Electronics and Data Acquisition System

Vehicle Sensor Layout

1. Electronics

Electronics goals were to have a faster and a reliable system with optimized main and DAQ wiring harness. Another objective was to collect useful data to validate and improve the performance car and driver. The wiring harness is custom made with PE3 ECU and Race Capture Data Logger. Keeping in mind the above goals the harness was designed to ensure minimal weight, better reliability, better safety, easy and neat routing. The loom is appropriately designed to reduce the total number of wires and their lengths.

Main Harness Layout
The harness has been segregated and color coded into 3 sub-harnesses for easy troubleshooting.
1st Sub-Harness – Main wiring logic which connects all sensors
2nd Sub-Harness – Powering all the electronic components to battery voltage
3rd Sub-Harness – Recharging circuit

Provisions were made to separate the front harness from the rear by use of connectors which were placed on the firewall. To make an automotive grade harness the wires have been twisted to make it less susceptible to electronic interferences. Heat Shrink, Tesa tape and automotive shroud is used to provide isolation from noise and fire.

Main Harness Layout
Harness Design Considerations and Manufacturing

For Faster Switching Speed and Low Power Dissipation the Mechanical Relays are replaced by Solid State Relays. For Waterproofing and better design PCB headers are included on the PCB. A separate PCB is made for Electro-Pneumatic Shifting Input through Arduino on the Dash Board. Rotary Potentiometer behind the steering wheel is used to control the Servo Clutch Motor. The main aim of this Servo Clutch and Electro-Pneumatic Shifting is to reduce driver’s effort and make it easier for driver to drive around the corners.

PCB Design and Final Product
Electro-Pneumatic and Servomotor Layout

b. Data Acquisition System

We incorporated a Data Acquisition System running on RaceCapture Pro MK3 unit equipped with telemetry for wireless data transmission during testing. Various sensors to measure parameters associated with vehicle dynamics are interfaced through Analog and PWM inputs on the module. The CAN Protocol is used in the rear to connect the engine sensors and other sensors to the data logger in the front and reduce the wire length. The module also features GPS in order to map the car's path and speed during testing. A lightweight Carbon Fiber Dash Board is used in front of the driver to contain the Data Logger and driver control and interface devices which include Cockpit Kill Switch, Radiator Fan Switch, Push Start Button, RPM and Gear Position Indicator.

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