Innovations in Formula 1 brake testing with virtual instrumentation

Citation

(2006), "Innovations in Formula 1 brake testing with virtual instrumentation", Assembly Automation, Vol. 26 No. 2. https://doi.org/10.1108/aa.2006.03326baf.002

Innovations in Formula 1 brake testing with virtual instrumentation

Innovations in Formula 1 brake testing with virtual instrumentation

Keywords: Assembly, Tests and testing, Systems software

With the power and flexibility of today’s computers, engineers and scientists are increasingly using virtual instrumentation for test, control and design applications. A key element of virtual instrumentation is the use of COTS (commercial off-the-shelf) technology including a PC processor, plug-in hardware and application software to build the system. AP Racing, a world leader in the technology and manufacture of brake calipers and race clutches, successfully used virtual instrumentation to build a new type of dynamometer that could match the high-speed and acceleration rates achieved by Formula 1 cars.

Challenge

Formula 1, also known as Grand Prix racing, is the highest class of single-seat open-wheel formula auto racing in the world with average speeds greater than 200 mph. An important part of the company’s product development is testing new parts using a dynamometer (Plate 6). AP Racing engineers use this dynamometer to accurately simulate acceleration profiles and operating conditions as well as collect temperature, torque, and other data for feedback into product development cycles. In order to keep up with the current speed and torque run conditions, AP Racing needed a new dynamometer that had the following capabilities:

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  it could test the brake and caliper both on a rig mounting and within the actual wheel and suspension assembly;

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  it had the power to accurately simulate Formula 1 speeds and acceleration rates;

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  it could simulate the air flow around the caliper and allow for investigation into the airflows through different ducting designs; and

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  it could import track data on the braking profiles and acceleration profiles.

Plate 6 Advanced dynamometer testing

Solution

Because of the strong design capabilities of AP Racing, they decided that the rig would be built in-house, which would provide cost benefits and absolute control on the system capabilities. For the software and electronics control system, AP Racing selected Computer Controlled Solutions (CCS) based on their experience in this field and the number of successful test machines previously provided and maintained for AP Racing. AP Racing and CCS chose to create a unique solution based on virtual instrumentation to meet these design challenges. Virtual instrumentation provided AP Racing with intuitive, flexible software for rapid test development and fast, precise modular I/O based on innovative technologies as the company’s engineers worked to define a nd create their next-generation dynamometer.

Hardware implementation

The system was based around an industrial Pentium 4 HT 3.2 GHz with 1 GB RAM and the following acquisition and control cards:

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  National Instruments PCI-DIO-96 providing 96 digital I/O.

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  National Instruments PCI-6033E providing eight digital and 64 analog inputs.

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  National Instruments PCI-7344 quad-axis controller.

These were used to perform the following high-speed control and measurement tasks:

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  torque, temperature, infrared temperature, pressure, and speed measurement.

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  inverters for control of the machine covers;

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  water cooling and monitoring;

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  bearing cooling and monitoring; and

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  disk wear capacitance displacement.

The system required the following closed-loop controls:

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  Torque control. Controlling the brake torque applied to match actual profiles, constant levels, or speed dependant levels.

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  Pressure control. Controlling the brake under pressure to match actual profiles, constant levels, or speed dependant levels.

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  Air flow control. Simulate air flow in the ducting and onto the brake based on output speed.

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  Speed control. Control of the motor using a 288 kW inverter.

CCS chose the low cost NI PCI-7344 quad-axis motion controller for implementing closed-loop control since it offered PID update rates up to 16 kHz and offered tight integration with software.

Software implementation

A key element of virtual instrumentation is the ability to define functionality of your system in software. National Instruments LabVIEW provides a single graphical development environment in which you can design, prototype and deploy your virtual instrumentation system (Plate 7). NI LabVIEW provides hundreds of analysis, simulation, measurement and control functions in addition to dozens of user interface controls and indicators, including graphs, buttons, knobs, sliders, text entry, and LEDs, for creating intuitive, interactive interfaces.

Plate 7 LabVIEW screen of the right control system screen

CCS engineers centered their user interface design around a single main menu so the AP Racing operator could check all I/O, build tests, run tests, and analyze data. With this design, the operator could select an option and switch focus to the appropriate screen for the task. Additionally, when AP Racing did not require a full range of options, CCS provided a simplified menu option, reducing the choices to running only pre-designed tests. Each of the run screens also provided run-time information on all I/O, test status, and progress. CCS also created a calibration screen to display all I/O in a tabular view on a monitor to the left while a second monitor on the right displayed a complete likeness of the rig with each transducer and controller identified.

Summary

Virtual instrumentation has opened up new ways of creating high-performance test and control systems that are defined in software and use COTS technology. The case study above effectively shows the use of a PC-based system with data acquisition and control hardware and application software for a complex brake test application.

For further information please contact: Rahul Kulkarni, Product Manager, National Instruments, 11500 N Mopac Expy, Austin TX 78729; Tel: +1-512-683-8784; Fax: +1-512-683-5501; e-mail: rahul.kulkarni@ni.com; web site: www.ni.com