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Dynamometer Automation |
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Innosiv develops a challenging simulation and control system using FPGA and Real Time technology. |
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ATE over Ethernet |
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Innosiv develops turnkey ATE solutions using COTS and LabVIEW for production quality testing |
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Mission Critical Data Logging |
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Innosiv develops rugged and mission critical data logger using cRIO, FPGA and LabVIEW.
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Repairing Composite Structures |
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Innosiv develops test and control application used for field repair of aircraft structures. |
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Optimizing Fuel Injection |
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Innosiv helps aviation research for optimizing turbine fuel injection with a laboratory automation. |
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Testing Radio Emission |
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Innosiv develops production test software for RF emission mask qualification. |
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Testing Automotive Parts |
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Innosiv develops comprehensive test automation software for automotive electromechanical assemblies. |
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Distributed Environmental Monitoring |
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Devloping a monitoring, logging and alarm management system for more than a hundred sensors. |
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Dynamometer Automation |
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Automating an All Wheel Drive Chassis Dynamometer with FPGA and Real Time Technology
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Emissions Research and Measurement Section of Air Quality Research Division is a Canadian national leader in measuring emissions from vehicles, engines and equipment powered by the internal combustion processes. The section provides state of the art vehicle dynamometers and test facilities for testing heavy and light duty vehicles.
When adding a simulation and control system for an all wheel drive dynamometer, Environment Canada awarded a contract to Innosiv Engineering to develop the software/hardware for this automations system.
The vehicle to be tested is placed with its wheels on the front and rear rolls of the dynamometer. As an operator drives the vehicle, the automation system measures vehicle speed, acceleration and torque while controlling the two DC motors. The motors are controlled to accurately simulate the road resistance and aerodynamic drag as if the vehicle was driven on a road.
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Equipped with advanced sampling and analysis equipment, the facility thus allows characterizing the vehicle emission and studying the effectiveness of alternative fuels amongst many other research uses.
Innosiv chose National Instruments compact RIO (cRIO) as the data acquisition and control platform for this application. While presenting a small footprint, cRIO with its FPGA backend and a high power real time controller provides a cost effective and yet technically advanced hardware. The cRIO controller operates in real time and is interfaced to a Windows desktop using Etherenet for all user interface and data logging tasks.
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Automating an all wheel drive dynamometer presents several technology challenges.
Fast & Real Time System:
Real time reaction to dynamics of a fast moving vehicle requires a fast control loop running within a small fraction of a second. In our solution, the cRIO FPGA loop, performing all measurements and safety checks, runs a million times every second. The control loop on the real time embedded processor iterates 250 times a second providing an excellent dynamic response.
Measurements:
The quality of all measurements and specially that of speed and acceleration directly reflects in the dynamometer’s ability to control and to simulate with high fidelity. The technology in our solution provides several unique and advanced measurement features including:
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Custom de-bouncing for digital inputs
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A novel and accurate acceleration measurement based on timing of encoder pulses instead of traditional pulse counting method
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Modular I/O modules with fast response time, large dynamic range, excellent linearity and industrial reliability
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NI LabVIEW empowered Innosiv to develop the Windows software as well as the real time and FPGA code running with high loop rates. A custom TCP/IP based data and messaging approach was used to link the Windows host computer running the user interface data logging and measurement tasks with real time controller located close to I/O wiring cabinet.
Researchers and operators benefit from viewing the real time live data in graphical views and in preferred units. A menu driven approach launches different windows for measurement and system configuration tasks making it a friendly and intuitive user interface.
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The new control system was designed, developed and deployed in a short period of a few months. Code modules and control algorithms were individually tested and validated to achieve the overall performance that now allowed to:
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Calibrate troque loss
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Calibrate load cell
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Zero sensor offsets
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Measure base inertia
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Find motor models
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Remote motion control
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Interface to breaks
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Interface to ventilation
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Analog speed output
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Manual torque control
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Manual speed control
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Vehicle data base
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Real time PID tuning of system
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Data logging and display
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Vehicle simulation for front or rear wheels
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All wheel drive vehicle simulation
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Interlocks and safety implementation
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SAE compliant coast down procedures to find vehicle coefficients in single and dual roll modes
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The control system provides a failsafe real time operation of the all wheel drive chassis dynamometer with remarkable performance:
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Vehicle coast down procedures determine the dynamometer simulation coefficients with a few iterations and as per industry standards. The coast down timing is reproduced within one tenth of a second and with a force error smaller than 10 N.
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In all wheel drive mode, the slippage between front and rear wheel speeds is kept to a minimum of ~0.01 m/s. With several km of drive, the differential distance traveled by front and rear wheels is of the order of a few cm.
“Innosiv proved their excellent engineering capabilities by designing and delivering our new all wheel drive dynamometer control system in a short period of a few months and within budget. Their professional expertise and enthusiasm to approach this challenging system was a key success element to get such outstanding results.”
Jacek L. Rostkowski, M.Eng, P.Eng
Head, Technology Development, Environment Canada
Emissions Research and Measurements Section, Ottawa
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