Sensor Developments 90305A Telemetry Transmitter User Manual
Sensor Developments Inc. Telemetry Transmitter Users Manual
Users Manual
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| Date Submitted | 2007-11-29 00:00:00 |
| Date Available | 2007-11-29 00:00:00 |
| Creation Date | 2007-08-31 10:17:48 |
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| Document Lastmod | 2007-08-31 11:04:26 |
| Document Title | Users Manual |
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FM Telemetry Steering Effort Sensor
from Sensor Developments
Model 01184
[Installation & Operators Manual 24
© October 1996, 2000
Sensor Developments
1050 W. Silver Bell Rd.
Orion, MI 48359
(888) SENSOR-1
(248) 391-3000
www.sendev.com
TOC
Table of Contents
Introduction
System Overview ....................................................
System Components
Installation 5
Operating the System 9
Calibration. 9
Collecting Data .. 9
_—.——-——-—-———————————-———-—————————_
Overview of System Electronics 10
Model 90338 FM Transmitter ......................................... 10
Model 90330 FM Receiver/Encoder to Analog Convener. 11
Appendix 16
Specifications ......................................................................... 16
Wm
Steering Effort Sensor Manual 2.4 ii
Installation
Introduction
System Overview
Sensor Developments‘ FM Telemetry Steering Effort Sensor (Model 01184) is designed to
measure the amount of effort needed to turn the steering wheel and the angular position of the
steering wheel. This system provides:
' a 10 in. through—hole for uninhibited deployment of an air bag without the
danger of the sensor being projected at the driver,
- a low mass-moment of inertia,
- selectable resolution for angular mmmement (0.2‘7 or 0.05“), and
- Non contacting torque signal transmission which permits unlimited wheel
rotation.
System Components
The system consists of the following:
- a steering effort sensor with,
- an FM teleme‘uy transmission system,
- an angular position sensor, and
' an analog converter.
The Steering Effort Sensor
The steering effort sensor is an auxiliary steering wheel with 12 in‘ 0D. The sensor mounts to the
vehicle's steering wheel with four cable ties The sensor has four adjustable mounting plates to fit
steering wheels fi'om 14.5—16 in. 0D. The sensor has a 2.6 in. offset from the steering wheel.
(See illustration on next page.)
The FM Telemetry Transmission System
The non-contact data coupling system consists of a Sensor Developments Model 90338
transmitter and Model 90330 receiver. The transmitter is mounted to the steering effort sensor.
Power to the transmitter is supplied by a 9 volt battery.
Note: SDI recommends replacing this battery at the beginning of each test day.
Steering Effort Sensor Manual 24 3
Installation
Steering Effort Sensor Manual 2.4
lnstallation
The Angular Position Sensor
Pm mused vacuum cup
. . . 00.5" Eur mounting to windshield
The angular posmon sensor 15 an
optical encoder mounted on the
inside of the front windshield. A
' ' ' - on a ' x a l
dnve tram assembly rotates the drive mmflmm;
shafi attached to the encoder as the m awwntlov steering
waking n a
wheel oocmuiciliesl: 0.5"] Entire! Oink
steering wheel sensor is turned.
Encoder Dliuefhin —/
Positivn'm Pin
Figure 2
@ Fen-am; @
JJ LL
Figure 3 - The Model 90330 FM Receiver/Encoder to Analog Converter
The Model 90330 (figure 3) produces analog outputs from both the torque sensor and the
encoder.
Installation
To install the system:
Step 1: Mount the steering effort sensor to the vehicle's steering wheel.
A. Position the sensor so that the it rests firmly against the front of the steering wheel,
keeping the antenna away from the steering wheel spokes.
Br Adjust all four mounting brackets for the proper fit. Make certain to adjust all four
brackets symmetrically.
Steering Effort Sensor Manual 2.4 5
Installation
(D Lansen inn screw
/ Q Steering Wheel Rim
Nnh (m cable m ONLV.
® Allyn Ihs mum
hvl- tar 1h. fleeting
wh-ul m on
(“Sm-15mm
the mummy brackei
tn 1m hale in ms
15 ‘ mm; mm plate
® Rumm- lowev maw
(D Tlghtsn bath screws
Figure 4
C. Tie the steering effort sensor to the steering wheel using one cable tie for each of the
four mounting brackets
Di Pull the cable ties finnly to lighten, and then trim the ties. (If not trimmed the ties
may interfere with the drive train.)
Step‘Z: Mount the angular position sensor to the inside of the windshield
A. Push the gear all the way up the linear ball slide, and place the positioning pin
through the holes in the front and rear of the optical encoder to limit its travel to the
midpoint,
Pump actuated vacuum cup
“5" to! mounting to windshleld
Encoder is mounted
aha linear ball slide
to aceounttat steering
wheel ecoemrieitiesu 0.5"1
Encoder Drive Chain —/
Figure 5
Steering Effort Sensor Manual 2.4 5
Installation
B. Place the drive chain around the gear of the steering effort sensor,
C4 Position the angular position sensor on the windshield so that:
- the angle encoder is NOT in the drivers direct line of Vision,
- {the drive chain is taut, and
0 the encoder gear is in the same plane as the gear on the steering
wheel
Approx. 185 in
Align arrow on label
with center line of
Steering Effort Sensor
Figure 6
Steering Effort Sensor Manual 2.4
Installation
D. Attach the angular position sensor to the windshield by pumping the
suction cup's plunger. Pump it until the red stripe is no longer visible.
E. [If necessary] adjust its position by loosening the knobs, and sliding the
bracket to the correct position (See drawing on page 5 or 8).
F. Adjust the angle ofthe encoder so the arrow on its label is pointing
directly toward the center of the steering wheel by loosening and the
tightening the ball and socket joint
G. Remove the positioning pin from the front and rear holes of the angular
position sensor, and place it through the side holes.
H. Rotate the steering wheel to ensure that the encoder (on the angle position
sensor) can travel along the linear ball slide without restriction.
Step 4: Connect the angular position sensor (encoder) to the Model 90330, and then connect the
encoder signal outputs of the Model 90330 to the data acquisition system.
Step 5: Connect the torque sensor signal outputs of the Model 90330 to the data
acquisition system.
Step 6: Connect a 9 V alkaline battery to the sensing element. Use the power switch to control
power to the transmitter.
Note: SDI recommends installing a new battery at the beginning of each test day.
Steering Effort Sensor Manual 2.4 8
Operating the System
Operating the System
Calibration
This unit was calibrated at the factory. Calibration sheets have been provided with the unit
specifying what each output will provide for a given input. The calibration on the torque output
can be measured very accurately using the shunt cal. Refer to figure 7 for location of the shunt
button. When the shunt button is pressed, a resistor is placed across a leg of the bridge, which
produces a very repeatable simulated torque on the sensor. The shunt button is a momentary type
button and will release the shunt when the button is released. To calibrate the torque sensor to
the data acquisition system:
Step 1: Place the steering effort sensor at the desired neutral position
Step 2: Adjust the “zero” potentiometer until the output voltage is 0 volts.
Step 3: Zero/tare the data acquisition system.
Step 4: Press the shunt calibration button on the sensing element and measure the simulated
output produced. The output should reflect the number on the data sheet provided by
the manufacturer.
Step 5: Input the simulated torque value to the data acquisition system.
Step 6: Alternate... use the capacity and full scale output numbers provided on the data sheet for
the values entered into the data acquisition system. Use the shunt to verify cal.
The angle outputs do not have a simple method of verifying calibration, and if more than a
“ballpark” verification is needed, an angle fixture will be required. To calibrate the angle outputs
to the data acquisition system:
Step 1: Place the steering effort sensor at the desired zero position,
Step 2: Momentarily press the encoder zero button on the Model 90330. See figure 10 for
location of this button.
Step 3: Zero/tare the data acquisition system on each encoder channel.
Step 4: Enter into the data acquisition system the range and output values from the data sheet
provided with the sensor.
Collecting Data
Torque and position data are transmitted automatically and continuously when the system is
powered up.
Steering Effort Sensor Manual 2.4 9
Overview of System Electronics
Overview of System Electronics
Model 90338 FM Transmitter
The transmitter consists of a strain gage amplifier, a 4 pole low pass butterworth filter, analog to
digital converter, control electronics, and a 900MHz FM radio transmitter. The basic operation
is that, when powered up, the transmitter amplifies the signal from the torque sensor, filters it,
digitizes it and sends it out on a radio carrier to a receiver on the same channel
Figure 7
Under normal operation, the power indicator (see figure 7) will blink indicating that the unit is
powered up and transmitting normally The power switch (figure 7) controls power to the unit.
The shunt button is used to verify calibration of both this sensor, and any subsequent data
acquisition system. It is a momentary switch that, when pressed, applies a shunt resistor to the
sensor bridge. This has the effect of producing a simulated output from the sensor, and likewise,
a signal will be produced at the receiver’s output. The shunt is very repeatable and calibration
information for its effect is documented in the calibration data provided with the sensor.
All data sent from the transmitter is encoded with a checksumr This is an error detection scheme
that is used by the receiver to tell if the received data was good. When the transmitter’s battery
gets low, the transmitter will intentionally corrupt the checksum before sending it. The receiver
will continually see the transmission as in error. Replace the transmitter’s battery when this
occurs.
This transmitter is equipped with 8 FM channels located in the 900MHz band The frequencies
are listed in table 1. Changing channels on this unit is done by selecting the proper switch
combination See figure Sr Be sure to switch the receiver to the same channel.
Steering Effort Sensor Manual 2.4 10
Overview of System Electronics
Table 1 - Channel Selections
C80 682
CS1
Figure 8 - Channel Select Switches
Model 90330 FM Receiver/Encoder to Analog Converter
The Model 90330 consists of a 900MHz radio receiver, control electronics, digital to analog
(D/A) converters and buffer/filters. Basic operation is:
Step 1: Connect to the required signal outputs as shown in figure 9a or 9b.
Step 2: Connect the encoder as shown in figure 10.
Step 3: Screw on the antenna as shown in figure 10.
Step 4: Select the desired channel by the proper switch combinations as shown in table 2, Use
Steering Effort Sensor Manual 2.4 1 1
Overview of System Electronics
figure 10 as a reference for the switch location.
Step 5: Connect power to the power input pins as shown in figure 10 and turn on the power
switch.
ENCODER SIGNAL OUT FM SIGNAL OUT
A ngh Resolution Sig A Sig
a High Reaolution Gnd n Gnu
C Low Resolution Slg C N10
[1 Low Resolulinn Gnd 9 <3 0 D we
E R515 Sig mm 91an our 5 : “$35 1955 E N/C
F Rate Gnd ° N F N/c
Figure 9a — Model 90330 PT Style Connections, side 1
com 6— SIGNAL @ ©
0 0
Rm 2: R2; New 5 2 am so.»
POWER IN & msrrAL OUT < ENCODER INPUT
A sz “$2333.35” I u n A +5v
BGnd mg; mt scna
0 Good Data Relay-N10 “W “ ' ‘ ' c on A
D Good Data Relay—Common Q Q 0 Wm D Gnu
5255232 Out “an" D V; fifli’l “5m“ W
Figure 10 - Model 90330 Connections, side 2
Steering Effort Sensor Manual 2.4 12
Overview of System Electronics
Table 2 - Channel Selections
The unit will receive a digital signal from a near-by transmitter on the channel selected in step 4
above. When this happens, the yellow “carrier detected” indicator will light. The green “good
data" indicator will light showing that the digital data was recovered without error, The good
data is then fed to the Digital to Analog converter, and on to the analog output. The analog
output is buffered and filtered. The filter is there to smooth the steps that are inherent in the
output of the D/A converter. In the event that the data is found to be in error, the good data light
will go out, a beeper will sound a short tone and the good data relay contacts will close. In the
event that the unit loses power, the relay contacts will rest in the closed position, indicating an
error. The contacts are available at the power connector as shown in figure 10.
The encoder’s position and rate of change are available at the encoder output connector. As with
the sensor output, the encoder outputs are buffered and filtered. Since the encoder input is
compatible with incremental encoders only, the position output must be zeroed. To do this,
position the encoder to the desired zero position, and press the “zero encoder” button See figure
10. This button is recessed in the panel to prevent accidental zeroing. The zero value will be lost
if power is removed. The encoder’s output connector prow'des 2 position signals, thus providing
2 available resolutions. Refer to page 16 of this document for specifications on resolution and
rate.
This unit comes with adjustments for zero and span on the sensor output, along with a span
adjustment for the meter. Note that, in pre-installed and pore—calibrated systems, the span
adjustments have been set at the factory, and covered with a calibration sticker. In this use, do
not adjust the sensor or meter span or the calibration information fiunished with the system will
be void, and a recalibration will be required. The meter is simply a voltmeter connected to the
sensor output signal. Adjusting the meter span has no effect on the sensor span, but adjusting the
sensor span will effect the meter span. For the sensor output, the zero adjustment range is +/—
20% of the full-scale output range and the span adjustment range is +/-10% of the full-scale
output range. The meter has a span adjustment range that covers 0 to 2000 counts with a decimal
point that is factory set. With 5 volts at the sensor output, units that have the meter configured
for voltage will be adjusted to show 5.00 counts. Units that have the meter configured for
engineering units will show those units in a unit that best fits the display. For example, if the
Steering Effort Sensor Manual 2.4 1 3
Overview of System Electronics
sensor capacity was 7000 pounds, the meter would display 7.00 and the units would be
understood to be in 1000’s of pounds.
When measuring the signal outputs, note that the signal ground is isolated from the power supply
ground to prevent ground loops. Measurements must be taken with respect to the signal ground
and not the power ground, The sigial ground is common for all output signals. The signal
ground may be connected to the power supply ground without damaging the unit. Some
applications may require that they be connected. For example, when using a DAQ system with
differential inputs to read these signals, it is important to ground the negative signal input on the
DAQ system to provide an absolute point of reference for the input. Without such a connection,
erroneous data may be collected For DAQ systems with grounded single-ended inputs, this is
not an issue.
The Model 90330 is equipped with an RS—232 serial port for connection to a computer. See
figure 10 for connector wiring. Data from the serial port reflects the sensor data only. The
encoder data is not sent out the serial port. The data output is a binary number (12 bit A/D
conversion) that requires the receiving program to scale the data and decide if the data is good or
not, based on a flag set or cleared by this receiver. Data is sent out at 38.4 Kbaud and the format
is 8 bits, 1 stop bit, no parity (8,1,N). The format of the data is high byte, low byte. The A/D’s
highest 6 bits are located in the lowest 6 bits of the first byte. The msb of the first byte is 1 to
mark it as first. The next bit is the error flag, which is 0 if the data is good, 1 if it was bad. The
second byte contains the A/D’s lowest 6 bits located in the lowest 6 bits of the byte. The msb of
the second byte is 0 to mark it as second. The next bit is a null bit that will always be 0. For
example, if the A/D reading was 4095 counts, the binary representation of the reading would be
111111111111. Assuming the data was good, the first packet sent would contain 10111111 and
the second packet would contain 00111111. If the data had been bad, the first packet would
contain 11 1 1 1 11 1 and the second packet would contain 00] l 1 l 11.
The following notice applies to both the Model 90338 transmitter and the 90330 receiver. In
each case, where it refers to “this device”, substitute both units.
Steering Effort Sensor Manual 2.4 14
Overview of System Electronics
FCC NOTICE
Changes or modifications not expressly approved by the manufacturer could void
the user’s authority to operate the equipment.
This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation. This device generates, uses, and can
radiate radio frequency energy and, if not installed and used in accordance with the instruction,
may cause harmful interference to radio communications However, there is no guarantee that
interference will not occur in the particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by turning the equipment
off and on, the user is encouraged to try to correct the interference by one or more of the
following measures:
1. Reorient or relocate the receiving antenna.
2. Increase the separation between the equipment and receiver.
3 Connect the equipment into an outlet on a circuit different fiom that to which the
receiver is connected,
4, Consult the dealer or an experienced radio/TV technician for help.
Steering Effort Sensor Manual 2.4 _ 15
Appendix
Appendix
SPECIFICATIONS
MunitmsdumLData
Capacities .....................
Output at Full Scale (nominal)
Optional Output at Full Scale (nominal)
200, 500, 1000 in-lbs
.:t 5 V
Overload Capacit .4 50%
Hysteresis O.25% ofF.S.
Non-linearity 0.25% of RS.
0.20 in—lbs sec2
12 bits (11 bit + sign)
Mass moment 0 inertia (calculated) .
Resolution ..
Sample rate . t 1250 samples/second
Low pass anti-aliasing filter . 4 pole @ 300Hz
Power supply input 7.5 — 20VDC
Power supply current 4444444 30mA
Recommended battery ................................................ . 9V Alkaline
Approximate battery life with recommended battery 8 Hours
SmmdanLSteefingflhml
0D
Offset
El! [ I . . 5
Analog Output (nominal)
i10V
Optional Analog Output (nominal)
Output low pass filter 2 pole @ 1000Hz
Resolution .. 0.05% of RS.
Transmitter . 9 V battery
Receiver . 12 V e unregulated
Transmitting range .................... 10 it.
I! . . 5! I I S
Encoder ................................................................................................................ 7,200 ppr
Low Resolution Output
Resolution ........ .0.20 degrees
Maximum Range 1638.4 degrees
Output at maximum range . ....... i 5VDC
Optional Output at maximum range ......... i 10VDC
Update rate 56 updates/second
Low pass filter ...42 pole @ 50Hz
Steering Effort Sensor Manual 2.4
Appendix
High Resolution Output
Resolution ................................................................... 0.05 degrees
Maximum Range ............. i 409.6 degrees
Output at maximum rang i 5VDC
Optional Output, at maximum range. .. i 10VDC
Update rate 56 updates/second
Low pass filter ..... 2 pole @ 50Hz
Rate Output
Resolution .............. 2.8 degrees/second
Maximum range +/- 1000 degrees/second
Signal Output at maximum range ...................... i 5VDC
Optional Signal Output at maximum range ......... t lOVDC
Update rate 56 updates/second
Low pass filte . ..... 2 pole @ 50Hz
5.12 nun] [S I] [ll]
Update Rate .................................................................................... 1250 updates/second
Baud rate ........................................................................................ 38.4Kbaud, 8, l, N
WWI]
Voltage range ......
Current Consumption
SERVICE WARRANTY
Sensor Developments warrants its products to be free fi'om defects in material and workmanship
for a period of one year from shipment from our factory. In that period we will, at our option,
repair or replace a defective component or entire product which has been submitted for our
examination. This is our sole obligation. We are not responsible for any costs or liabilities arising
from but not limited to de-installjng, consequent or collateral damage, delays, loss of use, re—
installing, or any others. The warranty is in effect provided the component or product is properly
used in the application for which it is intended. Products which have been modified without
Sensor Developments’ approval, on which repairs have been attempted by non—qualified persons,
which have been subjected to physical or electrical stress beyond our ratings, or which have had
their identifying marks removed or altered are not covered by this warranty.
In cases of incorporation of a product by the user in a larger system provided by a third party or
sold on to a third party, we make no warranties except those above. We assume no responsibility
for fitness for purpose in these circumstances.
Warranty retums must be authorized by us and shipped prepaid to us. Our return authorization
number must appear on the packaging and any correspondence. We will return the goods prepaid.
Products, which have been exposed to hazardous materials, will not be accepted unless they have
been properly decontaminated. Sensor Developments reserves the right to refiise any shipment
which it believes may create a physical or health hazard to our employees.
Steering Effort Sensor Manual 2.4 17
Appendix
Products returned out of warranty for repair are subject to a minimum inspection fee The fee is
waived if the repair is authorized. It is also waived if the product is un—repairable and/or a
replacement is purchased.
REPAIR SERVICES
Sensor Developments’ products requiring repair should be returned freight prepaid to: Attention —
Service Department. Information should be included stating what is wrong with the item(s)
returned and name of contact. No item shall be returned for repair which has been exposed to
hazardous materials Without suitable decontamination. Hazardous materials include, but are not
limited to: poisons, materials capable of producing toxic fumes, radioactive waste materials
which can spread viral or other diseases and materials which pose hazards by airborne ingestion,
such as asbestos. Sensor Developments reserves the right to refuse and/or return any shipment
which it believes poses any health risk to its employees. Unless the repair is covered under the
terms of Sensor Developments’ warranty, there will be a minimum inspection and evaluation fee
for each item returned. This fee may be waived if the item proves non—repairable, and a
comparable replacement is ordered.
Revised: August 10, 2007
Steering Effort Sensor Manual 2.4 18
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