation to put the forces and moments into a sta
Transducer Interface The angle output for a tire rotating at constant velocity can be represented by the following illustration: Angle Output 5V 1 rev = 360° 0 360° 0° q 360° S20-10 Although you may not routinely use it, the angle output information is available for tasks such as tire uniformity testing and troubleshooting. You may also calculate angular velocity by measuring the frequency of the angle output signal.
Transducer Interface TI Front Panel J4 I/O Connector J5 USB Connector Zero button and Indicators Shunt button and Indicators Power button and Indicator and Fail Indicator Transducer Interface Front Panel Power button and Indicator The power button turns power on and off. Pressing and holding the button turns on power and initializes the TI. During initialization, all indicators turn on momentarily.
Transducer Interface TI Rear Panel J1 Power Connector J2 Output Connector J3 Transducer Connector Transducer Interface Rear Panel J1 Power connector Connect a power cable from the external power source. J2 Output connector The J2 Output connector provides the conditioned sensor outputs that can be connected to a data acquisition or test control system. J3 Transducer connector SWIFT 10 MC Sensors Connect the data cable from the transducer slip ring to the Transducer Connector.
Interfacing with RPC Interfacing with RPC The SWIFT sensor is directly compatible with the MTS Remote Parameter Control (RPC) simulation software. The SWIFT system produces outputs that directly correspond to the uncoupled spindle forces that the MTS Model 329 Road Simulator applies to the vehicle. Traditional instrumentation techniques provide coupled suspension loads data. Using the SWIFT sensor, the RPC simulation software needs to apply less correction to obtain the road simulator drive signals.
Software Utilities Contents Introduction 36 TI2STATUS - Transducer Interface Status 37 Description of TI2STATUS Indications 37 TI2XFER - Transducer Interface Transfer 39 TI2SHUNT - Transducer Interface Shunt 41 Setting Up Shunt Calibration Reference Values Error Messages SWIFT 10 MC Sensors 43 44 Software Utilities 35
Introduction Introduction The SWIFT utility programs in this distribution are for Win32 Operating Systems (Windows 2000 and XP). They are designed to be run from the Command Prompt or MSDOS Shell. However, it is possible to create a shortcut to run the programs. If launched from a shortcut the application window may close immediately when the application terminates making it impossible to see any error messages.
TI2STATUS - Transducer Interface Status TI2STATUS - Transducer Interface Status This program gets status information from the SWIFT Transducer Interface (TI) when the TI has encountered a problem and the red failed indicator is lit. You can use this program to easily interpret the error. For certain errors this program may provide additional information. Syntax ti2status The following is an example of the ti2status command report: Example C:\bin>ti2status SWIFT Mini TI status (Version 1.
TI2STATUS - Transducer Interface Status Zero: 38 Indicates whether the transducer zeroing was successful or not (see, “Error Messages,” on page 44 for a list of the possible errors). F## Shunt: Indicates the status of shunt test for each bridge (see, “Error Messages,” on page 44 for a list of the possible errors). Calibration data is: Indicates the condition of the calibration data (see, “Error Messages,” on page 44 for a list of the possible errors).
TI2XFER - Transducer Interface Transfer TI2XFER - Transducer Interface Transfer This program is used to read the current settings in the TI and save them to the computer (upload) or write the values from a calibration file on the computer to a TI (download). Syntax Example ti2xfer The following is an example of the ti2xfer command: C:\bin>ti2xfer SWIFT Mini TI transfer (Version 1.0) Upload and download settings 0...Exit 1...Upload settings from TI box 2...
TI2XFER - Transducer Interface Transfer CAUTION Take the necessary measures to protect important files (such as those containing calibration data). If not protected, important data may get overwritten. Make important files read-only. Make backups of important data. CAUTION Check force and moment output signals after downloading new settings. Downloading new settings may affect Transducer Interface outputs.
TI2SHUNT - Transducer Interface Shunt TI2SHUNT - Transducer Interface Shunt This program is a utility with various functions related to shunts. The SWIFT system includes the ability to connect a shunt resistor across each of the resistive bridges in the transducer. This shunt function can be used as a simple verification that the SWIFT system is working normally. Shunt verification activates the shunts and compares the results to those recorded during calibration.
TI2SHUNT - Transducer Interface Shunt Option 2 Use this to set the shunt tolerance. When selected, the following is displayed: Enter choice: 2 The current shunt tolerance is 2% Enter new shunt tolerance in percent? Option 3 Use this option to apply a shunt to each bridge individually, read the output of the bridge, compare the result with the value stored in the Transducer Interface and display the difference each bridge. See the table on the next page. The shaded fields are the bridge being shunted.
TI2SHUNT - Transducer Interface Shunt Option 4 Use this option to command a Shunt Cal in the Transducer Interface. This is the same as pressing the Shunt button on the front panel of the TI. A period is displayed on the screen for every change in the shunt state. This gives you a quick view of the progress. Option 5 A valid shunt calibration should be performed prior to executing this command. This option allows an easy means of setting the Shunt Calibration Reference values after calibration.
Error Messages Error Messages When a SWIFT utility encounters an error, the red failed indicator on the TI front panel lights. Run the TI2STATUS program to identify the cause of the error.
Error Messages • Shunt Good – no problems were detected. Reference Bad – The shunt reference is out of range. Shunted Bad – A shunt value does not match the shunt reference. Unshunted Bad – While shunting one bridge another bridge output unexpectedly changed. • Calibration Data is: Good – No problems were detected. Bad – The unit has not been calibrated or the calibration memory is corrupted.
Error Messages 46 Software Utilities SWIFT 10 MC Sensors
Setting up the Transducer Interface Overview Two different software configurations are used by the TI, depending on whether you will be using the SWIFT sensor on the test track (typical for spinning application) or in the laboratory (typical for non-spinning or fixed application). Angular transformation is required on the test track only.
USB Driver Installation USB Driver Installation Two USB 2.0 drivers must be installed to recognize the Transducer Interface. Perform the following procedure to install these drivers on a laptop or desktop computer that does not already have these drivers installed. Important Do not allow Windows to search for or choose the drivers for you. Always direct Windows to the path containing the Mini TI USB drivers. 1. Copy the Mini TI USB drivers from the Utilities CD provided to your hard drive. 2.
USB Driver Installation 4. On the next window, select the Install from a list or specific location (Advanced) radio button. 5. If you copied the driver files from the CD to your hard drive, use the browser to direct the wizard to the location where you copied the files as shown in the next figure. 6. Click Next to install the loader for the MTS SWIFT TI Interface. 7. When the installation is complete, click Finish on the window that displays. 8. Another Found New Hardware Wizard will display.
Select a Zero Method Select a Zero Method Before you install a transducer and zero it, you must configure the transducer interface (TI) for the appropriate operating mode. Equipment required Modes You will need: • A laptop computer (at test track) or desktop PC with Window 2000 or XP operating system. • A USB 2.0 communication cable with type A to type B connectors. • SWIFT Transducer Interface Utilities diskette. • Some experience with DOS commands and text editors.
Select a Zero Method Calibration File Elements The following figure shows some elements of the calibration file: SerialNum=10237221A AngleMode=0 AngleOffset=0 AngleFixed=0 EncoderSize=2048 FXPolarity=0 FYPolarity=0 FZPolarity=0 MXPolarity=1 MYPolarity=0 MZPolarity=1 Angle Mode (0 = Spinning, 1 = Fixed) Angle Offset Fixed Angle Encoder Size Polarity for each output (0 = normal, 1 = inverted) ZFX1=0 ZFX2=0 ZFY1=0 ZFY2=0 ZFY3=0 ZFY4=0 ZFZ1=0 ZFZ2=0 Bridge Zeroes Do Not Modify FX1Channel=2 FX2Channel=6 FY
Upload the Calibration File Upload the Calibration File A unique calibration file was loaded into the TI memory by MTS before the transducer and transducer interface were shipped. Use the program TI2XFER to retrieve the calibration file. 1. Connect a USB cable from the laptop computer or PC to the TI. Note Ensure the proper USB 2.0 drivers are installed on the laptop or PC. Refer to, “USB Driver Installation,” on page 48, as necessary 2.
Edit the Calibration File Edit the Calibration File CAUTION The calibration file contains offset values for all of the bridge outputs. Changing any of the items other than those listed in the following procedure will cause your calibration file to be incorrect. Take care not to change any values except those listed in the following procedure. If your calibration file is incorrectly changed, reload the original file from the diskette provided by MTS. 1. Open the calibration file using a text editor.
Edit the Calibration File 2. If necessary, edit the value for Polarity (see the table below). The polarities that match the coordinate icon on the transducer are: Fx=0 Fz=0 My=0 Using these settings, the axis orientation of the transducer relative to the vehicle will vary depending on if the transducer output cable is on the right side or left side of the vehicle. The polarities for each axis can be reversed by changing the associates polarity value from a “0” to a “1” or from a “1” to a “0”.
Edit the Calibration File 4. Perform this step for non-spinning (fixed) applications. For spinning applications, skip to Step 5. A. Verify the value for AngleMode. Set the AngleMode=1 In this mode, the sine and cosine RAM address is fixed. The encoder is not used, nor is the encoder offset. B. Edit the value for AngleFixed. The AngleFixed value is used for non-spinning applications. This value addresses the sine and cosine in memory when the angle mode is set to 1 (fixed).
Download the Calibration File Download the Calibration File Use the program TI2XFER to download the modified calibration file to the TI. 1. Insert the CD or diskette into the laptop computer or PC. 2. Run the program TI2XFER. 3. Enter 2 at the prompt to download the calibration file. 4. Enter the name of the file you wish to download. 5. TI2XFER will prompt you when the file has successfully downloaded. 6. Enter 0 at the prompt to exit the program. SWIFT Mini TI transfer (Version 1.
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.
Hazard Icon Hazard Icon The following hazard icon is part of the label affixed to the side of the SWIFT 10 ATV Sensor. ICON DESCRIPTION Read the manuals. Become familiar with safety information.
Road and Track Vehicles Road and Track Vehicles Equipment required This procedure can be performed by one person. To install the SWIFT 10 sensor, you will need the following equipment: • Inner hub adapter (see next figure) • Stock spoked rim or modified rim (see next figure) • Outer hub/rim adapters • Washer plate (see next figure) • Small set of metric hex-head wrenches • Metric socket head drive set (up to 10 mm) with extension • Molykote g-n paste, 2.8 oz.
Road and Track Vehicles Axle Spacer Inner Hub Adapter - Sprocket Transducer Assembly Oil Seal Outer Spoke/Hub Adapter Sealed Oil Bearing Load Spacer Slip Ring Encoder Inner Hub Adapter - Brake Sealed Ball Bearing Axle Sleeve Load Spacer Oil Seal Axle Spacer S10MC-08 Typical Installation Components (rear shown) Importance of bolts Bolts provide exceptional clamp force at the transducer to rim/spindle interface. • Bolts on the inner hub secure the hub adapter to the SWIFT sensor.
Road and Track Vehicles 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.
Road and Track Vehicles Attaching SWIFT Components to the Wheel SWIFT 10 Fasteners QUANTITY FRONT AND REAR 20 (each side) M8 X 1.25 mm* 8 M8 X 1.25 mm† * The length of these fasteners is dependant on the thickness of the outer hub adapter and washer plate (when used). The fastener length must ensure a minimum thread engagement of 12 mm (0.47 in) into the transducer but must not exceed 17 mm (0.67 in) engagement where it could interfere with the fasteners from the opposite side.
Road and Track Vehicles A. Note Install a spoke hub adapter on each side of the transducer (see the next figure). Keep in mind, when mounting the hub adapters to the transducer, the path for routing the transducer cable. The transducer connectors should on the side of the vehicle that will provide cable routing to the TI box that will keep the cable away from moving parts, such as the sprocket and drive chain.
Road and Track Vehicles F. Repeat this entire step for the other wheel, as necessary. G. Continue with Step 6.
Road and Track Vehicles F. Loosely secure both rim hub adapters to the modified rim using the M6 socket head cap screws, a washer on each side of the rim hub adapters, and Nylok nuts (as required). G. Following the outer bolt pattern sequence shown in the Bolt Torque Sequence figure, torque the twenty M8 bolts (1 through 20) on one side of the transducer to the value for the first increment shown in the Bolt Torque Increments table.
Road and Track Vehicles 7. Assemble the non-slip ring/encoder side as follows: Note A. The sealed bearings and oil seals shown in the figures have already been installed in the delivered adapters. If you have not already done so, attach the stock sprocket or brake disk (as required) to the inner hub/sprocket or brake disk adapter using the fasteners provided. Apply Locktite 262 Threadblocker to the screws and torque to the manufacturers specifications. B.
Road and Track Vehicles B. Apply a little grease or oil to the outer surface of the axle spacer and insert it into the inner hub adapter from the oil seal/bearing side. Push until you feel it snap in place against the bearings. C. From the opposite side insert the load spacer.
Road and Track Vehicles D. Feed the slip ring wires for connection to the system cable assembly through the inner hub assembly. Note also at this time the Board 1 and Board 2 identifier stamped on the face of the slip ring next to the 9-pin connector wires (see the next figure). to facilitate assembly, mark each cable end to identify the cable by board number. Board 1 Identifier Keyway Board 2 Identifier Setscrew Pin Hole E.
Road and Track Vehicles I. Bend the slip ring wires 90° and into the slot on the end of the axle spacer. J. Insert the 9-pin connectors into their respective connector bracket on the side of the hub adapter. Note the orientation of the dovetail on the Board 1 and Board 2 connectors as shown in the figure on page 67. K. Secure each connector with two 2-56UNC flat head screws. Apply Locktite 222 Threadlocker to each screw and torque to 0.56 N•m (5 lbf•in).
Road and Track Vehicles C. Place the inner hub adapter with the slip ring/encoder over the transducer. Align the connectors on the hub adapter with the connectors on the transducer. Push the hub adapter onto the transducer to fully engage the connectors. D. Install the eight M8 bolts and flat washers through the hub adapter on the slip ring side. Lubricate the threads and under the head of each fastener with Molykote g-n paste. E.
Road and Track Vehicles 11. Use the stock axle, axle nut, washers, and tension adjust/slide plates, as required, to mount the wheels on the vehicle. Orient the flat on the axle spacer to the top of the swing arm (for rear wheel) or the front of the fork tube mount (for front wheel). Attach the anti-rotate bracket to the axle spacer and against the swing arm or fork tube mount using the two 6-32 UNC fasteners provided. Apply Locktite 222 Threadblocker to each fastener and torque to 2 N•m (18 lbf•in).
Road and Track Vehicles Installing the Transducer Interface Electronics The Transducer Interface (TI) electronics should be securely fastened to the vehicle. The TI box is designed to withstand the accelerations associated with the body of a vehicle during rugged durability and typical data acquisition testing. The TI box can be located anywhere on the vehicle that is convenient.
Road and Track Vehicles Note Some data acquisition systems, power systems, and alternators 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.
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.
Road and Track Vehicles Note When the inner hub is fully assembled, the encoder index mark is aligned with the square head set screw on the inner hub adapter and the index mark on the slip-ring is aligned with the cable slot in the axle spacer. When the set screw and cable slot are aligned with each other, the index mark is under the encoder sensor. 3.
Road and Track Vehicles Inclinometer Level Bracket Spoke Adapters (2) Beam Holes (4) S10MC-17 Inclinometer Mounting for Rear Wheel 6. Push the Zero button on the front of the TI box. The Zero indicators will toggle during the zero process. When the Zero indicators turn off the process is complete for this angle. Zero Button and Indicators 7. Remove the inclinometer and level bracket. 8. Repeat Step 4 through 7 three more times. Before Step 4 of each iteration, rotate the tire 90°.
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? The typical value should be <100 N. 4.
Road and Track Vehicles Effect of zero reference on SWIFT output When the SWIFT sensor is used in spinning applications, it is important that a correct absolute zero of each strain gage bridge is used to ensure the proper computation and transformation of the transducer outputs to a non-rotating vehicle coordinate system. An error in the absolute zero of each bridge will produce a one-time-per-revolution modulation error in the output signals.
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. 1. Spin the wheel twice to ensure that the TI can identify the index pulse.
Road and Track Vehicles 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.
Road Simulator Road Simulator Before you begin There are two methods of using a SWIFT on a road simulator. The traditional “non-spinning” or “fixed” mode relies on the orientation of the SWIFT during road simulator use maintaining the same orientation relative to the anti-rotate position used during road testing. The SWIFT outputs are given in set coordinates relative to the SWIFT sensor orientation, and no angular transformation is applied to the SWIFT outputs.
Road Simulator 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.
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) • Adapters to 329 simulator • Small set of metric hex-head wrenches • Metric socket head drive set (up to 14 mm) with extension • Transducer mounting bolts (per transducer)1 20 size M8 X 1.25 mm X 50 mm long 8 size M8 X 1.25 mm X 75 mm long 8 washers 17 mm O.D. X 8.4 mm I.D.
Road Simulator Attaching SWIFT Components to the Fixturing Note Install the transducer such that the orientation labeling is consistent with the reference orientation. In most cases, this means installing it so the labels are upright. If an additional angle correction is required after installation, you will need to measure the angle from zero, and then enter a new offset value for the AngleOffset in the TI calibration file (see earlier instructions, “Edit the Calibration File,” on page 53).
Road Simulator 4. Torque the twenty M8 fasteners. A. Following the outer bolt pattern sequence shown in the following figure, torque the twenty M8 bolts (1 through 20) to the value for the first increment shown in the Bolt Torque Increments table. B. Repeat Step 5A for the final increment.
Road Simulator 6. Temporarily secure the assembly to the spindle housing using four of the sixteen M10 fasteners installed 90° from each other. Lubricate the fasteners and mating surfaces with Molykote g-n paste and torque, in two equal increments, using a cross pattern to 53 N•m (39 lbf•ft). Spindle Housing Adapter Plate Transducer (connector side) M10 Fasteners (16) Washer Plate Spindle Housing Transducer M8 Fasteners (20) S10MC-34 7.
Road Simulator Stock Sprocket (rear) or Brake Disk (front) Axle Spacer Stock Sprocket or Brake Disk Inner Hub/ Sprocket or Brake Disk Adapter Apply grease to reduce friction between axle spacer and oil seal and bearings Load Spacer Axle Spacer Oil Seal Load Spacer Sealed Bearings (2) Inner Hub Assembly Sprocket Side – Rear (shown) S10MC-12R Assembling the Non-Slip Ring/Encoder Side (typical – rear shown) 8.
Road Simulator Square Head Setscrew Hole 6 Conductor, Board 1, 9-pin Slip Ring Connector (note orientation of dovetail on the connector shell) Inner Hub/Brake Disk Adapter Slip Ring/ Encoder Load Spacer Oil Seal Axle Sleeve Sealed Bearing 5 Conductor, Board 2, 9-pin Slip Ring Connector (note orientation of dovetail on the connector shell) Axle Spacer Stock Brake Disk 6 Conductor, Board 1, 9-pin Slip Ring Connector Axle Sleeve Pin Hole for Setscrew Slip Ring Wires to System Cable Assembly Slip Ri
Road Simulator D. Feed the slip ring wires for connection to the system cable assembly through the inner hub assembly. Note also at this time the Board 1 and Board 2 identifier stamped on the face of the slip ring next to the 9-pin connector wires (see the next figure). To facilitate assembly, mark each cable end to identify the cable by board number. Board 1 Identifier Keyway Board 2 Identifier Setscrew Pin Hole E.
Road Simulator H. While holding the slip ring wires against the channel in the axle spacer, insert the axle sleeve through the slip ring and the axle spacer. I. Bend the slip ring wires 90° and into the slot on the end of the axle spacer. J. Insert the 9-pin connectors into their respective connector bracket on the side of the hub adapter. Note the orientation of the dovetail on the Board 1 and Board 2 connectors as shown in the figure on page 88. K.
Road Simulator C. Install the eight M8 bolts and flat washers through the hub adapter on the slip ring side. Lubricate the threads and under the head of each fastener with Molykote g-n paste. D. Following the inner bolt pattern sequence shown in the Torque Sequence figure on page 85, torque the eight M8 bolts (A through H) to the value for the first increment shown in Bolt Torque Increment on page 85. E. Repeat Step 9D for the final increment. 10.
Road Simulator 12. Attach the transducer output cable to the slip ring encoder connector and the J3 Transducer connector on each TI box. Route the cables along the swing arm or front fork tube using tie wraps to secure it. Ensure the cables are routed such that they will not contact any moving parts, such as the brake disk or wheel. Allow enough slack to accommodate the range of motion of the front fork tubes and swing arm. 13. Connect the power source to the J1 Power connector on the TI box. 14.
Zeroing the Transducer Interface Zeroing the Transducer Interface For fixed mode For the non-spinning (fixed) zero mode, use the TI2Xfer to download the fixed calibration file (serialnumberf.ca)l to the appropriate TI box. The angle mode in the file should be: AngleMode=1 Rotate the transducer such that the orientation labeling is consistent with the reference orientation. In most cases, this means rotating the transducer so the labels are upright.
Zeroing the Transducer Interface Note When the square head setscrew on the slip ring/encoder is aligned opposite the center of the flat on the axle spacer (between the mounting screws on the anti-rotate bracket when it is installed) the index mark is under the encoder sensor. 2. Rotate the adapter plate, as necessary, until the Fz on the axes icon (see the next figure) printed on the transducer label is pointing up.
Zeroing the Transducer Interface 5. Push the Zero button on the front of the TI box. The Zero indicators will toggle during the zero process. When the Zero indicators turn off the process is complete for this angle. Zero Button and Indicators 6. Remove the inclinometer. 7. Repeat Step 3 through 6 three more times. Before Step 3 of each iteration, rotate the adapter plate 90°. Always rotate the adapter in the same direction.
Zeroing the Transducer Interface 96 Installing the Transducer SWIFT 10 MC Sensors
Maintenance Overview This chapter contains scheduling guidelines and detailed instructions for performing preventive maintenance. Preventive maintenance is a set of routine procedures that allow you to extend the operating life of your transducer and the transducer interface electronics. The information provided in this chapter is a recommendation only. The actual time intervals will depend on the operating conditions at your facility.
Transducer The transducer requires a minimum amount of maintenance. 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.
4. Inspect the label affixed to the side of the transducer. Replace the label if it becomes loose, has been lost or is unreadable. Transducer Interface The electronics for your transducer have no internal parts that can be serviced by the user. The case is sealed against moisture. Breaking the seal by opening the case can void any warranty. As required Before making any cable connections to the TI box, inspect the area of the connector for accumulated dirt.
Maintenance SWIFT 10 MC Sensors
Troubleshooting This chapter covers basic set-up related troubleshooting tips. Please read this section to investigate problems that you observe. In many cases, these problems will be setup related and can be corrected as described in this section. Important SWIFT 10 MC Sensors In the event that these troubleshooting tips indicate that there is a component failure, or the correction tips do not correct the problem, contact MTS.
CAUTION The SWIFT sensor, TI electronics, and accessory components are not intended to be disassembled, other than as outlined in this section. Disassembling or tampering with these components may result in damage to the sensor, loss of watertight seal, and voiding of the warranty. Do not disassemble the SWIFT sensor, Transducer Interface (TI) electronics, and accessory components.
Troubleshooting Guide (part 2 of 10) SYMPTOM POSSIBLE CAUSES SOLUTION Zero Procedure: The Zero indicators stay on too long, or they continue to blink slowly, even after the wheel has rotated twice. The angular output signal is not reaching the TI. If the encoder signal is not reaching the TI, it may eventually time out and red fail indicator will light. Check that all cables are attached and undamaged. In particular, check the main signal cable from the transducer to the TI.
Troubleshooting Guide (part 3 of 10) SYMPTOM POSSIBLE CAUSES SOLUTION Zero Offset: One or more Signal Outputs appear to have a zero offset after the TI electronics have been zeroed. The transducer was zeroed with load applied (or a different load than the intended tare weight for non-spinning applications only). Rezero the TI, being careful not to touch or load the transducer during the zero procedure. TI was not warmed up before zeroing.
Troubleshooting Guide (part 4 of 10) SYMPTOM POSSIBLE CAUSES SOLUTION Zero Offset: One or more Signal Outputs appears to have a zero offset after the TI electronics have been zeroed. (Continued) The reference angle of the transducer is set incorrectly in non-spinning (fixed) mode. The AngleFixed value in the TI calibration file is initially set to zero, indicating that the coordinate outputs shown on the transducer label are correct when the label is upright.
Troubleshooting Guide (part 5 of 10) SYMPTOM POSSIBLE CAUSES SOLUTION Output levels are much higher or lower than expected Gains in the TI calibration file have been overwritten or modified. Use the TI2XFER program to upload the current TI calibration file (refer to, “Upload the Calibration File,” on page 52). Check that the gain settings match the original calibration file sent with the transducer.
Troubleshooting Guide (part 6 of 10) SYMPTOM POSSIBLE CAUSES SOLUTION Failed indicator lights after Shunt Calibration The signal cable is not connected to the transducer or it is damaged or the transducer is damaged. Perform TI2STATUS. Check that the proper calibration file was downloaded (the serial number in the report matches the transducer serial number. Check the error messages in the report.
Troubleshooting Guide (part 7 of 10) SYMPTOM POSSIBLE CAUSES SOLUTION The shunt reference values were changed. Use the TI2XFER program to upload the current calibration file. Check the file to verify that the variables ShuntDeltaRef are the same as shown on the original calibration file provided by MTS. The eight ShuntDeltaMeas values should read approximately 0.85 V. The shunt tolerance is not set correctly. Use the TI2XFER program to upload the current calibration file.
Troubleshooting Guide (part 8 of 10) SYMPTOM POSSIBLE CAUSES SOLUTION Reference Angle is 180° off. If the reference angle is 180° off, the output polarity of some channels may appear to be reversed. The reference angle can be verified as described later in this table. Reference Angle is incorrect Zero was done with antirotate device not attached, or attached with orientation different than test set-up.
Troubleshooting Guide (part 9 of 10) SYMPTOM POSSIBLE CAUSES SOLUTION A two-time-per-revolution of tire signal is showing up when the vehicle is driving straight on a flat surface. Gain settings: Verify that the TI electronics calibration file gain settings have not been modified. Using the T2IXFER program, upload the current TI settings and compare them to the original gain setting on the disk provided.
Troubleshooting Guide (part 10 of 10) SYMPTOM POSSIBLE CAUSES SOLUTION Spinning Application: Vehicle Coordinate System Outputs have unusual or incorrect waveform shapes to them. (Continued) A four-time-per-revolution of tire signal is showing up when the vehicle is driving straight on a flat surface. Wheel force transducers often have a modulation error with a cyclic frequency equal to the number of beams on the transducer.
Troubleshooting SWIFT 10 MC Sensors
Assembly Drawings This chapter contains the assembly drawings and parts lists relevant to the SWIFT 10 transducers.
Assembly Drawings SWIFT 10 MC Sensors
Cable Drawings Cable Drawings Cable Drawings PART NUMBER CABLE DESCRIPTION 572750-XX Cable Assy- SWIFT mini TI, 4 Bridge 572129-XX Cable Assy - SWIFT Mini TI, Power w/PT 572143-XX Cable Assy - SWIFT Mini TI Power w/lug 100-179-353 Cable Assy - SWIFT mini TI, Monitor SWIFT 10 MC Sensors Assembly Drawings 115
Cable Drawings 120 Assembly Drawings SWIFT 10 MC Sensors
SWIFT 10 Mechanical Drawings SWIFT 10 Mechanical Drawings SWIFT 10 MC Mechanical Drawings PART NUMBER PART DESCRIPTION 700-004-298 Slip Ring/Encoder - Reference, SWIFT 10 MC 700-004-142 Rim Assy - Ref Dimension, SWIFT 10 MC 100-180-624 Rim Assembly - Front 21 X 1.60 Rim, SWIFT 10 100-174-333 Rim Assembly - Rear 19 X 2.
M8 X 1.25MM TORX PAN HD SCR (20 THIS SIDE, 20 OPP. SIDE) 7 STOCK RIM 3 REF LEFT HAND OUTER HUB IS 1 STAMPED WITH "1L", TO BE LOCATED AT BEAM 1 ON TRANSDUCER RLJ 3 2 OUTER HUB 2 3 OUTER 2 HUB 3 LETTER 11-07 RAM REPLACED ITEM 5, P/N 100-179-595, ON SHEET 2 WITH P/N 100-199-670. REPLACED ITEM 4, P/N 100-179-594, ON SHEET 3 WITH P/N 100-199-669. ADDED ITEM 27, P/N 100-198-826. RLJ TRANSDUCER ASSEMBLY RULE 1 B 43.4 1.71 1 DATE ADDED SHEET 2-5, BALLOONS AND NOTES. C 2 16 40 ENGR DRAWN 86.
LETTER ENGR DRAWN ECN NO REVISIONS DESCRIPTION DATE AXLE SPACER 11 20 28 2 OIL SEAL O-RING SEALED BALL BEARING 19 INNER HUB ADAPTER 5 4 SEALED BALL BEARING 19 INNER HUB ADAPTER 5 B .
6 CONDUCTOR, BOARD 1, 9-PIN SLIP RING CONNECTOR ENGR DRAWN LETTER DESCRIPTION ECN NO REVISIONS PIN HOLE FOR SETSCREW (USE FOR ORIENTATION) 11 DATE SLIP RING LEAD OUT WIRES 11 TO SYSTEM CABLE ASSEMBLY 24 SQUARE HD, FULL DOG 11 POINT SETSCREW AXLE SLEEVE 13 18 2 AXLE SLEEVE 13 SLIP RING/ENCODER 12 CONNECTOR BRACKET 4 INNER HUB/ BRAKE DISC ADAPTER 8 SLIP RING/ENCODER 19 SEALED BALL BEARING 8 10 LOAD SPACER 10 LOAD 10 SPACER 5 CONDUCTOR, BOARD 2, 9-PIN SLIP RING CONNECTOR 4 INNER HUB/
ENGR DRAWN LETTER DESCRIPTION ECN NO REVISIONS FRONT FORKS (REF) 17 M8 X 1.25MM X 16MM LG 8 HELI-COIL INSERT DATE 15 FLAT WASHER 8 14 M8 X 1.
ENGR DRAWN LETTER 140 5.51 ECN NO REVISIONS DESCRIPTION DATE 70 2.76 RUN SLIP RING/ENCODER OUTPUT CABLE THRU ANTI-ROTATE BRACKET AND RESTRAIN ALONG THE BRAKE CABLE AS NECESSARY D O-RING TO SEAL O.D. OF SLIP RING 1 .040 41.1 1.62 82.3 3.
LETTER ENGR DRAWN ECN NO REVISIONS DESCRIPTION DATE B OUTER HUB ASSY RLJ C STOCK RIM 3 7 RLJ A 6 36 LEFT HAND OUTER HUB IS 1 STAMPED WITH "1L" TO BE LOCATED AT BEAM 1 ON TRANSDUCER 11-07 RAM ADDED PLUG SEAL, ITEM 28, P/N 100-198-825. RULE 1 126.24 4.970 RULE 1 ADDED SHEETS 2-5, BALLOONS AND NOTES. 7-08 RAM 63.12 2.485 23 MODIFIED STRAIGHT SPOKES 3 REF W/STOCK SPOKE NIPPLES M8 X 1.25MM TORX PAN HD SCR (20 THIS SIDE, 20 OPP.
LETTER ENGR DRAWN ECN NO REVISIONS DESCRIPTION DATE AXLE SPACER 11 OIL SEAL 20 B 6 STOCK SPROCKET 30 REF SEALED BALL BEARING 5 5 19 2 INNER HUB/ SPROCKET ADAPTER OIL SEAL 20 30 STOCK SPROCKET REF AXLE SPACER 11 PLUG SEAL 28 INNER HUB/ SPROCKET ADAPTER O-RING 5 29 2 LOAD SPACER 9 10 LOAD SPACER 4 APPLY GREASE ON DIAMETER TO REDUCE FRICTION BETWEEN AXLE SPACER AND OIL SEAL B 27 6 28 REF 29 REF M8 X 1.
31 STOCK BRAKE DISC REF 6 CONDUCTOR, BOARD 1, 9-PIN SLIP RING CONNECTOR SLIP RING LEAD OUT WIRES TO SYSTEM CABLE ASSEMBLY 12 ENGR DRAWN LETTER DESCRIPTION ECN NO REVISIONS PIN HOLE FOR SETSCREW 12 (USE FOR ORIENTATION) DATE INNER HUB/ BRAKE DISC ADAPTER 4 SLIP RING KEYWAY AXLE SLEEVE 13 SQARE HD, FULL DOG 24 POINT SETSCREW 12 THRU SLOT (2 LOCATED 180 APART) FOR ROUTING 9-PIN SLIP RING CONNECTORS (REF) 12 13 SLIP RING/ENCODER 8 5 CONDUCTOR, BOARD 2, 9-PIN SLIP RING CONNECTOR 19 SEALED BALL
ENGR DRAWN 15 8 14 8 23 2 25 1 FLAT WASHER M8 X 1.25MM X 110MM LG 16 SOCKET HEAD CAPSCREW 17 LETTER DESCRIPTION M8 X 1.
96 3.78 18 ANTI-ROTATE BRACKET 23 2 25 1 DATE O-RING IS TO SEAL O.D. OF SLIP RING D DETAIL E SCALE 1 : 1 ROUTE SLIP RING/ENCODER CABLE THRU ANTI-ROTATE BRACKET AND RUN ALONG SWINGARM AS NECESSARY SOURCE/REF DRAWING PROPRIETARY DATA THE INFORMATION AND DESIGN(S) DISCLOSED HEREIN ARE CONFIDENTIAL AND THE PROPERTY OF MTS SYSTEMS CORPORATION AND MAY NOT BE USED, REPRODUCED OR DISCLOSED IN ANY FORM EXCEPT AS GRANTED IN WRITING BY MTS SYSTEMS CORPORATION.
ENGR DRAWN LETTER 4X 3.074 DATE CHANGED .346 DIA THRU (4) TO .500 DIA THRU. B 4X 2.560 4X 2.210 RLJ 4X 1.792 4X .500 THRU RULE 1 DESCRIPTION ECN NO REVISIONS 2X 3.125 11-07 JLS .125 4X .564 20X .001 .346 THRU .001 A A 5.620 4X 3.125 4X 3.074 4X 2.560 4X 2.210 4X 1.792 4X .564 6.
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 Internet: www.mts.
