DEWETRON Automotive Applications & General Test and Measurements.

Transcription

1 DEWETRON Automotive Applications & General Test and Measurements

2 DEWETRON Company Profile DEWETRON Ges.m.b.H. with its headquarters in Graz / Austria was founded in 1989 and today is a market leading provider of test and measurement systems. With more than 200 employees in more than 25 countries around the world, we offer products and service for demanding test and measurement applications. DEWETRON develops, manufactures, and distributes highprecision PC based systems with robust housings for portable and laboratory use. The scalability, modularity and innovative platform technology of the hardware and software allow the systems to be deployed in almost all areas of research and development. Test and measurement engineers and technicians from many well known companies rely on our 20 years expertise. All over the world, around measurement channels and more than systems are in permanent operation in Automotive, Energy & Power, Aerospace & Defense, Transportation, as well as in General Test & Measurement applications. DEWETRON is part of the AUGUSTA Technologie AG located in Munich. Automotive Power & Energy Aerospace Transportation General T & M In shortest time to highest quality test and measurement data DEWETRON systems help users to produce highest quality test and measurement data in shortest time. Both, our hardware and software are optimized to support this general target. How? The hardware offers vastly different signal inputs like analog, digital, counter/encoder, video, GPS and various bus systems like CAN bus which are all recorded perfectly synchronized. Thus data analysis can be done very easily. Additionally a picture paints a thousand pieces of data. Of course sensor connection is matched to practical needs, that s why we offer various connector options for most inputs. The software contributes by its ease of use and powerful features. Setup of the amplifiers is a matter of a few clicks and sensors can either be automatically setup by TEDS or chosen from a sensor database. You can record as easily as pressing the STORE button, or as elaborately as having separate even multiple triggers on each input channel. Once data are stored, press ANALYZE and you can replay it to the screen as easily as replaying a movie, with PLAY controls. Cursors can be used to zoom in and inspect specific areas of interest. In a matter of seconds nice looking reports can be printed. If you are using 3rd party analysis software you are also well served, export of the whole recording or just the interesting part to many different file formats is supported. So you can e.g. keep your Excel spreadsheets. 2 Mixed signal measurement Online data evaluation Combustion measurement on engine test stand Analysis of measurement results

3 Quality Quality Our commitment to Total Quality Management is based on the understanding of what is important for the success of our customers. It starts with the definition of the technical specification, covers the development, production, quality control, shipment, and ends with support and service of our systems during operation. DEWETRON is ISO 9001:2008 and ISO 14001:2009 certified. Environmental and quality management is more than just a compliance issue for us; it is an integral part of our business operations. We take quality very seriously! That is why we have our own environmental test facilities in our building in Austria, where all DEWETRON products are tested repeatedly at several stages. Prototypes are tested for EMC, EMI, RFI, temperature extremes, shock and vibration. This helps us identify and correct problems before we start production. Each revision is tested until the DEWETRON quality standards are met. In addition if traceability is required we use certified labs for even more robust and compliance testing. Total Quality Management We have established a Quality Management framework that defines processes and assures the proper execution. It incorporates the responsibility of our employees and enables efficient execution across all parts of our global organization. EMI tests according to CE and other standards Extensive temperature tests (-40 to +70 C) Shaketest procedure DAQ module assembling Precision in all components Production of instruments System assembling 3

4 Combustion Analysis (page 7) Road Load Data (page 19) Key Features In-vehicle and test-bed applications Direct pressure and angle sensor connection Battery powered CAN-out, link to test-bed Electrical power calculations, isolated voltage, current inputs Key Features High channel count (16 to 1000 channels) 24 bit aliasing free sampling Multiple inputs (voltage, acceleration, strain, etc.) Support for Kistler RoaDyn measurement wheels Export to different file formats (supports RPC III ) Battery powered, portable system for in-vehicle use Real-time analog output ADAS System (page 11) Advanced Driver Assistance Systems Key Features Easy mounting, setup, alignment and calibration Online data transfer to master system High accurate combined GPS and Gyro measurement Comparable and reproducible tests Automated report generation for predefined maneuvers Quick and easy installation Online calculation of relative distance, speed, acceleration etc. High accurate combined GPS and Gyro measurement 3D representation of vehicles Basic Brake Test (page 25) Key Features Integrated 100 Hz GPS receiver Quick and easy test setup Automated workflow with DEWESoft sequencer Automated report generation Ready-to-print report Functional Safety Testing (page 15) Key Features Quick system installation and setup Ready-to-print report generator CAN, FlexRay and XCP support Ride and Handling (page 31) Key Features Synchronized multichannel data acquisition without phase errors Proven package due to DTA Guaranteed compatibility of the whole system Compact and rugged equipment for in-vehicle use Easy mounting, setup, alignment, and calibration Multisensor inputs (voltage, acceleration, strain, etc.) Aliasing free sampling and flexible filtering capabilities Real-time Mathematics Support for Kistler RoaDyn measurement wheels Export to different file formats 4

5 Content Electro Mobility (page 39) Order Tracking (page 57) Key Features ALL-IN-ONE Power Analyzer, Combustion Analyzer, Recorder and Scope on a single machine Same software interface for all instruments, easy to learn and use, online or offline calculation Synchronized analog & digital signals, counter, CAN bus and video inputs to simplify analysis High isolation and high accuracy High bandwidth up to 2 MHz Test bench for electric drive trains Key Features Dedicated re-sampling method for sharp order separation Measurement in time domain to keep all benefits 2D, 3D waterfall in order or frequency domain Amplitude, phase extraction Recalculation in post processing Phase synchronous rpm input with 12.5 ns resolution EASY TO SETUP Torsional and Rotational Vibration (page 51) Balancing (page 61) Key Features Time domain measurement Angle based view Additional to all other functions (analog, CAN, GPS, video,...) Configurable display Direct sensor connection 80 MHz time base High resolution rpm +-2 mdeg@12000 rpm Key Features User interface which guides through all steps Order tracking based balancing method Single or dual plane Multiple balancing for two directions saves time 2D graph for plane view RPM channel with color indicator (rpm range) Alarm output if velocity exceeds predefined value Displays tacho probe time signal to set trigger Vector polar plots of 1st order of all runs (initial, trail,...) Weight splitting Acceleration, velocity, displacement in recorder Time domain measurement Modal Analysis (page 53) Key Features SISO, SIMO, MIMO configurations Spectral ODS Geometry editor Mode indicator function MIF Circle fit analyze tool Function generator up to 16 channels FRF from stored time data Triggered-, free-run measure mode Roving hammer excitation support Unv-file export for modal packages (ME-Scope,...) Animated FRFs Up to 1000 channels linked over NET Ballistic and Ammunition Testing (page 65) Key Features Smallest all-in-one instrument for isolation amplifiers AC, DC or battery powered High accuracy, 16 bit resolution Fast sampling, 3 MS/s per channel Powerful Intel Core 2 Duo, 2.4 GHz 90 MB/s stream-to-disk rate Bright 15.4 display with touch-screen 8-channel signal conditioning inputs, interchangeable for all type of signal in-puts (charge, voltage, charge, etc.) Expansion socket for adding more signal conditioning modules High Speed Camera support 5

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7 Combustion Analysis Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement Combustion Analysis DEWETRON internal combustion analysers are suitable for mobile application, like in-car usages and also for test-bed applications. The system supports time and angle based measurement, and also provides various interfaces for test-bed automation and control. The build-in and changeable amplifiers (DAQP-series), give the flexibility for upcoming requirements, and provides a compact design. Highlights In-vehicle and testbed application Direct pressure and angle sensor connection Engine calibration Cold start testing CAN input and output, various testbed links Time and angle based measurement E-MOB RAH BT RLD FS ADAS CA /ca 7

8 Synchronous Input Signals Isolated charge amplifiers, bridge amplifiers with constant current supply feature, are used for high-pressure sensors and for the absolute pressure sensors of inlet and exhaust. Due to the changeable amplifier concept of the instrument, almost any signal like torque, current, acceleration, temperature, etc. can be measured. Voltage inputs cover, start of injection, end of injection and ignition, and any other additional signal captured in time or angle domain. The isolated voltage and current inputs can be used to calculate electrical power. Indicating pressure (charge) Absolute pressure (bridge, voltage) SOI EOI SOI EOI SOI EOI Injection, timing signals (voltage, current) TDC Sensors (voltage) Crank angle signals (CDM, TRG, tooth) CAN-in, CAN-out XCP via LAN FlexRay, LIN Vibration Strain Temperature Electrical power Crankangle CPU Included Crank Angle CPU, is able to handle all kinds of crank marker disc signals which provides CDM- and TRIG- signal. In case more angle resolution is required, Crank Angle CPU will do the interpolation up to 0,1deg. Pickup sensors, for the native CDM signals, like 60-2, can be directly connected. The isolated input can handle voltages from 0,5V up to 60V. Crank Angle CPU will do gap filling and interpolation. 8

9 Combustion Analysis Software Software provides easy to use user interface with preconfigured analyse screens. All major parameters are calculated online. All parameters can be corrected and recalculated in the Analyse mode. File Export Data can be exported into various file formats (.txt,.ifl,.xls ). Testbed Interface Testbed interface, via RS232 or TCP/IP is provided to link the analyzer to a testbed for automated measurements. An open AK-protocol, or native interfaces for AVL PUMA Open, DT2,.. is supported. In addition, calculated results can be also transferred via CAN-out. Results can be recorded from mapping tools to get immediate feedback. MEP values Heat release, I5, I50, SOC, EOC Min. max pressure and pos. Thermodynamic zero correction Various average possibilities of pressure (running, overall,.. ) Knocking CA noise CA noise calculation is provided for time and angle based measurement. The open architecture allows the user to integrate an engine specific transfer filter. Statistical values User definable calculations In case additional results or special calculations, like custom volume, are required, the open architecture provides the possibility to adapt the configuration. Suitable for Cold Start DEWETRON CA instrument can record time and angle based data simultaneously. At cold start tests combustion analyser runs and records signals already before piston make the first move. So the whole start process will be recorded, for further investigation. E-MOB RAH BT RLD FS ADAS CA 9

10 Additional Measurements and Analyses The instrument is not limited to CA measurement only. Caused by the hard and software architecture it can be used for various other measurements too. Recorder, FFT analyser, scope, power measurement, long time measurement are only a few examples. Recorder FFT Analyser Order tracking Rotational and torsional vibration Transient recorder Electrical power (after frequency converter) Large engines In-vehicle testing Testbed High performance apps 19 mount Battery powered Portable Configuration Examples DEWE-2600-CA2-PROF DEWE-800-CA2-PROF Analog input channels 8, 16 (expandable to 32, 64) 8, 16 (expandable to 32, 64) Optional low speed temperature and voltage inputs (5 Hz) voltage 64 (in groups of 8) 64 (in groups of 8) Amplitude resolution 16 bit 16 bit Sampling rate 1 MHz 1 MHz Input range ±10 V ±10 V Charge inputs variable 1 to 16 depending on amplifier configuration (DAQP-CHARGE-B) variable 1 to 16 depending on amplifier configuration (DAQP-CHARGE-B) Charge input range 10 to pc 10 to pc Drift compensation AC coupling AC coupling CAN input input and output up to 1 Mb/s Input and output up to 1 Mb/s FlexRay optional optional XCP interface optional optional Storage memory 1 TB 1 TB Digital input channels 8 if digital out is used, 16 TTL - Digital outputs 8 TTL 8 TTL Crank angle inputs TTL based CDM and TRG (BNC) TTL based Encoder (A,B,Z on Multicore connector) CA input for native pickup sensors like 60-2 (BNC) TTL based CDM and TRG (BNC) TTL based Encoder (A,B,Z on Multicore connector) CA input for native pickup sensors like 60-2 (BNC) Temperature range 0 to +50 C 0 to +50 C Power supply Dimensions Dimensions (W x D x H) 100 to 240 V AC input (50/60 Hz) 120 W max. 9 to 36 V DC, battery powered up to 2 h 417 x 246 x 303 mm (16.4 x 9.6 x 11.9 in.) 100 to 240 V AC input (50/60 Hz) 120 W max. 437 x 443 x 181 mm (17.2 x 17.4 x 7.1 in.) Weight without batteries Typ. 14 kg (31 lb.) Typ. 12 kg (26.4 lb.) 1) Please find current specifications in the latest price list DEWETRON GmbH Parkring 4 A-8074 Graz-Grambach Tel (0043) Fax (0043) info@dewetron.com 10

11 Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement Advanced Driver Assistance Systems ADAS Advanced Driver Assistance Systems DEWETRON provides the ideal solution for developing and benchmarking Advanced Driver Assistance Systems. Whether you are conducting ACC or FCW tests, where multiple vehicles are involved, or tests for LDW or LKA systems, where the distance to a given path is of main interest. All data between one or more vehicles stays fully synchronized, can be used in online calculations and visualized in a live, 3D display. Based on high-precise measurement of position and movement with GPS based IMUs (Inertial Measurement Units), this system features position accuracy down to the centimeter range. Key Features Easy mounting, setup, alignment and calibration Online data transfer to master system High accurate combined GPS and Gyro measurement Comparable and reproducible tests Automated report generation for predefined maneuvers Quick and easy installation Online calculation of relative distance, speed, acceleration etc. High accurate combined GPS and Gyro measurement 3D representation of vehicles E-MOB RAH BT RLD FS ADAS CA 11

12 Master Unit WLAN GPS Video SYNC-CLOCK Technology: Synchronisation DEWE-ORION card CAN CONFIGURATION Counter input Digital input Analog input ADMA interface The master unit collects all synchronized data from the master vehicle and the slave unit via WLAN. Data from all vehicles is recorded fully synchronized Online checking of the measurement data quality Master manages the measurement and the configuration of the slave so the driver can concentrate on his task. Online data transfer of selected channels from slave to master. Measurement data is redundantly stored on each measurement unit and can be transferred after the measurement The ADAS system uses the GeneSys inertial measurement system ADMA for six degree of freedom motion analysis in combination with high performance GPS position measurement. This combination avoids the drawbacks of each system on one hand the drift of the gyro platform and on the other hand outages and jumps in GPS position. Kalman filters are used for optimizing the measured result. Additional Sensors: Multiple video cameras Measurement steering wheel Optical velocity sensors Height level sensors Wheel pulse sensor Wheel vector sensor Wheel force sensor Tire temperature Brake pressure Acceleration Temperature Strain gages Steering robot Potentiometric sensors Data-Acquisition System GPS-Antenna WLAN-Antenna ADMA Camera 12

13 Advanced Driver Assistance Systems Slave Units WLAN via sate lite clock MEASUREMENT DATA MEASUREMENT DATA MEASUREMENT DATA The measurement systems are synchronized and send the data to the master measurement unit. RF-modem: Interface DGPS data ADAS Display The ADAS display visualises the distance between the cars, the relative position and the heading Differential GPS: GPS base station and antenna Differential GPS is required to gain the required accuracy for the vehicle or obstacle coordinates. GPS Map GPS data on map overlay GPS Video DEWE-ORION card CAN Counter input Digital input Analog input ADMA interface ADAS Channels Relative vehicle distance, speed, heading CAN BusData Synchronized data from CAN-bus Video Information Synchronized video information Analog Data Synchronized data E-MOB RAH BT RLD FS ADAS CA 13

14 ADAS Configuration 80 MHz clock Selectable GPS time synchronization GPS-Clock Clock-Divider (Phase synchronous) Definable Clock-Divider A/D-converter CAN-bus Video Counter Dig. I/O Serial-bus RS-232 RS-485 ADAS requires very high accuracy of the measured parameters, which is achieved using the latest technology of data acquisition, inertial measurement, GPS technology and test methodology. SYNC-CLOCK technology: For the exact position of the vehicles or obstacles, synchronisation of the different systems is required. To achieve the required accuracy we implemented a high precision system clock. All data channels, analog and digital signals, CAN information or video are synchronized. DGPS - Differential GPS This technology improves the measurement accuracy where a second stationary GPS receiver is required. Due to the known position of this base receiver errors in the GPS signal transmission can be calculated. The data of the DGPS corrections are transmitted vie WLAN to mobile GPS receiver for an online correction of the position data. Elimination of GPS outages Suppression of jumps in GPS position Residual accuracy is better than Inertial Measurement Unit or GPS accuracy on its own Position data with high dynamic and bandwidth Highly accurate motion states of a vehicle with low setup time All motion states in body-fixed, levelled and NED coordinates All motion states in 3D (t, a, v, p, d /dt, ) via CAN or RS-232 or Ethernet GPS-Antenna WLAN Antenna GPS base Hardware Configuration DEWE2-M4-ADAS DEWE-510-ADAS-16 Analog input channels 2 free slots for TRION series modules 16 DAQ series modules Digital channels Channel expansion 8 DIO and 2 CTR or 8 DI CAN interfaces 4 Video Display Power supply Dimensions (W x D x H) 11 to 32 V DC rated (max. 10 to 36 V DC ) isolated; external AC power supply adapter included 317 x 252 x 108 mm 12.5 x 9.9 x 4.3 in. Yes DEWE-CAM-GIGE-120 or USB External MOB-DISP-x Battery powered, V DC (max) external AC power supply 439 x 308 x 181 mm x x 7.13 in. Weight Typ. 3.9 kg (8.6 lb) Typ. 8 kg (17.6 lb.) Additionally required sensor GeneSys ADMA INS/Gyro system TRION and MDAQ series modules are available for almost all kinds of sensors 14

15 Functional Safety Testing Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement 16 ANALOG INPUTS 8 DIGITAL INPUTS 2 COUNTER INPUTS CAN-BUS DEWE-CAM01 Functional Safety Testing according to ISO What happens in case of a malfunction of a safety-relevant system such as ESP or active steering in a vehicle? Can the driver still control the vehicle or does it spin? Does it deviate from its former trajectory, maybe even into the counter-traffic? The international standard ISO deals with such questions by defining requirements, processes and methods to mitigate the effects of systematic faults and random hardware faults in the automotive field. Together with the leading European car manufacturers DEWETRON has developed a unique measurement system that tests active safety systems and outputs a comprehensive, printable report of the test results. CAN ECU Highlights CAN SYNC XCP MOB-DISP Quick system installation and setup Ready-to-print report generator CAN, FlexRay and XCP support GPS-ANTENNA ADMA E-MOB RAH BT RLD FS ADAS CA 15

16 Test Procedure Any functional safety test consists of two phases: constant phase (pre-trigger) and dynamic phase (post-trigger). The simulation of a sensor error triggers the measurement and separates the pre-trigger phase (constant phase) from the post-trigger phase (dynamic phase). In the constant phase, the vehicle is driving in a steady state under constant conditions (e.g. constant speed, lateral acceleration, curve radius, ) in order to get reproducible test results. When the vehicle is in steady state for a defined time, a malfunction of the safety system is simulated (e.g. one wheel suddenly brakes, breakdown of active steering, ). This so called error-trigger marks the beginning of the dynamic phase. In the dynamic phase, the safety-relevant variables such as yaw rate or deviation from the original vehicle trajectory are measured/calculated. If one of these variables exceeds a defined limit (test criteria), the test is considered failed. Otherwise, if it s within safe boundaries, the test is considered passed. CONFIGURATION PHASE ARM MEASUREMENT CONSTANT PHASE TRIGGER DYNAMIC PHASE STOP STORING ANALYZE PHASE High-precision Sensors Functional safety measurements for active-safety systems are based on precise measurement of rotation, acceleration and position in all three axes. DEWETRON therefore relies on one of the best motion sensors on the market: the GeneSys ADMA. The GeneSys ADMA is a 6 DOF motion sensor which combines rotational data (from high-accuracy fiber-optic gyros), acceleration data (from servo-type accelerometers) and position data (from a RTK-enabled GPS receiver) in one compact unit and combines the raw sensor data in a fast Kalman-filter to achieve the best possible accuracy. Key Features Rotation (drift < 1 /h) Acceleration accuracy of 1mg Position down to 0,02m L1/L2 GPS receiver capable of receiving RTK correction data from base station Up to 400 Hz output rate Synchronization to DEWETRON measurement systems Sensor Error Simulation 16

17 Functional Safety Testing Ready-to-Print Reports Even though the test result (test criteria passed/failed) is available right after the measurement, a printed report is sometimes required to give an overview over the whole test series. DEWETRON has created an MS-Excel based report that automatically creates a ready-to-print report of all performed test. This report contains: General test information such as vehicle data, environmental data, test engineer information etc. A manoeuvre overview over all performed tests to immediately see the most important values of each test in one tabular view Detailed report with graphs for each manoeuvre XCP and FlexRay Support The DEWE2 systems also support the XCP protocol which allows you to record the ECU internal status during your tests and measurements. Also the upcoming FlexRay bus, the successor of the widespread but meanwhile overloaded CAN bus, is supported. Tough and Reliable The industry-approved PXI standard and the new internal construction of the DEWE2 series make them our most ruggedized measurement system so far. Tested for shock up to 30g and vibration up to 20 m/s² as well as an operating temperature range of -20 C to +50 C (-4 F to +122 F) they are well prepared for testing under harsh conditions. Internal Buffer Battery to Bridge Supply Gaps or Independent Power Supply In most cases the measurement system and the sensors are supplied by the vehicle battery. This can be problematic however, because the power management of modern vehicles might suddenly cut the supply if a high-priority system (like active-safety systems) requires more battery power. Or the ECU unit might need a reset turning the engine off and on again after an error trigger or system malfunction. Or you need a gas refill but don t want to turn off the engine because the measurement should not be stopped These short power outages can be cumbersome if you need to get your test-cycles done in time. To solve that, the DEWE2 systems can be upgraded with an internal buffer battery to bridge supply outages of up to 10 minutes. The scarcity of available energy in modern vehicles might make it necessary to be independent from the vehicle power network. DEWETRON offers a fully battery powered solution with hot-swappable batteries for such applications. E-MOB RAH BT RLD FS ADAS CA 17

18 Configuration Examples Analog input channels Digital channels Channel expansion DEWE2-M4-FS 2 free slots for TRION series modules 8 DIO and 2 CTR or 8 DI CAN interfaces 4 Video Yes DEWE-CAM-GIGE-120 or USB DEWE2-A4-FS Display External MOB-DISP-x Internal 13 display Power supply Dimensions (W x D x H) 318 x 253 x 108 mm (12.5 x 10 x 4.3 in.) 11 to 32 V DC rated (max. 10 to 36 V DC ) isolated; external AC power supply adapter included 318 x 253 x 128 mm (12.5 x 10 x 5 in.) Weight Typ. 3.9 kg (8.6 lb) Typ. 5.9 kg (13 lb.) Additionally required sensor TRION and MDAQ series modules are available for almost all kinds of sensors GeneSys ADMA INS/Gyro system 18

19 Road Load Data Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement Road Load Data The DEWETRON RLD system is used to record road load data during real test drives or at test rigs either for a whole vehicle or certain components. The measured data can be replayed on a testbed to simulate all forces and vibrations in the laboratory. As an option, DEWETRON RLD systems can be equipped with a real time analog output for testbed integration. DEWETRON devices offer a rugged and portable design for in-vehicle use and fulfill the requirement for high channel count. The devices cover a wide range of input types like voltage, strain, temperature, counters, GPS, Video, CAN and OBD II. For testbed simulation the aquired data is exported to RPC III file format. Key Features High channel count (16 to 1000 channels) 24 bit aliasing free sampling Multiple inputs (voltage, acceleration, strain, etc.) Support for Kistler RoaDyn measurement wheels Export to different file formats (supports RPC III ) Battery powered, portable system for in-vehicle use Real-time analog output E-MOB RAH BT RLD FS ADAS CA 19

20 Overview Power Supply AC DC Battery powered Interface USB, Ethernet, WLAN DEWE-VGPS Position interface DEWE-CAM Video DEWE-ORION card Sensors Forces Accelerations Strain Gauges and Rosettes Temperatures CAN Counter input Digital input Digital output Industrial PC PC DEWESoft Road Load Data DAQ or MDAQ module Signal conditioning Sensor supply Analog input Dual Use Real time analog output for test rig application External Clock e.g. Kistler RoaDyn ext. clock int. clock 20

21 Road Load Data CAN-Bus Data/OBD II Synchronous data from CAN-bus CAN DBC export and import J1939 decoding Analog Channels Strain, temperature, acceleration, force, torque, etc. Wheel Force Measurement Telemetric recipient for all wheel forces Video Synchronized video information GPS Information Position data E-MOB RAH BT RLD FS ADAS CA 21

22 Road Load Data Application Road Load Data measurement is used in material research, process and parts approvals and vehicle testing. The data collection is done on the test track on the road or on a test rig. This data is used to calibrate simulation models and to develope and optimize control loops. The measured data can be replayed on a testbed to simulate all forces and vibrations in laboratory boundaries. Systems and components are tested under specific customer and environmental conditions (e.g. higher temperature, corrosive atmosphere, etc.) using road load data inputs as well as duty cycle inputs correlated to real world conditions on a test rig. To optimize mechanical components it is necessary to know the loads that the product undergo during its lifetime. Therefore precise and synchronous measurement of a high number of sensors is required. The basic requirement for Road Load Data measurement systems are: Simultaneous and aliasing free recording High channel count Connectivity for a broad range of sensors - including a flexible power supply for sensors Sensor database, TEDS functionality Shunt calibration Amplifier and sensor blance Offline instrument setup Online overload detection and failure detection for e.g. damaged sensors Various trigger options Powerful online mathematics Fast and efficient data analysis Traceability of the measurement results Compact and rugged hardware design CAN Input Synchronous recording of data from the vehicle CAN bus or from sensors with CAN interface. CAN.dbc import J1939 decoding The CAN setup dialog allows to set up the required CAN channels as measurement channels. These channel are treated like physical measurement channels and can be used for visualization, mathematics or to trigger an event. Dual Use - Real Time Analog Output for Test Rig Application Dual-Use allows to use the DEWETRON RLD System also on the testbed. The same measuring situation as on the road is measured on the test rig. Additionally, the system provides realtime conditioned and filtered (typ.±10 V) analog output signals of each input signal. 22

23 Road Load Data DEWESoft-NET DEWESoft-NET allows the communication between different DEWETRON instruments. Each unit can be configured as stand alone, as master or as slave. It s also possible to use any PC to control a measurement unit remotely. For road load data measurement DEWESoft-NET is used to combine several instruments and to increase the total amount of measurement channels Offline Setup To standardize and to simplify the setup procedure of a DEWETRON measurement system, it is possible to do this task using your office PC. Together with the sensor database, the setup can be performed independent from the measurement hardware. This feature allows you to use a central setup database. A standard office PC using DEWESoft 7 can export XML based file format with all this setup information. Simply loading this file on a DEWETRON measurement system adjusts all settings for this setup which is required for the measurement. The set-up time of the whole system can be significantly reduced and this also avoids user errors. Shunt Calibration Shunt calibration is a very useful feature to quick check the measurement chain of bridge amplifiers. The automated procedure starts per mouse click and in parallel all amplifiers start the calibration procedure: Red and green indicators showthe result of the calibration. Shunt check of all sensors Red or green indicator to show the calibration result Amplifier and Sensor Balance The amplifier balancing is integrated within the amplifier module automatically the input is shorted and the offset of the amplifier is checked. This feature is a quick check of the amplifier and allows to measure absolute output from from a strain gage. Amplifier balancing - for all amplifiers at a time: Automated amplifier balancing Check of the amplifier offset Quick overview of adjust value Absolute strain gage measurement The sensor balancing allows a quick zero adjustment of all sensors. In static conditions the offset of the amplifiers are adjusted, to compensate the offset of the strain gage. Sensor balancing - for all sensors at a time: Automated sensor balancing Quick overview of adjust value Easy to detect fatigue of material E-MOB RAH BT RLD FS ADAS CA 23

24 Analyze Mode - Replay, Export, Share Data You can replay any captured data file, zoom in with the recorder graph cursors, make measurements, print in full color to any printer, and export the data to a wide variety of formats compatible with today s popular analysis software package, like FlexPro, Matlab, Excel, DIAdem, UNV, Famos, Nsoft, Text and many more. You can even export the whole measurement view to an AVI video file from your recorded data to create moving documentation. NO LICENSE is needed to use DEWESoft in the ANALYZE mode, so you can install the software on all your computers, or even distribute it to your customers, and they can view to the results. In this way, all of your colleagues and customers can replay your data files and do all of the functions that you can just by sharing the data file! The export dialog allows selecting different export file formats. RPC III ComTrade WAV ATI SDF CAN AVI Clipboard Google Earth FlexPro MS Excel Diadem Matlab UNV Famos Nsoft Text And many more DEWETRON RLD Hardware Configuration DEWE2-M4-RLD DEWE2-M13s-RLD DEWE2-A13-RLD DEWE-501-RLD-128 Analog input channels 2 free slots for TRION series modules 11 free slots for TRION series modules 64 MDAQ inputs (64 ch. Expansion box) Digital channels 8 DIO and 2 CTR or 8 DI Channel expansion Yes CAN interfaces 4 Video DEWE-CAM-GIGE-120 or USB Display External MOB-DISP-x 17 (1920 x 1080) External MOB-DISP-x Power supply Dimensions (W x D x H) 318 x 253 x 108 mm 12.5 x 10 x 4.3 in. 11 to 32 V DC (max. 10 to 36 V DC ) isolated; incl. external AC power supply 441 x 230 x 177 mm 17.4 x 9.1 x 7 in. 100 to 240 V AC (max. 90 to 264 V AC ) 450 x 246 x 303 mm 17.7 x 9.7 x 11.9 in. Battery powered, 18 to 24 V DC or 11 to 33 V DC (UPS battery 1 min.) per 64 ch. box: 439 x 209 x 181 mm x 8.23 x 7.13 in. Weight Typ. 3.8 kg (8.6 lb) Typ kg (28.6 lb) Typ kg (33 lb) Typ. 9 kg (19.8 lb.) 24 TRION and MDAQ series modules are available for almost all kinds of sensors

25 Brake Test Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement Basic Brake Test The DEWETRON Brake Test system covers all kind of braking tests and ABS tests due to its flexibility it also covers test vehicles using regenerative braking. Online checks for validation, visualized online results including post-processing and reporting make the DEWETRON Brake Test system a complete all-in-one solution. The Brake Test system is based on a 100 Hz GPS system which is very simple and easy to set up. It is not sensitive to road surface conditions.the classical sensors like 5th wheel can be hooked up for comperative testing. Brake testing is a wide field of different requirements and a flexible and multifunctional solution guarantees a safe investment. Therefore the same equipment is capable to make also tire tests, acceleration tests, odo calibration, fuel consumption, etc. in a very efficient way. Key Features Integrated 100 Hz GPS receiver Quick and easy test setup Automated workflow with DEWESoft sequencer Automated report generation Ready-to-print report E-MOB RAH BT RLD FS ADAS CA 25

26 Speed and Distance GPS system Optical, radar or 5th wheel sensor Temperature Sensors Thermocouple Infrared sensor Tire temperature measurement Vehicle CAN-Bus Wheel Pulse Transducer Sensors Brake System String sensor: Brake pedal position Swatch: Brake valve timing Brake pedal sensor: Brake pedal force Pressure switch: Brake pressure Steering Wheel Sensor Steering wheel angle and torque Master Unit WLAN GPS Video DEWE-ORION card CAN Counter input Digital input Analog input GYRO Platform Yaw rate Video ADMA interface USB Printer 26

27 Brake Test Online Mathematics Distance, MFDD, further calculated channels Video Information Synchronized video information Post processing allows you to generate additional mathematical channels for result calculation. DEWESoft is able to generate reports and also export your measurement as a video clip. For a more advanced interpretation, DEWESoft supports a wide range of export format such as FlexPro, DIAdem, etc. Recorder CAN Bus Data/OBD II Synchronous data from CAN bus like Speed Acceleration ABS status Wheel speed Brake signal Brake pressure Acceleration Speed graph over time Steering wheel angle GPS Information Overlay actual position data to a map of the test track E-MOB RAH BT RLD FS ADAS CA 27

28 Simple Brake Test Application Brake testing is usually done according to standardized brake test procedures. Setting up a test sequence including the online check of the test boundaries allows performing the required tests for a standardized procedure. These tests are required for development and homologation of vehicles. On the other hand, brake testing is a wide field of different requirements and a flexible and multifunctional solution guaranties a safe investment. The same equipment is also capable of performing tire testing, acceleration tests, odo calibration, fuel consumption, etc. DEWETRON's measurement equipment is designed for highly robust data acquisition in the vehicle. All user interface and user interaction is done in an easy and economic way. Effective gadgets help the user to make the daily work simple and easy. Features like Offline Setup, Sensor Database, TEDS or Global Header and powerful Export Features integrate the measurement equipment in the whole process of testing. The main steps performed for a brake test are supported with the DEWESoft sequencer: Setup of the sensors Setup the brake test conditions Close the setup and start the test Accelerate the vehicle to the start velocity Press the brake pedal for maximum braking force Perform the measurement within the braking phase Validate the data and analyze Finally generating a report or export the data. The brake test requires simply the mounting of the GPS antenna and of the pedal switch. The DEWETRON measurement system can be mounted on the passanger seat via a belt using a snap closure. The display is mounted on the front screen via vacuum cups or on a telescopic pillar. The channels for velocity, distance and acceleration need to be set up. The start and stop conditions of the test need to be defined in the brake test setup dialog. Starting the test aktivates the sequencer which guides you through the test and starts the measurement of the required data automatically. For the simple brake test the vehicle accelerates to the defined speed. The sequencer now releases the brake phase which is detected by the switch on the brake pedal. The test is finished, when the car stands still and the software detected the stop chriteria. Now the report can be generated automatically and sent to a small printer GPS System GPS System is the easiest and up to now the most elegant way to measure speed and position with the required accuracy. Other devices such as optical, radar or 5th wheel are also supported with DEWETRON Brake Test systems. GPS is the preferred one because it is easy to install, easy to use and gives robust and precise data. GPS is not sensitive to the road surface, it also can be used off road on muddy streets, snow, ice etc. The GPS receiver is integrated inside a DEWETRON measurement device, so only the antenna has to be put on top of the vehicle and connected to the measurement device. Features of the DEWETRON GPS system: Easy to install and use Real-time vehicle speed Lowest latency time No calibration required GPS is not sensitive to road surface therefore can be used even off-road, snow, ice etc. Analog speed output and digital displacement output 28

29 Brake Test Brake Test Sequence Comparing GPS data with conventional optical sensor data shows that signal accuracy and signal latency of the GPS signal is comparable according its noise even better. A constant latency time of 8 ms of the optical sensor is corrected for this comparison. A DEWETRON system can handle all types of those sensors whether it is an optical sensor, a radar sensor or a 5th wheel sensor. The sequencer is a tool to predefine a process of steps in a sequential format. The interface can be graphically programmed or in a code oriented view. The sequence is stored in a file format. Therefore it is possible to manage these sequences centrally to guarantee a standardized and defined measurement procedure. Within the sequencer you can access all relevant DEWESoft features. In addition you can apply actions, apply formulas and make decisions, wait for interaction or a preset delay and define your customized sequences. So it s possible to define different sequences and fit them together in a single sequence, where the sub sequences are done sequentially. The sequences can be controlled by the user or by an event caused by a certain channel. For a specific test which consists of different steps and loops it s possible to configure such a test sequence. As shown in this simple example for brake testing. Brake Test Setup The setup of the Brake Test is shown in this screenshot. Start and stop conditions are set and also the required channels can be setup. For each output channel you can choose a name and choose the proper unit. You can also configure the color and preset a minimum and a maximum value used as a preset for its indicating instrument. Clicking on the arrow you can scroll through all the brake test specific channels. E-MOB RAH BT RLD FS ADAS CA 29

30 Calculated Parameters The math for those tests will be done in custom math module of DEWESoft. The values which need to be calculated are interpolated tables of v, a, t, s (velocity, acceleration, time and distance) where the reference could be time, velocity or distance in predefined steps. The additional parameters which are calculated are: Start speed when pushing brake pedal Stopping time Corrected brake distance, calculated as Sc=Sm*Vd²/Va² Mean fully developed deceleration MFDD (calculation see ECE R13-H) Brake deceleration over complete measurement Derivation of acceleration, used to check the passenger comfort Where: v o initial vehicle speed in km/h v b vehicle speed at 0.8 v o in km/h v e vehicle speed at 0.1 v o in km/h S b distance travelled between v o and v b in meters S e distance travelled between v o and v e in meters The speed and distance shall be determined using instrumentation having an accuracy of ± 1 % at the prescribed speed for the test. The dm may be determined by other methods than the measurement of speed and distance; in this case, the accuracy of the dm shall be within ± 3 %. USB Printer for printing results This printer is used to print the most important result parameters direct after the test and makes the documentation very easy. DEWETRON BT Hardware Configuration DEWE2-M4-BT Analog input channels Digital channels Channel expansion 2 free slots for TRION series modules 8 DIO and 2 CTR or 8 DI Yes CAN interfaces 4 Video Display Power supply Dimensions (W x D x H) Weight DEWE-CAM-GIGE-120 External MOB-DISP-12-A 11 to 32 V DC (10 to 36 V DC ) isolated; incl. external AC power supply 318 x 253 x 108 mm (12.5 x 10 x 4.3 in.) Typ. 3.8 kg (8.6 lb) TRION series modules are available for almost all kinds of sensors 30

31 Ride and Handling Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement Ride and Handling DEWETRON systems offer a rugged and portable design for in-vehicle and fulfill the requirement of a high channel count for vehicle dynamics investigations. The system covers a wide range of input types e.g. for voltage, strain, temperature and also for GPS, Video, CAN and OBD II. In addition to the application of Ride and Handling testing, the system is capable of being expanded with additional hardware and software features. Further automotive measurement tasks such as hybrid testing on the power train, brake test, together with synchronized video are also possible. Key Features Synchronized multichannel data acquisition without phase errors Proven package due to DTA Guaranteed compatibility of the whole system Compact and rugged equipment for in-vehicle use Easy mounting, setup, alignment, and calibration Multisensor inputs (voltage, acceleration, strain, etc.) Aliasing free sampling and flexible filtering capabilities Real-time Mathematics Support for Kistler RoaDyn measurement wheels Export to different file formats E-MOB RAH BT RLD FS ADAS CA 31

32 Sensors Gyro-platform Measurement steering wheel Steering robot Optical velocity sensors Height level sensors Wheel vector sensor Wheel force sensor Tire temperature Vehicle CAN Power Supply AC DC (isolated) Battery powered Interface USB, Ethernet, WLAN DEWE-VGPS Position interface DEWE-CAM Video DEWE-ORION card Sensors Forces Accelerations Strain Gages Rosettes Temperatures Potentiometric sensors CAN Counter input Digital input Digital output Industrial PC PC DEWESoft Ride & Handling DAQ or MDAQ module Signal conditioning Sensor supply Analog input External Clock e.g. Kistler RoaDyn ext. clock int. clock 32

33 Ride and Handling CAN-Bus Data/OBD II Synchronous data from CAN-bus CAN DBC export and import J1939 decoding Reports Video Synchronized video information Wheel Force Measurement Telemetric recipient for all wheel forces -12,0-10,0-8,0-6,0-4,0-2,0-100,0 2,0 4,0 6,0 8,0 10,0 12,0 Right turn R = 100 m m/s² Right turn 3 m/s² Right turn Steering angle ( ) Steering angle ( ) Left turn Lateral acceleration (m/s²) Analog Channels Strain, temperature, acceleration, force, torque, etc GPS Information Position data Lateral acceleration (m/s²) Roll angle ( ) Float angle ( ) E-MOB RAH BT RLD FS ADAS CA 4 m/s² Right turn 5 m/s² Right turn 6 m/s² Right turn 33

34 Ride and Handling Application Cars and trucks are designed on computers, and built by robots under computer control. But there is no substitute for testing the car with a human being, under a wide variety of road conditions and environments. That s where ride handling tests start. Most vehicle manufacturers have their own test track or proving grounds, where they can put their creations to the test. What normal people would consider subjective criteria like how a car feels under certain conditions must be precisely quantified and then tested over and over again within an optimization loop, on every vehicle. Standardized tests guarantee reproducible and comparable results. Those standards are available and supported with our measurement system. This is furthermore important for a globalised comparison of test results. For the measurement process efficient setup time and simple system handling is a key to fulfill efficient measurement tasks. Our unique DEWESoft, the portable packages and rugged construction makes DEWETRON products popular for ride handling, drivability, vehicle dynamics, and related applications. Typical tests for Ride and Handling are: Stationary circle test (DIN ISO 4138) ISO Lane Change Test (ISO /2) Braking from stationary circle test ( ISO 7975) VDA-evasion test according to ISO Load change from stationary circle test according to ISO 9816 Steering angle step and sinus test according to ISO 7401, ,-2 (with steering robot) Fishhook Test (NCAP) FMVSS-126 (Sine with Dwell) Ride and Handling often also called vehicle dynamics - is a wide range of applications and investigations in the development process of an vehicle and its components. One goal of the investigations is an objective assessment of the vehicle behavior and the drivability. Furthermore also the development of control loops and the parameterization for the chassis control is within the view of the ride and handling application. Ride and Handling Sensor Installation Depending on the measurement goal, many different sensors are required for different tests. With a DEWETRON Ride and Handling System you can implement all established sensors available on the market. Together with the DTA (Drivability Testing Alliance) our system compatibility is proven. The table shows the required the minimum sensor equipment for each standardized tests. The following table is a suggestion for the sensor equipment of each test. The table beside shows the physical parameters of the main measurement systems. The synchronous and aliasing-free acquisition of the physical channels is guaranteed furthermore all mathematical processing of additional channels can be done online. 34

35 Ride and Handling Synchronous measurement Synchronous measurement is absolutely essential for the measurement quality. All the sensors within this complex system have their own timing behavior. Within a DEWETRON system all the channels are strictly synchronous. This guarantees the measurement quality required for a correct interpretation of the measured results. Sensor assembly of a Vehicle Adapting and calibrating all sensors is a major effort for Ride and Han-dling tests on a vehicle. Therefore the compatibility of the sensors the signals, the plugs, the data acquisition, the initialization routine and further software features therefore the proven compatibility plays an essential role for a complete test system. Due to the proven compatibility of all sensors and the DEWETRON measurement system, the time to assemble the car can be optimized to a minimum. This will ensure cost effective wiring and assembly of the complete system. CAN Input Synchronous CAN interfaces are required for the communication with the ADMA (gyro sensor) and the vehicle bus. CAN bus data can be visualized and recorded. The CAN setup dialog allows to set up the required CAN channels as measurement channels. These channel are treated like physical measurement channels and can be used for visualization, mathematics or to trigger an event. Offline Setup Especially in large channel count situations a standard PC can be used to create the measurement setups off-line independent from the measurement hardware. Multisensor Input Each channel of a multisensor input supports different sensor types via MSI (Modular Smart Input) modules. These interfaces are automatically detected and configured by the software. Thermocouple PT100, PT1000, etc. Voltage Acceleration E-MOB RAH BT RLD FS ADAS CA 35

36 Sequence Control The sequencer is a tool to predefine process steps in a sequential format. The interface can be graphically programmed or in a code oriented view. It is possible to manage these sequences centrally to guarantee a standardized and defined measurement procedure. Within the sequencer you can access all relevant DEWESoft features - apply actions and formulas and make decisions, wait for interaction or a preset delay and define your customized sequences. So it s possible to define different sequences and fit them together in a single sequence, where the sub sequences are done sequentially. The sequences can be controlled by the user or by an event caused by a trigger of a certain channel. Sensor Database and TEDS The entire channel setup and scaling is just a click away, which keeps a comprehensive list of sensors and all their parameters, including scaling, units and calibration date info. Linear scaling and offset Non linear scaling Polynomial scaling Calibration table The entire channel setup and scaling is just a click away. If necessary it s possible to zero the sensor or even to renew the calibration parameters. This guarantees the reproducibility, traceability and quality of your measurement results. To make the sensor setup even more automated, our signal conditioning modules support TEDS, which is the new smart sensor interface". TEDS is an acronym for Transducer Electronic Datasheet. It is a table of parameters (manufacturer ID, model number, serial number, version, and many more) that identifies the transducer. The screenshot shows a view to the sensor database dialog. DEWESoft Net DEWESoft Net allows the communication between different Dewetron Systems. The system can be configured as stand alone, as master or as a slave unit. It s also possible to use another PC for remote control. Cascading two or more devices in the vehicle DEWESoft Net can synchronic and interface the devices. For testing in two or more vehicles, using a master slave configuration, the data can be send via WLAN to the master. Global Header The global header adds additional information to the measurement project for documentation. Entries like project name, test engineer, test description, unit under test and comments etc. can be configured. The setup of the header file can be stored and used as a standard header file. All data and setup parameters are stored in the data file. This allows a traceable measurement procedure. 36

37 Ride and Handling Triggers and Alarms DEWESoft includes a versatile TRIGGER section, which includes with following types of trigger method: Simple edge Filtered edge Window trigger Pulse width trigger Window and pulse width Slope Trigger The same type of dialog is available to set up an alarm event. All of these sources are available to STOP the acquisition or configure a condition where no data will be stored. It's also possible to enter a pre-aquisition time, a post-acquisition time and a holdoff time. Data Visualization One of the most powerful and yet easy to use aspect of DEWESoft is the creation of displays. Each of the standard displays mentioned above can be modified in seconds, as easily as clicking the DESIGN button and clicking widgets from the screen design tool bar! Pictures Discrete displays Oscilloscope FFT chart Digital meter Bar graphs Video GPS Analog meter Recorder XY-chart Text FlexPro Report FlexPro combines the power of a high-end data analysis tool with the ease of use and familiar interface of Excel. But unlike Excel, there are no limits to the size of a file that FlexPro can open, analyze, chart, and print! Tightly integrated with DEWESoft, FlexPro is a worthy option for any DEWETRON data acquisition system. Using a FlexPro template, your report is generated after the measurement sequence. Programming is as simple as usage of Excel and Word and at the same time very fast, even when dealing with large data volumes.the template defines all tables and graphes you want to see within ypur report this has only to be done once. -12,0-10,0-8,0-6,0-4,0-2,0-100,0 2,0 4,0 6,0 8,0 10,0 12,0 Right turn R = 100 m m/s² Right turn 3 m/s² Right turn 4 m/s² Right turn 5 m/s² Right turn 6 m/s² Right turn Steering angle ( ) Steering angle ( ) Left turn Lateral acceleration (m/s²) Lateral acceleration (m/s²) Roll angle ( ) Float angle ( ) E-MOB RAH BT RLD FS ADAS CA Once you have defined the calculations and the layout, you have a template that you can be re-use for future tests. Simply import the data from a new test into FlexPro and update your documents with a mouse click. 37

38 DEWETRON RAH Hardware Configuration DEWE2-M4-RAH DEWE2-M13s-RAH DEWE2-A13-RAH DEWE2-F13s-RAH DEWE-501-RAH-128 Analog input channels 2 free slots for opt. TRION series modules 11 free slots for opt. TRION series modules 64 MDAQ inputs (64 ch. expansion box) Digital channels 8 DIO and 2 CTR or 8 DI Channel expansion Yes CAN interfaces 4 Video DEWE-CAM-GIGE-120 or USB Display External MOB-DISP-x 17 (1920 x 1080) External MOB-DISP-x Power supply 11 to 32 V DC (max. 10 to 36 V DC ) isolated; incl. external AC power supply 100 to 240 V AC (max. 90 to 264 V AC ) Battery powered, 18 to 24 V DC or 11 to 33 V DC (UPS battery 1 min.) Dimensions (W x D x H) 318 x 253 x 108 mm 12.5 x 10 x 4.3 in. 441 x 230 x 177 mm 17.4 x 9.1 x 7 in. 450 x 246 x 303 mm 17.7 x 9.7 x 11.9 in. 441 x 230 x 177 mm 17.4 x 9.1 x 7 in. per 64 ch. box 439 x 209 x 181 mm x 8.23 x 7.13 in. Weight Typ. 3.8 kg (8.6 lb) Typ kg (28.6 lb) Typ kg (33 lb) Typ. 8.0 kg (17.6 lb) Typ. 9 kg (19.8 lb.) TRION and MDAQ series modules are available for almost all kinds of sensors 38

39 Electro-Mobility Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement Electro-Mobility DEWE-E-Mobile In the race to produce an electric vehicle with a range practical for everyday use, the development of energy efficient components is an important focus for automotive research centres all over the globe. Consequently there is an enormous need for test and measurement systems to monitor the energy flow and storage through vehicle activity such as charging, startup, driving, parking and potential misuse of the vehicle. DEWE-E-Mobile systems can do so much more than just capture voltage and current signals. An extra library for power measurement (DEWESoft POWER Module) makes the calculation of, for example, power flow, losses, harmonics and voltage fluctuations possible. With the help of this functionality the user can - beside the DC measurement on batteries - make synchronized analysis of the other components like converters and motors. Adding transducers such as accelerometers, rpm sensors or thermocouples can be handled through flexible and isolated signal conditioning, recorded in a synchronized way alongside hundreds of channels of vehicle CAN bus data. Add a GPS sensor to give information about position, distance, velocity and direction, along with video camera s to monitor road or environmental conditions and you have a very clear view of the E-vehicles performance characteristics. Applications ALL-IN-ONE Power Analyzer, Combustion Analyzer, Recorder and Scope on a single machine Same software interface for all instruments, easy to learn and use, online or offline calculation Synchronized analog & digital signals, counter, CAN bus and video inputs to simplify analysis High isolation and high accuracy High bandwidth up to 2 MHz Test bench for electric drive trains E-MOB RAH BT RLD FS ADAS CA 39

40 E-Mobile Instruments Nothing is required to complete these instruments. Dynamic analog input channels Included DAQP modules for DC circuit Included DAQP modules for two E-Drives External quasi-static channel expansion A/D conversion Sampling method Sampling rate / channel Resolution Digital I/O and counters DEWE-2600-E-Mobile voltage, 7 current, 2 additional channels possible 1x HSI-HV and 1x HSI-LV-D 6x HSI-HV and 6x HSI-LV-D DEWE-510-E-Mobile-1000 EPAD interface, up to 16 EPAD2 modules = 128 channels Simultaneous sampling Digital I/O, TTL level 8 Counters or digital inputs, TTL level (1 counter equals 4 digital inputs) Options UP-CNT8-TTL adds 8 synchronous counter / encoder or 32 digital inputs, TTL level 1 MS/s 16 bit 2 included / 8 optional optional UP-CNT8-DIFF adds 8 sync. counter / encoder or 24 digital inputs with programmable threshold levels (0..40 V), input voltage range -35 to 60 V, AC/DC coupling, and 8 sync. digital inputs protected up to 25 V DC, TTL level optional CAN bus option UP-CAN-2 2 highspeed CAN bus interfaces Video input option UP-DEWE-CAM-01 adds synchronized video picture acquisition of up to 200 fps (frames per second) up to 70 fps at 640 x 480 pixel up to 200 fps at 640 x 120 pixel Combustion Analyzer option DEWE-CA Speed and distance sensors DEWE-VGPS-200C with 20 Hz engine and interpolated 200 Hz output Current sensors PNA-Clamp-150-DC (DC 100 khz) - TEDS detection EMC included optional optional optional 300 A DC or AC peak ESD; EMC IEC ; EN Power supply Voltage inputs Current inputs Shock and vibration Surge IEC kv Burst IEC kv; L, N, PE Surge IEC kv Burst IEC kv Surge IEC kv Burst IEC kv Shock EN Vibration Environmental Operating temperature EN , EN class 2M2 0 to +50 C (0 to +45 C with batteries) Storage temperature -20 to +70 C Humidity Data storage Technology 10 to 80 % non cond., 5 to 95 % rel. humidity Hard disk Capacity 600 GB 1000 GB Max. gap free storing to disk Typical 80 MB/s Typical 70 MB/s Typical duration of recording (16 ch. / 10 ks/s/ch. / 16 bit) 20 days 35 days Power supply Standard Optional Main system 1) Battery powered, 3 battery slots 2), incl. 3 batteries for ~2 hours operation, incl. external AC power supply 95 to 260 V AC 50 / 60 Hz or 110 / 220 V DC 510-DC-12V Power supply 9 to 18 V DC (no internal battery), incl. external AC adaptor Display 15 TFT (1024 x 768) Optional MOB-DISP-12 Processor Current transducer power supply ±15 V / 9 V Interfaces Dimensions Housing Intel Core 2 Duo 2 GHz 8x Lemo sockets 4x USB, 2x Ethernet, 1x RS-232 Portable instrument Dimensions (W x D x H) 417 x 246 x 303 mm (16.4 x 9.6 x 11.9 in.) 439 x 308 x 181 mm (17.2 x 12.1 x 7.1 in.) Weight without batteries Typ. 14 kg (31 lb.) Typ. 8 kg (17.6 lb.) 1) Please find current specifications in the latest price list 2) Weight of one battery: 660 g (1.45 lb.) 40

41 Electro-Mobility PNA-CLAMP-150-DC PNA-CLAMP-1800-DC Current range 300 A DC or AC peak Power supply ±15 V ±10 %, external Cont. current measurement 150 A DC or AC RMS OPTION for Overload capability 500 A DC (for 1 min) * DEWE-2600/2602: 0.5U-CLAMP-DC-POWER-4/-8 * For others: CLAMP-DC-POWER-4/-8 Output sensitivity 20 mv/a (w.r.t. 0 V) Connector SUB D (TED) ; (SUBD modules Accuracy (+ 25 C) ±0.3 % of reading ±2 ma required for TEDS support) Supply (LEMO; incl. jaws Resolution ±1 ma status); Adapter SUB D-banana included Frequency Range DC to 100 khz (-1 db) Max. conductor size 32 mm diameter Jaw status 0 V (Lo) / +15 V (Hi) Relative zero correction Auto zero at switch on Current range 1800 A DC or AC peak Power supply ±9 V ±5 %, external Output sensitivity 1 mv/a (w.r.t. ±2.5 V) OPTION for Accuracy (+ 25 C) * DEWE-2600/2602: 0.5U-CLAMP-DC-POWER-4/-8 DC Accuracy (0-1000A) 1 ±0.8 % of reading ±0.5 A * For others: CLAMP-DC-POWER-4/-8 DC Accuracy ( A) 1 ±1.8 % of reading ±0.5 A Connector SUB D (TED) ; (SUBD modules Overall Accuracy (0-1000A)² ±2.5 % of reading ±0.5 A required for TEDS support) Overall Accuracy ( A)² ±3.5 % of reading Supply (LEMO); Adapter SUB Overall Accuracy ( A)² ±5 % of reading D-banana included Resolution ±20 ma Max. conductor size 32 mm diameter Frequency Range DC to 20 khz (-1 db) Relative zero correction Push button E-MOB RAH BT RLD FS ADAS CA 41

42 Accuracy Example for Instrument Inputs Voltage [V]: 400 V Current [A]: 30 A Frequency [Hz]: 50 Phi [ ] : 30 Current module: Range: Filter: DAQP-LV 1 V 300 khz Voltage module: Range: Filter: DAQP-HV-S3 800 V 700 khz Maximum P-error and Q, S as function of Phi Maximum P-error as function of current for different cosphi Maximum P-error as function of frequency with cariable current/max current (f max = Hz) 42

43 Electro-Mobility Hybrid Vehicles and other Alternative Drive Concepts Application Example for E-Mobility Introduction Due to the worldwide energy situation alternative energy concepts for vehicles of all kinds are getting more and more important. Hybrid vehicles are already serialized and more and more electric drive concepts appear on the market. The electric motors with electronically controlled feed, that is also able to recuperate braking energy, are the future. Batteries and fuel cells are used more and more. Task Modern drive systems work with very fast converters that have both high pulse frequencies and steep rising edges. The power measurement is thus confronted with all tasks of modern power measurement instruments: broadband input modules, high sampling rates, highly accurate identification of reactive and active power, determination of rotation speed and torque. Beside the measurements of motors (3~, permanently energized synchronization instruments), also measurements of battery circuits and intermediate circuits are of interest and this absolutely synchronous (DC, single-phase). Further interesting parameters could be temperature, oscillation, acoustics, sound emission, torsion and rotation oscillation and analysis of combustion engines provided that they are used in parallel. On the one side, such systems should be as portable as maximally possible for mobile applications. On the other side, it should be possible to integrate them in engine test benches. This requires adequate data interfaces. Solution Hardware Broadband, isolated measuring inputs, high sampling rates and robust design combined with high flexibility this unifies DEWETRON in its instruments of DEWE-E-Mobile series; be it the 510 as engine test bench solution or integrated in the car, respectively the 2600 that is battery-powered. They all have the modular construction in common that allows an arbitrary number of current and voltage input channels. Temperature, charge or bridge amplifiers can also be used as can CAN bus adapters or counter interface for e.g. tachometers. For highly accurate current measurements zero flux transducers are used that not only feature high dynamics (startup current versus idle current with an accuracy of 0.05 %) but also high bandwidth. As for voltage inputs also in this case several 100 khz are a must (-3 db@700 khz). Sampling rates of up to 1 MHz allow exact analysis of pulse packages of the frequency converters. E-MOB RAH BT RLD FS ADAS CA 43

44 Software The software DEWESoft with its option POWER was especially developed for the electric power measurement. It includes the conventional and approved DEWESoft functions and moreover provides all parameters that are necessary for electric drives: P, Q, S, PF U, I, cos Phi Harmonics FFT up to 500 khz M, n X/Y recorder Sound Vibration Rotational and torsional vibration Further Functions Several Power Modules at Same Time With the DEWESoft power module several power systems can be measured at the same time. Motors, for example: UMotor 3~ / U DC / UBattery Sound and Vibration Exact and high-resolution noise level measurement according to IEC 60651, 60804, With its user-friendly operator interface DEWESoft brings the sophisticated noise/acoustics analsyis to the user. Rotational and Torsional Vibrations With this module you can easily measure rotational vibrations, bearing damages, unbalances, etc. and can record - in parallel to the power data discussed so far - as well as evaluate them. Analyses on Combustion Engines CA-Option Should, as it is the case with classical hybrid vehicles, combustion engines also be in use beside electrical drive systems, then these engines can simultaneously be analyzed with the DEWESoft-CA. CAN-Bus Beside a number of sensors, also direct CAN-bus systems can be provided. CAN-bus data can here be used by the DEWESoft as all other measurement channels. 44

45 Electro-Mobility Driveability Tests DEWESoft offers a wide range of functions for drive ability tests that can, of course, be used simultaneously. GPS systems for deceleration measurements, in parallel to the recuperation of drive systems, are only one of several possibilities provided. Video The use of synchronous DEWESoft VIDEO functions allows the parallel storing of video data and measurement values and opens a wide range of application possibilities whenever optical information is needed. Remote Control With the remote control system the instruments can be configured and the data can be evaluated from afar for example while being in your office. The transmission of data from vehicle to vehicle via WLAN is also a special feature. Open Interface (DCOM) The programming interface DCOM offers every user the possibility to arrange one s individual integration into test bench systems. Several protocols already generated are available (OPC, Modbus, ) just contact us and we are pleased to find your individual solution for your applications. Customers Vehicle producers R & D departments for electrical drive systems Research centers and testing laboratories E-MOB RAH BT RLD FS ADAS CA 45

46 Measurements on Electrical Energy Storage Systems Application Example for E-Mobility Introduction For hybrid and electric cars electric energy storage is a key component in relation to costs. Owing to the trend towards electro mobility, electric storage systems are increasingly falling under the global spotlight. Manufacturers efforts are predominantly focused on improving range and performance as well as durability, safety and reliability. DEWE-E-Mobile series offers a wide range of opportunities, allowing these core areas to be tested in great detail for cells, battery modules, super capacitors and energy management systems thereby forming the basis for efficient, powerful and reliable traction batteries in electric vehicles of the future. Task The requirements of reliability and performance of the electrical system of modern cars are continuously rising. In the overall concept, storage for electrical energy plays the central role. Modern applications in motor vehicles such as stop/start, hybrid-drives, plug-in hybrid and electric vehicle result in new requirements for energy storage. Future hybrid and electric vehicles will mainly be equipped with lithium-ion batteries. These batteries promise to have a high storage density. But in order to tap their full potential and to guarantee long-term and high-level operation period, intelligent and elaborate testing is absolutely necessary. Another challenge is the integration of batteries in the drive train and the entire vehicle. Further interesting parameters could be temperature, oscillation and acoustics or sound emission. On the one side, such systems should be as portable as maximally possible for mobile applications. On the other side, it should be possible to integrate them in engine test benches. This requires adequate data interfaces. Measurements with high dynamic range for voltages & currents are required to fulfill the following tasks: Cell characterization: measurement and performance profile under defined environmental conditions Charge-discharge cycles, respectively utilization cycles Environmental simulations: including temperature, pressure, vibration, weathering Misuse tests: behavior of batteries under extreme electrical, mechanical and thermal loads or overload such as overloading, short-circuit, mechanical damage, overheating Endurance tests: endurance and ageing tests during storage or cycling in increased temperatures Solution Hardware Broadband, isolated measuring inputs, high sampling rates and robust design combined with high flexibility this unifies DEWETRON in its instruments of DEWE-E-Mobile series; be it the DEWE-510 as test bench solution or integrated in the car, respectively the DEWE-2600 that is battery-powered. They all have the modular construction in common that 46

47 Electro-Mobility allows an arbitrary number of current and voltage input channels. Temperature, charge or bridge amplifiers can also be used as CAN-bus adapters or digital in- and outputs. For highly accurate current measurements zero flux transducer are used that not only feature high dynamics (load current versus idle current with an accuracy of 0.05%) but also high band-width. As for voltage inputs also in this case several 100 khz are a must (-3dB@700kHz). The battery behavior during highly dynamic loads is particularly interesting when evaluating hybrid batteries. The internal resistance of batteries significantly affects the maximum current especially at pulse-shaped loads. Sampling rates of up to 1 MHz allow exact analysis of this. Software The option POWER for the DEWESoft makes the calculation of for example power flow, losses, harmonics and voltage fluctuations possible. With the help of this functionality the user can, beside the DC measurement on batteries, make synchronized analysis of the other drive components like converters and motors. All this together makes a total view on the system E-drive and its losses very simple and also has also a very high accuracy. For each measurement the sensor settings are saved together with the other test parameters in the measurement data. This allows a smooth and complete processing of the measured data as well as a comparable and re-traceable repetition of tests. Analyses typical for batteries such as HPPC (Hybrid Pulse Power Characterization) can be done online as well as offline. Further Functions Several Power Modules at the Same Time With the DEWESoft power module several power systems can be measured at the same time. For example, batteries: while more cells or reference electrodes Sound and Vibration Vibration or impacts to the battery measured during the trip. Exact and high-resolution noise level measurement according to IEC 60651, 60804, With its user-friendly operator interface DEWESoft brings the sophisticated noise/acoustics analysis to the user. Temperature Measurement Batteries have a limited temperature frame in which they work efficiently. You would like to fix some sensors such as thermal elements by yourself, or some hundred temperatures should be recorded? Our systems can record asynchronous input channels with different time resolutions SYNCHRONOUSLY (one clock for all channels!). Dynamic Measurements The behavior of batteries under load cycles that are typical of driving cycles for hybrid applications are the subject of intense testing efforts. Or the evaluation of batteries with load cycles under different temperatures. In this case batteries will be tested with different driving cycles or user-specific profiles. For practical testing, it is necessary to charge the batteries not only with relatively constant cycles but with real load cycles that occur in everyday use, e.g. Starter or electric drive motors for electric and hybrid vehicles. In real tests, a variety of data drops of. The data can be displayed online and offline comfortable in DEWESoft. The minimum standard sampling rate is 2 s. DEWESoft provides a modern, event-oriented data storage for dynamic measurements that allows space-saving and easy management of data. E-MOB RAH BT RLD FS ADAS CA 47

48 CAN-Bus Beside a number of sensors, also direct CAN-bus systems can be provided. CAN-bus data can here be used by the DEWESoft as all other measurement channels. The synchronous recording of CAN-bus data from battery management systems and control units is just one of several possibilities provided. Video The use of synchronous DEWESoft VIDEO functions allows the parallel storing of video data and measurement values and opens a wide range of application possibilities whenever optical information is needed. Having a defined load profile thermal analysis for monitoring the heating-up and temperature distribution of the battery can be done with the help of synchronous infrared videos. In misuse-tests that lead to exploding and out gassing of the battery the current and voltage curves can be recorded time-synchronously with the help of video and audio signals. Thus the moment of damage can be synchronized with the electrical parameters. Remote Control With the remote control system the instruments can be configured and the data can be evaluated from afar for example while being in your office. Open Interface (DCOM) Test bench connection: For test sequences a central administration of the test results is mandatory in order to receive statistical analyses such as scattering of parameters in one test. The data basis offers the possibility to derivate a mathematical model from an accumulation of parameters. Batteries can furthermore be simulated mathematically. Via its DCOM-interfaces DEWETRON offers the possibility to link to these test benches flexibly and individually. The programming interface DCOM offers every user the possibility to arrange his individual integration into test bench systems. Several protocols already generated are available (OPC, Modbus, ) just contact us and we are pleased to find your individual solution for your applications. Customers Battery producers for electric vehicles (EV) or hybrid electric vehicles (HEV) R & D departments for electrical energy storage systems Research centers and testing laboratories 48

49 Electro-Mobility Testing on Test Track, on Test Bench or in the Lab Application Example for E-Mobility Universal and High Dynamic Systems to do more than one Task The shift from the conventional veicle towards the various hybrid technologies and purely electrically driven vehicles has already begun. The range of micro, mild, full and plug-in hybrids already available or poised for launch is a clear indicator that electro mobility is regarded as our biggest short-to-medium-term hope for environmentally-friendly mobility. In recent years, DEWETRON has positioned itself as a recognised partner for E-Mobile instruments, helping both manufacturers and suppliers adapt to the electric era. There are three major areas of testing, that are relevant to today s OEM manufacturers, tier 1 and 2 suppliers: Task Testing complete power train and components on test benches Testing on roller test stands Drive tests to find out performance characteristics and reliability The development of new vehicle concepts necessitates detailed information about the electrical, thermal and mechanical characteristics of individual components and entire drives. Thanks to sophisticated test equipment, DEWETRON is able to provide these data for all relevant components from electrical machines and power electronics to electric energy storage systems and entire vehicles. Key criteria related to E-Mobile instruments for this application: Universal and multi-functional measurement system for each vehicle Very small form factor and wide voltage input range DYNAMIC inputs with high bandwidth Synchronized measurement of all data High accurate GPS measurement CAN-bus interfaces for direct reading of vehicle parameters Video interface for synchronous video recording Easy to use software Easy mounting, setup, alignment and calibration Comparable and reproducible tests Solution Hardware DEWETRON s E-Mobility instruments are investments in the future; they can grow with your requirements and replace several application-specific solutions on the test track, on test benches, or in the lab. E-MOB RAH BT RLD FS ADAS CA 49

50 DEWETRON systems are flexible and powerful enough to perform all measurements at once saving valuable test time and cost. DEWETRON offers several instruments that are suitable for measurements in the area of e-mobility. The basis is always a basic DEWE-E-Mobile instrument with a rack for DAQP module. Special focus was put on the stability and capacity of the instruments independently from the fact that a DEWE-510 as test bench solution or integrated in the car, respectively the DEWE-2600 that is battery-powered is used. Software The identification of dynamic processes, the calculation of power and the measurement of harmonics are only a few of the numerous functions of the measurement software DEWESoft with its option POWER. Unbalances, frequency and revolution per minute are some more that are nowadays necessary for the power analysis. Besides, it is very important to reach high sampling rates that can be processed by the software: 500 khz for the calculation of power are a must-have for controlled drive systems. Some Details Dynamic Measurements Imagine for example an electric motor. During the test drives, your task is to check the electric motor for mechanical performance (RPM, torque), electrical performance with over all analysis (voltage, current, power, efficiency, electrical troubles), for operational parameters like temperatures over a longer period of time as well as sound and vibration, usually related to load and speed. Optional: synchronized image data from a camera improve the documentation and the understanding. DEWESoft provides a modern, event-oriented data storage for dynamic measurements that allows space-saving and easy management of data. CAN-Bus Beside a number of sensors, also direct CAN-bus systems can be provided. CAN-bus data can here be used by the DEWESoft as all other measurement channels. The synchronous recording of CAN-bus data for direct reading of vehicle parameters is just one of several possibilities provided. GPS and Video Add a GPS sensor to give information about position, distance, velocity and direction, along with video camera s to monitor road or environmental conditions and you have a very clear view of the E-vehicles performance characteristics. Customers Vehicle producers R & D departments for the power train Research centers and testing laboratories 50

51 Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement Torsional & Rotational Vibration Torsional and Rotational Vibration Rotating machines and engines are sources of rotational and torsional vibration. Rotational vibration is a result of the change in shaft speed during one revolution and torsional vibration is due to angular twist in the shaft or drive train which may cause fatigue. So you will observe: vibration, force, strain, voltage, current, power, CAN data and rotational- and torsional vibration with only one instrument at the same time. That s unique! Key Features Time domain measurement Angle based view Additional to all other functions (analog, CAN, GPS, video,...) Configurable display Direct sensor connection 80 MHz time base High resolution +-0,03rpm +-2mdeg@12000rpm Applications Power train Paper mill Combustion engine Belt drive Engine test bench Power plant testing and monitoring Examination of rotating field Ballistic Balancing Order Tracking Modal Analysis Tor/Rot Vibration 51

52 Overview Additional Sensors Strain Gauge Current Voltage Temperature Electrical Power Acceleration DAQP Module Signal conditioning DEWE-ORION-card Digital input Digital output Industrial PC PC Sensor supply Analog input Crankangle encoder Counter input DEWESoft OPTION Torsional- & Rotational Vibration Crankangle encoder ext. clock int. clock Setup For rotational vibration measurement one rpm sensor is used to determine the rpm deviation and for torsional vibration there is one at each end of the power train. DEWETRON supports a wide range of different sensors e.g. encoder, pickup, RIE-360/720 and many other sensors. All these are connected directly to a counter input of the DEWETRON system. Each counter input provides a power supply, three differential inputs with selectable trigger level compatible with all sensor outputs. A ready to use template makes it easy to setup the measurement within a few minutes. Digital input filters, a sensor database and a reference curve eliminates sensor errors. Various output channels are immediately provided for further investigation: Reference angle [deg] RPM [rpm] Rotational angle [deg] Rotational velocity [deg/s] Rotational acceleration [w/s] Torsion angle [deg] Torsion velocity The picture on the right shows a typical analysis screen. Data is shown either in time domain or angle domain together with all other measured channels. By selecting the order analysis module you will get order based results. System Requirements Any DEWETRON system equipped with DEWE-ORION series AD card 4 available counter inputs Software option DEWESoft-OPT-TORVIB Please ask for your costumized solution! 52

53 Modal Analysis Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement Modal Analysis Modal Analysis is needed in every modern construction. The measurement of system parameters, called modal parameters, are essential to predict the behavior of a structure. These modal parameters are needed also for mathematical models. Parameters like resonant frequency(s), structural damping, and mode shapes are experimentally measured and calculated. DEWETRON provides a hard and software solution which is adapted to your application. Starting up from 8 channels used for maintenance, service and troubleshooting till up to 1000 channels used for complex structures. The easy-to-use software is suitable for professional and occasional users. Key Features SISO, SIMO, MIMO configurations Spectral ODS Geometry editor Mode indicator function MIF Circle fit analyze tool Function generator up to 16 channels FRF from stored time data Triggered-, free-run measure mode Roving hammer excitation support Unv-file export for modal packages (ME-Scope,...) Animated FRFs Up to 1000 channels linked over NET Ballistic Balancing Order Tracking Modal Analysis Tor/Rot Vibration 53

54 Overview To measure a FRF of a structure basically two channels are needed. One channel is used to measure the excitation force, which could be an Impact hammer or a shaker. This excitation force excites the structure, and at least one acceleration sensor measures the response of the structure. Out of that the transfer characteristic (FRF) and the modal parameters are calculated. To determine the structure you have to measure several points to get the whole system identified. This could be done either with one response or up to hundred or thousand channels depending on the complexity of the structure. Channel Setup In the channel setup the excitation-, and the response channels are defined. DEWETRON amplifiers support the state of the art TEDs interface which gives the maximum comfort especially at high channel count. The FRF Setup provides all parameters needed for the measurement Free run, triggered mode Average Excitation window length Response decay Trigger levels Overlap Also the channel definition according to structure is done in the FRF setup. A structure could be imported from any other software with unv. file format or created with the included geometry editor. 54

55 Modal Analysis Measurement The tool bar provides all important and necessary functions which are needed during the measurement. At Single Input Single Output (SISO) measurement either the excitation or the response could be moved, because sometimes it is easier to move the excitation than the response. DEWETRON supports both types of this measurement. Analysis In the analyze screen the FRF spectra are shown together with the geometry. The included analyze tools like animation of the geometry, Circle Fit, MIF Excitation are provided to determine the results immediately. In case of an error the spectrum could be re-measured immediately. This saves time and money. Display options could be set according to the needs, Phase, Coherence, Re-, Imag, are only a few possibilities which could be set. Response Channel Overload Indicator Phase Coherence RE-Img Transfer Curve The prepared measurement screen will give you all the control possibilities for either running or triggered FRF. Ballistic Balancing Order Tracking Modal Analysis Tor/Rot Vibration 55

56 FRF Export For further investigation and analyses in modal packages like ME-Scope the FRF data, coherence and excitation can be exported to the UFF (Universal File Format) or simply copied to clipboard and used in standard applications like Microsoft Excel or Word. Function Generator For a running FRF the structure is excited with a shaker. Here either one shaker or multiple shakers for big structures are used. The shaker(s) have to be controlled mainly in amplitude, phase, waveform and frequency. DEWESoft offers an integrated function generator up to 16 Channels which is fully software controlled. Various time patterns like Fixed Sweep Step sweep Burst Chirp are configurable for any application. Technical Data Function Generator Up to 16 channels Smooth change for shaker control 16 bit D/A +-1 mv to +-10 V Sine, square, triangle, ramp, noise,.. Watchdog Frequency resolution 1 mhz with 10 ppm Phase adjustment 0,05 Hardware Requirements ICP -Inputs Orion1624 Series AD card DEWETRON Option FG Shock Response Spectrum (SRS) The shock response spectrum shows the maximum responses of a series of uniformly damped singledegree-of-freedom (SDOF) systems caused by a shock waveform applied on the structure. After setting damping, resolution (12,24,48,96/ octave) and primary section the spectra are calculated out of the time domain signals. The time domain signals are recorded with DEWESoft and exported to FlexPro.A prepared SRS-Script with user interface supports a convenient straight forward procedure for fast results. Up to 1 MHz D/A rate SNR>80 db, THD<0,05% Arbitrary output/file replay Fix frequency, lin/log SWEEP, CHIRP, BURST Mode or STEP sine DEWESoft Option FRF DEWESoft Option SRS 56

57 Order Tracking Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement Order Tracking Rotating machines under operational conditions require additional analysis such as order tracking. Compared to normal FFT the spectrum is based to orders instead of frequency (time). The orders describe the fundamental or a multiple of the actual rotation speed [Hz]. With this method you can separate frequency components which are related to engine speed and that are related to structure. DEWETRON provides a powerful and very easy to use order tracking module for fast and efficient results. The data and the rpm information is recorded simultaneously in time domain and re-sampled in the order tracking module. Therefore we can show narrow band FFT, waterfall spectra, and still keep all other convenient functions in time domain. Key Features Dedicated re-sampling method for sharp order separation Measurement in time domain to keep all benefits 2D, 3D waterfall in order or frequency domain Amplitude, phase extraction Recalculation in post processing Phase synchronous rpm input with 12.5 ns resolution EASY TO SETUP Ballistic Balancing Order Tracking Modal Analysis Tor/Rot Vibration 57

58 Overview Order tracking requires two signals, the vibration signal and the rpm information. The measurement is done in time domain, and all the order related channels are calculated out of these time signals. A fast state of the art re-sampling method produces the results online. Run-ups, coast-down or both are possible online. Time based data recording enables recalculation even in post processing. Narrow band FFT, CPB spectrum and order tracking information could be shown at the same test run, saving time. DEWE-CAM Video Additional Sensors Strain Gauge Current Voltage Temperature Electrical Power Acceleration DEWE-ORION-card Digital input Digital output Industrial PC PC DAQP Module Signal conditioning Sensor supply Analog input DEWESoft OPTION Order Tracking Digital input Trigger probe Counter input ext. clock int. clock 58

59 Order Tracking Channel Setup Simply specify the channels to analyze, define the rpm channel and set the parameters for your run. This will only take a few minutes and you are ready for the test. After configuration, you will get the calculated results which could be shown in dedicated instruments for analysis and reporting. Immediately after configuration, you will get the calculated results which could be shown in dedicated instruments for analyze and report. Amplitude Phase RE- Imag- Part Order resolution up to 1/64 order Upper- lower- rpm limits Extract specific orders for further investigation Analysis In the easy to use analyze screens data could be shown and analyzed in many different ways. So you could draw orders or narrow band FFT in 2D and 3D waterfall diagrams. Either displayed with time history or rpm. Specific orders or phase information could be recorded over time, rpm or any other physical value. All analysis screens could be arranged in a convenient way. Amplitude or phase is shown over rpm, RE- IM- Part displayed in XY diagram to observe resonant frequencies. Ballistic Balancing Order Tracking Modal Analysis Tor/Rot Vibration 59

60 Orbit view together with Order Tracking? In addition, the order tracking module is also used to show an orbit plot which is used to observe bearings or movements of rotating machines. The Order tracking module extracts specific harmonics in the orbit view and also averages them. Example: Paper Mill Sensors Acceleration sensor(s) Trigger probe for rpm Orbit View Features Free definable angle position Averaged or free run Harmonic extraction Easy to use Any DEWETRON system equipped with DEWE-ORION series AD card 4 available counter inputs Software option DEWESoft-OPT-OrderTracking 2 ICP input channels Please ask for your customized solution! 60

61 Balancing Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement Balancing Rotating machines and engines produce vibration from many sources, including torsional and rotational vibration. Also unbalanced rotating parts are sources for vibration. Unbalanced masses are distributed by the rotor causing vibration. To balance a system, we have to measure and correct the masses so that the rotor is returned to a balanced condition. DEWETRON provides an easy to use and straight-forward tool for single and dual plane balancing. This add-on is included as an option in every DEWETRON instrument. One or two acceleration sensors and a tacho probe are needed. Key Features User interface which guides through all steps Order tracking based balancing method Single or dual plane Multiple balancing for two directions saves time (X, Y) 2D graph for plane view RPM channel with color indicator (rpm range) Alarm output if velocity exceeds predefined value Displays tacho probe time signal to set trigger Vector polar plots of 1st order of all runs (initial, trail,...) Weight splitting Acceleration, velocity, displacement in recorder Time domain measurement Ballistic Balancing Order Tracking Modal Analysis Tor/Rot Vibration 61

62 Overview DEWE-CAM Video DEWE-ORION-Card Digital input Industrial PC PC Digital output DAQP Module Signal conditioning Sensor supply Analog input DEWESoft OPTION Balancing Counter input Acceleration sensor ext. clock int. clock Acceleration sensor Trigger probe 62

63 Balancing General During construction or assembly of a machine or even through abrasion, a rotor could become unbalanced. This condition causes vibration, noise and fatigue of the material. DEWETRON provides an in-field-balancing method, which enables balancing of the machine. This saves time and money because balancing can be done in situ and the rotor is balanced in its operating condition, which includes the whole structure of the machine. Balancing includes in general five steps: 1. Measuring the imbalance 2. Add a trial mass 3. Add the correction mass (balancing) 4. Measuring the balanced system 5. Repeat steps 2 to 4 if needed Balancing is done either for one plane or two planes. One plane is used for small rotors, where two plane is used for long rotors. The prepared balancing template in DEWESoft provides step by step guide through the whole balancing procedure. For this measurement one or two acceleration sensors (1 plane 2 plane) and a tacho input are needed. The acceleration signals are recalculated into velocity and used in the order tracking module together with the rpm channel to extract the first harmonic and phase. Ballistic Balancing Order Tracking Modal Analysis Tor/Rot Vibration 63

64 Multiple templates linked together! If a triaxial sensor is used, the balancing can be done on x and y direction of the plane(s) at the same time. Depending where you get the best result (x or y direction) you choose the correction mass. This saves time and guarantees a high quality of balancing. System Requirements Any DEWETRON system equipped with DEWE-ORION series AD card 4 available counter inputs Software option DEWESoft-OPT-Balancing 2 ICP input channels Sensors 2 acceleration sensors Trigger probe for rpm Please ask for your customized solution! 64

65 Ballistic Automotive Energy & Power Analysis Aerospace & Defense Transportation General Test & Measurement Ballistic and Ammunition Testing A typical configuration for ammunition testing is containing of either one, two or three pressure sensors in the test barrel. However, other sensor inputs might be required for extended test requirements, such as: Firing pin accelerometers Light barrieres Photo cells Microphones High speed thermocouple sensors Anemometer, weather station Key Features Smallest all-in-one instrument for isolation amplifiers AC, DC or battery powered High accuracy, 16 bit resolution Fast sampling, 3 MS/s per channel Powerful Intel Core 2 Duo, 2.4 GHz 90 MB/s stream-to-disk rate Bright 15.4 display with touch-screen 8-channel signal conditioning inputs, interchangeable for all type of signal in-puts (charge, voltage, charge, etc.) Expansion socket for adding more signal conditioning modules High Speed Camera support Triggered Measurement or continuous storing Ballistic Balancing Order Tracking Modal Analysis Tor/Rot Vibration 65

66 Weather station wind speed/direction barometric pressure ambient temperature Quartz Sensor for Ballistic Pressure Measurement High Speed video camera DEWE-3020 with direct sensor input The award winning software DEWESoft provides ready to use templates which makes it easy to setup the measurement within a few minutes. Setup Cartridge pressure - Case mouth measurement - Conformal pressure - Port pressure - For pressure measurement in the barrel minimum one, or up to three Quartz Sensor for Ballistic pressure are used. Dewetron supports a wide range of different sensors and other signal inputs such as firing pin acceleration, target control systems (Light screens), Microphones for rate of fire measurement or high-speed cameras can be easily integrated into the system. The configuration can be adopted to the current needs and above all can be easily configured for other measurement in the field or in the laboratory. Our DEWEPARTNERS are available to discuss with you your exact requirements and will support you to configure the most suitable system configuration with you. Internal Solid State Disk for maximum reliability PS-BAT Battery power supply Optional battery charger (range: 90 to 260 V AC ) 15.4 touch-screen The carrying bag is included as standard accessory 66

67 Training Training is offered on demand or at regular intervals. We run training centers at DEWETRON Ges.m.b.H in Graz/ Austria and at DEWETRON Inc. located in Rhode Island, USA. At both locations there is a nice training facility and class sizes are limited in order to preserve the quality of the presentation. Engineers and technicians from many well-known companies participated our classes. The trainings help users to stay up to date on the latest enhancements and updates as well as become more effective utilizing their DEWETRON systems. The trainings cover effectively using the DEWETRON hardware with DEWESoft software for a wide range of measurement applications. Sub-topics include instrument setup, sensor connection as well as digging into math modules, triggers, filtering, shock, vibe, pressure, displacement, stress, strain, video, GPS and more. Of course onsite training is offered, too. DEWE-ACADEMY In the DEWE-ACADEMY single or multi-day events are offered. We teach the practical application of our measurement systems, based on the relevant theory. The seminars cover various application areas for engineers with different levels of knowledge - from newbie to expert. Practical exercises and high interactivity with the trainers ensure the lasting learning success and the suitability for daily use. The course language is GERMAN and courses take place in Austria or Germany. For English courses please contact us directly. ACADEMY Calibration DEWETRON maintains two top-notch calibration facilities with the same equipment: one at our worldwide headquarters in Austria, and another one at DEWETRON USA in Rhode Island. Our cal lab is based on the Fluke 5500 series calibrator, and we run the METCAL calibration system, which allows us to automate nearly every process. For customers running their own calibration lab we offer a calibration hardware kit (CAL-KIT) and METCAL software procedures. 67

68 Headquarters: DEWETRON Offices Worldwide Sales offices in 25 countries Service centers in Europe, USA, Middle East and Asia DEWETRON Ges.m.b.H. Parkring Grambach AUSTRIA (+43) (+43) sales@dewetron.com DE-B090303E All trademarks are acknowledged to be the property of their owners. Specification subject to change without notice. DEWETRON Ges.m.b.H. 06/2013 Find your local distributor on