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Dynamometer	
  Project	
  Data	
  Acquisition	
  Filtering	
  
	
  
	
  
Name:	
  Rauf	
  Tailony	
  
	
  
Rocket	
  number:R01368594	
  
	
  
Supervisor:	
  Prof.Sorin	
  cioc	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
1.	
  Introduction:	
  
	
  
Data	
  acquisition	
  is	
  used	
  in	
  this	
  project	
  to	
  give	
  an	
  indication	
  of	
  the	
  engine	
  power	
  by	
  
extracting	
   data	
   from	
   a	
   load	
   cell	
   and	
   then	
   convert	
   the	
   load	
   data	
   into	
   torque	
   and	
  
power	
  using	
  relevant	
  equations.	
  
	
  
Data	
  acquisition	
  is	
  a	
  very	
  sensitive	
  part	
  of	
  this	
  project	
  and	
  any	
  project	
  because	
  the	
  
more	
   clear	
   the	
   data	
   the	
   more	
   clear	
   the	
   decisions	
   could	
   be	
   made	
   related	
   to	
   the	
  
project	
  success.	
  
	
  
Collecting	
  data	
  is	
  usually	
  a	
  process	
  that	
  uses	
  sensor	
  of	
  different	
  types	
  to	
  collect	
  data	
  
for	
  certain	
  parameter	
  in	
  order	
  to	
  compare	
  the	
  result	
  produced	
  by	
  these	
  parameters	
  
with	
  the	
  existing	
  ones.	
  
	
  
Analog	
  sensor	
  reading	
  are	
  usually	
  accompanied	
  with	
  a	
  lot	
  of	
  noise	
  of	
  different	
  types,	
  
that	
  could	
  lead	
  to	
  a	
  non	
  clear	
  vision	
  for	
  the	
  parameters	
  that	
  we	
  are	
  trying	
  to	
  answer	
  
some	
  questions	
  about,	
  so	
  in	
  order	
  to	
  eliminate	
  any	
  unwanted	
  noise	
  or	
  unwelcomed	
  
data	
  its	
  necessary	
  to	
  use	
  filters	
  depending	
  on	
  what	
  kind	
  of	
  data	
  we	
  want	
  present	
  on	
  
the	
  output	
  screen.	
  
	
  
2.	
  Objective:	
  
	
  
In	
  this	
  section	
  of	
  the	
  project	
  we	
  are	
  trying	
  to	
  do	
  the	
  following	
  objectives:	
  
	
  
1. filtering	
  and	
  fine-­‐tuning	
  the	
  data	
  acquisitioned	
  from	
  the	
  sensor	
  ;which	
  is	
  in	
  
our	
  case	
  a	
  load	
  cell	
  that	
  measures	
  the	
  force	
  delivered	
  through	
  a	
  beam	
  by	
  the	
  
alternator	
  that	
  is	
  connected	
  	
  by	
  a	
  belt	
  with	
  the	
  engine.	
  
2. Comparing	
  the	
  filtered	
  and	
  non	
  filtered	
  force	
  data	
  using	
  graph	
  indicators.	
  
3. Presenting	
  the	
  torque	
  generated	
  using	
  graph	
  indicator	
  after	
  passing	
  the	
  force	
  
data	
  through	
  related	
  equations.	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
3.	
  Procedure:	
  
	
  
3.1	
  Engine	
  power	
  delivery:	
  
	
  
engine	
  power	
  is	
  delivered	
  to	
  the	
  alternator	
  through	
  a	
  belt	
  and	
  the	
  alternator	
  varies	
  
the	
  load	
  on	
  the	
  engine	
  depending	
  on	
  a	
  lighting	
  system	
  connected	
  to	
  the	
  alternator	
  
which	
   is	
   power	
   by	
   a	
   latching	
   button	
   ,	
   reflected	
   as	
   a	
   load	
   on	
   the	
   engine	
   which	
  
changes	
  engine	
  power	
  produced	
  relating	
  to	
  the	
  load,	
  this	
  load	
  fluctuation	
  leads	
  to	
  a	
  
angular	
  force	
  produced	
  by	
  the	
  alternator	
  ,	
  and	
  this	
  force	
  in	
  delivered	
  via	
  arm	
  to	
  be	
  
applied	
  on	
  the	
  load	
  cell	
  located	
  at	
  the	
  end	
  of	
  the	
  arm,	
  as	
  shown	
  in	
  figure1.	
  
	
  
	
  
	
  
	
  
Figure1,	
  connecting	
  arm	
  between	
  Alternator	
  and	
  Load	
  cell	
  
	
  
	
  
	
  
	
  
3.2	
  	
  sensor	
  connection	
  and	
  reading:	
  
	
  
the	
  used	
  sensor	
  is	
  load	
  cell	
  (omegadyne),Figure	
  2,	
  and	
  connected	
  in	
  full	
  bridge	
  mode	
  
through	
  an	
  NI9949	
  module	
  as	
  shown	
  in	
  figure	
  3,	
  and	
  this	
  module	
  is	
  connected	
  via	
  
serail	
  port(RJ50)	
  through	
  analog	
  input/output	
  module	
  NI9237,Figure4,	
  and	
  fixed	
  on	
  
NI	
   cDAQ-­‐9172,Figure	
   5,	
   and	
   connected	
   to	
   a	
   lab	
   view	
   software	
   of	
   custom	
  
design(designed	
  by	
  Rauf	
  Tailony).	
  
	
  
	
  
 
	
  
Figure	
  2,Omegadyne	
  load	
  cell	
  
	
  
	
  
	
  
	
  
	
  
	
  
Figure3,NI9949	
  
	
  
	
  
	
  
 
	
  
Figure4,NI9237	
  
	
  
	
  
	
  
	
  
Figure5,NI	
  cDAQ-­‐9172	
  
	
  
	
  
	
  
	
  
	
  
3.3	
  Terminals	
  connection	
  tables	
  and	
  technical	
  information:	
  
	
  
Load	
  cell-­‐NI9949	
  connections	
  table:	
  
	
  
Terminal	
  name	
   Load	
  cell	
  colour	
  code	
   NI9949	
  pin	
  number	
  
Signal	
  +(AL+)	
   Green	
   2	
  
Signal	
  –	
  (AL-­‐)	
   White	
   3	
  
Excitation	
  +(EX+)	
   Red	
   6	
  
Excitation	
  –(EX-­‐)	
   Black	
   7	
  
	
  
	
  
*Note:	
  previously	
  the	
  students	
  where	
  converting	
  the	
  wires	
  of	
  AL+	
  and	
  AL-­‐,	
  which	
  
was	
  causing	
  the	
  data	
  to	
  be	
  in	
  minus.(fixed)	
  
	
  
	
  
NI9949	
  –	
  NI9237	
  connection	
  table:	
  
	
  
Device	
   Channel	
  
NI9949	
   Single	
  channel	
  
NI9237	
   CH0	
  
	
  
	
  
	
  
	
  
	
  
*	
  Technical	
  data:	
  
	
  
Load	
  cell	
  excitation	
  voltage	
  range(3-­‐10mv)	
  
	
  
Used	
  excitation	
  voltage	
  (5mv)	
  
	
  
Load	
  cell	
  Load	
  range(0-­‐20	
  LB)	
  
	
  
Arm	
  length	
  (connecting	
  between	
  alternator	
  and	
  load	
  cell)	
  =	
  6	
  in	
  
	
  
	
  
	
  3.4	
  Filtering	
  and	
  Fine-­‐tuning:	
  
	
  
	
  	
  The	
  filtering	
  procedure	
  we	
  are	
  using	
  is	
  software	
  dependent,	
  which	
  means	
  we	
  didn’t	
  
use	
  any	
  physical	
  filters	
  or	
  data	
  conditioning	
  modules,	
  we	
  used	
  the	
  LV	
  express	
  filters	
  
in	
  the	
  Block	
  diagram	
  mode	
  ,Figure6,	
  to	
  filter	
  the	
  data	
  extracted	
  from	
  the	
  load	
  cell.	
  
	
  
We	
  used	
  Butterworth	
  low	
  pass	
  filter	
  with	
  cutoff	
  frequency	
  of	
  25	
  HZ,	
  and	
  the	
  order	
  of	
  
the	
  filter	
  to	
  be	
  5,	
  with	
  	
  signals	
  view	
  mode,	
  and	
  the	
  data	
  have	
  been	
  peak	
  limited	
  using	
  
mask	
  and	
  limit	
  testing,	
  and	
  these	
  filtered	
  signals	
  are	
  transferred	
  to	
  graph	
  indicators	
  
to	
  be	
  presented	
  to	
  the	
  user,Figure6.	
  
	
  
Filtered	
  data	
  are	
  sent	
  to	
  spectral	
  measurement	
  tools,	
  to	
  have	
  an	
  idea	
  about	
  what	
  
kind	
  of	
  peaks	
  we	
  get	
  from	
  the	
  readings,	
  and	
  sent	
  to	
  a	
  spectral	
  indicator	
  to	
  be	
  read	
  by	
  
the	
  user,Figure	
  7.	
  
	
  
We	
  adjusted	
  the	
  Butterworth	
  filter	
  ,	
  in	
  the	
  sotware	
  to	
  have	
  a	
  slider	
  to	
  control	
  the	
  
cutoff	
   frequency	
   in	
   real	
   time	
   mode	
   during	
   the	
   data	
   presentation	
   on	
   the	
   graph	
  
indicator,Figure	
  8,	
  so	
  we	
  give	
  a	
  better	
  control	
  and	
  understanding	
  of	
  the	
  signal	
  form.	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
Figure6,Block	
  Diagram	
  Mode.	
  
 
Figure7,Spectrum	
  graph	
  
	
  
	
  
	
  
Figure8,Cutoff	
  frequency	
  Slider	
  
	
  
	
  
 
	
  
3.5	
  Lab	
  view	
  Software’s	
  design	
  detailed	
  information:	
  
	
  
since	
  we	
  are	
  using	
  NI	
  cDaQ-­‐9172	
  as	
  interface	
  between	
  the	
  sensor	
  and	
  the	
  Lab	
  view	
  
software,	
  we	
  started	
  the	
  design	
  in	
  the	
  block	
  diagram	
  mode	
  by	
  adding	
  DAQ	
  assistant	
  
block,	
   and	
   then	
   passing	
   the	
   data	
   line	
   to	
   subtracter	
   to	
   apply	
   the	
   data	
   offset	
  
compensation	
  of	
  15	
  lb,after	
  that	
  the	
  data	
  line	
  passed	
  to	
  a	
  low	
  pass	
  analogue	
  filter	
  
with	
  cutoff	
  frequency	
  of	
  10HZ	
  and	
  Butterworth	
  type	
  filter	
  of	
  order	
  5,and	
  connected	
  
a	
  graph	
  indicator	
  on	
  the	
  line	
  to	
  represent	
  the	
  force	
  with	
  time	
  and	
  after	
  that	
  the	
  data	
  
line	
   passed	
   to	
   a	
   multiplier	
   with	
   a	
   magnitude	
   of	
   (6in)	
   which	
   is	
   the	
   arm	
   length	
  
between	
  the	
  alternator	
  and	
  the	
  load	
  cell	
  in	
  order	
  to	
  calculate	
  the	
  torque(Lb.	
  In)	
  after	
  
filtering	
  ,	
  and	
  in	
  order	
  to	
  fine-­‐tune	
  the	
  data	
  more	
  precisely	
  we	
  passed	
  the	
  data	
  line	
  
to	
  a	
  mean(averaging)	
  block	
  to	
  make	
  the	
  signal	
  more	
  smooth,	
  and	
  at	
  last	
  data	
  passed	
  
to	
  a	
  data	
  recording	
  block(write	
  to	
  measurement	
  file)	
  to	
  save	
  the	
  data	
  on	
  hard	
  disk	
  
depending	
   on	
   user	
   command,	
   all	
   the	
   previously	
   reported	
   blocks	
   are	
   shown	
   in	
  
Figure9.	
  
	
  
	
  
	
  
	
  
Figure9,	
  Block	
  diagram	
  design.	
  
 
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
The	
   graphical	
   user	
   interface	
   mode,	
   is	
   only	
   a	
   representation	
   of	
   the	
   output	
   tools	
  
inserted	
  in	
  the	
  block	
  diagram,	
  which	
  contains	
  a	
  force-­‐time	
  graph,	
  and	
  Torque-­‐time	
  
graph,	
   and	
   timer,	
   stop	
   button	
   and	
   cutoff	
   frequency	
   slider	
   and	
   sampling	
  
rate,sampling	
  frequency	
  boxes,	
  as	
  shown	
  in	
  figure	
  10.	
  
	
  
	
  
	
  
	
  
	
  
Figure10,GUI	
  mode	
  
	
  
	
  
 
*	
  Sensor	
  calibration	
  and	
  reset:	
  
	
  
Since	
   our	
   load	
   cell	
   sensor	
   is	
   a	
   bridge	
   circuit	
   ,	
   we	
   need	
   to	
   enter	
   for	
   the	
   lab	
   view	
  
software	
   and	
   assign	
   the	
   first	
   two	
   values	
   of	
   calibration	
   provided	
   by	
   the	
  
manufacturing	
  company	
  of	
  the	
  load	
  cell,	
  in	
  the	
  load	
  cell	
  we	
  are	
  using	
  we	
  could	
  find	
  
some	
  calibration	
  data	
  on	
  the	
  manufacturer’s	
  website(Omegadyne.com),	
  and	
  we	
  can	
  
find	
   the	
   place	
   to	
   calibrate	
   the	
   bridge	
   by	
   clicking	
   right	
   on	
   DAQ	
   assistant	
   in	
   block	
  
diagram	
  mode	
  and	
  in	
  properties,	
  you	
  will	
  find	
  configure	
  scale,Figure11,	
  and	
  then	
  the	
  
table	
  of	
  calibration	
  data,Figure12.	
  
	
  
	
  
Figure11,DAQ	
  assistant	
  properties	
  window.	
  
	
  
 
Figure12,Configure	
  scale	
  window	
  
	
  
	
  
Note:	
  electrical	
  values	
  are	
  0.0000	
  and	
  0.9668	
  respectively,	
  and	
  physical	
  values	
  are	
  0	
  
and	
  2.5	
  respectively.	
  
	
  
Physical	
  sensor	
  calibration:	
  
	
  
	
  To	
  make	
  sure	
  that	
  the	
  data	
  we	
  are	
  getting	
  in	
  the	
  software	
  are	
  real	
  and	
  there	
  is	
  no	
  
error	
  in	
  the	
  reading	
  ,	
  we	
  made	
  physical	
  calibration	
  for	
  the	
  sensor	
  side	
  by	
  side	
  with	
  
the	
  sensor	
  software	
  calibration.	
  
	
  
	
  We	
  made	
  the	
  calibration	
  using	
  (0.25,0.65,1.3,5lb)	
  weights	
  ,	
  and	
  loading	
  it	
  on	
  the	
  top	
  
of	
  the	
  load	
  cell	
  after	
  isolating	
  it	
  from	
  the	
  system	
  and	
  then	
  observing	
  the	
  readings	
  
presented	
  on	
  the	
  load	
  graph,	
  and	
  adjusting	
  the	
  subtraction	
  magnitude	
  in	
  order	
  to	
  
make	
   the	
   load	
   cell	
   give	
   as	
   much	
   precise	
   data	
   as	
   it	
   is	
   capable	
   of,	
   as	
   described	
   in	
  
figures	
  13,14	
  respectively.	
  
	
  
	
  Its	
  worth	
  it	
  to	
  mention	
  that	
  after	
  taking	
  the	
  data	
  on	
  the	
  graph	
  read	
  by	
  the	
  sensor	
  
from	
  the	
  previous	
  weights,	
  we	
  found	
  that	
  there	
  is	
  an	
  offset	
  in	
  the	
  factor	
  of	
  (3.39)	
  
which	
   we	
   could	
   deal	
   with	
   it	
   by	
   multiplying	
   the	
   data	
   line	
   with	
   this	
   factor	
   before	
  
presenting	
  it	
  on	
  the	
  graph,	
  Figure	
  15.	
  
	
  
	
  
 
	
  	
   	
  
	
  
Figure	
  13,	
  weights	
  used	
  in	
  calibration.	
  
	
  
	
  
	
  
Figure	
  14,	
  mounted	
  weight	
  on	
  load	
  cell	
  structure.	
  
	
  
	
  
	
  
 
	
  
Figure15,offset	
  compensation	
  block	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
3.6	
  Displaying	
  calculated	
  rpm	
  in	
  the	
  GUI	
  :	
  
	
  
As	
  it	
  is	
  known	
  ,	
  Torque(Lb.	
  IN)	
  has	
  a	
  relation	
  with	
  power(HP)	
  and	
  RPM	
  which	
  is	
  
shown	
  the	
  relation	
  below:	
  
	
  
Torque	
  (lb.in)	
  =	
  63,025	
  x	
  Power	
  (HP)	
  /	
  Speed	
  (RPM)……………………….(1)	
  
	
  
and	
  using	
  this	
  relation	
  allows	
  us	
  to	
  show	
  the	
  calculated	
  engine	
  RPM	
  in	
  the	
  Labview	
  
software	
  since	
  the	
  power	
  is	
  known	
  for	
  the	
  engine,	
  but	
  with	
  a	
  limitation	
   that	
   this	
  
RPM	
   will	
   be	
   precise	
   only	
   for	
   the	
   engine	
   in	
   the	
   Idle	
   state,	
   but	
   after	
   coupling	
   the	
  
engine	
   with	
   the	
   alternator	
   ,it	
   will	
   be	
   very	
   complex	
   to	
   predict	
   the	
   RPM	
   in	
   the	
  
calculation	
  torque	
  based	
  method	
  which	
  will	
  give	
  correct	
  data	
  representation	
  only	
  
when	
  engine	
  have	
  no	
  load	
  and	
  running	
  on	
  high	
  rpm(>6000rpm)	
  ,	
  Figure16.	
  
	
  
 
Figure16,RPM	
  in	
  the	
  GUI	
  mode	
  
	
  
	
  
Before	
  we	
  pass	
  the	
  data	
  line	
  to	
  RPM	
  indicator	
  we	
  passed	
  it	
  to	
  a	
  formula	
  box	
  ,	
  which	
  
contain	
  the	
  following	
  formula	
  which	
  is	
  number	
  substitution	
  to	
  formula	
  (1)	
  :	
  
	
  
(63025*0.611)/X1	
  ………………………….(2)	
  
	
  
	
  
	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  	
  Torque	
  data	
  	
  
	
   Power(HP)	
  
	
  
	
  
Eq.(1)	
  constant	
  
	
  
	
  
We	
   got	
   the	
   power	
   value	
   of	
   0.611	
   ,by	
   running	
   the	
   engine	
   on	
   RPM	
   =	
   7500,	
   and	
  
coupling	
  it	
  with	
  the	
  alternator,	
  and	
  Using	
  the	
  ProCal	
  software	
  to	
  get	
  the	
  rpm	
  ,	
  we	
  
could	
  calculate	
  the	
  real	
  power	
  after	
  coupling	
  using	
  eq.(1),	
  and	
  you	
  can	
  trace	
  the	
  data	
  
line	
  passing	
  through	
  the	
  formula	
  block	
  by	
  looking	
  to	
  figure	
  17.	
  
	
  
	
  
 
	
  
Figure17,Full	
  block	
  diagram	
  
	
  
	
  
We	
   compared	
   the	
   data	
   we	
   got	
   from	
   our	
   design	
   of	
   labview	
   GUI	
   RPM,	
   with	
   Procal	
  
RPM,	
  the	
  results	
  were	
  almost	
  the	
  same	
  in	
  the	
  same	
  running	
  conditions,	
  as	
  indicated	
  
in	
  Figure18.	
  
	
  
 
	
  
Figure18,	
  Labview	
  RPM	
  VS.	
  Procal	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
4.	
  Conclusion:	
  
	
  
Data	
  filtering	
  can	
  enhance	
  the	
  data	
  we	
  extract	
  from	
  the	
  load	
  cell	
  sensor	
  even	
  its	
  not	
  
a	
  physical	
  filtering	
  but	
  it	
  could	
  fairly	
  enhance	
  the	
  results	
  to	
  the	
  user	
  in	
  order	
  to	
  give	
  
a	
  better	
  understanding	
  of	
  the	
  parameters	
  that	
  we	
  are	
  trying	
  to	
  observe	
  which	
  is	
  in	
  
our	
  case	
  the	
  torque	
  and	
  power.	
  
	
  
	
  
	
  
	
  
Figure	
  19,	
  Original	
  Data	
  with	
  noise	
  
	
  
In	
  the	
  previous	
  graph	
  we	
  are	
  presenting	
  the	
  original	
  data	
  that	
  is	
  extracted	
  in	
  real	
  
time	
  directly	
  from	
  the	
  sensor,	
  as	
  you	
  can	
  see	
  in	
  figure	
  13,	
  the	
  data	
  have	
  a	
  lot	
  of	
  noise	
  
which	
  make	
  it	
  hard	
  for	
  the	
  observer	
  to	
  decide	
  of	
  the	
  torque	
  he	
  is	
  getting	
  from	
  the	
  
engine	
  is	
  good	
  or	
  bad	
  ,	
  and	
  following	
  to	
  that	
  we	
  have	
  pasted	
  the	
  filtered	
  force	
  and	
  
torque	
  graphs	
  with	
  time	
  for	
  the	
  engine	
  in	
  the	
  Idle	
  state,	
  so	
  that	
  you	
  can	
  observe	
  the	
  
change	
  happened	
  to	
  the	
  data	
  after	
  filtering,	
  and	
  what	
  kind	
  of	
  enhancement	
  made	
  to	
  
make	
  the	
  data	
  more	
  stable	
  and	
  readable.	
  
	
  
	
  
 
	
  
Figure	
  20,	
  Filtered	
  Data	
  
	
  
	
  
*	
  Mean	
  and	
  averaging:	
  
	
  
even	
  we	
  have	
  implemented	
  the	
  averaging	
  property	
  to	
  the	
  block	
  diagram	
  as	
  you	
  saw	
  
previously,	
  but	
  related	
  to	
  a	
  limitation	
  in	
  the	
  Labview	
  software	
  you	
  can’t	
  present	
  the	
  
data	
   of	
   the	
   averaging	
   and	
   mean	
   or	
   RMS	
   as	
   a	
   graph	
   but	
   only	
   as	
   numbers,	
   as	
  
presented	
  previously	
  in	
  the	
  GUI	
  screenshot.	
  
	
  
5.	
  Recommendations:	
  
	
  
I	
   would	
   recommend	
   for	
   the	
   coming	
   teams	
   who	
   will	
   work	
   on	
   this	
   project	
   for	
   the	
  
software	
   side	
   to	
   use	
   FPGA	
   software	
   to	
   represent	
   more	
   filtered	
   and	
   averaged	
   and	
  
stable	
  data	
  that	
  could	
  look	
  more	
  professional	
  for	
  future	
  use	
  of	
  the	
  project,	
  or	
  using	
  
matlab	
  since	
  its	
  supporting	
  the	
  graphical	
  representation	
  more	
  than	
  lab	
  view,	
  and	
  
also	
  have	
  a	
  lot	
  of	
  resources	
  that	
  could	
  help	
  researcher	
  do	
  a	
  better	
  design	
  than	
  the	
  
Labview	
  do.	
  
	
  
6.	
  Index:	
  
	
  
Filter	
  used	
  and	
  related	
  concepts:	
  
	
  
Butterworth	
  Filter:	
  
	
  	
  
In	
  applications	
  that	
  use	
  filters	
  to	
  shape	
  the	
  frequency	
  spectrum	
  of	
  a	
  signal	
  such	
  as	
  in	
  
communications	
  or	
  control	
  systems,	
  the	
  shape	
  or	
  width	
  of	
  the	
  roll-­‐off	
  also	
  called	
  the	
  
“transition	
   band”,	
   for	
   a	
   simple	
   first-­‐order	
   filter	
   may	
   be	
   too	
   long	
   or	
   wide	
   and	
   so	
  
active	
   filters	
   designed	
   with	
   more	
   than	
   one	
   “order”	
   are	
   required.	
   These	
   types	
   of	
  
filters	
  are	
  commonly	
  known	
  as	
  “High-­‐order”	
  or	
  “nth-­‐order”	
  filters.	
  
	
  
The	
   complexity	
   or	
   Filter	
   Type	
   is	
   defined	
   by	
   the	
   filters	
   “order”,	
   and	
   which	
   is	
  
dependant	
  upon	
  the	
  number	
  of	
  reactive	
  components	
  such	
  as	
  capacitors	
  or	
  inductors	
  
within	
  its	
  design.	
  We	
  also	
  know	
  that	
  the	
  rate	
  of	
  roll-­‐off	
  and	
  therefore	
  the	
  width	
  of	
  
the	
   transition	
   band,	
   depends	
   upon	
   the	
   order	
   number	
   of	
   the	
   filter	
   and	
   that	
   for	
   a	
  
simple	
  first-­‐order	
  filter	
  it	
  has	
  a	
  standard	
  roll-­‐off	
  rate	
  of	
  20dB/decade	
  or	
  6dB/octave.	
  
	
  
Then,	
  for	
  a	
  filter	
  that	
  has	
  an	
  nth	
  number	
  order,	
  it	
  will	
  have	
  a	
  subsequent	
  roll-­‐off	
  rate	
  
of	
   20n	
   dB/decade	
   or	
   6n	
   dB/octave.	
   So	
   a	
   first-­‐order	
   filter	
   has	
   a	
   roll-­‐off	
   rate	
   of	
  
20dB/decade	
  (6dB/octave),	
  a	
  second-­‐order	
  filter	
  has	
  a	
  roll-­‐off	
  rate	
  of	
  40dB/decade	
  
(12dB/octave),	
   and	
   a	
   fourth-­‐order	
   filter	
   has	
   a	
   roll-­‐off	
   rate	
   of	
   80dB/decade	
  
(24dB/octave),	
  etc,	
  etc.	
  
High-­‐order	
   filters,	
   such	
   as	
   third,	
   fourth,	
   and	
   fifth-­‐order	
   are	
   usually	
   formed	
   by	
  
cascading	
  together	
  single	
  first-­‐order	
  and	
  second-­‐order	
  filters.	
  
For	
  example,	
  two	
  second-­‐order	
  low	
  pass	
  filters	
  can	
  be	
  cascaded	
  together	
  to	
  produce	
  
a	
  fourth-­‐order	
  low	
  pass	
  filter,	
  and	
  so	
  on.	
  Although	
  there	
  is	
  no	
  limit	
  to	
  the	
  order	
  of	
  
the	
  filter	
  that	
  can	
  be	
  formed,	
  as	
  the	
  order	
  increases	
  so	
  does	
  its	
  size	
  and	
  cost,	
  also	
  its	
  
accuracy	
  declines.	
  
	
  
	
  
Decades	
  and	
  Octaves	
  
One	
  final	
  comment	
  about	
  Decades	
  and	
  Octaves.	
  On	
  the	
  frequency	
  scale,	
  a	
  Decade	
  is	
  a	
  
tenfold	
  increase	
  (multiply	
  by	
  10)	
  or	
  tenfold	
  decrease	
  (divide	
  by	
  10).	
  For	
  example,	
  2	
  
to	
  20Hz	
  represents	
  one	
  decade,	
  whereas	
  50	
  to	
  5000Hz	
  represents	
  two	
  decades	
  (50	
  
to	
  500Hz	
  and	
  then	
  500	
  to	
  5000Hz).	
  
An	
  Octave	
  is	
  a	
  doubling	
  (multiply	
  by	
  2)	
  or	
  halving	
  (divide	
  by	
  2)	
  of	
  the	
  frequency	
  
scale.	
   For	
   example,	
   10	
   to	
   20Hz	
   represents	
   one	
   octave,	
   while	
   2	
   to	
   16Hz	
   is	
   three	
  
octaves	
   (2	
   to	
   4,	
   4	
   to	
   8	
   and	
   finally	
   8	
   to	
   16Hz)	
   doubling	
   the	
   frequency	
   each	
   time.	
  
Either	
   way,	
   Logarithmic	
   scales	
   are	
   used	
   extensively	
   in	
   the	
   frequency	
   domain	
   to	
  
denote	
  a	
  frequency	
  value	
  when	
  working	
  with	
  amplifiers	
  and	
  filters	
  so	
  it	
  is	
  important	
  
to	
  understand	
  them.	
  
	
  
	
  
	
  
	
  
Logarithmic	
  Frequency	
  Scale	
  
	
  
	
  	
  
Since	
   the	
   frequency	
   determining	
   resistors	
   are	
   all	
   equal,	
   and	
   as	
   are	
   the	
   frequency	
  
determining	
   capacitors,	
   the	
   cut-­‐off	
   or	
   corner	
   frequency	
   (	
  ƒC	
  )	
   for	
   either	
   a	
   first,	
  
second,	
  third	
  or	
  even	
  a	
  fourth-­‐order	
  filter	
  must	
  also	
  be	
  equal	
  and	
  is	
  found	
  by	
  using	
  
our	
  now	
  old	
  familiar	
  equation:	
  
	
  
	
  	
  
As	
  with	
  the	
  first	
  and	
  second-­‐order	
  filters,	
  the	
  third	
  and	
  fourth-­‐order	
  high	
  pass	
  filters	
  
are	
   formed	
   by	
   simply	
   interchanging	
   the	
   positions	
   of	
   the	
   frequency	
   determining	
  
components	
  (resistors	
  and	
  capacitors)	
  in	
  the	
  equivalent	
  low	
  pass	
  filter.	
  High-­‐order	
  
filters	
  can	
  be	
  designed	
  by	
  following	
  the	
  procedures	
  we	
  saw	
  previously	
  in	
  the	
  Low	
  
Pass	
  and	
  High	
  Pass	
  filter	
  tutorials.	
  However,	
  the	
  overall	
  gain	
  of	
  high-­‐order	
  filters	
  is	
  
fixed	
  because	
  all	
  the	
  frequency	
  determining	
  components	
  are	
  equal.	
  
	
  
Filter	
  Approximations	
  
So	
  far	
  we	
  have	
  looked	
  at	
  a	
  low	
  and	
  high	
  pass	
  first-­‐order	
  filter	
  circuits,	
  their	
  resultant	
  
frequency	
   and	
   phase	
   responses.	
   An	
   ideal	
   filter	
   would	
   give	
   us	
   specifications	
   of	
  
maximum	
  pass	
  band	
  gain	
  and	
  flatness,	
  minimum	
  stop	
  band	
  attenuation	
  and	
  also	
  a	
  
very	
  steep	
  pass	
  band	
  to	
  stop	
  band	
  roll-­‐off	
  (the	
  transition	
  band)	
  and	
  it	
  is	
  therefore	
  
apparent	
   that	
   a	
   large	
   number	
   of	
   network	
   responses	
   would	
   satisfy	
   these	
  
requirements.	
  
Not	
  surprisingly	
  then	
  that	
  there	
  are	
  a	
  number	
  of	
  “approximation	
  functions”	
  in	
  linear	
  
analogue	
   filter	
   design	
   that	
   use	
   a	
   mathematical	
   approach	
   to	
   best	
   approximate	
   the	
  
transfer	
  function	
  we	
  require	
  for	
  the	
  filters	
  design.	
  
Such	
  designs	
  are	
  known	
  as	
  Elliptical,	
  Butterworth,	
  Chebyshev,	
  Bessel,	
  Cauer	
  as	
  well	
  
as	
  many	
  others.	
  Of	
  these	
  five	
  “classic”	
  linear	
  analogue	
  filter	
  approximation	
  functions	
  
only	
  the	
  Butterworth	
  Filter	
  and	
  especially	
  the	
  low	
  pass	
  Butterworth	
  filter	
  design	
  will	
  
be	
  considered	
  here	
  as	
  its	
  the	
  most	
  commonly	
  used	
  function.	
  
	
  
Low	
  Pass	
  Butterworth	
  Filter	
  Design	
  
	
  
The	
   frequency	
   response	
   of	
   the	
   Butterworth	
   Filter	
   approximation	
   function	
   is	
   also	
  
often	
  referred	
  to	
  as	
  “maximally	
  flat”	
  (no	
  ripples)	
  response	
  because	
  the	
  pass	
  band	
  is	
  
designed	
  to	
  have	
  a	
  frequency	
  response	
  which	
  is	
  as	
  flat	
  as	
  mathematically	
  possible	
  
from	
   0Hz	
   (DC)	
   until	
   the	
   cut-­‐off	
   frequency	
   at	
   -­‐3dB	
   with	
   no	
   ripples.	
   Higher	
  
frequencies	
   beyond	
   the	
   cut-­‐off	
   point	
   rolls-­‐off	
   down	
   to	
   zero	
   in	
   the	
   stop	
   band	
   at	
  
20dB/decade	
   or	
   6dB/octave.	
   This	
   is	
   because	
   it	
   has	
   a	
   “quality	
   factor”,	
   “Q”	
   of	
   just	
  
0.707.	
  
However,	
   one	
   main	
   disadvantage	
   of	
   the	
   Butterworth	
   filter	
   is	
   that	
   it	
   achieves	
   this	
  
pass	
   band	
   flatness	
   at	
   the	
   expense	
   of	
   a	
   wide	
   transition	
   band	
   as	
   the	
   filter	
   changes	
  
from	
  the	
  pass	
  band	
  to	
  the	
  stop	
  band.	
  It	
  also	
  has	
  poor	
  phase	
  characteristics	
  as	
  well.	
  
The	
  ideal	
  frequency	
  response,	
  referred	
  to	
  as	
  a	
  “brick	
  wall”	
  filter,	
  and	
  the	
  standard	
  
Butterworth	
  approximations,	
  for	
  different	
  filter	
  orders	
  are	
  given	
  below.	
  
	
  
Ideal	
  Frequency	
  Response	
  for	
  a	
  Butterworth	
  Filter	
  
	
  
	
  	
  
Where	
  the	
  generalised	
  equation	
  representing	
  a	
  “nth”	
  Order	
  Butterworth	
  filter,	
  the	
  
frequency	
  response	
  is	
  given	
  as:	
  
	
  
Where:	
  n	
  represents	
  the	
  filter	
  order,	
  Omega	
  ω	
  is	
  equal	
  to	
  2πƒ	
  and	
  Epsilon	
  ε	
  is	
  the	
  
maximum	
  pass	
  band	
  gain,	
  (Amax).	
  If	
  Amax	
  is	
  defined	
  at	
  a	
  frequency	
  equal	
  to	
  the	
  cut-­‐
off	
  -­‐3dB	
  corner	
  point	
  (ƒc),	
  ε	
  will	
  then	
  be	
  equal	
  to	
  one	
  and	
  therefore	
  ε2	
  will	
  also	
  be	
  
one.	
  However,	
  if	
  you	
  now	
  wish	
  to	
  define	
  Amax	
  at	
  a	
  different	
  voltage	
  gain	
  value,	
  for	
  
example	
  1dB,	
  or	
  1.1220	
  (1dB	
  =	
  20logAmax)	
  then	
  the	
  new	
  value	
  of	
  epsilon,	
  ε	
  is	
  found	
  
by:	
  
	
  
• 	
  Where:	
  
• 	
  	
  H0	
  =	
  the	
  Maximum	
  Pass	
  band	
  Gain,	
  Amax.	
  
• 	
  	
  H1	
  =	
  the	
  Minimum	
  Pass	
  band	
  Gain.	
  
Transpose	
  the	
  equation	
  to	
  give:	
  
	
  
	
  	
  
The	
  Frequency	
  Response	
  of	
  a	
  filter	
  can	
  be	
  defined	
  mathematically	
  by	
  its	
  Transfer	
  
Function	
  with	
  the	
  standard	
  Voltage	
  Transfer	
  Function	
  H(jω)	
  written	
  as:	
  
	
  
• 	
  Where:	
  
• 	
  	
  Vout	
  =	
  the	
  output	
  signal	
  voltage.	
  
• 	
  	
  Vin	
  	
  =	
  the	
  input	
  signal	
  voltage.	
  
• 	
  	
  	
  	
  	
  j	
  	
  	
  =	
  to	
  the	
  square	
  root	
  of	
  -­‐1	
  (√-­‐1)	
  
• 	
  	
  	
  	
  ω	
  	
  =	
  the	
  radian	
  frequency	
  (2πƒ)	
  
	
  	
  
Note:	
  (	
  jω	
  )	
  can	
  also	
  be	
  written	
  as	
  (	
  s	
  )	
  to	
  denote	
  the	
  S-­‐domain.	
  and	
  the	
  resultant	
  
transfer	
  function	
  for	
  a	
  second-­‐order	
  low	
  pass	
  filter	
  is	
  given	
  as:	
  
	
  
	
  	
  
Normalised	
  Low	
  Pass	
  Butterworth	
  Filter	
  Polynomials	
  
To	
  help	
  in	
  the	
  design	
  of	
  his	
  low	
  pass	
  filters,	
  Butterworth	
  produced	
  standard	
  tables	
  
of	
  normalised	
  second-­‐order	
  low	
  pass	
  polynomials	
  given	
  the	
  values	
  of	
  coefficient	
  that	
  
correspond	
  to	
  a	
  cut-­‐off	
  corner	
  frequency	
  of	
  1	
  radian/sec.	
  
n	
   Normalised	
  Denominator	
  Polynomials	
  in	
  Factored	
  Form	
  
1	
   (1+s)	
  
2	
   (1+1.414s+s2)	
  
3	
   (1+s)(1+s+s2)	
  
4	
   (1+0.765s+s2)(1+1.848s+s2)	
  
5	
   (1+s)(1+0.618s+s2)(1+1.618s+s2)	
  
6	
   (1+0.518s+s2)(1+1.414s+s2)(1+1.932s+s2)	
  
7	
   (1+s)(1+0.445s+s2)(1+1.247s+s2)(1+1.802s+s2)	
  
8	
   (1+0.390s+s2)(1+1.111s+s2)(1+1.663s+s2)(1+1.962s+s2)	
  
9	
   (1+s)(1+0.347s+s2)(1+s+s2)(1+1.532s+s2)(1+1.879s+s2)	
  
10	
   (1+0.313s+s2)(1+0.908s+s2)(1+1.414s+s2)(1+1.782s+s2)(1+1.975s+s2)	
  
Filter	
  Design	
  –	
  Butterworth	
  Low	
  Pass	
  
Find	
   the	
   order	
   of	
   an	
   active	
   low	
   pass	
   Butterworth	
   filter	
   whose	
   specifications	
   are	
  
given	
  as:	
  Amax	
  =	
  0.5dB	
  at	
  a	
  pass	
  band	
  frequency	
  (ωp)	
  of	
  200	
  radian/sec	
  (31.8Hz),	
  
and	
  Amin	
  =	
  -­‐20dB	
  at	
  a	
  stop	
  band	
  frequency	
  (ωs)	
  of	
  800	
  radian/sec.	
  Also	
  design	
  a	
  
suitable	
  Butterworth	
  filter	
  circuit	
  to	
  match	
  these	
  requirements.	
  
Firstly,	
   the	
   maximum	
   pass	
   band	
   gain	
   Amax	
   =	
   0.5dB	
   which	
   is	
   equal	
   to	
   a	
   gain	
   of	
  
1.0593	
  (0.5dB	
  =	
  20log	
  A)	
  at	
  a	
  frequency	
  (ωp)	
  of	
  200	
  rads/s,	
  so	
  the	
  value	
  of	
  epsilon	
  ε	
  
is	
  found	
  by:	
  
	
  
	
  	
  
Secondly,	
  the	
  minimum	
  stop	
  band	
  gain	
  Amin	
  =	
  -­‐20dB	
  which	
  is	
  equal	
  to	
  a	
  gain	
  of	
  -­‐10	
  
(20dB	
  =	
  20log	
  A)	
  at	
  a	
  stop	
  band	
  frequency	
  (ωs)	
  of	
  800	
  rads/s	
  or	
  127.3Hz.	
  
Substituting	
  the	
  values	
  into	
  the	
  general	
  equation	
  for	
  a	
  Butterworth	
  filters	
  frequency	
  
response	
  gives	
  us	
  the	
  following:	
  
 
	
  	
  
Since	
  n	
  must	
  always	
  be	
  an	
  integer	
  (	
  whole	
  number	
  )	
  then	
  the	
  next	
  highest	
  value	
  to	
  
2.42	
  is	
  n	
  =	
  3,	
  therefore	
  a	
  “a	
  third-­‐order	
  filter	
  is	
  required”	
  and	
  to	
  produce	
  a	
  third-­‐
order	
  Butterworth	
  filter,	
  a	
  second-­‐order	
  filter	
  stage	
  cascaded	
  together	
  with	
  a	
  first-­‐
order	
  filter	
  stage	
  is	
  required.	
  
From	
  the	
  normalised	
  low	
  pass	
  Butterworth	
  Polynomials	
  table	
  above,	
  the	
  coefficient	
  
for	
  a	
  third-­‐order	
  filter	
  is	
  given	
  as	
  (1+s)(1+s+s2)	
  and	
  this	
  gives	
  us	
  a	
  gain	
  of	
  3-­‐A	
  =	
  1,	
  
or	
  A	
  =	
  2.	
  As	
  A	
  =	
  1	
  +	
  (Rf/R1),	
  choosing	
  a	
  value	
  for	
  both	
  the	
  feedback	
  resistor	
  Rf	
  and	
  
resistor	
  R1	
  gives	
  us	
  values	
  of	
  1kΩ	
  and	
  1kΩ	
  respectively,	
  (	
  1kΩ/1kΩ	
  +	
  1	
  =	
  2	
  ).	
  
We	
  know	
  that	
  the	
  cut-­‐off	
  corner	
  frequency,	
  the	
  -­‐3dB	
  point	
  (ωo)	
  can	
  be	
  found	
  using	
  
the	
  formula	
  1/CR,	
  but	
  we	
  need	
  to	
  find	
  ωo	
  from	
  the	
  pass	
  band	
  frequency	
  ωp	
  then,	
  
 
	
  	
  
So,	
   the	
   cut-­‐off	
   corner	
   frequency	
   is	
   given	
   as	
   284	
   rads/s	
   or	
   45.2Hz,	
   (284/2π)	
   and	
  
using	
   the	
   familiar	
   formula	
   1/CR	
   we	
   can	
   find	
   the	
   values	
   of	
   the	
   resistors	
   and	
  
capacitors	
  for	
  our	
  third-­‐order	
  circuit.	
  
	
  
Note	
  that	
  the	
  nearest	
  preferred	
  value	
  to	
  0.352uF	
  would	
  be	
  0.36uF,	
  or	
  360nF.	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
Third-­‐order	
  Butterworth	
  Low	
  Pass	
  Filter	
  
	
  
and	
  finally	
  our	
  circuit	
  of	
  the	
  third-­‐order	
  low	
  pass	
  Butterworth	
  Filter	
  with	
  a	
  cut-­‐off	
  
corner	
  frequency	
  of	
  284	
  rads/s	
  or	
  45.2Hz,	
  a	
  maximum	
  pass	
  band	
  gain	
  of	
  0.5dB	
  and	
  a	
  
minimum	
  stop	
  band	
  gain	
  of	
  20dB	
  is	
  constructed	
  as	
  follows.	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
	
  
7.	
  Acknowledgment:	
  
	
  
Very	
   big	
   thanks	
   for	
   Prof.	
   Sorin	
   Cioc,	
   Assistant	
   professor,UT,	
   for	
   giving	
   me	
   the	
  
opportunity	
  to	
  use	
  his	
  Internal	
  combustion	
  lab,	
  and	
  giving	
  me	
  a	
  solid	
  pathway	
  to	
  use	
  
it	
  in	
  order	
  to	
  reach	
  the	
  goal	
  in	
  this	
  work	
  using	
  the	
  shortest	
  road.	
  
	
  
Special	
   thanks	
   for	
   Sabin	
   Bati,Masters	
   student,MIME,UT,	
   for	
   his	
   help	
   in	
   practical	
  
work,	
  and	
  for	
  his	
  bright	
  Ideas	
  that	
  he	
  shared	
  with	
  me	
  in	
  order	
  to	
  make	
  the	
  data	
  look	
  
and	
  behave	
  more	
  precise.	
  
	
  
	
  
8.	
  References:	
  
	
  
	
  
1. http://www.ni.com/community/	
  
2. http://www.omegadyne.com/nav/entry.html	
  
3. http://www.electronics-­‐tutorials.ws	
  
	
  
	
  
	
  

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Dynometer project data acquisition filtering

  • 1. Dynamometer  Project  Data  Acquisition  Filtering       Name:  Rauf  Tailony     Rocket  number:R01368594     Supervisor:  Prof.Sorin  cioc                                                                              
  • 2. 1.  Introduction:     Data  acquisition  is  used  in  this  project  to  give  an  indication  of  the  engine  power  by   extracting   data   from   a   load   cell   and   then   convert   the   load   data   into   torque   and   power  using  relevant  equations.     Data  acquisition  is  a  very  sensitive  part  of  this  project  and  any  project  because  the   more   clear   the   data   the   more   clear   the   decisions   could   be   made   related   to   the   project  success.     Collecting  data  is  usually  a  process  that  uses  sensor  of  different  types  to  collect  data   for  certain  parameter  in  order  to  compare  the  result  produced  by  these  parameters   with  the  existing  ones.     Analog  sensor  reading  are  usually  accompanied  with  a  lot  of  noise  of  different  types,   that  could  lead  to  a  non  clear  vision  for  the  parameters  that  we  are  trying  to  answer   some  questions  about,  so  in  order  to  eliminate  any  unwanted  noise  or  unwelcomed   data  its  necessary  to  use  filters  depending  on  what  kind  of  data  we  want  present  on   the  output  screen.     2.  Objective:     In  this  section  of  the  project  we  are  trying  to  do  the  following  objectives:     1. filtering  and  fine-­‐tuning  the  data  acquisitioned  from  the  sensor  ;which  is  in   our  case  a  load  cell  that  measures  the  force  delivered  through  a  beam  by  the   alternator  that  is  connected    by  a  belt  with  the  engine.   2. Comparing  the  filtered  and  non  filtered  force  data  using  graph  indicators.   3. Presenting  the  torque  generated  using  graph  indicator  after  passing  the  force   data  through  related  equations.                                  
  • 3. 3.  Procedure:     3.1  Engine  power  delivery:     engine  power  is  delivered  to  the  alternator  through  a  belt  and  the  alternator  varies   the  load  on  the  engine  depending  on  a  lighting  system  connected  to  the  alternator   which   is   power   by   a   latching   button   ,   reflected   as   a   load   on   the   engine   which   changes  engine  power  produced  relating  to  the  load,  this  load  fluctuation  leads  to  a   angular  force  produced  by  the  alternator  ,  and  this  force  in  delivered  via  arm  to  be   applied  on  the  load  cell  located  at  the  end  of  the  arm,  as  shown  in  figure1.           Figure1,  connecting  arm  between  Alternator  and  Load  cell           3.2    sensor  connection  and  reading:     the  used  sensor  is  load  cell  (omegadyne),Figure  2,  and  connected  in  full  bridge  mode   through  an  NI9949  module  as  shown  in  figure  3,  and  this  module  is  connected  via   serail  port(RJ50)  through  analog  input/output  module  NI9237,Figure4,  and  fixed  on   NI   cDAQ-­‐9172,Figure   5,   and   connected   to   a   lab   view   software   of   custom   design(designed  by  Rauf  Tailony).      
  • 4.     Figure  2,Omegadyne  load  cell               Figure3,NI9949        
  • 5.     Figure4,NI9237           Figure5,NI  cDAQ-­‐9172            
  • 6. 3.3  Terminals  connection  tables  and  technical  information:     Load  cell-­‐NI9949  connections  table:     Terminal  name   Load  cell  colour  code   NI9949  pin  number   Signal  +(AL+)   Green   2   Signal  –  (AL-­‐)   White   3   Excitation  +(EX+)   Red   6   Excitation  –(EX-­‐)   Black   7       *Note:  previously  the  students  where  converting  the  wires  of  AL+  and  AL-­‐,  which   was  causing  the  data  to  be  in  minus.(fixed)       NI9949  –  NI9237  connection  table:     Device   Channel   NI9949   Single  channel   NI9237   CH0             *  Technical  data:     Load  cell  excitation  voltage  range(3-­‐10mv)     Used  excitation  voltage  (5mv)     Load  cell  Load  range(0-­‐20  LB)     Arm  length  (connecting  between  alternator  and  load  cell)  =  6  in        3.4  Filtering  and  Fine-­‐tuning:        The  filtering  procedure  we  are  using  is  software  dependent,  which  means  we  didn’t   use  any  physical  filters  or  data  conditioning  modules,  we  used  the  LV  express  filters   in  the  Block  diagram  mode  ,Figure6,  to  filter  the  data  extracted  from  the  load  cell.     We  used  Butterworth  low  pass  filter  with  cutoff  frequency  of  25  HZ,  and  the  order  of   the  filter  to  be  5,  with    signals  view  mode,  and  the  data  have  been  peak  limited  using  
  • 7. mask  and  limit  testing,  and  these  filtered  signals  are  transferred  to  graph  indicators   to  be  presented  to  the  user,Figure6.     Filtered  data  are  sent  to  spectral  measurement  tools,  to  have  an  idea  about  what   kind  of  peaks  we  get  from  the  readings,  and  sent  to  a  spectral  indicator  to  be  read  by   the  user,Figure  7.     We  adjusted  the  Butterworth  filter  ,  in  the  sotware  to  have  a  slider  to  control  the   cutoff   frequency   in   real   time   mode   during   the   data   presentation   on   the   graph   indicator,Figure  8,  so  we  give  a  better  control  and  understanding  of  the  signal  form.                     Figure6,Block  Diagram  Mode.  
  • 8.   Figure7,Spectrum  graph         Figure8,Cutoff  frequency  Slider      
  • 9.     3.5  Lab  view  Software’s  design  detailed  information:     since  we  are  using  NI  cDaQ-­‐9172  as  interface  between  the  sensor  and  the  Lab  view   software,  we  started  the  design  in  the  block  diagram  mode  by  adding  DAQ  assistant   block,   and   then   passing   the   data   line   to   subtracter   to   apply   the   data   offset   compensation  of  15  lb,after  that  the  data  line  passed  to  a  low  pass  analogue  filter   with  cutoff  frequency  of  10HZ  and  Butterworth  type  filter  of  order  5,and  connected   a  graph  indicator  on  the  line  to  represent  the  force  with  time  and  after  that  the  data   line   passed   to   a   multiplier   with   a   magnitude   of   (6in)   which   is   the   arm   length   between  the  alternator  and  the  load  cell  in  order  to  calculate  the  torque(Lb.  In)  after   filtering  ,  and  in  order  to  fine-­‐tune  the  data  more  precisely  we  passed  the  data  line   to  a  mean(averaging)  block  to  make  the  signal  more  smooth,  and  at  last  data  passed   to  a  data  recording  block(write  to  measurement  file)  to  save  the  data  on  hard  disk   depending   on   user   command,   all   the   previously   reported   blocks   are   shown   in   Figure9.           Figure9,  Block  diagram  design.  
  • 10.                                 The   graphical   user   interface   mode,   is   only   a   representation   of   the   output   tools   inserted  in  the  block  diagram,  which  contains  a  force-­‐time  graph,  and  Torque-­‐time   graph,   and   timer,   stop   button   and   cutoff   frequency   slider   and   sampling   rate,sampling  frequency  boxes,  as  shown  in  figure  10.             Figure10,GUI  mode      
  • 11.   *  Sensor  calibration  and  reset:     Since   our   load   cell   sensor   is   a   bridge   circuit   ,   we   need   to   enter   for   the   lab   view   software   and   assign   the   first   two   values   of   calibration   provided   by   the   manufacturing  company  of  the  load  cell,  in  the  load  cell  we  are  using  we  could  find   some  calibration  data  on  the  manufacturer’s  website(Omegadyne.com),  and  we  can   find   the   place   to   calibrate   the   bridge   by   clicking   right   on   DAQ   assistant   in   block   diagram  mode  and  in  properties,  you  will  find  configure  scale,Figure11,  and  then  the   table  of  calibration  data,Figure12.       Figure11,DAQ  assistant  properties  window.    
  • 12.   Figure12,Configure  scale  window       Note:  electrical  values  are  0.0000  and  0.9668  respectively,  and  physical  values  are  0   and  2.5  respectively.     Physical  sensor  calibration:      To  make  sure  that  the  data  we  are  getting  in  the  software  are  real  and  there  is  no   error  in  the  reading  ,  we  made  physical  calibration  for  the  sensor  side  by  side  with   the  sensor  software  calibration.      We  made  the  calibration  using  (0.25,0.65,1.3,5lb)  weights  ,  and  loading  it  on  the  top   of  the  load  cell  after  isolating  it  from  the  system  and  then  observing  the  readings   presented  on  the  load  graph,  and  adjusting  the  subtraction  magnitude  in  order  to   make   the   load   cell   give   as   much   precise   data   as   it   is   capable   of,   as   described   in   figures  13,14  respectively.      Its  worth  it  to  mention  that  after  taking  the  data  on  the  graph  read  by  the  sensor   from  the  previous  weights,  we  found  that  there  is  an  offset  in  the  factor  of  (3.39)   which   we   could   deal   with   it   by   multiplying   the   data   line   with   this   factor   before   presenting  it  on  the  graph,  Figure  15.      
  • 13.           Figure  13,  weights  used  in  calibration.         Figure  14,  mounted  weight  on  load  cell  structure.        
  • 14.     Figure15,offset  compensation  block                         3.6  Displaying  calculated  rpm  in  the  GUI  :     As  it  is  known  ,  Torque(Lb.  IN)  has  a  relation  with  power(HP)  and  RPM  which  is   shown  the  relation  below:     Torque  (lb.in)  =  63,025  x  Power  (HP)  /  Speed  (RPM)……………………….(1)     and  using  this  relation  allows  us  to  show  the  calculated  engine  RPM  in  the  Labview   software  since  the  power  is  known  for  the  engine,  but  with  a  limitation   that   this   RPM   will   be   precise   only   for   the   engine   in   the   Idle   state,   but   after   coupling   the   engine   with   the   alternator   ,it   will   be   very   complex   to   predict   the   RPM   in   the   calculation  torque  based  method  which  will  give  correct  data  representation  only   when  engine  have  no  load  and  running  on  high  rpm(>6000rpm)  ,  Figure16.    
  • 15.   Figure16,RPM  in  the  GUI  mode       Before  we  pass  the  data  line  to  RPM  indicator  we  passed  it  to  a  formula  box  ,  which   contain  the  following  formula  which  is  number  substitution  to  formula  (1)  :     (63025*0.611)/X1  ………………………….(2)                                                          Torque  data       Power(HP)       Eq.(1)  constant       We   got   the   power   value   of   0.611   ,by   running   the   engine   on   RPM   =   7500,   and   coupling  it  with  the  alternator,  and  Using  the  ProCal  software  to  get  the  rpm  ,  we   could  calculate  the  real  power  after  coupling  using  eq.(1),  and  you  can  trace  the  data   line  passing  through  the  formula  block  by  looking  to  figure  17.      
  • 16.     Figure17,Full  block  diagram       We   compared   the   data   we   got   from   our   design   of   labview   GUI   RPM,   with   Procal   RPM,  the  results  were  almost  the  same  in  the  same  running  conditions,  as  indicated   in  Figure18.    
  • 17.     Figure18,  Labview  RPM  VS.  Procal                
  • 18. 4.  Conclusion:     Data  filtering  can  enhance  the  data  we  extract  from  the  load  cell  sensor  even  its  not   a  physical  filtering  but  it  could  fairly  enhance  the  results  to  the  user  in  order  to  give   a  better  understanding  of  the  parameters  that  we  are  trying  to  observe  which  is  in   our  case  the  torque  and  power.           Figure  19,  Original  Data  with  noise     In  the  previous  graph  we  are  presenting  the  original  data  that  is  extracted  in  real   time  directly  from  the  sensor,  as  you  can  see  in  figure  13,  the  data  have  a  lot  of  noise   which  make  it  hard  for  the  observer  to  decide  of  the  torque  he  is  getting  from  the   engine  is  good  or  bad  ,  and  following  to  that  we  have  pasted  the  filtered  force  and   torque  graphs  with  time  for  the  engine  in  the  Idle  state,  so  that  you  can  observe  the   change  happened  to  the  data  after  filtering,  and  what  kind  of  enhancement  made  to   make  the  data  more  stable  and  readable.      
  • 19.     Figure  20,  Filtered  Data       *  Mean  and  averaging:     even  we  have  implemented  the  averaging  property  to  the  block  diagram  as  you  saw   previously,  but  related  to  a  limitation  in  the  Labview  software  you  can’t  present  the   data   of   the   averaging   and   mean   or   RMS   as   a   graph   but   only   as   numbers,   as   presented  previously  in  the  GUI  screenshot.     5.  Recommendations:     I   would   recommend   for   the   coming   teams   who   will   work   on   this   project   for   the   software   side   to   use   FPGA   software   to   represent   more   filtered   and   averaged   and   stable  data  that  could  look  more  professional  for  future  use  of  the  project,  or  using   matlab  since  its  supporting  the  graphical  representation  more  than  lab  view,  and   also  have  a  lot  of  resources  that  could  help  researcher  do  a  better  design  than  the   Labview  do.    
  • 20. 6.  Index:     Filter  used  and  related  concepts:     Butterworth  Filter:       In  applications  that  use  filters  to  shape  the  frequency  spectrum  of  a  signal  such  as  in   communications  or  control  systems,  the  shape  or  width  of  the  roll-­‐off  also  called  the   “transition   band”,   for   a   simple   first-­‐order   filter   may   be   too   long   or   wide   and   so   active   filters   designed   with   more   than   one   “order”   are   required.   These   types   of   filters  are  commonly  known  as  “High-­‐order”  or  “nth-­‐order”  filters.     The   complexity   or   Filter   Type   is   defined   by   the   filters   “order”,   and   which   is   dependant  upon  the  number  of  reactive  components  such  as  capacitors  or  inductors   within  its  design.  We  also  know  that  the  rate  of  roll-­‐off  and  therefore  the  width  of   the   transition   band,   depends   upon   the   order   number   of   the   filter   and   that   for   a   simple  first-­‐order  filter  it  has  a  standard  roll-­‐off  rate  of  20dB/decade  or  6dB/octave.     Then,  for  a  filter  that  has  an  nth  number  order,  it  will  have  a  subsequent  roll-­‐off  rate   of   20n   dB/decade   or   6n   dB/octave.   So   a   first-­‐order   filter   has   a   roll-­‐off   rate   of   20dB/decade  (6dB/octave),  a  second-­‐order  filter  has  a  roll-­‐off  rate  of  40dB/decade   (12dB/octave),   and   a   fourth-­‐order   filter   has   a   roll-­‐off   rate   of   80dB/decade   (24dB/octave),  etc,  etc.   High-­‐order   filters,   such   as   third,   fourth,   and   fifth-­‐order   are   usually   formed   by   cascading  together  single  first-­‐order  and  second-­‐order  filters.   For  example,  two  second-­‐order  low  pass  filters  can  be  cascaded  together  to  produce   a  fourth-­‐order  low  pass  filter,  and  so  on.  Although  there  is  no  limit  to  the  order  of   the  filter  that  can  be  formed,  as  the  order  increases  so  does  its  size  and  cost,  also  its   accuracy  declines.       Decades  and  Octaves   One  final  comment  about  Decades  and  Octaves.  On  the  frequency  scale,  a  Decade  is  a   tenfold  increase  (multiply  by  10)  or  tenfold  decrease  (divide  by  10).  For  example,  2   to  20Hz  represents  one  decade,  whereas  50  to  5000Hz  represents  two  decades  (50   to  500Hz  and  then  500  to  5000Hz).   An  Octave  is  a  doubling  (multiply  by  2)  or  halving  (divide  by  2)  of  the  frequency   scale.   For   example,   10   to   20Hz   represents   one   octave,   while   2   to   16Hz   is   three   octaves   (2   to   4,   4   to   8   and   finally   8   to   16Hz)   doubling   the   frequency   each   time.   Either   way,   Logarithmic   scales   are   used   extensively   in   the   frequency   domain   to   denote  a  frequency  value  when  working  with  amplifiers  and  filters  so  it  is  important   to  understand  them.          
  • 21. Logarithmic  Frequency  Scale         Since   the   frequency   determining   resistors   are   all   equal,   and   as   are   the   frequency   determining   capacitors,   the   cut-­‐off   or   corner   frequency   (  ƒC  )   for   either   a   first,   second,  third  or  even  a  fourth-­‐order  filter  must  also  be  equal  and  is  found  by  using   our  now  old  familiar  equation:         As  with  the  first  and  second-­‐order  filters,  the  third  and  fourth-­‐order  high  pass  filters   are   formed   by   simply   interchanging   the   positions   of   the   frequency   determining   components  (resistors  and  capacitors)  in  the  equivalent  low  pass  filter.  High-­‐order   filters  can  be  designed  by  following  the  procedures  we  saw  previously  in  the  Low   Pass  and  High  Pass  filter  tutorials.  However,  the  overall  gain  of  high-­‐order  filters  is   fixed  because  all  the  frequency  determining  components  are  equal.     Filter  Approximations   So  far  we  have  looked  at  a  low  and  high  pass  first-­‐order  filter  circuits,  their  resultant   frequency   and   phase   responses.   An   ideal   filter   would   give   us   specifications   of   maximum  pass  band  gain  and  flatness,  minimum  stop  band  attenuation  and  also  a   very  steep  pass  band  to  stop  band  roll-­‐off  (the  transition  band)  and  it  is  therefore   apparent   that   a   large   number   of   network   responses   would   satisfy   these   requirements.   Not  surprisingly  then  that  there  are  a  number  of  “approximation  functions”  in  linear   analogue   filter   design   that   use   a   mathematical   approach   to   best   approximate   the   transfer  function  we  require  for  the  filters  design.   Such  designs  are  known  as  Elliptical,  Butterworth,  Chebyshev,  Bessel,  Cauer  as  well   as  many  others.  Of  these  five  “classic”  linear  analogue  filter  approximation  functions   only  the  Butterworth  Filter  and  especially  the  low  pass  Butterworth  filter  design  will   be  considered  here  as  its  the  most  commonly  used  function.     Low  Pass  Butterworth  Filter  Design     The   frequency   response   of   the   Butterworth   Filter   approximation   function   is   also   often  referred  to  as  “maximally  flat”  (no  ripples)  response  because  the  pass  band  is   designed  to  have  a  frequency  response  which  is  as  flat  as  mathematically  possible   from   0Hz   (DC)   until   the   cut-­‐off   frequency   at   -­‐3dB   with   no   ripples.   Higher   frequencies   beyond   the   cut-­‐off   point   rolls-­‐off   down   to   zero   in   the   stop   band   at   20dB/decade   or   6dB/octave.   This   is   because   it   has   a   “quality   factor”,   “Q”   of   just  
  • 22. 0.707.   However,   one   main   disadvantage   of   the   Butterworth   filter   is   that   it   achieves   this   pass   band   flatness   at   the   expense   of   a   wide   transition   band   as   the   filter   changes   from  the  pass  band  to  the  stop  band.  It  also  has  poor  phase  characteristics  as  well.   The  ideal  frequency  response,  referred  to  as  a  “brick  wall”  filter,  and  the  standard   Butterworth  approximations,  for  different  filter  orders  are  given  below.     Ideal  Frequency  Response  for  a  Butterworth  Filter         Where  the  generalised  equation  representing  a  “nth”  Order  Butterworth  filter,  the   frequency  response  is  given  as:     Where:  n  represents  the  filter  order,  Omega  ω  is  equal  to  2πƒ  and  Epsilon  ε  is  the   maximum  pass  band  gain,  (Amax).  If  Amax  is  defined  at  a  frequency  equal  to  the  cut-­‐ off  -­‐3dB  corner  point  (ƒc),  ε  will  then  be  equal  to  one  and  therefore  ε2  will  also  be   one.  However,  if  you  now  wish  to  define  Amax  at  a  different  voltage  gain  value,  for   example  1dB,  or  1.1220  (1dB  =  20logAmax)  then  the  new  value  of  epsilon,  ε  is  found   by:     •  Where:   •    H0  =  the  Maximum  Pass  band  Gain,  Amax.   •    H1  =  the  Minimum  Pass  band  Gain.   Transpose  the  equation  to  give:         The  Frequency  Response  of  a  filter  can  be  defined  mathematically  by  its  Transfer  
  • 23. Function  with  the  standard  Voltage  Transfer  Function  H(jω)  written  as:     •  Where:   •    Vout  =  the  output  signal  voltage.   •    Vin    =  the  input  signal  voltage.   •          j      =  to  the  square  root  of  -­‐1  (√-­‐1)   •        ω    =  the  radian  frequency  (2πƒ)       Note:  (  jω  )  can  also  be  written  as  (  s  )  to  denote  the  S-­‐domain.  and  the  resultant   transfer  function  for  a  second-­‐order  low  pass  filter  is  given  as:         Normalised  Low  Pass  Butterworth  Filter  Polynomials   To  help  in  the  design  of  his  low  pass  filters,  Butterworth  produced  standard  tables   of  normalised  second-­‐order  low  pass  polynomials  given  the  values  of  coefficient  that   correspond  to  a  cut-­‐off  corner  frequency  of  1  radian/sec.   n   Normalised  Denominator  Polynomials  in  Factored  Form   1   (1+s)   2   (1+1.414s+s2)   3   (1+s)(1+s+s2)   4   (1+0.765s+s2)(1+1.848s+s2)   5   (1+s)(1+0.618s+s2)(1+1.618s+s2)   6   (1+0.518s+s2)(1+1.414s+s2)(1+1.932s+s2)   7   (1+s)(1+0.445s+s2)(1+1.247s+s2)(1+1.802s+s2)   8   (1+0.390s+s2)(1+1.111s+s2)(1+1.663s+s2)(1+1.962s+s2)   9   (1+s)(1+0.347s+s2)(1+s+s2)(1+1.532s+s2)(1+1.879s+s2)   10   (1+0.313s+s2)(1+0.908s+s2)(1+1.414s+s2)(1+1.782s+s2)(1+1.975s+s2)   Filter  Design  –  Butterworth  Low  Pass   Find   the   order   of   an   active   low   pass   Butterworth   filter   whose   specifications   are   given  as:  Amax  =  0.5dB  at  a  pass  band  frequency  (ωp)  of  200  radian/sec  (31.8Hz),   and  Amin  =  -­‐20dB  at  a  stop  band  frequency  (ωs)  of  800  radian/sec.  Also  design  a   suitable  Butterworth  filter  circuit  to  match  these  requirements.   Firstly,   the   maximum   pass   band   gain   Amax   =   0.5dB   which   is   equal   to   a   gain   of   1.0593  (0.5dB  =  20log  A)  at  a  frequency  (ωp)  of  200  rads/s,  so  the  value  of  epsilon  ε   is  found  by:         Secondly,  the  minimum  stop  band  gain  Amin  =  -­‐20dB  which  is  equal  to  a  gain  of  -­‐10   (20dB  =  20log  A)  at  a  stop  band  frequency  (ωs)  of  800  rads/s  or  127.3Hz.   Substituting  the  values  into  the  general  equation  for  a  Butterworth  filters  frequency   response  gives  us  the  following:  
  • 24.       Since  n  must  always  be  an  integer  (  whole  number  )  then  the  next  highest  value  to   2.42  is  n  =  3,  therefore  a  “a  third-­‐order  filter  is  required”  and  to  produce  a  third-­‐ order  Butterworth  filter,  a  second-­‐order  filter  stage  cascaded  together  with  a  first-­‐ order  filter  stage  is  required.   From  the  normalised  low  pass  Butterworth  Polynomials  table  above,  the  coefficient   for  a  third-­‐order  filter  is  given  as  (1+s)(1+s+s2)  and  this  gives  us  a  gain  of  3-­‐A  =  1,   or  A  =  2.  As  A  =  1  +  (Rf/R1),  choosing  a  value  for  both  the  feedback  resistor  Rf  and   resistor  R1  gives  us  values  of  1kΩ  and  1kΩ  respectively,  (  1kΩ/1kΩ  +  1  =  2  ).   We  know  that  the  cut-­‐off  corner  frequency,  the  -­‐3dB  point  (ωo)  can  be  found  using   the  formula  1/CR,  but  we  need  to  find  ωo  from  the  pass  band  frequency  ωp  then,  
  • 25.       So,   the   cut-­‐off   corner   frequency   is   given   as   284   rads/s   or   45.2Hz,   (284/2π)   and   using   the   familiar   formula   1/CR   we   can   find   the   values   of   the   resistors   and   capacitors  for  our  third-­‐order  circuit.     Note  that  the  nearest  preferred  value  to  0.352uF  would  be  0.36uF,  or  360nF.                    
  • 26. Third-­‐order  Butterworth  Low  Pass  Filter     and  finally  our  circuit  of  the  third-­‐order  low  pass  Butterworth  Filter  with  a  cut-­‐off   corner  frequency  of  284  rads/s  or  45.2Hz,  a  maximum  pass  band  gain  of  0.5dB  and  a   minimum  stop  band  gain  of  20dB  is  constructed  as  follows.                                                      
  • 27. 7.  Acknowledgment:     Very   big   thanks   for   Prof.   Sorin   Cioc,   Assistant   professor,UT,   for   giving   me   the   opportunity  to  use  his  Internal  combustion  lab,  and  giving  me  a  solid  pathway  to  use   it  in  order  to  reach  the  goal  in  this  work  using  the  shortest  road.     Special   thanks   for   Sabin   Bati,Masters   student,MIME,UT,   for   his   help   in   practical   work,  and  for  his  bright  Ideas  that  he  shared  with  me  in  order  to  make  the  data  look   and  behave  more  precise.       8.  References:       1. http://www.ni.com/community/   2. http://www.omegadyne.com/nav/entry.html   3. http://www.electronics-­‐tutorials.ws