Axiometrix Solutions imc WFT-Cx Manual

Wheel force transducer

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WFT-C

Manual

imc Test & Measurement GmbH • Voltastr. 5 • 13355 Berlin • Germany

and -C

6-component wheel

Edition 4 - 08.07.2022

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Page 1 WFT-C and -C 6-component wheel Manual Edition 4 - 08.07.2022 © 2022 imc Test & Measurement GmbH imc Test & Measurement GmbH • Voltastr. 5 • 13355 Berlin • Germany...
Page 2 Disclaimer of liability The contents of this documentation have been carefully checked for consistency with the hardware and software systems described. Nevertheless, it is impossible to completely rule out inconsistencies, so that we decline to offer any guarantee of total conformity. We reserve the right to make technical modifications of the systems.
Page 3: Table Of Contents
Table of Contents Table of Contents 1 General introduction ....................5 1.1 Customer support / Hotline ......................5 1.2 Legal notice ............................. 5 1.3 Customized cable manufacturing ....................8 1.4 Notes regarding this manual ......................8 2 Safety ........................9 3 Delivery and operation .................... 12 3.1 After unpacking ..........................
Page 4 Table of Contents Index .......................... 57 © 2022 imc Test & Measurement GmbH imc WFT 6-component wheel - Manual, Edition 4 - 08.07.2022 Page 4...
Page 5: General Introduction
Customer support / Hotline Chapter 1 1 General introduction 1.1 Customer support / Hotline If you have problems or questions, please contact our Customer Support / Hotline. imc Test & Measurement GmbH Hotline: +49 30 467090-26 E-Mail: hotline@imc-tm.de Internet: www.imc-tm.de International partners You can find the international sales partners on the Internet at https://www.imc-tm.com/imc-worldwide/...
Page 6 Legal notice Chapter 1 Liability restrictions All information and notes in this manual have been compiled taking into account the applicable standards and regulations, the state of the art and our many years of knowledge and experience. The manufacturer accepts no liability for damage due to: ·...
Page 7 Legal notice Chapter 1 Notes on radio interference suppression WFT-C or -C sensors satisfy the EMC requirements for an use in industrial settings. WFT-C or -C sensors satisfy the EMC requirements for unrestricted use in industrial settings. Any additional devices connected to the WFT-C or -C sensors must satisfy the EMC requirements as specified by the responsible authority (within Europe...
Page 8: Customized Cable Manufacturing
Legal notice Chapter 1 1.3 Customized cable manufacturing To comply with the limits for Class B equipment under Part 15 of the FCC Rules, all signal lines connected to the meter must be shielded and the shield must be connected. Unless otherwise indicated, all connecting cables must not be long cables as defined by IEC 61326-1 (< 30 m).
Page 9: Safety
Chapter 2 2 Safety This section provides an overview of all important aspects of protection of the users for reliable and trouble-free operation. Failure to comply with the instructions and protection notes provided here can result in serious danger. Responsibility of the operator Along with the work safety procedures described in this document, the user must also conform to regulations for safety, accident prevention and environmental protection which apply to the work site.
Page 10 Chapter 2 Special hazards This segment states what residual dangers have been identified by the hazard analysis. Observe the safety notes listed here and the warnings appearing in subsequent chapters of this manual in order to reduce health risks and to avoid dangerous situations.
Page 11 Chapter 2 Observe notes and warnings Devices from imc have been carefully designed, assembled and routinely tested in accordance with the safety regulations specified in the included certificate of conformity and has left imc in perfect operating condition. To maintain this condition and to ensure continued danger-free operation, the user should pay particular attention to the remarks and warnings made in this chapter.
Page 12: Delivery And Operation
After unpacking Chapter 3 3 Delivery and operation 3.1 After unpacking The delivery must be checked for completeness and transport damage immediately upon receipt. In case of externally visible transport damage, proceed as follows: · Do not accept the delivery or accept it only with reservations, ·...
Page 13 Before commissioning Chapter 3 Before putting the WFT-C and -C into operation, the user must have read and understood the instruction manual, especially its information concerning installation and operation. Safe working is conditional on compliance with all safety measures and instructions provided. It is particularly important that the hub and rim adapters and the wheel bolts are inspected and maintained –...
Page 14: Notes On Connecting
Before commissioning Chapter 3 3.3 Notes on connecting 3.3.1 Precautions for operation Certain ground rules for operating the system, aside from reasonable safety measures, must be observed to prevent danger to the user, third parties, the device itself and the measurement object. These are the use of the system in conformity to its design, and the refraining from altering the system, since possible later users may not be properly informed and may ill-advisedly rely on the precision and safety promised by the manufacturer.
Page 15 Notes on connecting Chapter 3 3.3.2 Important Safety Considerations Safety of all persons operating or observing test vehicles is a primary concern when using WFT-C and -C . Please regard the following safety considerations: · It is strongly recommended to create and use a check list of critical items and operations that must be verified before and after each test routine.
Page 16: Maintenance And Service
Maintenance Chapter 4 4 Maintenance and service 4.1 Maintenance No special maintenance is required. Corrective work may only be carried out by imc Test & Measurement GmbH. If you have any complaints, please enclose a note with the device containing a brief description of the fault. If the name and telephone number of the sender are also written on the note, this will help us to process the complaint quickly.
Page 17: Wft - 6-Component Wheel Force Transducer
Chapter 5 5 WFT - 6-component wheel force transducer In motor vehicle development, 6 component wheel force transducers (WFTs) are used to determine and record forces and torques at the wheels during test drives – in all three dimensions, resulting in 3 forces (Fx, Fy, Fz) and 3 torques (Mx, My, Mz).
Page 18: Fundamentals
Chapter 6 6 Fundamentals The ring-shaped wheel which carries the sensors is installed between the vehicle wheel's mounting attachment (i.e. the five lugs protruding from the wheel hub) and the rim, and is thus positioned directly in the path of the mechanical force applied.
Page 19: Forces And Torques
Chapter 6 6.1 Forces and Torques The WFT-C and -C is a device to measure the forces and torques at the vehicle's wheels in all three spatial directions. Please see your sensor's spec sheet for the maximum forces and torques allowed. The Fig. 2 to Fig. 4 indicates the designations of the spatial dimensions in relation to the vehicle's forward motion.
Page 20 Forces and Torques Chapter 6 In the receiver unit, the measurement values recorded are transformed from the rotating coordinate system of the wheel to the stationary coordinate system of the vehicle, (see Coordinate Transformation of the Measurement Values Fig. 4: Forces and moments in the vehicle coordinate system ©...
Page 21: Coordinate Transformation Of The Measurement Values
Forces and Torques Chapter 6 6.2 Coordinate Transformation of the Measurement Values The forces and torques on the wheel are recorded by the rotating WFT-C or the -C . For further analysis, it is useful to transform these forces to the non-rotating vehicle coordinate system. The following signals are transmitted to the receiver unit: ·...
Page 22: Radial Displacement
Coordinate Transformation of the Measurement Values Chapter 6 6.3 Radial displacement Please set this parameter, the radial displacement r, only if you want to place the coordinate system from the wheel center e.g. to the road. The additional torque generated by the Fy forces is calculated out. Compare the formulas for Mx on page 17 and:...
Page 23 Axial displacement: Offset a Chapter 6 Axial displacement Fig. 6: Axial displacement: Offset a Overview of axial offset for the WFT-C : ET = Einpresstiefe, HO = hub offset, RO = rim offset. and -C Modified rim (grey), hub adaptor (red), WFT-C (blue), rotary transformer ("Y", green) Reference point = wheel center: Reference point = wheel center:...
Page 24: Sample Rate
Axial displacement: Offset a Chapter 6 6.5 Sample rate With the WFT-C and the -C , sample rates of up to 10 kHz per channel are possible with the CRFX/WFT-2 module . A common sampling rate and filter settings apply to all of a connector's channels. Reference Configuration in imc STUDIO The sample rate settings of your WFT system are modified with the configuration software imc STUDIO, see...
Page 25: Technical Components
Sensor with integrated electronics Chapter 7 7 Technical Components 7.1 Sensor with integrated electronics Fig. 7: WFT-C measurement wheel with stator for mobile applications Reference Please find here the technical specs 7.2 WFT adaptor for stationary application For stationary applications, the stator unit for mobile applications can be replaced by this module. Fig.
Page 26: Wft Interface (Crfx/Wft-2)
WFT interface (CRFX/WFT-2) Chapter 7 7.3 WFT interface (CRFX/WFT-2) The WFT-2 is a imc CRONOSflex module for the capture of data from two WFT sensor systems. WFT sensor systems are used to determine and record forces and torques at the wheels during test drives - in all three dimensions, resulting in 3 forces and 3 torques.
Page 27: Hub Adaptor, Modified Rim
WFT interface (CRFX/WFT-2) Chapter 7 7.4 Hub adaptor, modified rim Fig. 12: WFT hub adaptor (left) and modified rim (right) The hub adaptors and modified rims have been manufactured according to your specifications. For further information concerning your individual application, please contact imc or your local distributor. ©...
Page 28: Installation And Configuration
Installation of the sensor Chapter 8 8 Installation and Configuration 8.1 Installation of the sensor 8.1.1 Overview The ring-shaped measuring wheel (WFT) with the sensor system is mounted between the wheel hub and the modified rim by means of a hub adapter and is thus in the direct path of mechanical power transmission. The inner ring and outer ring of the measuring wheel body are internally connected by bending beams which deform due to the force transmission.
Page 29 Installation of the sensor Chapter 8 8.1.2 Check list for the WFT installation Required materials and tools (copy template) Component example photo available WFT-C or -C left front wheel: SN: right front wheel: SN: left rear wheel: SN: right rear wheel: SN: Rotary transmitter ("Y") left front wheel: SN: right front wheel: SN:...
Page 30 Installation of the sensor Chapter 8 Required materials and tools (copy template) Component example photo available Torque wrench (up to 80 Nm) with extension and 16 mm socket Screws (according to left front wheel: SN: screwing instructions) right front wheel: SN: left rear wheel: SN: right rear wheel: SN: Screwing instructions in the current version...
Page 31 Installation of the sensor Chapter 8 8.1.3 Mounting Screwing of external adaptor and WFT Screw the modified rim (= external adaptor) to the WFT. It is essential to observe the current screwing instructions. The tire must already be mounted on the rim. Attention Observe the screwing instructions It is mandatory that the screws are attached in accordance with the current screwing instructions.
Page 32 Installation of the sensor Chapter 8 Screwing of inner adaptor and WFT Now screw the hub adapter (= inner adaptor) to the WFT. It is mandatory to observe the current screwing instructions. Attention Observe the screwing instructions It is mandatory that the screws are attached in accordance with the current screwing instructions. Fig.
Page 33 Installation of the sensor Chapter 8 Wheel balancing Now balance the wheel. Check first whether the balancing machine is suitable for wheel adaptation. Additional adapters may be necessary. For further questions, please contact the imc staff (hotline@imc-tm.de). Prepare all desired wheels Prepare all wheels that you want to equip with a WFT-C or -C according to the points shown so far.
Page 34 Installation of the sensor Chapter 8 Mounting the rotary transmitter ("Y") to the WFT Now mount the rotary transmitter ("Y") to the WFT. Attention Torque Attention: Use a torque of 5 Nm when mounting the rotary transmitter ("Y") to the WFT. Warning Rotary transmitter The WFT is only sealed with a screwed rotary transmitter and inserted O-ring.
Page 35 Installation of the sensor Chapter 8 Fig. 16: Screw the rotary transmitter ("Y", green) to the WFT (blue). Attention Torque Attention: Use a torque of 5 Nm when mounting the rotary transmitter ("Y") to the WFT. © 2022 imc Test & Measurement GmbH imc WFT 6-component wheel - Manual, Edition 4 - 08.07.2022 Page 35...
Page 36 Installation of the sensor Chapter 8 Warning Rotary transmitter The WFT is only sealed with a screwed rotary transmitter and inserted O-ring. Fig. 17: The mounted WFT (blue) with hub adaptor (red), rotary transmitter ("Y", green) and modified rim. Mount stator connection Mount the fork and mount the torque arm e.g.
Page 37 Installation of the sensor Chapter 8 Warning Stability of the stator mounting The stability of the stator connection is decisive for the accuracy of the angle measurement and for the overall accuracy of the measurement data! Fig. 18: Stator connection to the WFT, rear wheel (example photo) ©...
Page 38 Installation of the sensor Chapter 8 Warning Stabilität der Statoranbringung The stability of the stator connection is decisive for the accuracy of the angle measurement and for the overall accuracy of the measurement data! Fig. 19: Stator connection to the WFT, front wheel (example photo) ©...
Page 39 Installation of the sensor Chapter 8 Connect and place WFT connection cable Connect the WFT connection cable and place it along the torque arm. Leave the cable enough clearance to compensate for the spring deflection. Warning Connecting or disconnecting the sensor data cable When plugging or unplugging the sensor data cable, it is imperative to ensure that no moisture or dirt can affect the LEMO plugs.
Page 40: Crfx/Wft-2 Hardware Setup
Installation of the sensor Chapter 8 Check for clearance Estimate the spring travel and check the torque arm for clearance to the sensor and vehicle parts. Please make sure that there is no pull on the cable during all driving maneuvers later on - including all up/down and lateral movements.
Page 41 Configuration with imc STUDIO Chapter 8 Global settings The sampling rate and filter settings apply jointly to all channels on the same terminal. © 2022 imc Test & Measurement GmbH imc WFT 6-component wheel - Manual, Edition 4 - 08.07.2022 Page 41...
Page 42 Configuration with imc STUDIO Chapter 8 8.3.1 Channels and parameters Channels whose data are transmitted from the sensor (separately for the left and right wheels). The signals are managed as analog channels and are included in the calculation of the maximum number per device. Channels Unit Associated parameter...
Page 43 Configuration with imc STUDIO Chapter 8 Status-Flags State- Description (bit active/passive) Code WFT detected / not detected not yet activated; always 1 Offset-balancing running / not running Shunt active/passive Remote active/passive Bubble level mode active/passive 32768 Error / no error The status channel can be displayed in the STUDIO panel with a DIO widget.
Page 44 Configuration with imc STUDIO Chapter 8 LED-Status Active channels LED indicator State-Code Description red continuously WFT not detected green continuously (=1+2) WFT detected / Measured values plausible green 5 Hz (=1+4) Offset-balancing running green 0.5 Hz (=1+2+32) Bubble level mode active WFT detected / Measured values plausible red/green 1Hz WFT detected / Measured values not plausible red 5 Hz...
Page 45: Preparing And Performing Measurement
Configuration with imc STUDIO Chapter 8 8.4 Preparing and performing measurement The measurement ranges are fixed and would only be changed if the measurement wheel type was changed. The wheel itself provides the system with its associated ranges and scaling. The following steps must be performed in order to prepare for measurement: ·...
Page 46 Preparing and performing measurement Chapter 8 8.4.2 Angle Alignment After installation of the WFT-C or -C , the angle signal has to be aligned for each WFT-C and -C sensor. For this procedure the vehicle must be located at a horizontal and smooth surface. If a lifting platform is to be used, make sure that the vehicle is aligned around the longitudinal and transverse axes.
Page 47 Preparing and performing measurement Chapter 8 · Go to the page Channel balance and click on the button "Spirit level". The deviation is measured and saved in the module. Fig. 24: Perform angle alignment Important: For the next steps, the setting for the Coupling on the page "Analog channels" must be restored to TTI. Fig.
Page 48 Preparing and performing measurement Chapter 8 8.4.2.2 Manual Angle Alignment (Spirit Level) · Turn the WFT-C or -C to the 0° position (Fz mark at the sensor shows up). · Open the angle channel of the respective WFT-C or -C in the dialog Chanel balance.
Page 49 Preparing and performing measurement Chapter 8 8.4.3 Zero Balance After coordinate transformation from the rotating to the stationary coordinate system, offset errors appear as a periodic interference signal. It is therefore necessary to reduce all zero offsets to a minimum. The zero offset is stored permanently within the WFT-C or -C electronics.
Page 50 Preparing and performing measurement Chapter 8 · Count of revolutions for rotary balancing . For a complete adjustment, the entered number of revolutions is run through three times. Fig. 30: Number of revolutions for rotary adjustment © 2022 imc Test & Measurement GmbH imc WFT 6-component wheel - Manual, Edition 4 - 08.07.2022 Page 50...
Page 51 Preparing and performing measurement Chapter 8 8.4.3.1 Operating Mode "mobile (rotary)" With this zero balance mode, forces and torques are balanced during a number "x" of revolutions. The vehicle's weight g plays a role as a component of F ; conversely g has no influence on F or F in angle alignment.
Page 52 Preparing and performing measurement Chapter 8 8.4.3.2 Operating Mode "mobile (stationary)" For a rotating zero adjustment, you need a flat road of sufficient length. If this is not available, the rotating zero adjustment cannot be performed with the desired accuracy. In this case, a stationary zero adjustment can be performed at two angle positions.
Page 53 Preparing and performing measurement Chapter 8 8.4.3.3 Operating Mode "stationary" With this zero adjustment routine, all forces and torques exerted on the sensor at the time of the adjustment are zeroed. This includes canceling out the mean weight of the vehicle. ·...
Page 54: Compensation "Axial/Radial Displacement
Preparing and performing measurement Chapter 8 8.5 Compensation "Axial/Radial displacement" Axial displacement · Open the F channel of the respective WFT-C or the -C sensor on page "Analog channels", e.g. channel Fx_l_xx for the wheel force transducer connected to the TTI input "WFT- In1 ( left)" at the CRFX/WFT-2 ·...
Page 55: Technical Specs
WFT sensors Chapter 9 9 Technical Specs 9.1 WFT sensors Value Parameter Remarks WFT-C WFT-C Material Aluminium Titan Steel Aluminium Measurement temperature compensated principle strain gauge application Measurement ranges Forces = ±45 kN = ±60 kN = ±25 kN = ±25 kN = ±30 kN = ±20 kN Torsional...
Page 56: Crfx Module (Crfx/Wft-2)
CRFX module (CRFX/WFT-2) Chapter 9 9.2 CRFX module (CRFX/WFT-2) Parameter Value Remarks Inputs for two WFT measuring wheels Terminal connection LEMO 2x LEMO.ERA.1E.306 measuring wheel connection Input supply plug (female) 1x LEMO.EGE.1B.302 multicoded 2 notches, for optional individually power supply EtherCAT connection 2x RJ45 system bus for expanded...
Page 57 Index Index Operating personnel adjustment angle alignment prepare measurement automatic manual Radial displacement axial displacement compensation compensation Read sensor information cable sample rate calibration Service commissioning CRFX-WFT-2 Special hazards Condensation spirit level configuration imc STUDIO Standards coordinate transformation IATA CRFX/WFT-2 Storage Technical Specs symbols...

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