Automotive

The automotive category contains case studies and blogs related to ITM’s engineering and testing services for automobile design and manufacture.

Modern Tools Series: What’s In The Box?

Modern Tools Series: What’s In The Box? 

This box reveal may not be quite as dramatic as the ending of “Seven,” the ’95 serial killer thriller that blew moviegoers’ minds, but the ITM team is throwing open the latches nonetheless. 

In this case, our team is taking you on a quick tour of a recently deployed Rugged Data Acquisition System. These particular black boxes of tech are riding around on high-dollar fracking equipment to remotely monitor all sorts of triggering events. Our crew builds them on the regular, and the end result is that our clients can better understand what sorts of stress, strain and vibration is taking place both en-route to their site and once operations begin.  

ITM is known for building rugged measurement systems and data logging solutions that are deployed on everything from Class A trucks, to well frac trailers, to dam and bridge structures, oil pipelines, gensets, boilers and more.

So, without further ado, what’s in the box?  

We recommend a handful of essential components and elements if you are looking to build your own rugged measurement system:

  • An Industrial Embedded PC. We love the Nuvo-7000LP. Another favorite is the Advantech UNO-2484G-9S55. 
  • You’ll need industrial grade connectivity, and you can’t beat Peplink’s cellular router options. And remember to outfit that unit with an AT&T or Verizon plan and get that activated card installed. 
  • A remote desktop application is a must, and we usually turn to LogMeIn for our remote access and file management. This allows us to pull up any of our units no matter where they are in the world to check in on status or grab some data for our clients. 
  • Speaking of data, depending on your job, you’ll likely need lots of data storage capability. Our preference is a 2 terabyte USB drive, which gives us an almost unlimited amount of space. If needed, we can store about six months worth of data before hitting capacity.
  • Since our industrial PC is running Windows, we use iTestSystem, our proprietary engineering measurement software platform that enables test engineers to organize, acquire, view, and analyze data from machinery, processes, vehicles and other complex systems.
  • To complete the box, our industrial PC is connected to an NI c-DAQ outfitted with strain, vibration and voltage modules.
  • What about power you ask? In our fracking instance, we connected to an alternator which charges a bank of batteries in the RAC. 

So there you have it. That’s what’s in the box. Build your own, or get in touch with our team, and we’ll customize a system for your specific needs.  

We also install and service all of our equipment. So if something breaks in the field, we can get you back up and collecting data or even assist with data analysis.

For more information about our rugged data acquisition systems, on-site system deployment or data analysis services, contact Josh Fishback via email at josh.fishback@itestsystem.com or phone at (844) 837-8797 x705.

 

ITM gives back to UC’s future engineers

ITM gives back to UC’s future engineers

The team at ITM spent half a day at the University of Cincinnati recently in an effort to invest in the next generation of engineers.

Integrated Test and Measurement President and Founder Tim Carlier volunteered to judge senior capstone projects developed by students in UC’s College of Engineering and Applied Science. Joining Carlier inside Great Hall of UC’s Tangeman University Center were Josh Fishback, ITM’s administrative director, and Chase Petzinger, a computer engineer with the Milford, Ohio, engineering firm. 

A few of the projects they judged included a Mars Rover prototype, a homemade emergency rescue drone and an autonomous object avoidance system that uses lidar technology to prevent crashes. 

As a whole, ITM’s crew left campus feeling encouraged by the impressive engineering skills, presentation styles and ingenuity of UC’s students. For Carlier, a day like this is an opportunity to connect with young people entering the industry. While he is always on the lookout for potential co-op connections or to recruit talented employees, building relationships and supporting young engineers is the main objective. 

“These guys and gals are going to be out in the workforce, and they will have jobs that could use our services someday,” said Carlier. “It is exciting to see how well they are doing.” 

 For Fishback and Petzinger, both UC alumni and former track and field athletes, it was a chance to return to their alma mater.  

 “It is always good to come back and see how UC has progressed,” said Fishback, an accountant who graduated from UC’s Lindner College of Business. “I like seeing how the students carry themselves and how they present their senior design projects. I was pretty impressed.” 

Petzinger was excited to see his favorite professor’s name — Thomas Mantei — had been added to UC’s Engineering Research Center. He also found it helpful to learn what types of programming languages today’s students are favoring.  

“They are doing a lot more web-based machine learning now than when I was on campus,” said Petzinger. “It is pretty interesting to see the direction things are going. They knew their stuff. I didn’t have a single student stumble over a technical question that I gave them.” 

Carlier handed out business cards to those he engaged with and invited them to connect on LinkedIn so he could follow their career achievements.

For more information about Engineering or CO-OP positions at ITM contact Josh Fishback via email at josh.fishback@itestsystem.com or phone at (844) 837-8797 x705.

Endless Testing Options Through Finite Element Analysis (FEA) 

Endless Testing Options Through Finite Element Analysis (FEA) 

Whether our customers need us to validate their Finite Element Analysis (FEA) models or perform both the physical testing and the FEA, our engineers are used to helping customers with complex testing and analysis of high-value equipment. 

As a recent example, our team is involved in a large-scale project to do engine testing for a client that requires ITM to do both the physical testing as well as the FEA simulations. This requires using a custom high-channel count telemetry system to transmit engine data to a receiver that is sampling at an extremely high rate. 

“Once you are able to bring in the test data and compare it to the simulated data, you are able to fine tune your FEA simulation to better reflect the real-world application,” said ITM engineer Ryan Matthews. “We can also simulate the test in software and predict how it is going to react to the test when we can actually measure such things as strain, stress and vibration.” 

Matthews points out that FEA technology also helps the team determine the precise best placement of strain gauge during physical testing. And depending on complexity, a single simulation can take a few seconds or months to run. 

For obvious reasons — mainly the cost of bringing high-value assets to failure — running repeated strain gauge tests on components simply isn’t feasible, but ITM’s in-house capabilities and close partnership with sister firm SixDOF opens up endless FEA simulation options to clients. 

“Sometimes you are only going to be able to test a structure or a part once before it fails,” says Matthews. “So it becomes crucial to do a limited number of physical tests then correlate that to your FEA. Then you can pretty much run unlimited simulations.” 

For more information about our testing, strain gauging, and FEA modeling services contact Ryan Welker via email at ryan.welker@itestsystem.com of phone @ (844) 837-8797.

ITM Helps Miami University Students Succeed SAE Baja

The students and advisors huddled around the computer react as they watch the signal yield an immediate spike within ITM’s iTestSystem software…

In Vehicle Vibration Testing

building a rugged and flexible in-vehicle testing solution to measure the vibration levels.

Vehicle Component Testing

…more than a thousand miles away. A display of gauges, needles and dials showed precisely how their product performed during every day over-the-road stress.

Going Old School to Deliver New Solutions

High-tech measurement systems? Not a problem.

Complex data acquisition or custom software solutions? Right in our wheelhouse.

At ITM, these kinds of challenges have become commonplace in our lab, but one recent project that hit our doorstep stretched our engineers, and not for the reasons you may be thinking.

Our customer wanted an old-school manual operator control station. Think classic-style red and green, push-button start and stop controls, which they wanted to energize various parts of a large test cell for a military marine application.

The ask was a bit out of ITM’s typical range of services simply because most systems they develop don’t require manual control stations to run their equipment. Instead, their customers usually opt for computer-controlled testing, which ITM crafts regularly. Still, the job required a complete CAD design, a custom cabinet enclosure and hundreds of electrical components to be designed and assembled, which our team successfully delivered to the satisfaction of the client.

Modern Integration

The same customer also wanted to be able to collect complex data from the tests, and ITM, of course, delivered on this challenge as well thanks to its proprietary iTestSystem software, which computer engineer Chase Petzinger deployed to build a custom DAQ. 

iTestSystem is an engineering measurement software platform that enables test engineers to organize, acquire, view and analyze data from machinery, processes, vehicles and other complex rugged measurement systems. iTestSystem was specifically designed for use with NI cDAQ or FieldDAQ hardware for data collection and data logging, so it was no stretch to equip it to pull down data from the military equipment test. 

In the end, the job required running new-school modern technology to handle the data collection and reporting simultaneously alongside the old-school analog operator control panel. From successfully assembling hundreds of electrical components to deploying custom software that can handle hundreds of channels of data from a wide variety of sensors at once, ITM truly showed its range on this project.

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

Test Cell Vibration Monitoring

A large-engine manufacturer had test cells with severe vibration levels…

Collect Vehicle CAN Bus data with NI 9862 and iTestSystem

Automotive and off-highway engineers and designers often need to log vehicle bus data along with vibration, strain gauge, and other sensor data during normal operation to evaluate their design.  Using data from all these sources enables these engineers and designers to pinpoint a vehicle’s response to staged or damaging events.  For example, engineers can see how steering wheel position and speed effect structural response when the vehicle hits a pothole.

How does steering wheel position and speed effect structural response when the vehicle hits a pothole?

In situations where our engineers need to tap into the vehicle’s on-board diagnostics using CAN bus data and analog sensor data to identify and solve a problem, we will deploy a rugged measurement solution based on NI CompactDAQ (cDAQ) hardware.  These systems usually include an industrial compact pc or standalone cDAQ running the iTestSystem engineering measurement application.  iTestSystem logs data from the vehicle bus connected to NI 9862 CAN module and other analog sensors connected to NI cDAQ modules like NI 9234, NI 9236, and NI 9229 into one data file.

NI 9862 CAN Module Specifications and Connections

According to the NI data sheet, the NI 9862 modules is a single CAN port device that is isolated from the other modules in the system. The port has a Bosch DCAN CAN controller that is CAN 2.0B-compatible and fully supports both 11-bit and 29-bit identifiers. The port also has an NXP TJA1041AT High-Speed CAN transceiver that is fully compatible with the ISO 11898 standard and supports baud rates up to 1 Mbps.  This module requires +9 to +30 VDC supply voltage to operate.

The table below shows the connections between the NI 9862 9 pin D-Sub and the SAE J1962 connector that are required for CAN communication.  NI sells a OBDII9M-DB9F CAN Cable cable if you don’t want make your own cable.

iTestSystem CAN Channel Setup

Setting up a vehicle CAN bus connection can be difficult, especially if you need to acquire non-standard, proprietary messages and frames.  iTestSystem simplifies this setup by leveraging the NI XNET and CAN drivers to view and configure CAN bus data, import databases, and assign scale factors. iTestSystem then allows users to browse and choose which CAN signals to acquire.

For more information about collecting CAN bus data with an NI 9862 and iTestSystem, or our testing services, contact Chase Petzinger via email at chase.petzinger@itestsystem.com or phone at (844) 837-8797 x704

Related Links

Strain Gauge Installation – M-Bond AE-10 Epoxy

This video shows how to install a strain gauge on a curved surface using M-Bond AE-10 two part epoxy. Watch an ITM test technician walk through each step of the M-Bond AE-10 strain gauge installation procedure.