Application areas:
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car
challenge:
Create a new dynamometer that can accommodate the high speed and acceleration levels of a Formula 1 car and complete these tests in actual wheel and suspension assembly.
application solution:
The new system will be based on an industrial Pentium 4 HT 3.2g Hertz computer with 1GB of memory, using NI data acquisition and control cards, and software compilation is done in the LabVIEW graphical programming environment.
Products used:
Data Acquisition (DAQ), Dynamic Control, PXI/CompactPCI
For more than 30 years, AP Racing has been a world leader in the technology and production of brake calipers and racing clutches. AP Racing has come to the conclusion that in the process of continuously surpassing existing products, if a new dynamometer has the following capabilities, it will have obvious advantages:
* It is capable of testing the equipment and testing the brakes and brake calipers during actual wheel and suspension assembly.
* It has enough power to accurately simulate the speed and acceleration of a Formula 1 car.
* It simulates the air flow around the brake calipers and enables air flow studies through different pipe designs.
* It can import tracking data for braking conditions and acceleration conditions.
Because AP Racing has a very strong design capability, they decided to build the equipment in the site, which will help reduce costs and better control system performance. For software and electronic control systems, AP Racing selected our Computer Control Solutions (CCS) based on our experience in the field and a range of test machines we have previously used for AP Racing maintenance.
The system is based on an industrial computer with a Pentium 4 HT 3.2 Hz, 1GB of memory and the following capture cards:
*PCI-DIO-96 provides 96-bit input and output
*PCI-6033E provides 8-bit and 64 analog input
*PCI-7344 four-axis controller
We connect these boards through various signal conditioning devices to control and measure the following system links.
*288 kW converter
*240 kph inflow air flow control
*Hydraulic servo control system for brake pressure
*Measurement of torque, temperature, infrared temperature, pressure and speed
* Converter for controlling the mechanical plane
*Water cooling and monitoring
*heating and monitoring
* on-board capacitors and replacement
We write software entirely in the LabVIEW graphical programming environment. The main design elements are the following:
*Intuitive: We put all the functions of the design process into the main menu, so that the operator can find all the input and output item by item, establish the test, run the test, and analyze the data. There is also a simplified menu option that turns this interface into a basic form that can run pre-design tests.
* Calibration screen: We made full use of the TFT dual display and designed the calibration screen to provide a tabular display of all input and output on the left screen. These tables are great for verifying engineers to look at and check inputs and outputs. The screen on the right includes a complete device simulation map that is very useful for identifying the location of the drive and controller.
* Modular for test development: We subdivide each aspect of a test into each module (for example, applying brakes, turning speeds, cycling, acquisition start and stop). Users can build the entire test component by adding these modules to a simple list.
* Intuitive running screen: Using the speed advantage of LabVIEW, we were able to display the entire running screen, marking the location of the test, the simulation, double page display and status information.
Use the latest version of LabVIEW and NI-DAQmx control
During the final system development process, NI released LabVIEW 7.1 and NI-DAQmx. After researching this software, we decided to upgrade to the latest version of the system, because this latest version of the system brings several important advantages, as follows:
* Smooth and convenient LabVIEW version upgrade: Before the product was released, we assisted in the debugging of the beta version, which gave us initial confidence in the product. We also found that the newly released products are very stable and easier to upgrade.
* High-speed data acquisition: The system's design capabilities include continuous save and display control of graphs and charts. It is displayed on two screens at a rate of 2 kHz per channel. With the implementation of the NI-DAQmx code, we saw that the data acquisition rate has increased by about 5 times, so we free up space for the system to achieve more real-time control and display.
*Nonlinear acquisition: By using NI-DAQmx, we automatically apply a set of nonlinear acquisitions to the infrared temperature drive, which eliminates post-processing and allows these linearized channels to be displayed in real time.
* Installation screen implementation: We used the latest implementation of the installation screen, showing the status of each specific point in the test on the installation screen on the main running screen. One of the advantages we have experienced is that its main screen is always the focus, so when we run the installation screen, the end button is always active.
Design Challenge: High Speed ​​Independent Closed Loop Control
The system requires the following closed loop control:
* Torque Control: Controls the applied brake torque to match the level of actual conditions, general level and speed.
* Pressure Control: Control the pressure on the brakes to match the level of actual conditions, general levels and speed.
* Simulate air flow in ducts and brake-based speed output
*Speed ​​Control: Motorized Reverser Control
For this application, there are servo control cards with a variety of similar or DSP solutions. However, we found that the NI four-axis dynamic controller is fully adapted to this system. The main reasons for this solution are as follows:
* It is fully controlled in the LabVIEW environment: it is very important from a software maintenance perspective because it avoids version control issues and additional installations that occur with other software products and associated code bases. Inconvenience caused.
* Low cost: Compared to other DSP implementations or servo controllers, the price/performance ratio is unparalleled.
* It has a high PID loop rate: a PID loop rate of up to 16 kHz ensures that the PID control consists of macro commands that are easier to control than some general controllers, providing very smooth mechanical activity and control.
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