Introduction: Data Acquisition and Data Visualization System for a MotoStudent Electric Racing Bike
A data acquisition system is a collection of hardware and software working together in order to collect data from external sensors, store and process it afterwards so that it can be visualized graphically and analyzed, allowing the engineers to make the necessary adjustments to obtain the best performance of the vehicle or device.
The Data Acquisition System works together with a Data Visualization System which allows the pilot to see the relevant real-time data for the driving. It consists on a HMI screen which communicates with the Data Acquisition System in order to retrieve and show data from it.
This System communicates with the bike’s ECU (Engine Control Unit) and receives internal information and engine variables from it via CAN bus. It uses a USB for the storage of the received data as well as the data retrieved from the sensors connected to the Data Acquisition System.
Microcontroller Texas Instruments F28069M C2000
Nextion Enhanced 5.0’’ screen
PC with Matlab software
AIM suspension Sensor
Inductive sensor IME18-08BPSZC0S
Voltage regulator LMR23615DRRR
Voltage regulator LM25085AMY/NOPB
Voltage regulator MAX16903SAUE50 x2
Temperature Sensor pt100
5-103669-9 connector x1
5-103639-3 connector x1
5-103669-1 connector x1
TPS2051BDBVR Power Switch
Resistor 1K Ohm x5
Resistor 10K Ohm
Resistor 100 Ohm x1
Resistor 100k Ohm x7
Resistor 51K Ohm
Resistor 22,1 K Ohm x2
Resistor 6 Kohm x2
Resistor 6K8 Ohm x2
Resistor 2.55K Ohm
Resistor 38.3K Ohm x1
Resistor 390 Ohm x1
Resistor 20K Ohm x2
resistor 33K Ohm x2
Capacitor 15 uF x5
Capacitor 10 uF x3
Capacitor 4.7uF x4
Capacitor 47uF x2
Capacitor 0.1uF x1
Capacitor 1nF x1
Capacitor 100nf x1
Capacitor 470nF x1
Capacitor 2.2uF x2
Capacitor 220 uf x1
Capacitor 100uF x1
Inductor 22uH x1
Inductor 4.5uH x1
Inductor 4.7uH x1
Instrumental Amplifier AD620
2-pin Header x3
4-pin Header x6
5-pin Header x3
Step 1: Microcontroller Texas Instruments F28069M C2000 Launchpad
This microcontroller is embedded in a development board whose features makes it suitable for developing applications such as the Data Acquisition System and the ECU:
- USB debugging and programming interface
- CAN bus interface with integrated transceiver
- 14 ADC pins (Analog to Digital Converters)
- 34 GPIO pins (General Purpose Input/Output)
- 2 serial protocol (SCI) communication channels
- 2 I2C protocol communication channels
- Programming with the free software Code Composer Studio
It manages the external sensors, the GPS, the storage of the data inside the USB, the communication with the ECU and the communication with the dashboard’s screen.
Step 2: PC With Matlab Software
Matlab software is used to process and analyze the data stored in the USB. The position and trajectory of the bike can be visualized together with the value of the sensors, simultaneously, as can be seen on the picture.
Step 3: Nextion Enhanced 5.0’’ Screen
It’s used to show the most relevant information to the pilot, as well as the status of the bike’s systems. It receives the data from the F28069M C2000 microcontroller via serial communication.
Step 4: GPS GY-GPS6MV2
The GPS gets the instant position of the bike, so that its trajectory can be afterwards plotted in Matlab software along with the values of the other sensors. It sends the GPS data to the F28069M C2000 microcontroller via serial communication.
Step 5: AIM Suspension Sensor
Installed on the front and rear suspension, the suspension displacement of the bike can be measured.
Step 6: Accelerometer VMA204
It is used to measure the acceleration and forces the bike withstands in the axes x, y, and z. It sends the acceleration data to the F28069M C2000 microcontroller via I2C bus communication.
Step 7: Keypad
The keypad is used to select the driving mode (ECO, Sport), configure the pilot’s screen and control the data acquisition times.
Step 8: USB
It stores the data from the sensors, the GPS and the ECU.
Step 9: Inductive Sensor IME18-08BPSZC0S
It is used to count the pulses of a magnetic part of the wheel. The higher the speed, the more turns will the wheels do and the more pulses will the inductive sensor count. That’s how the measurement of the speed works.
The connection diagram is showed on the image.
Step 10: Temperature Sensor Pt100
The pt100 sensors are an specific type of temperature detectors. It varies its resistance depending on the temperature. The most important feature is that its composed of platinum and have an electrical resistance of 100 Ohm at 0ºC.
Step 11: Voltage Regulators
The system needs 4 different voltage regulators in order to obtain the voltage levels needed for the microcontroller and the sensors:
It is able to convert from a wide voltage range supply to a fixed output voltage. For this application, we need it to supply 3.3 V to the Texas Instruments F28069M C2000 microcontroller.
It is able to convert from a wide voltage range supply to a fixed output voltage. For this application, we need it to supply 5 V to the Texas Instruments F28069M C2000 microcontroller.
It is able to convert from a wide voltage range supply to a fixed output voltage. For this application, we need 2 of them:
One to supply 5 V to the external sensors that require such voltage.
The other one to supply 3.3 V to the external sensors that require such voltage.
Step 12: FDD5614P Mosfet
A mosfet is a semiconductor device similar to a transistor used to commute signals.
Step 13: TPS2051BDBVR Power Switch
This component is used to prevent short circuits. When the output load exceeds the current-limit threshold or a short is present, the device limits the output current to a safe level by switching into a constant-current mode. If the overload does not stop, it cuts off the supply voltage.
Step 14: LEDs and Diodes
LEDs are used to visualize whether the system has power or not. They also keep the current flowing in only one direction, preventing the wrong polarization of the circuit.
Diodes work as a LED but without the light; they keep the current flowing in only one direction, preventing the wrong polarization of the circuit.
Step 15: Connectors, Pin Headers and Adaptors
The PDB board requires a certain amount of connectors, pin headers and adaptors of different characteristics in order to work and integrate with the different peripheral devices. The units used are the following:
Step 16: Resistors, Capacitors, Inductors
The basics for any electronic circuit
Step 17: Schematich Design of the Board: External Connectors for Power Supply and CAN Communication
Step 18: Schematich Design of the Board: Microcontroller Texas Instruments F28069M C2000 Launchpad
- Sensor’s connection, via pin headers of different sizes for analog and digital inputs
- Signal conditioning for the sensors:
o Low pass filters for preventing electromagnetic interference to disturb the signals. The cut off frequency is 15Hz.
o Wheatstone bridge and an instrumental amplifier for the pt100 temperature sensor to work correctly
- Communication pins for external devices:
o SCI for the screen and the GPS
o I2C for the accelerometer
Step 19: Schematich Design of the Board: Power Supply to the Microcontroller
Via Voltage regulators, which convert 24V (low voltage coming from the battery) to 3.3V (LMR23615DRRR) and 5V (LM25085AMY/NOPB)
Step 20: Schematich Design of the Board: USB Connection
Step 21: Schematich Design of the Board: Power Supply to the Sensors and External Devices
Via Voltage regulators (MAX16903SAUE50), which
convert 24V (low voltage coming from the battery) to 3.3V and 5V. The system is redundant and can also provide power to the microcontroller in case its voltage regulator fails.
Step 22: Design the PCB Board
1) Power supply for the microcontroller
2) Microcontroller Texas Instruments F28069M C2000 launchpad
3) Digital and analog inputs and signal filtering (3.1)
4) USB connection
5) External devices pin headers
6) pt100 temperature sensor signal conditioning
7) Power supply for the sensors and external devices
Step 23: Order the PCB Board
With the design completed, it’s time to order the PCB in the web JLCPCB.com. The process is simple, as you just have to go to JLCPCB.com , add the dimensions and layers of your PCB board and click the QUOTE NOW button.
JLCPCB are also sponsor of this project. JLCPCB (ShenzhenJLC Electronics Co., Ltd.), is the largest PCB prototype enterprise in China and a high-tech manufacturer specializing in quick PCB prototype and small-batch PCB production. You can order a minimum of 5 PCBs for just $2.
You need to generate the gerber files of your project and put them in a ZIP file. By clicking to the “add your gerber file” button, the design is uploaded to the web. The dimensions and other features can still be changed on this section.
When uploaded, JLCPCB will check everything is correct and show a previous visualization of both sides of the board.
After making sure the PCB looks good, we can now place the order at a reasonable price by clicking on the “Save to cart” button.