SWIFT® 50 GLP Sensor Installation Instructions Spinning Wheel Integrated Force Transducer For Medium and Heavy Trucks 100-176-179 A m
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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 In
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.
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.
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.
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.
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.
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 Pre
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.
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.
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.
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 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.
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.
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).
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.
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.
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.
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.
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 Ma
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 Icons Hazard Icons The following hazard icon is part of the label affixed to the side of the SWIFT 50 GLP Sensor.
Road and Track Vehicles Road and Track Vehicles Equipment required This procedure requires two people.
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
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 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.
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.
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).
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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