NAVISTAR PROVING GROUNDS

NEW CARLISLE, IN
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INSTRUMENTATION & DATA ACQUISITION

Overview

Navistar instrumentation capabilities include a wide variety of transducers, data acquisition systems and analysis devices. These instrumentation capabilities support collection, analysis and reduction of experimental, research and design, and certification data.

Navistar Proving Grounds has the capability to measure the following parameters:
  • Acceleration
  • Displacement
  • Force
  • Fuel consumption
  • GPS coordinates
  • Pressure
  • Road surface friction coefficient
  • Simultaneous XYZ wheel load
  • Simultaneous yaw, pitch, roll and XYZ acceleration
  • Sound pressure level
  • Steering wheel torque and angle
  • Strain
  • Temperature
  • Velocity/Stopping distance
  • Vibration
  • Wheel torque

Data acquisition systems are available to measure, record, report and analyze vehicle parameters. Specifically, the following acquisition devices are available at the Navistar Proving Grounds:

  • AIC Swissline Fuel Flow Meters
  • Bruel & Kjaer Sound Level Meter
  • Campbell Scientific Weather Station
  • Capacitec Proximity Sensors
  • Crossbow Fiber Optic Gyroscope
  • Dewetron 2010
  • Dewetron VGPS
  • Pacific Instruments
  • Rion Spectrum Analyzer
  • SoMat eDAQ
  • SoMat eDAQ Lite
  • AIC Fuel Flow Meter
    Increasing fuel economy and reducing emissions are common goals in the effort to “go green.” AIC flow meters can assist in that effort. These meters are used for precision measurement of fuel consumption for either gasoline or diesel engines up to 700 horsepower. The measurement cells produce 2,000 digital pulses per liter of fuel used for extremely accurate measurements. These meters can be used with any data acquisition system capable of counting digital pulses.

    The gas flow meters can be used on a wide variety of fuel system configurations. They can also be used to measure ethanol fuel blends.

    The diesel flow meters utilize an internal pump to draw fuel from the tank and recirculate it through a heat exchanger inside the unit to ensure uniform fuel temperature throughout the system. This uniform fuel temperature helps ensure proper engine operation and precise fuel consumption measurements.

    A total of six AIC flow meters are available for simultaneous data collection on multiple vehicles. This helps maintain consistency of test results when comparing and contrasting different vehicle configurations.
  • CADCAR
    CADCAR is an acronym for computer-aided data collection and reporting. CADCAR is a custom fabricated data acquisition system utilizing Pacific Instruments model 3210 precision instrumentation amplifiers and a Keithley Metrabyte 12-bit analog-to-digital converter and counter timer. The data acquisition and reporting software was developed by software engineers at Bosch to meet the specific requirements of vehicle brake performance testing.

     

    CADCAR data acquisition systems have the following capabilities:

    • 14 analog channel signal conditioning
    • 16 K-type thermocouple channels
    • Five pulse/frequency channels
    • Multiple data triggering options
    • Simultaneous data acquisition and reduction for immediate driver feedback of important brake performance parameters
    • Test sequencing and data management
    Data can be provided in other formats such as Excel
  • Capacitec
    Capacitec Proximity Sensors are high-precision electronic measuring devices used for quantifying very small surface variations or changes in displacement. These proximity sensors have a measurement range of +1 millimeter and are accurate to 3 microns. They are well-suited for measurements such as brake rotor dynamic run-out or brake rotor disc thickness variation.

    Capacitec Proximity sensors have the following capabilities:

    • Compact size — 0.375” diameter by 0.750” length
    • Very high precision — accuracy to 3 microns
    • Very high sensitivity— +5 volts equals +1 millimeters
    • Robust packaging capable of dynamic brake system measurements at elevated temperatures
  • Dewetron 2010
    The Dewetron 2010 is a complete Windows-based data acquisition package that is ideally suited for in-vehicle data acquisition. The unit consists of a data acquisition computer, power supply, interchangeable signal condition modules and computer monitor in a single compact package. It is equipped with a daylight-readable windshield-mounted display for immediate driver feedback. Its high channel count and sample rate make it an excellent package for brake performance and NVH data acquisition.

     

    Dewetron 2010 has the following capabilities:

    • Wide range of operational voltage — 10 to 30 volts
    • AC or DC powered
    • Equipped with a HUD for immediate driver feedback
    • Wireless Ethernet capability
    • Supports a wide range of input types, including:
      - Bridge
      - Encoders
      - ICP
      - LVDT
      - Thermocouples, etc.
    • Supports 64 analog, 10 digital and five pulse inputs
    • Sample rates up to 50k Hertz with 12-bit ADC
    • Supports multiple sample rates
    • Excitation can be defined on a per-channel basis
    • Capable of performing simultaneous data acquisition and reduction in real time

    Data can be provided in other formats such as Excel.

     

    Dewetron VGPS

    The Dewetron VGPS is a high-precision GPS sensor suitable for use in measuring vehicle velocity, stopping distance and GPS coordinates. It has both analog and digital outputs for use in conjunction with a data acquisition system such as the Dewetron 2010 or the SoMat eDAQ. It also provides velocity and GPS coordinates in either Dewetron Proprietary or NMEA mode. It features a multifunction HUD to provide instant driver feedback.

     

    Dewetron VGPS has the following capabilities:

    • Wide range of operational voltage — 10 to 30 volts
    • Zero to 10-volt analog output
    • TTL pulse output – 200 pulses per meter
    • NMEA compatible serial output
    • HUD with speed in mph or kph, heading in degrees, vertical elevation and Greenwich Mean Time (GMT)
    • Supports “stand-alone” operation with a laptop computer for off-site route tracking
  • Load Cell Fabrication

    Navistar Proving Grounds has the equipment, experience and expertise to fabricate custom load cells for specialized testing requirements. Whether large or small, a wide variety of vehicle components can be turned into load cells. Navistar Proving Grounds can fabricate load cells designed for extreme environmental or high temperature applications.

    Components that have been converted into load cells:

    • Class 3 trailer hitch
    • 30K trailer axles
    • Class 8 tractor exhaust after-treatment system
    • Class 8 tractor suspension components
    • Tractor leaf springs
    • Brake caliper anchor brackets
    • Brake caliper slide pins
    • Brake pads and shoes
    • Park brake cables and actuators
    • Brake booster and master cylinder components
    • Tie rods and steering components
    • Engine mounting hardware

  • SoMat eDAQ
    The SoMat eDAQ is a compact, rugged data acquisition system that is ideal for testing in very harsh environments. It is a completely sealed unit that can withstand repeated exposure to extreme environmental elements. It has been tested to withstand a swept sine wave of 20 Gs. The eDAQ uses Ethernet-based communications, which allows for both unattended data acquisition and networking of multiple systems for extremely high channel counts.  

    SoMat eDAQ Lite Data Acquisition Hardware

    The SoMat eDAQ Lite is a very compact, light-weight version of the larger eDAQ. Its small footprint makes it the system of choice where space is a premium. The eDAQ Lite has a lower channel count but offers the same great specifications as its big brother.

    SoMat eDAQ has the following capabilities:

    • Wide operational input voltage of 10 to 60 volts
    • AC or DC powered
    • Wireless Ethernet capability
    • Supports a wide range of input types including:
      - Bridge
      - Encoders
      - ICP
      - LVDT
      - Thermocouples, etc.
    • Supports analog, digital, pulse and CAN bus inputs
    • Simultaneous sampling of low-level and high-level channels
    • Sample rates up to 50k Hertz with 16-bit ADC
    • Supports simultaneous data collection mode, including:
      - Burst mode
      - Peak/Valley matrix
      - Rainflow
      - Time history
    • Sample rates can be defined on a per-channel basis
    • Excitation can be defined on a per-channel basis
    Data can be provided in other formats such as Excel.
  • Specialized Instrumentation

    Navistar maintains a variety of specialized transducers and instrumentation to assist with vehicle testing. Transducers and instrumentation systems are calibrated to NIST-traceable standards.

    Available instrumentation includes:

    • Sensor development torque steering wheel for measuring steering effort and steering wheel angle
    • MTS SWIFT (spinning wheel integrated force transducer) for measuring wheel loads on passenger cars and light trucks
    • Crossbow fiber optic digital gyroscope for simultaneous measurement of yaw, pitch, roll and three-axis acceleration
    • Dewetron VGPS system with 200 Hertz update rate; used for high-precision speed and distance measurements and GPS coordinate mapping
    • Garmin general purpose 5-Hertz GPS sensors
    • Global Sat general purpose 1-Hertz GPS sensors
    • AMCO mechanical fifth wheels for speed and distance measurement
    • Optical and microwave fifth wheels for speed and distance measurement
    • AIC 1204 gasoline fuel economy flow meters
    • AIC 6404 diesel fuel economy flow meters
    • Michigan scientific torque wheel systems for passenger car/light truck brake testing
    • Campbell Scientific Weather Station, which includes ambient temperature, brake level temperature, imbedded track temperature, wind speed and direction, relative humidity, barometric pressure, wind chill and heat index
    • Bruel & Kjaer Sound Level Meter (meets IEC 60651 Type 1 and ANSI S1.4 Type S1A specifications)
    • Larson Davis random-incident microphones
    • Rion handheld frequency spectrum analyzer
    • Larson Davis model 3200 six-channel frequency spectrum analyzer
    • PCB Piezotronic free-field microphones with removable A-weight filters
    • Single-axis, 500-g, ICP-type accelerometers; range 0.5 to 17K Hertz
    • Integrated tri-axial accelerometers, 50-g, ICP-type; range 0.5 to 4 kHz
    • Four-channel proximity sensor systems for measurements at the micron level; accuracy +/-3 microns
    • Digital tachometers
    • Dynatest/Bosch pavement friction coefficient test trailer
    • Luxor CCTV cameras with controller for simultaneous in-vehicle video acquisition
    • Digital microscope with both still camera and video output
    • Fluke 5500A Multi-Product Calibrator
  • Weather Station
    Navistar maintains an on-site weather station to provide timely and accurate weather information 24 hours a day. The weather station utilizes a Campbell Scientific data logger to record relative humidity, barometric pressure, wind velocity and direction, ambient temperature and track surface temperature. Wind chill and heat index are also calculated and recorded. All sensors are calibrated on an annual basis to NIST traceable standards.

    Weather data is recorded at the track entrance and then transmitted via radio modem to a host computer within the office area. The host computer generates both archive files and the following web page for easy access to current and historical data.

    The Navistar Proving Grounds has additional handheld and stationary anemometers and temperature sensors that can be placed trackside if required for specific tests.

    View a screenshot of the Navistar Weather Station