Posts

Mobile Data Acquisition Key to Vehicle Component Testing at ITM

ITM delivers mobile data acquisition solutions to capture real-time feedback under actual conditions

Whether we are testing a new component on a truck that’s a thousand miles away or putting an off-highway vehicle through its paces right in front of us, it’s our mobile data acquisition products that often lead to ITM’s successes.

How have ITM engineers employed mobile data acquisition to create successful tests and find solutions for their clients? Here are two recent examples:

Example 1: Custom in-vehicle data logging solution captures CAN bus information alongside analog sensor data

The R&D office was filled with our client’s application engineers as they eagerly awaited a first-ever view of their product — a fan drive— as it performed under the hood of a commercial truck more than a thousand miles away.

A display of gauges, needles and dials showed precisely how our client’s product performed during everyday over-the-road stresses. The mobile data acquisition feeds showed fan speed, temperatures around the fan drive, and CAN bus data including engine speed and torque along with coolant, air and oil temperatures. It was an impressive view they had never seen before.

For years this global powertrain technologies company has turned to ITM to gather data for engine-cooling components. Thanks to software innovations at ITM, the firm has taken mobile data acquisition to the next level. Important vehicle information from the CAN (Control Area Network) bus alongside sensor data can be collected and shared real-time, which allows their client to remotely monitor tests as they happen.

“Not only are we correlating information that is broadcast by the vehicle with analog sensor information,” says ITM VP of Operations Ryan Welker, “we can gather data and feed it back to our customer in a way that is configurable to their needs. We can also incorporate GPS technology, which is very valuable. Now they can see if a vehicle is traveling up and down steep hills and see what influence it has on duty cycles of their product.”

To perform the tests, ITM used a RAC-88 data acquisition package that consists of a National Instruments cDAQ chassis and associated hardware as well as an embedded PC that runs ITM’s off-the-shelf iTestSystem DAQ software application. The package is equipped with a broadband router and cellular air cards for remote data connectivity and transmission.

From a pragmatic perspective, Welker points out that the constant monitoring also allows for a far more efficient testing process. Not only do their customers get data quickly (instead of waiting months until a test is complete to begin analysis), but also, any issues that disrupt data collection are brought to light immediately.

Beyond having the ability to build more efficient tests, Welker reiterates the importance of being able to gather more complete data by accessing the vehicle’s CAN bus network.

“This opens the doors to a lot more opportunities for customers that build engines and components,” he says. “Those vehicles are spitting out all kinds of valuable information over the CAN system that we can now correlate with analog signal test data. This allows us to provide customers with a far more accurate picture of exactly what is going on with their equipment.”

Example 2: In-vehicle testing employs mobile data acquisition to assess exhaust system

ITM was challenged with creating a rugged and flexible in-vehicle testing solution to determine the vibration levels of an on-highway vocational vehicle’s exhaust system during operation.

ITM engineers chose the high-performance and rugged NI cDAQ-9139 stand-alone system with NI C Series modules along with our LabVIEW-based data acquisition software, iTestSystem, to create a rugged, high-performance and portable exhaust test system for large vocational vehicles. Our solution provided a wireless interface to the stand-alone NI CompactDAQ system to allow the operator remote control and monitoring of the embedded acquisition and logging system.

“The new stand-alone NI CompactDAQ system provides a high-performance and portable system for demanding in-vehicle testing applications,” says Mark Yeager, ITM engineer and lead programmer. “Our iTestSystem software, based on NI LabVIEW, combined with stand-alone NI CompactDAQ allows us to build flexible mobile data acquisition systems faster than using traditional logging systems.”

ITM has used USB and Ethernet-based NI CompactDAQ systems, and its iTestSystem software, based on NI LabVIEW, for years to build high-performance mobile data acquisition and test systems for our customers in the transportation and in-vehicle space. The stand-alone NI CompactDAQ systems provide a new line of portable and flexible hardware from National Instruments by combining an embedded processor with the modular NI CompactDAQ platform.

Since these new NI cDAQ-913x systems can be used with the same NI LabVIEW system design software, NI DAQmx driver and 50+ existing NI C Series modules, ITM can build new flexible logging solutions for its customers in a very short amount of time.

Designing a Flexible Logging Solution for Exhaust Testing

For this mobile data acquisition application, ITM engineers chose the high-performance and rugged NI cDAQ-9139 stand-alone system with seven NI 9234 accelerometer modules and one NI 9229 module to interface directly to the sensors we leveraged in this application. The standalone cDAQ-9139 was bundled with a cellular network interface and packaged inside a rugged carrying case. For the sensors, ITM mounted 28 piezoelectric accelerometers to the exhaust system and connected them to the seven NI 9234 accelerometer modules. Engineers also installed a magnetic pickup sensor and connected it to the simultaneous, differential NI 9229 analog module to determine rotational speed that would be used later in a post processing order analysis algorithm.

Yeager says they leveraged the Windows Embedded OS running on the NI cDAQ-9139 to make the transition from using NI CompactDAQ USB-based systems connected to a laptop or PC a seamless process. The team used ITM’s iTestSystem software, based on NI LabVIEW system design software, to stream data from staged events and operation directly to the NI cDAQ-9139’s non-volatile hard drive in a TDMS file format. They were able to control and monitor the daq systems remotely via Remote Desktop by connecting the cDAQ-9139 to a Wi-Fi network using a high speed cellular broadband modem and router with Wi-Fi.

After conducting the mobile data acquisition, all of the TDMS data files were transferred to a computer for post processing and analysis. The analysis for this project included calculating the overall vibration levels for each accelerometer using the order analysis plug-in for iTestSystem software that leverages the built-in analysis functions within NI LabVIEW. Additionally, with the iTestSystem software, they were able to provide the customer with a professional report containing overall vibration levels and order analysis graphs that identified which sensor locations failed or met the design criteria.

Leveraging the stand-alone CompactDAQ systems and  iTestSystem software for this project was a huge success, and the customer was amazed at how quickly ITM was able to integrate new technologies including both NI and third-party hardware and software. With this system, ITM was also able to reduce the overall cost of their test by reducing the manpower needed to perform the test and providing them with instantaneous feedback of the system functionality by utilizing new technologies.

In the end, the customer liked the mobile data acquisition system so much that instead of sending the system back to ITM, they redeployed it onto another on-highway vehicle to solve a different problem.

Contact Ryan Welker via email at ryan.welker@itestsystem.com for more information about our mobile data acquisition products or iTestSystem.

Vibration and Strain Gauge Level Report Automation with iTestSystem

Our test engineers are often called upon to deploy unattended or “black box” data acquisition systems in the field.  These systems are deployed on machinery, vehicles, and industrial processes to constantly record strain and vibration data at sample rates between 100 and 100,000 Hz. That adds up to a lot of data to sift through.

In situations where we are trying to identify system operation outliers or damaging events, we utilize the Automated Analytics application in iTestSystem to limit the amount of data searches required. The Automated Analytics application allows users to analyze, build, and send sensor level reports only when specific vibration and strain limits are exceeded.  Instead of searching through data files, engineers can easily review the report and download relevant data files from deployed systems for further analysis.

This video demonstrates how to build and send vibration and strain reports using Automated Analytics and other iTestSystem tools and applications.

For more information about our iTestSystem or ITM’s testing services, contact Ryan Welker @ (844) 837-8797 x702.

Related Links

iTestSystem Tip: Sensor Auto-zero Utility Update

Our iTestSystem customers who routinely acquire data with high channel counts and data from full-bridge transducers recently requested that we update the sensor auto-zero utility to improve test setup efficiency.   In the latest version of iTestSystem, we updated the sensor auto-zero utility to include all channels that use the From Custom Scale option.  This update enables users to quickly adjust selected channel offsets with only a few mouse clicks.

One of our test engineers recently used this feature to test and calibrate a new load cell design for measuring loads in a manufacturing process.  He was able to quickly calibrate and zero the strain gauges along with a calibrated load cell and a pressure transducer prior to testing and before each directional test. The offset values are included in the calibration data files for traceability.

Contact Information: For more information about this update or iTestSystem contact:

Chase Petzinger – Integrated Test & Measurement (ITM), LLC. Email: chase.petzinger@itestsystem.com or Phone: 1.844.TestSys

Troubleshooting Machine Failures Caused by Intermittent Damaging Events

Over the years we have been tasked with identifying the root cause of machine structural failures. In many cases, we can determine the failure mode through strain and vibration testing, order analysis, modal analysis, and operating deflection shape analysis.  What tests can you run when the damaging conditions are intermittent and not easily identified?

In these cases, we like to install a cellular networked temporary data acquisition (DAQ) system that can autonomously log vibration and strain data along with machine status data. We have deployed two types of DAQ systems to collect data remotely.  An interactive system that includes an industrial PC running our iTestSystem software and National Instruments (NI) Compact DAQ hardware and a headless system that utilizes NI Compact RIO hardware.  Our test engineers prefer using the interactive solution for troubleshooting because they can view real-time signal waveforms and collected data files, and then adjust the test parameters accordingly without having to reprogram the hardware.

Figure 1: Headless networked data acquisition system

When potentially damaging events are identified in the vibration and strain data collected by these systems, it is important to know the machine’s operating status. Collecting the machine status information is just as important as collecting the structural data.  Many machines transmit these operating variables and operating stages over their network/bus.  Recently we have recorded process data from Allen Bradley Control Logix PLCs via Ethernet/IP, mining machine data from a Siemens controller via proprietary TCP/IP protocol, boiler condition data from a DCS via Modbus TCP,  machine pressures from PI historian via the UFL connector (TCP), and vehicle speeds and pressure via CAN.  Fortunately, we were able to use and adapt LabVIEW communication protocol tools to build applications and addons that allow this network tag data to be collected along with structural data.

Figure 2: Modbus to Shared Variable Tool

After the data collection phase, our engineers perform statistical analysis on the sensor and status channels in all data files and aggregate the results into a database for searchability. To identify the root cause probabilities, you can process the channel statistics data using your favorite correlation algorithm or application.  The image below shows an example data set containing related sensor data that was processed using a LabVIEW correlation test tool.

Figure 3: Correlation Test Example vi

Contact Information: For more information about our remote data acquisition service, our LabVIEW development service, or iTestSystem contact:

Mark Yeager – Integrated Test & Measurement (ITM), LLC.  Email: mark.yeager@itestsystem.com or Phone: 1.844.TestSys

Recent News:  Ohio University Asphalt Cracking Prediction System Project

ITM adds FieldDAQ Sound & Vibration Module compatibility to iTestSystem

The FieldDAQ™ FD-11634 sound and vibration input module from National Instruments (NI) can now be used with the latest version of iTestSystem.  The FD-11634 is similar to the NI-9234, NI-9232, NI-9231, and NI-9230 cDAQ dynamic input modules and can be used with IEPE type sensors such as accelerometers and microphones.  Like the other FieldDAQ™ modules, this module is IP65/IP67 dust and water resistant with an operating temperature range of  -40 °C to 85 °C.  Our test engineers would use these modules for collecting vibration data on mining and construction equipment, vibration data on rotating machinery within manufacturing facilities and test cells, and acoustic data for measuring equipment noise emissions.

The FieldDAQ™ FD-11634 module has 8 simultaneous sampled, ±1V or ±10 V, 24-bit differential input channels with AC/DC coupling. It has a maximum sample rate of 102.4kS/s and features built in anti-aliasing filters that automatically adjust to the sampling rate.

For advice about using the FieldDAQ™ FD-11634 sound and vibration modules in iTestSystem monitoring applications or with custom cRIO RT and FPGA control applications contact Mark Yeager or Chase Petzinger.

Click Here to view a video showing one of our test engineer collecting data from a submerged FieldDAQ™ module with iTestSystem.

Click Here for more information about iTestSystem.

Machine Design Article: Feeding the Next Generation of Product Development

well frac

Check out the article “Feeding the Next Generation of Product Development” in Machine Design magazine.  In this article, ITM president Tim Carlier describes how engineers are collecting real-world data to get a true look at how their designs are used in the field, and how to design a better machine.  By utilizing iTestSystem and its automation tools, test engineers can implement unattended field tests that continuously analyze and send data based on specific operating conditions.  Armed with data from these tests, designers can better quantify and predict future performance and develop products that satisfy the complete range of actual customer usage.

For more information about this article, iTestSystem or our Testing Services, contact Ryan Welker @ (844) 837-8797 x702

ITM adds NI-9203 Compatibility to iTestSystem

We are pleased to announce that the NI-9203 current input module can now be used with iTestSystem and NI CompactDAQ.

The NI-9203 features 8 current inputs , 16-bit resolution, +/- 20 mA range, 200 kS/s maximum sample rate in the C Series form factor.  This module is intended for high-performance control and monitoring applications. The NI-9203 uses multiplexed sampling and an SAR type ADC.

For advice about using the NI-9203 versus other current modules in iTestSystem monitoring applications or with custom cRIO RT and FPGA control applications contact Mark Yeager or Chase Petzinger.

ITM Live Demo Series: Customer DAQ

As a part of our new ITM Live Demo series, we’re excited to release this video featuring our custom Data Acquisition solutions. During our 17 years in business, we’ve found that every test is a little bit different, especially in ruggedized environments. The best way to account for these custom problems is to create a custom solution.

Watch now to see as I demonstrate some of the features available with a custom DAQ and explain how this may be just the solution you’re looking for.

If you’re interested in learning more about how a custom DAQ solution built by ITM can help meet your specific testing needs, feel free to contact one of our test specialists by e-mail at info@itestsystem.com or phone at (844) 837-8797.