Kistler 5612A Owner's manual

Instruction

Manual

5612A_002-861e-03.19

MSW DTI sensors

Measurement

steering wheels

Type 5612A...

Instruction

Manual

5612A_002-861e-03.19

MSW DTI sensors

Measurement

steering wheels

Type 5612A...

Page 15612A_002-861e-03.19

The information in this manual is subject to change without

notice. To keep pace with technical advancement, Kistler

reserves the right to make improvements and changes

to the product without obligation to notify any person or

organization of such changes.

by various intellectual property rights. For more details visit

www.kistler.com. The Kistler Group includes Kistler Hold-

ing AG and all its subsidiaries in Europe, Asia, the Ameri-

cas and Australia.

Kistler Group

Eulachstrasse 22

8408 Winterthur

Switzerland

Tel. +41 52 224 11 11

info@kistler.com

Kistler Instrumente GmbH

Automotive Research & Test Division

Charlotte-Bamberg-Str. 12

35578 Wetzlar

Germany

Phone +49 6441 9282 0

info.de@kistler.com

www.kistler.com

Foreword

MSW DTI sensors: Measurement steering wheels , Type 5612A...

5612A_002-861e-03.19Page 2

Inhaltsverzeichnis

1. Introduction .................................................................................................................................4

2. Important remarks ......................................................................................................................5

2.1 For your safety ....................................................................................................................5

2.2 Disposal information for electronic devices ........................................................................6

2.3 Software upgrades and updates .........................................................................................6

3. Product description ....................................................................................................................7

3.1 General ...............................................................................................................................7

3.2 Functional principle .............................................................................................................8

3.2.1 Steering torque acquisition ....................................................................................8

3.2.2 Steering angle acquisition .....................................................................................8

3.2.3 Steering speed ......................................................................................................8

3.3 Features .............................................................................................................................9

3.4 Application ..........................................................................................................................9

3.5 Accessories ........................................................................................................................9

3.5.1 Steering angle stop (optional) .............................................................................10

4. Technische Daten ......................................................................................................................11

4.1 Spezikationen .................................................................................................................11

4.2 Pin assignments ...............................................................................................................13

5. Set-up and connection .............................................................................................................15

5.1 Pre-installation safety instructions ....................................................................................15

5.2 Application notes: steering shaft and steering wheel adapters ........................................15

5.3 Sensor sketch ...................................................................................................................16

5.4 Mounting the sensor in the vehicle ...................................................................................17

5.4.1 Sensor with standard steering wheel and standard steering shaft adapter ........17

5.4.2 Sensor with special versions of the steering wheel or steering shaft adapters ...17

5.5 Connecting the sensor ......................................................................................................18

5.5.1 Forconguration .................................................................................................18

5.5.2 For measurement ................................................................................................18

5.6 Start-up .............................................................................................................................19

Page 35612A_002-861e-03.19

Total number of pages: 57

6. KiCenter Software ....................................................................................................................20

6.1 Toolbar ..............................................................................................................................20

6.1.1 Explanation of the buttons in the toolbar .............................................................21

6.2 Sensor settings MSW DTI ................................................................................................23

6.2.1 Sensor node ........................................................................................................24

6.2.2 Measurement display ..........................................................................................25

6.2.3 Sensorconguration ...........................................................................................26

6.2.4 Digital outputs......................................................................................................28

6.2.5 Analog outputs ....................................................................................................30

6.2.6 CAN Bus ..............................................................................................................31

6.3 Firmware Update .............................................................................................................34

7. Troubleshooting ........................................................................................................................36

7.1 Cables and power supply .................................................................................................36

7.2 Software ...........................................................................................................................36

7.3 CAN ..................................................................................................................................36

7.4 EMC interference ..............................................................................................................37

7.5 Service ..............................................................................................................................37

8. Appendix ....................................................................................................................................38

MSW DTI sensors: Measurement steering wheels , Type 5612A...

5612A_002-861e-03.19Page 4

1. Introduction

Thank you for choosing a Kistler quality product. Read

this instruction manual carefully so that you can make full

use of your product’s many features.

Where permitted by law, Kistler accepts no liability if this

instruction manual is disregarded or if products other than

those listed under accessories are used.

Kistler offers a wide range of measuring technology

products and complete solutions:

Piezoelectric sensors for the measurement of

pressure, force, torque, strain, acceleration, shock and

vibration

Strain gauge sensor systems for the measurement of

force and torque

Piezoresistive pressure sensors and transmitters with

thecorrespondingampliers

Correspondingampliers(chargeampliers,

piezoresistiveampliers,etc.),indicatorsandcharge

calibrators

Devices for electronic control, monitoring and evalu-

ationunitsaswellasapplication-specicsoftwarefor

measurement technology

Data transmission modules (telemetry)

Kistler also designs entire measurement systems for

specicpurposes,forexample,intheautomotiveindustry,

in plastics processing and in biomechanics.

Our complete catalog provides an overview of our product

range. Detailed data sheets are available for nearly all

products.

Ifyoustillhaveanyspecicquestionsafterstudyingthese

instructions, Kistler’s customer service is available to you

around the world and can also provide you with competent

adviceonapplication-specicproblems.

Important remarks

Page 55612A_002-861e-03.19

2. Important remarks

2.1 For your safety

Observe the following remarks before you commission

the device. Kistler accepts no responsibility for damages

that could arise from improper use of this product.

Prerequisite for the proper and safe use of the device

is that it be correctly stored, professionally installed and

commissioned, as well as operated as intended and

carefully maintained. Only persons who are familiar

with the installation, commissioning, operation and

maintenance of comparable devices and who possess the

qualicationsnecessaryforthegiventaskmayworkwith

the device.

Mounting a device on a vehicle invalidates the general

operating permit of the vehicle for use on public roads

(possibly also on testing grounds). Please observe the

relevant legal requirements!

Working with an airbag-equipped wheel requires utmost

caution due to high risk of injury. It is imperative to ob-

serve all instructions of the wheel manufacturer!

Do not use defective or damaged equipment.

Do not modify or change the equipment or its accessories

in any way.

Improper use or mounting of the equipment may affect

the safety of the vehicle and/or occupants. The equip-

ment may not be mounted and/or operated in any way

that could compromise the vehicle and/or the occupant’s

safety.

Overloading can cause damage that may not be visible.

Therefore, always observe that the overload limits of

torque and bending moment are not exceeded.

Be sure to install and secure the sensor and the cables in

a way that does not impair the vehicle‘s steering.

MSW DTI sensors: Measurement steering wheels , Type 5612A...

5612A_002-861e-03.19Page 6

When connecting to the power supply, data acquisition

and evaluation systems and other usable components,

pay attention to the proper pin assignment and correct

operating voltage.

Only use the original components included in the scope

of delivery.

Should it be necessary to use your own cables, always

pay attention to the correct pin assignment.

Kistler accepts no liability for damages caused by the use

of cables other than those supplied by Kistler.

For further information, please contact Kistler:

+49 6441 9282 0

info.de@kistler.com

2.2 Disposal information for electronic devices

Waste electronic equipment must not be disposed of with

household waste. At the end of its service life, return the

device to the nearest electronic disposal point or contact

your Kistler sales outlet.

2.3 Software upgrades and updates

If Kistler supplies upgrades or updates for embedded

software, they must be installed.

Kistler assumes no liability for direct or consequential

damages caused by products whose embedded software

is not up-to-date.

Product description

Page 75612A_002-861e-03.19

3. Product description

3.1 General

TheMSWDTIsensorisspecicallydesignedtobeused

with modern steering wheels of passenger cars and utility

vehicles and is applied for non-contact measurement of

steering moment, steering angle and steering speed.

The MSW DTI sensor offers high dynamics and excellent

resolution without impairing steering wheel functions (air-

bag) and control elements.

Normally, the sensor is installed between the steering

wheel and the steering shaft. To permit universal applica-

tion, the sensors may be equipped quickly and easily with

an inter changeable adapter to connect to the steering

shaft gearing.

The MSW DTI sensor is equipped with a switch-key to

reset the steering moment and angle. The offset is stored

and still available after voltage loss or restart. Via CAN

bus, outputs can be set to zero at any point. Calibration

data are stored in the sensor element, enabling the user

to exchange sensor elements, if required.

An optional steering angle stop improves the performance

of special driving maneuvers.

Fig. 1: MSW DTI measurement steering wheel,

mounted

MSW DTI sensors: Measurement steering wheels , Type 5612A...

5612A_002-861e-03.19Page 8

3.2 Functional principle

3.2.1 Steering torque acquisition

Torque values are acquired using a specially designed

measuring body equipped with strain gauges. Friction and

clearanceoftheintegratedballbearingsdonotinuence

the accuracy of the sensor. Torque applied to the steering

wheel is transferred directly through the measuring body

and into the steering shaft. Bearing friction may have a

minor inuence on the subjective judgment of the test

driver.

The torque signal is transmitted from the rotor to the stator

via a short-distance telemetry system, which operates on

the basis of frequency coding. Power supply of the DMS

application is inductively coupled via the telemetry anten-

nas (no internal battery required). A beep indicates when

the measuring range is exceeded.

The sensor is equipped with a push button to reset the

steering moment. It can also be reset via KiCenter soft-

ware or CAN Bus.

3.2.2 Steering angle acquisition

A non-contact optical measuring system acquires the

steering angle. To initialize the steering angle, a rotation

of max. 7.5° is required. It is output absolutely and can be

reset via a push button, KiCenter or CAN Bus. The angle

zero-point is stored and remains available even after a

voltage loss or a restart. The steering wheel must be posi-

tioned≤180°tothestoredzero-pointwhenrestarting.

The measurement steering wheel is capable of spinning

without restriction.

3.2.3 Steering speed

Steering speed must be calculated by differentiating the

angle signal. High steering speeds of up to 2 000 °/s are

possible.

Product description

Page 95612A_002-861e-03.19

3.3 Features

Non-contact, optical steering angle sensor

50 N·m version for passenger cars

250 N·m version for utility vehicles

Small size

High dynamics

Preservation of airbag function

Fast and easy installation

3.4 Application

Universal measurement steering wheel for measurement

of steering moment, steering angle and steering speed;

for vehicle driving dynamics tests like ISO 4138, steady-

state circular course drive

3.5 Accessories

Included accessories ordering no.

Connecting cables

CAN, l = 2 m 55155606

USB, l = 1,8 m 55155609

DTI, l = 0,5 m 55155607

ETH, l = 2 m 55155608

Power cable DTI sensors, l = 2 m 55155612

Distributor cables

KiMSW LEMO OUT Ana, l = 1m 55181949

KiMSW LEMO OUT Dig, l = 1m 55181959

USB stick software and manuals 55158846

Adapter VGA connector/socket 90° 55120394

Transport case complete, with inlays 55066887

Optional accessories ordering no.

Steering wheel adapter ø280 ... 420 mm 22001141

Steering wheel adapter ø400 ... 560 mm 22001142

1-point suction holder for mounting 18025571

at the windshield (car)

1-point suction holder for mounting 18029307

at the windshield (truck)

Kistler angle lock adaptation,basic set 18026445

Transport case 55120723

Custom adaptations on request

MSW DTI sensors: Measurement steering wheels , Type 5612A...

5612A_002-861e-03.19Page 10

3.5.1 Steering angle stop (optional)

Features of the steering angle stop:

Fixes the steering angle to a pin point

Enables steering movement between two different

steering angles

Easy handling

Use of existing steering shaft adapters is possible

Unrivaled mechanical setup (size and height)

Typical applications:

Sudden steering input

Sinus steering

Zero-point determination

Fig. 2: Steering angle stop for MSW DTI sensors

Technical data

Page 115612A_002-861e-03.19

4. Technical data

4.1 Specications

Performance specifications

Power supply V 10 ... 28

Power consumption at 12 V W <20

Adjustable filter time ms 2 ... 512 (or unfiltered)

Measurement frequency Hz 1 000

Temperature ranges

Nominal temperature range °C 0 ... 70

Operating temperature range °C –20 ... 80

Degree of protection

Sensor (cable mounted) IP40

Electronics (cable mounted) IP40

Mass moment of inertia kg·cm2 80

Weight (without steering wheel and

electronics)

Passenger car version 1) kg 2,7

Commercial vehicle version 1) kg 2,8

Steering moment

Measurement range

Passenger car N·m ±50

Commercial vehicle N·m ±250

Overload

Passenger car

torque

N·m ±100

bending moment N·m ±150

Commercial vehicle

torque

N·m ±500

bending moment N·m ±750

Accuracy %FSO ±0,15

Linearity deviation %FSO ±0,15

Temperature influence

On the zero signal %FSO/10K 0,5

On the index value %FSO/10K 0,5

Zero-point stability (above 24 h) %FSO 0,05

Steering angle

Measurement range (absolute principle) ° ≥±1250

Steering speed °/s ≤2000

Resolution ° 0,015

Accuracy ° ±0,1

MSW DTI sensors: Measurement steering wheels , Type 5612A...

5612A_002-861e-03.19Page 12

Steering wheel adaptation

Diameter of the hollow shaft ø mm 75

Max. height of the measuring body mm 33

Pitch circle for screw-on threads

(M4/16 pcs)

ø mm 90

Signal outputs 2)

Analog outputs

DA converter resolution Bit 16

Non-linearity LSB ±16

Steering moment M1 (±50/250 N·m) 3) V –10 ... 10

Steering moment M2 (±10/50 N·m) 3) V –10 ... 10

Steering angle L1 (±1 250 °) 3) V –10 ... 10

Steering angle L2 (±200 °) 3) V –10 ... 10

Steering speed (±1 000 °/s) 3) V –10 ... 10

Digital outputs

Steering moment TTL yes

Steering angle TTL yes

Steering speed TTL 0 ° pulses/rev 20 000

Steering speed TTL 90 ° pulses/rev 20 000

Interfaces

CAN (Motorola/Intel) 2.0B

USB (Full Speed) 2.0

Ethernet yes

DTI yes

1) Withstandardsteeringwheelange,withoutsteeringwheelandsteeringshaftadapter

2) All outputs are protected against overvoltage and short-circuit

3) Standard settings; can be individually adjusted via KiCenter

Technical data

Page 135612A_002-861e-03.19

4.2 Pin assignments

Fig. 3: MSW DTI electronics, connector view front plate

Power, 8-pin LEMO, connector

Pin Signal

1 Internal use

2 Internal use

3 Internal use

4 Internal use

5 Vin_EXT

6 Vin_EXT

7 GND_EXT

8 GND_EXT

CAN, 7-pin LEMO, socket

Pin Signal

1 CAN high

2 CAN low

3 DGND

4 DGND

5 nc

6 nc

7 nc

MSW DTI sensors: Measurement steering wheels , Type 5612A...

5612A_002-861e-03.19Page 14

USB/ETH, 7-pin Binder, socket

Pin Signal

1 TX+

2 TX–

3 RX+

4 RX–

5 USB D+

6 USB D–

7 DGND

OUT, 14-pin. HD-Sub, socket

Pin Signal

1 Ana_out 1

2 Ana_out 2

3 Ana_out 3

4 Ana_out 4

5 Ana_out 5

6 AGND

7 Dig_out 1

8 Dig_out 2

9 Dig_out 3

10 Dig_out 4

11 DGND

12 nc

13 nc

14 nc

A description of the pin assignments for sensor connector

and GPS connector is not necessary for the intended use

of the sensor.

Set-up and connection

Page 155612A_002-861e-03.19

5. Set-up and connection

5.1 Pre-installation safety instructions

Improper mounting of the sensor may affect the safety

of the vehicle.

The replacement of the steering wheel must be carried

out by trained technical staff who is familiar with the in-

stallation, commissioning and operation of comparable

equipmentandwhohasthenecessaryqualications

for this job.

Mounting the sensor on the vehicle may invalidates

the general operating permit for the vehicle.

Working with an airbag-equipped wheel requires utmost

caution due to high risk of injury. It is imperative to ob-

serve all instructions of the wheel manufacturer!

The overload limits for torque and bending moment

must always be observed. Overload can cause dam-

age.

If you apply a steering wheel adapter to use the

MSW DTI sensor with the original manufacturer’s

steering wheel, functions like horn, cruise control, etc.

installed in the steering wheel will be put out of opera-

tion by the adapter; the airbag must be deactivated in

this case.

5.2 Application notes: steering shaft and steering wheel adapters

If user applications require modication of the device or

operationinexcessofloadspecications,contactKistler

Instrumente GmbH for approval.

Mounting of the steering shaft adapter and steering wheel

must not generate or transfer mechanical stress or ten-

sion to the housing area of the Kistler MSW. Make sure

that you have the correct screw length, strength class and

tightening torque (see chapter 5.3).

MSW DTI sensors: Measurement steering wheels , Type 5612A...

5612A_002-861e-03.19Page 16

When returning a measurement steering wheel for

calibration to Kistler, it should be the original extent of

delivery to ensure that service will run smoothly.

Improper operation invalidates the warranty.

Improper,unauthorizedmodicationsirretrievablychange

the calibration!

5.3 Sensor sketch

Fig. 4: MSW DTI sensor element

Set-up and connection

Page 175612A_002-861e-03.19

5.4 Mounting the sensor in the vehicle

5.4.1 Sensor with standard steering wheel and standard steering shaft adapter

Essentially, mounting the measuring steering wheel corre-

sponds to mounting an original equipment steering wheel.

Remove the original steering wheel according to the

manufacturer’s instructions.

Afxthesteeringshaftgearingadaptertothe

MSW DTI sensor.

Remove the plastic horn cover from the standard

steering wheel.

If required, unscrew the horn contact from the stan-

dard steering wheel.

Place the MSW DTI sensor onto the steering shaft.

Screw on the steering shaft nut or bolt. Note: Observe

thevehiclemanufacturer’storquespecicationswhen

tightening the bolt.

Re-attach the horn contact.

Replace the plastic horn cover.

Locate a suitable moment stabilization device at one

ofthescrew-onpointsandafxittothesteeringcon-

sole. Hose clamps, cable clips, adhesive tape, etc.,

can be used for this purpose. Alternatively, the “1-point

suction holder for mounting at the windshield” (see

optional accessories) can be used.

Take the sensor cable to connect the MSW DTI sensor

element to the electronics. Connect signal and power

cable.

Apply supply voltage (10 ... 28 VDC).

5.4.2 Sensor with special versions of the steering wheel or steering shaft

adapters

Customers who order adaptations of a serial steering

wheel (also airbag steering wheel) including the steering

shaftadapterwillreceivespecicmountinginstructions.

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