data acquisition project report

Black Group Data Acquisition Project 1

Prepared for Christopher Finch

Prepared by Preston Bremer, Brett Gutwein, Joseph Legan, Logan Sprung

October 14, 2016

The purpose of this project is to create a mock wiring harness and data acquisition system for the IUPUI Motorsports Engineering MGB GT solo car. The car will be competing in the Sports Car Club of America D Prepared class. The project demanded investigation and selection of data loggers, sensors, wire, heat shrink, connectors, boots and all other components of a proper motorsports harness. Contained within this report are the details of each of the above sections and includes an economic breakdown and justification.

Introduction

The purpose of this report is to document the work completed by the Black group for Project #001 during the MSTE 330 Data Acquisition Motorsports 1 class. The purpose of the project is to assist the MG group with developing a data system for the MGB. The data system is to contain a Motec logger, wiring harness, sensors, heat shrink, protective boots, connectors, all pertinent extras and an economic breakdown. This will assist the MG group in selecting the best data system for their needs.

Data System Selection

Given that the MGB uses an engine that is carbureted and uses an electronic distributor it is not necessary to purchase an ECU. Instead the Motec ADL3 dash logger was chosen along with a VIM expander. Between these two units the selected data system has room for all the selected sensors and allows for room to expand in the future. The ADL3 is a fully configurable display that can do calculations, activate alarms and control external devices. Please note, during the time elapsed while working on the project, Motec removed the ADL3 from their website. However the data sheet is still available in their download section and the unit is readily available from online vendors. The same holds true for the VIM expander unit. Complete specs for the ADL3 and the VIM expander can be found on their respective data sheets in the Appendix. The ADL3 was chosen because it has internal 3 axis accelerometers that eliminates the need for a separate accelerometer unit. The ADL3 also serves as a replacement for all the gauges currently in the car. As such it will be mounted in the same location as the current gauge cluster. The ADL3 comes with 16MB of internal storage but can upgraded to 250MB if needed. Lastly it will log at rates up to 1000 Hz. The ADL3 will serve as display for the data system and will log the chassis data directly.

The Motec VIM expander was chosen to expand the capability of the dash logger to include all the chosen sensors while leaving room for future additions. The ADL3 dash communicates with the VIM via CAN wires and respective busses on the units themselves. Due to the configuration of the connectors on the ADL3 and the VIM, the engine data channels will be logged by the VIM. The Vim expander will be mounted to a fabricated tray that is suspended from the passenger side dash hoop of the role cage. This location will protect it from the heat of the firewall and allow for superior access to the engine harness.

The ADL3 and the VIM expander were also chosen with a consideration on cost. While Motec offers more advanced dash loggers, expanders and other components, these were considered more advanced than the MGB and therefore overkill for the project. Being that the car has limited adjustability, there are a number of possible channels that were deemed un-necessary by either lack of adjustability or the nature of the solo event.

Figure 1 ADL3

Figure 2 VIM Expander

Wiring Harness

The wiring harness began with once the list of sensors was finalized. The complete list of sensors is listed in the next section of this report. Once the sensors were finalized a path from each sensor installation point was established. These paths were then grouped together for packaging purposes with a consideration for protecting the harness along its length and methods of support. The general layout of the harness can be seen in the following picture.

The harness was then broken up into individual sections of the physical car. These sections are as follows:

Left Front Outboard Right Front Outboard Engine and Gearbox Cockpit and Dash Rear External

Each of these sections will now be detailed for loom length, pinout schedule, required heat shrink, required heat shrink transitions, required connectors and heat shrink boots. Please note that all wire lengths were rounded up to the nearest inch to provide material for service loops and stress relief of the harness. The wire chosen to construct the harness is 22 Gauge 55A011 spec

wire for all but the CAN specific wiring. The CAN specific is to be constructed from 31361705-54 wire. Also the Ethernet download port is connector is to be constructed from M27500 wire.

LF Outboard

The LF outboard harness consists of 3 sensors with a total of 7 wires that will return to the logger. This is accomplished with the use of power and ground splices within the harness. Each splice is documented in the complete pinout in the Appendix. The use of splices is carried throughout the entirety of the harness. It should be noted that both the LF and RF Outboard spring force sensors have a separate pinout as they come with a connector on the sensor body.

LF Outboard Sensors

For all wheel speeds the Texys DHE Wheel Speed Sensor was selected. On the front corners these sensors will be mounted on a bracket similar to the one in Figure 3. The bracket will then be mounted opposite the caliper onto the actual upright.

Figure 3

The tone wheel will be fastened onto the back side of the wheel hub by means of stand-off brackets creating something similar to Figure 4

Figure 4

For damper travel on all four dampers the Motec Linear Potentiometers 150mm were chosen due to the extended range capability and price. These will be mounted parallel to the centerline of each damper. Specifically the front will mount to a fabricated mount located on top of the upper control arm mount and concentrically to the upper damper bolt. On the bottom they will be mounted again by means of a fabricated bracket directly to the bolt that locates the lower end of the damper. This is illustrated in Figure 5.

Figure 5

Spring force sensors will be mounted directly to the damper unit themselves under the torsion relief bearing on the lower adjuster. This is illustrated in Figure 6.

Figure 6

LF Outboard Pinout

C7 LF

Connector Name LF Out Board Label LF OUTBOARD

Connector AS610-35PA Keyway Color Shell Size 10

Boot 202K132-25-0 Notes:

All LF Sensors

S'#' denotes a spliced wire

Pin Name Function MOD Gauge Wire Spec Wire Color Dest 1 Dest 2

7-1 Supply Voltage 4V - 25V LF Wheel Speed 22 55A0111 Red 4-1

7-2 Ground LF Wheel Speed 22 55A0111 Black 4-S1

7-3 Digital Signal LF Wheel Speed 22 55A0111 White 4-3

7-4 Supply Voltage 5V LF Damper Travel 22 55A0111 Red 4-4

7-5 Ground LF Damper Travel 22 55A0111 Black 4-S1

7-6 Analog Signal LF Damper Travel 22 55A0111 Yellow 4-6

7-7 Ground LF Spring Force 22 55A0111 Black 4-S1

7-8 Ground LF Spring Force 22 55A0111 Black 4-S1

7-9 Supply Voltage 8-36V LF Spring Force 22 55A0111 Red 4-9

7-10 Signal LF Spring Force 22 55A0111 Blue 4-10

7-11

7-12

7-13

LF Spring Force Pinout

C6 LF SF

Connector Name LF Spring Force Label LF SF

Connector ASL606-05SN Keyway Color Shell Size 06

Boot 204W221-25-0 Notes:

LF Spring Force to LF Outboard



6-1 Ground LF Spring Force 23 55A0111 Black 7-7

6-2 Ground LF Spring Force 23 55A0111 Black 7-8

6-3

6-4 Supply Voltage 8-36V LF Spring Force 23 55A0111 Red 7-9


RF Outboard

The RF Outboard harness has 4 sensors with a total of 8 pins. The same three sensors are carried over from the LF and a Front ARB Drop Link force sensor is added.

RF Outboard Sensors

The same mounting techniques will be used for the RF as the LF. The ARB Drop Link sensor chosen is the Beru F1 Systems Push Rod Load Cell. The cost of this particular sensor will need to be obtained from a direct quote. It will be mounted to the upper end of the drop link as illustrated in Figure 7.

Figure 7

RF Outboard Pinout

C8 RF

Connector Name RF Out Board Label RF OUTBOARD

Connector AS610-35PA Keyway Color Shell Size 10


All RF Sensors



8-1 Supply Voltage 4V - 25V RF Wheel Speed 22 55A0111 Red 4-39

8-2 Ground RF Wheel Speed 22 55A0111 Black 4-S2

8-3 Digital Signal RF Wheel Speed 22 55A0111 White 4-41

8-4 Supply Voltage 5V RF Damper Travel 22 55A0111 Red 4-42

8-5 Ground RF Damper Travel 22 55A0111 Black 4-S2

8-6 Analog Signal RF Damper Travel 22 55A0111 Yellow 4-44

8-7 Ground RF Spring Force 22 55A0111 Black 4-S2

8-8 Ground RF Spring Force 22 55A0111 Black 4-S2

8-9 Supply Voltage 8-36V RF Spring Force 22 55A0111 Red 4-47

8-10 Signal RF Spring Force 22 55A0111 Blue 4-48

8-11 Ground RF ARB Drop Link Force 22 55A0111 Black 4-S2

8-12 Signal RF ARB Drop Link Force 22 55A0111 White 4-50

8-13

RF Spring Force Pinout

C9 RF SF

Connector Name RF Spring Force Label RF SF

Connector ASL606-05SN-HE Keyway Color Shell Size 06


RF Spring Force to RF Outboard



9-1 Ground RF Spring Force 23 55A0111 Black 8-7

9-2 Ground RF Spring Force 23 55A0111 Black 8-8

9-3

9-4 Supply Voltage 8-36V RF Spring Force 23 55A0111 Red 8-9


Engine

The engine harness serves two purposes. It links the LF and RF Outboard harnesses with the data loggers and routes the engine and gearbox sensors to the loggers as well. The harness has a total of 10 sensors for 13 pins then another 17 pins come from the LF and RF Outboards. All this goes back to a bulkhead connector installed on the passenger side of the firewall, just inboard of where the current oil vapor tank is currently located. This allows the pressure transducers for oil, fuel, and front and rear brake to be mounted on the shelf just below the oil vapor tank and then plumbed into their respective systems. Please note that included in the engine harness is the pitot tube wiring that will be mounted in the passenger front fender.

Engine Sensors

The engine sensors chosen are the following:

Sensor SpecificsOil Pressure RaceGrade M APT-G2-DTM-100A

Fuel Pressure Motec M KP41 100G

Oil Temp RaceGrade M 25-2197 D

Water Pressure Motec M KP41 100G

Water Temp Hot Racegrad M 25-2197D

Water Temp Cold Racegrade M 25-2197D

Gearbox Temp

Racegrade M 25-2197D

Pitot Tube Texys 4mm Pitot Sensor - ProRG PI-4-Range

The oil pressure and fuel pressure will be mounted using plastic cradles along with the front and rear brake pressures on the shelf under the oil vapor catch can. Then they will be plumbed via a braided hose to their respective systems. The water pressure will be mounted into a bung that is welded onto the upper radiator outlet. Oil temp will be mounted in the braided line that connects the rear block oil galley exit to the oil filter adaptor. Hot water temp can reuse the current 1/8” NPT port in the water outlet. For cold water temp a bung will need to be welded onto the

aluminum tube that connects with the lower radiator outlet. Lastly, gearbox temp will require modification to the lower sump portion of gearbox housing for a 1/8” NPT port.

Engine Pinout

C4 ENGINE

Connector Name Engine Bulkhead Connector Label ENG BULKHD

Connector AS024-61SN Keyway Color Shell Size 24


Sensors and LF, RF outboards to Front Bulk head



4-1 Supply Voltage 4V - 25V LF Wheel Speed 22 55A0111 Red 3-43 3-34

4-2 Ground Splice GND 22 55A0111 Black 3-S1

4-3 Digital Signal LF Wheel Speed 22 55A0111 White 3-41

4-4 Supply Voltage 5V LF Damper Travel 22 55A0111 Red 3-18

4-5

4-6 Analog Signal LF Damper Travel 22 55A0111 Yellow 3-2

4-7

4-8

4-9 Supply Voltage 8-36V LF Spring Force 22 55A0111 Red 3-S2


4-11 Supply Voltage 5V Front Brake Pressure 22 55A0111 Red 3-S3

4-12 Ground Front Brake Pressure 22 55A0111 Black 3-S1

4-13 Analog Signal Front Brake Pressure 22 55A0111 White 3-49

4-14 Supply Voltage 5V Rear Brake Pressure 22 55A0111 Red 3-S3

4-15 Ground Rear Brake Pressure 22 55A0111 Black 3-S1

4-16 Analog Signal Rear Brake Pressure 22 55A0111 White 3-50

4-17 Ground Gearbox Temp 22 55A0111 Black 3-S4

4-18 Analog Signal Gearbox Temp 22 55A0111 White 3-3

4-19 Supply Voltage 5-16V Pitot Tube 22 55A0111 Red 3-S5

4-20 Signal Pitot Tube 22 55A0111 Blue 3-14

4-21 Ground Pitot Tube 22 55A0111 Black 3-S4

4-22 Braid connected to Case Pitot Tube 22 55A0111 Brown N/A

4-23 Supply Voltage 5V Oil Pressure 22 55A0111 Red 3-S5

4-24 Ground Oil Pressure 22 55A0111 Black 3-S4

4-25 Analog Signal Oil Pressure 22 55A0111 White 3-6

4-26 Supply Voltage 5V Fuel Pressure 22 55A0111 Red 3-S6

4-27 Ground Fuel Pressure 22 55A0111 Black 3-S7

4-28 Analog Signal Fuel Pressure 22 55A0111 White 3-7

4-30 Ground Oil Temp 22 55A0111 Black 3-S7

4-31 Analog Signal Oil Temp 22 55A0111 White 3-48

4-32 Supply Voltage 5V Water Pressure 22 55A0111 Red 3-S6

4-33 Ground Water Pressure 22 55A0111 Black 3-S7

4-34 Analog Signal Water Pressure 22 55A0111 White 3-47

4-35 Ground Water Temp Hot 22 55A0111 Black 3-S8

4-36 Analog Signal Water Temp Hot 22 55A0111 White 3-8

4-37 Ground Water Temp Cold 22 55A0111 Black 3-S8

4-38 Analog Signal Water Temp Cold 22 55A0111 White 3-9

4-39 Supply Voltage 4V - 25V RF Wheel Speed 22 55A0111 Red 3-44 3-33

4-40 Ground Spliced GND 22 55A0111 Black 3-S8

4-41 Digital Signal RF Wheel Speed 22 55A0111 White 3-42

4-42 Supply Voltage 5V RF Damper Travel 22 55A0111 Red 3-S6

4-43

4-44 Analog Signal RF Damper Travel 22 55A0111 Yellow 3-13

4-45

4-46

4-47 Supply Voltage 8-36V RF Spring Force 22 55A0111 Red 3-S2


4-49

4-50 Signal RF ARB Drop Link Force 22 55A0111 White 3-51

4-51

4-52

4-53

4-54

4-55

4-56

4-57

4-58

4-59

4-60

4-61

4-S1 0V LF Wheel Speed 22 55A0111 Black 7-2

4-S1 0V LF Damper Travel 22 55A0111 Black 7-5

4-S1 0V LF Spring Force 22 55A0111 Black 7-7

4-S1 0V LF Spring Force 22 55A0111 Black 7-8

4-S2 0V RF Wheel Speed 22 55A0111 Black 8-2

4-S2 0V RF Damper Travel 22 55A0111 Black 8-5

4-S2 0V RF Spring Force 22 55A0111 Black 8-7

4-S2 0V RF Spring Force 22 55A0111 Black 8-8

4-S2 0V RF ARB Drop Link Force 22 55A0111 Black 8-11

Cockpit

The cockpit is the most complex portion of the data system and wiring harness. Within the cockpit all the outlying harnesses have their terminus within a connector on either the ADL3 or the VIM. Also within the cockpit there are multiple static sensors that need to logged as well. These include the video system, GPS antenna, yaw gyro, driveshaft torque receiver, three ride heights, beacon receiver, engine rpm, throttle and brake travel, steering angle, steering torque and lambda. All this along with the required communication harness between the ADL3 and the VIM, Ethernet download port and the lambda to CAN adaptor make for a very complex system. It is assumed that a Power Distribution Module (PDM) will be used so a flying lead is being left on the harness in the middle of the passenger floorboard area. Included below are pinouts for the ADL3, VIM, cockpit and the Lambda to CAN (LTC).

Cockpit Sensors

The following sensors were chosen for the cockpit.

Sensor SpecificsGPS Motec M GPS-L10

Beacon Receiver Motec BR2-Reciever

Yaw Gyro Texys 1 axis gyroscope GYRP

Drive Shaft Torque Dsts-511 DSTS Dynamic wireless drive shaft torque measurement

Laser RH KA Sensors RHL3 Series RHL3-A08-ASL-S-N-A40

Throttle Travel Motec M ADL SPOT 4.7

Brake Travel Motec M ADL SPOT 4.7

Steer Angle Motec Steering angle sensor, 10 turns #59103

Steer Torque KA sensors SGT series strain gauge SGT-412

Video Reuse current systemLambda Reuse current Bosch LSU-4.9 Sensor

The GPS antenna and the driveshaft torque receiver will be hard mounted on a plate. The plate will then be fastened to the top of the tunnel with Lord Mounts to dampen vibration. The driveshaft torque transmitter will be mounted on the actual driveshaft. The yaw gyro will also be mounted on the top of the tunnel but it will be hard mounted. There will be three laser ride heights used in the car. They will be located in the left front, right front and right rear corners of the car. All three ride height sensors will be mounted on underside of the car with brackets similar to Figure 8. The beacon receiver will be mounted on the passenger door skin by means of a custom fabricated tray. There will be a hole through the door skin for the receiver as well. It should be noted that two beacon transmitters will be required. The throttle travel and brake travel sensors will require a bracket to be fabricated on the firewall to anchor the sensors. Then the cable end can be affixed to the pedals with a welded on bolt. The steer angle pot can be mounted directly to the steering column brace. The steer torque strain gauge can be mounted directly onto

the steering column shaft. The video system will be reused including the roll cage mount. The lambda sensor can be reused but will require a new bung to be welded on downstream of the collector.

Figure 8

Cockpit Pinouts

COCKPIT Connector Name Cockpit Label COCKPIT

C5Connector AS024-61SN Keyway

Color Shell Size 24


From the ADL3 to all cockpit sensors, rear outboard, and lambda


Pin Name Function MOD Gauge Wire Spec Wire Color Dest 1 Dest 25-1 Supply Voltage 4V - 25V Rear Wheel Speed 22 55A0111 Red 1-S1

5-2 Ground Splice GND 22 55A0111 Black 1-6

5-3 Digital Signal Rear Wheel Speed 22 55A0111 White 1-63

5-4 Supply Voltage 5V RR Damper Travel 22 55A0111 Red 1-S1

5-5

5-6 Analog Signal RR Damper Travel 22 55A0111 Yellow 1-2

5-7 Supply Voltage 5V LR Damper Travel 22 55A0111 Red 1-S1

5-8

5-9 Analog Signal LR Damper Travel 22 55A0111 Yellow 1-3

5-10

5-11 Signal RR ARB Drop Link Force 22 55A0111 White 1-1

5-12

5-13 Analog Signal Dif Temp 22 55A0111 Orange 1-34

5-14 Supply Voltage 11-30 LF Ride Height 22 55A0111 Red S-TO PDM

5-15 Ground LF Ride Height 22 55A0111 Black 1-S2

5-16 Digital Signal LF Ride Height 22 55A0111 White 1-52

5-17 Supply Voltage 11-30 RF Ride Height 22 55A0111 Red S-TO PDM

5-18 Ground RF Ride Height 22 55A0111 Black 1-S2

5-19 Digital Signal RF Ride Height 22 55A0111 White 1-53

5-20 Supply Voltage 11-30 RR Ride Height 22 55A0111 Red S-TO PDM

5-21 Ground RR Ride Height 22 55A0111 Black 1-S2

5-22 Digital Signal RR Ride Height 22 55A0111 White 1-54

5-23 Ground Throttle Travel 22 55A0111 Brown 1-S3

5-24 Signal Throttle Travel 22 55A0111 Green 1-20

5-25 Supply Voltage 5V Throttle Travel 22 55A0111 Red 1-S4

5-26 Ground Brake Travel 22 55A0111 Brown 1-S3

5-27 Signal Brake Travel 22 55A0111 Green 1-21

5-28 Supply Voltage 5V Brake Travel 22 55A0111 Red 1-S4

5-29 Supply Voltage 8-36V Steer Torque 22 55A0111 Red 1-S5

5-30 Ground Steer Torque 22 55A0111 Black 1-S6

5-31 Signal Steer Torque 22 55A0111 White 1-22

5-32 Ground Steer Torque 22 55A0111 Blue 1-S6

5-33 Supply Voltage 5V Steer Angle 22 55A0111 Red 1-S4

5-34 Signal Steer Angle 22 55A0111 Purple 1-23

5-35 Ground Steer Angle 22 55A0111 Black 1-40

5-36 Digital Signal RPM / MSD 22 55A0111 White 1-55

5-37 Supply Voltage 8V Beacon Receiver 22 55A0111 Red 1-S5

5-38 Ground Beacon Receiver 22 55A0111 Black 1-43

5-39 CAN Hi Beacon Receiver 22 31361705-54 Blue 1-S7

5-40 CAN Lo Beacon Receiver 22 31361705-54 Green 1-S8

5-41 BAT - GPS 22 55A0111 Black 1-S9

5-42 RS32 Tx GPS 22 M27500 Green 1-S10

5-43 Supply Voltage 5V GPS 22 55A0111 Red 1-S11

5-44 Supply Voltage 5V Gyro 22 55A0111 Red 1-S11

5-45 Ground Gyro 22 55A0111 Black 1-6

5-46 Signal Gyro 22 55A0111 White 1-5

5-47 Supply Voltage 5V Drive Shaft Torque 22 55A0111 Red 1-S11

5-48 Ground Drive Shaft Torque 22 55A0111 Black 1-56

5-49 Signal Drive Shaft Torque 22 55A0111 White 1-69

5-50 Rx Drive Shaft Torque 22 M27500 Orange 1-70

5-51 Tx Drive Shaft Torque 22 M27500 Yellow 1-S10

5-52 Signal Video 22 55A0111 White 1-4

5-53 Ground Video 22 55A0111 Black 1-61

5-54 BAT - LTC to CAN 22 55A0111 Black 1-S9

5-55 CAN Lo LTC to CAN 22 31361705-54 Green 1-S8

5-56 CAN Hi LTC to CAN 22 31361705-54 Blue 1-S7

5-57 BAT + LTC to CAN 22 55A0111 Red 1-72

5-58

5-59

5-60

5-61

5-S1 0V Rear Wheel Speed 22 55A0111 Black 10-2

5-S1 0V RR Damper Travel 22 55A0111 Black 10-5

5-S1 0V LR Damper Travel 22 55A0111 Black 10-8

5-S1 0V RR ARB Drop Link Force 22 55A0111 Black 10-10

5-S1 0V Dif Temp 22 55A0111 Black 10-12

ADL3 Pinout

C1 ADL3

Connector Name ADL3 Dash Logger Label ADL3

Connector MS AS620-35SN Keyway Color Shell Size 20

Boot 202K153-25-0 Notes: Main connector into ADL3 S'#' denotes a spliced wire

Pin Name Function MOD Gauge Wire Spec Wire Color Dest 1 Dest 21-1 AV input 15 RR ARB Drop Link Force 22 55A0111 White 5-11 1-2 AV input 16 RR Damper Travel 22 55A0111 Yellow 5-6 1-3 AV input 17 LR Damper Travel 22 55A0111 Yellow 5-9 1-4 AV input 18 Video 22 55A0111 White 5-52 1-5 AV input 19 Gyro 22 55A0111 White 5-46 1-6 Sensor 0V Spliced GND 22 55A0111 Black 5-2 1-7 BAT - Battery Negative -, Spliced 0V 22 55A0111 Black 1-S9 TO PDM1-8 BAT + Battery Positive + 22 55A0111 Red TO PDM 1-9 Aux output 1

1-10 Aux output 2 1-11 Aux output 3 1-12 Aux output 4 1-13 Aux output 5 1-14 Aux output 6 1-15 Aux output 7 1-16 Aux output 8 1-17 Sensor 0V Spliced 0V 22 55A0111 Black 1-S2 1-18 Sensor 5V Spliced V+ 22 55A0111 Red 1-S1 1-19 AV input 7 1-20 AV input 8 Throttle Travel 22 55A0111 Green 5-24 1-21 AV input 9 Brake Travel 22 55A0111 Green 5-27 1-22 AV input 10 Steer Torque 22 55A0111 White 5-31 1-23 AV input 11 Steer Angle 22 55A0111 Purple 5-34 1-24 AV input 12 1-25 AV input 13 1-26 AV input 14 1-27 Sensor 0V Spliced 0V 22 55A0111 Black 1-S3 1-28 Sensor 5V Spliced V+ 22 55A0111 Red 1-S4 1-29 AV input 21 1-30 AV input 22 1-31 AV input 23 1-32 AV input 24 1-33 Sensor 0V Spliced 0V 22 55A0111 Black 1-S6 1-34 Analog Temp 1 Dif Temp 22 55A0111 Orange 5-13 1-35 Analog Temp 2 1-36 Analog Temp 3 1-37 Analog Temp 4 1-38 Analog Temp 5 1-39 Analog Temp 6 1-40 Sensor 0V Steer Angle 22 55A0111 Black 5-30 1-41 Analog Temp 7 1-42 Analog Temp 8 1-43 Sensor 0V Beacon Receiver 22 55A0111 Black 5-38 1-44 Sensor 5V Spliced V+ 22 55A0111 Red 1-S11 1-45 AV input 1 1-46 AV input 2 1-47 AV input 3 1-48 AV input 4 1-49 AV input 5 1-50 AV input 6 1-51 Sensor 0V Gyro 22 55A0111 Black 5-45 1-52 Digital 1 LF Ride Height 22 55A0111 White 5-16 1-53 Digital 2 RF Ride Height 22 55A0111 White 5-19

1-54 Digital 3 RR Ride Height 22 55A0111 White 5-22 1-55 Digital 4 RPM / MSD 22 55A0111 White 5-36 1-56 Sensor 0V Drive Shaft Torque 22 55A0111 Black 5-48 1-57 Switch Input 1 1-58 Switch Input 2 1-59 Switch Input 3 1-60 Switch Input 4 1-61 Sensor 0V Video 22 55A0111 Black 5-53 1-62 Sensor 8V Spliced V+ 22 55A0111 Red 1-S5 1-63 Speed 1 Rear Wheel Speed 22 55A0111 White 5-3 1-64 Speed 2 1-65 Speed 3 1-66 Speed 4 1-67 Ethernet TX + ETHERNET Connector 22 M27500 Orange TO DL CABLE 1-68 Ethernet TX - ETHERNET Connector 22 M27500 Yellow TO DL CABLE 1-69 AV input 20 Drive Shaft Torque 22 55A0111 White 5-49 1-70 RS32 Tx Drive Shaft Torque Rx 22 M27500 Orange 5-50 1-71 CAN 0V Vim 0V 22 55A0111 Black 2-1 1-72 CAN 8V Vim 8V, Lambda LTC 22 55A0111 Red 2-3 5-57

1-73 CAN LO vim-can lo 22 31361705-54 Green 2-4

1-74 CAN HI vim-can high 22 31361705-54 Blue 2-5

1-75 CAN 2 Lo Beacon Receiver, Lambda LTC 22 31361705-54 Green 1-S8

1-76 CAN 2 Hi Beacon Receiver, Lambda LTC 22 31361705-54 Blue 1-S7

1-77 Ethernet RX + ETHERNET Connector 22 M27500 Purple TO DL CABLE 1-78 Ethernet RX - ETHERNET Connector 22 M27500 Brown TO DL CABLE

1-79RS32 Rx Spliced Tx

22 M27500 Green 1-S10

1-S1 V+ Supply Voltage 4V - 25V 22 55A0111 Red 5-1 1-S1 V+ Supply Voltage 5V 22 55A0111 Red 5-4 1-S1 V+ Supply Voltage 5V 22 55A0111 Red 5-7 1-S2 0V LF Ride Height 22 55A0111 Black 5-15 1-S2 0V RF Ride Height 22 55A0111 Black 5-18 1-S2 0V RR Ride Height 22 55A0111 Black 5-21 1-S3 0V Throttle Travel 22 55A0111 Brown 5-23 1-S3 0V Brake Travel 22 55A0111 Brown 5-26 1-S4 V+ Throttle Travel 22 55A0111 Red 5-25 1-S4 V+ Brake Travel 22 55A0111 Red 5-28 1-S4 V+ Steer Angle 22 55A0111 Red 5-33 1-S5 V+ Steer Torque 22 55A0111 Red 5-29 1-S5 V+ Beacon Receiver 22 55A0111 Red 5-37 1-S6 0V Steer Torque 22 55A0111 Black 5-30 1-S6 0V Steer Torque 22 55A0111 Black 5-32

1-S7 CAN HI Beacon Receiver 22 31361705-54 Blue 5-39

1-S7 CAN HI LTC to CAN 22 31361705-54 Blue 5-56

1-S8 CAN LO Beacon Receiver 22 31361705-54 Green 5-40

1-S8 CAN LO LTC to CAN 22 31361705-54 Green 5-55

1-S9 0V GPS 22 55A0111 Black 5-41 1-S9 0V LTC to CAN 22 55A0111 Black 5-54

1-S10 Tx GPS 22 M27500 Green 5-42 1-S10 Tx Drive Shaft Torque 22 M27500 Green 5-51 1-S11 V+ GPS 22 55A0111 Red 5-43 1-S11 V+ Gyro 22 55A0111 Red 5-44 1-S11 V+ Drive Shaft Torque 22 55A0111 Red 5-47

VIM Expander Pinout

C2 VIM-A

Connector Name VIM Expander Small Label VIM-A


Boot 202A111-25-0 Notes:

ADL3 to small VIM port



2-1 CAN 0V Vim 0V 22 55A0111 Black 1-71

2-2

2-3 CAN 8V Vim 8V 22 55A0111 Red 1-72

2-4 CAN LO vim-can lo

22 31361705-54 Green 1-73

2-5 CAN HI vim-can high 22 31361705-54 Blue 1-74

C3 VIM-B

Connector Name VIM Expander Big Label VIM-B

Connector AS616-35SN Keyway Color Shell Size 16


VIM big port to engine bulkhead



3-1 Sensor 0V 1 Spliced GND 22 55A0111 Black 3-S1

3-2 AV hi res 1 LF Damper Travel 22 55A0111 Yellow 4-6

3-3 AV hi res 2 Gearbox Temp 22 55A0111 White 4-18

3-4 Sensor 0V 4


3-6 AV hi res 3 Oil Pressure 22 55A0111 White 4-25

3-7 AV hi res 4 Fuel Pressure 22 55A0111 White 4-28

3-8 AV hi res 5 Water Temp Hot 22 55A0111 White 4-36

3-9 AV hi res 6 Water Temp Cold 22 55A0111 White 4-38

3-10 Sensor 0V 4

3-11 pull up R1

3-12 pull up R2

3-13 AV hi res 7 RF Damper Travel 22 55A0111 Yellow 4-44

3-14 AV hi res 8 Pitot Tube 22 55A0111 Blue 4-20

3-15 AV diff +

3-16 AV diff -

3-17 Sensor 0V 3

3-18 Sensor 5V LF Damper Travel 22 55A0111 Red 4-4

3-19 AV hi res 9 LF Spring Force 22 55A0111 Blue 4-10

3-20 AV hi res 10 RF Spring Force 22 55A0111 Blue 4-48

3-21 AV diff hi res 8 +

3-22 AV diff hi res 8 -




3-26 Sensor 5V Spliced V+ 22 55A0111 Red 3-S3






3-32 Sensor 0V 2

3-33 pull up R3 RF Wheel Speed 22 55A0111 Red 4-39

3-34 pull up R4 LF Wheel Speed 22 55A0111 Red 4-1







3-41 Speed 1 LF Wheel Speed 22 55A0111 White 4-3

3-42 Speed 2 RF Wheel Speed 22 55A0111 White 4-41

3-43 Sensor 5V LF Wheel Speed 22 55A0111 Red 4-1

3-44 Sensor 5V RF Wheel Speed 22 55A0111 Red 4-39



3-47 AV fast 1 Water Pressure 22 55A0111 White 4-34

3-48 AV fast 2 Oil Temp 22 55A0111 White 4-31

3-49 AV fast 3 Front Brake Pressure 22 55A0111 White 4-13

3-50 AV fast 4 Rear Brake Pressure 22 55A0111 White 4-16

3-51 AV fast 5 RF ARB Drop Link Force 22 55A0111 White 4-50

3-52 AV fast 6


3-54

3-55

3-S1 0V Splice GND 22 55A0111 Black 4-2

3-S1 0V Front Brake Pressure 22 55A0111 Black 4-12

3-S1 0V Rear Brake Pressure 22 55A0111 Black 4-15

3-S2 +V LF Spring Force 22 55A0111 Red 4-9

3-S2 +V RF Spring Force 22 55A0111 Red 4-47

3-S3 +V Front Brake Pressure 22 55A0111 Red 4-11

3-S3 +V Rear Brake Pressure 22 55A0111 Red 4-14

3-S4 0V Gearbox Temp 22 55A0111 Black 4-17

3-S4 0V Pitot Tube 22 55A0111 Black 4-21

3-S4 0V Oil Pressure 22 55A0111 Black 4-24

3-S5 +V Pitot Tube 22 55A0111 Red 4-19

3-S5 +V Oil Pressure 22 55A0111 Red 4-23

3-S6 +V Fuel Pressure 22 55A0111 Red 4-26

3-S6 +V Water Pressure 22 55A0111 Red 4-32

3-S6 +V RF Damper Travel 22 55A0111 Red 4-42

3-S7 0V Fuel Pressure 22 55A0111 Black 4-27

3-S7 0V Oil Temp 22 55A0111 Black 4-30

3-S7 0V Water Pressure 22 55A0111 Black 4-33

3-S8 0V Water Temp Hot 22 55A0111 Black 4-35

3-S8 0V Water Temp Cold 22 55A0111 Black 4-37

3-S8 0V Spliced GND 22 55A0111 Black 4-40

Lambda to CAN (LTC)

C11

LAMBDA IN

Connector Name Lambda to CAN (A) Label LAMBDA A

Connector N/A Keyway Color N/A Shell Size N/A

Boot N/A Notes:

Lambda sensor into the LTC



11-1 Pump current IP Lambda to LTC 22 55A0111 Purple TO LTC

11-2 Ground Lambda to LTC 22 55A0111 Black TO LTC

11-3 Heater voltage - Lambda to LTC 22 55A0111 Brown TO LTC

11-4 Heater voltage + Lambda to LTC 22 55A0111 Orange TO LTC

11-5 Trim resistor IR Lambda to LTC 22 55A0111 Purple TO LTC

11-6 Supply Voltage Lambda to LTC 22 55A0111 Red TO LTC

C12

LAMBDA OUT

Connector Name Lambda to CAN (B) Label LAMBDA B

Connector DTM 4pin (M) (#68055

Keyway Color N/A Shell Size N/A

Boot N/A Notes:

LTC to Lambda bulkhead



12-1 BAT - LTC to CAN 22 55A0111 Black 13-1

12-2 CAN Lo LTC to CAN 22 31361705-54 Green 13-2

12-3 CAN Hi LTC to CAN 22 31361705-54 White 13-3


C13

LTC

Connector Name LTC to CAN Label LTC



Terminal Lambda Bulkhead into Cockpit loom

Positioner S'#' denotes a spliced wire


13-1 BAT - LTC to CAN 22 55A0111 Black 5-54

13-2 CAN Lo LTC to CAN 22 31361705-54 Green 5-55

13-3 CAN Hi LTC to CAN 22 31361705-54 White 5-56


13-5

Rear External

The rear external harness originates with a bulkhead connector on the rear firewall located on the passenger side of the car. Once through the shell the harness follows the flexible brake line onto the top of the axle. Here it branches out to reach both dampers, the passenger side ARB drop link and the differential housing itself for wheel speed and differential temperature. Due to the car still having leaf springs in the rear suspension spring force was disregarded. This can be added later if and when the rear suspension is redesigned to coil over dampers with control arms. This harness has 5 sensors for a total of 9 pins.

Rear External Sensors

The sensors chosen for the rear are as follows.

Sensor SpecificsDamper Travel Motec Linear Potentiometers 150mm

M LPS-150

ARB Drop Link Beru F1 Pushrod Load Cell

Wheel Speed Texys DHE Wheel Speed SensorRG VR-09-P

Differential Temp Racegrade 1/8" NPT Liquid Temp SensorM 25-2197D

The damper travel sensors will be mounted in the same method as the front units. The ARB drop link force will require a new drop link to be fabricated. The differential temp will require a 1/8” NPT port to be machined into the oil sump of the center section. Lastly the wheel speed sensor will be mounted directly onto the rear cover with the appropriate shims. A tone wheel will have be machined and fastened to the back side of the ring gear. This is possible due to the differential effectively being a spool, causing no side to side discrepancy. This concept is illustrated in Figure 9.

Figure 9

Rear External Pinout

C10

REAR Connector Name Rear Bulkhead Connector Label REAR BULKHD

Connector AS620-16PN Keyway Color Shell Size 20


Sensors to the rear bulkhead



10-1 Supply Voltage 4V - 25V Rear Wheel Speed 22 55A0111 Red 5-1

10-2 Ground Rear Wheel Speed 22 55A0111 Black 5-S1

10-3 Digital Signal Rear Wheel Speed 22 55A0111 White 5-3

10-4 Supply Voltage 5V RR Damper Travel 22 55A0111 Red 5-4

10-5 Ground RR Damper Travel 22 55A0111 Black 5-S1

10-6 Analog Signal RR Damper Travel 22 55A0111 Yellow 5-6

10-7 Supply Voltage 5V LR Damper Travel 22 55A0111 Red 5-7

10-8 Ground LR Damper Travel 22 55A0111 Black 5-S1

10-9 Analog Signal LR Damper Travel 22 55A0111 Yellow 5-9

10-10 Ground RR ARB Drop Link Force 22 55A0111 Black 5-S1

10-11 Signal RR ARB Drop Link Force 22 55A0111 White 5-11

10-12 Ground Dif Temp 22 55A0111 Black 5-S1

10-13 Analog Signal Dif Temp 22 55A0111 Orange 5-13

10-14

10-15

10-16

Steering Wheel Requirements and Exceptions

For this system there will be no modifications or substitutions needed that pertain to the steering wheel. For recording purposes one beacon transmitter will be placed just before the start lights and the other just after the shutdown lane past the finish lights. Typically, solo event courses allow the car to achieve max speed at the finish lights so max braking occurs in the shutdown lane. The ADL3 will be configured to start recording when the receiver sees the first transmitter and likewise stops recording at the second transmitter.

There are many other sensors that are typical for complete data systems that have been omitted from this system. Some of these are brake rotor and pad temp along with upright temp. Most solo events do not provide opportunity to build much heat in any of these systems. A complete list of sensors was examined and those that were deemed non-critical were left out of the system.

Wiring Totals

Below are the total lengths of wire, Raychem and boots. Also below are the nut plates that will need to have prices obtained. Prices for all components can be seen in the Appendix.

Raychem DR-25 Size Length (ft)

1/8 34.133/16 0.831/4 5.673/8 0.331/2 0.461 0.25

BootsType Quantity

202K153-25-0 2202K174-25-0 2202A111-25-0 1202K142-25-0 1204W221-25-0 3202K132-25-0 2

Rules Compliance

The SCCA Solo rule book is precise in the way that it handles data acquisition. Per rule 13.2.B data acquisition systems are allowed but cannot perform any function other than collection or displaying the data. However they have also said on multiple occasions that they are not going to investigate data systems that are in use. They deem this type of investigation a poor use of the official’s time. This leaves room for exploitation in several places.

If the MGB were using an ECU to control ignition then a system of traction and launch control could be created using the wheel speed. If for some reason an ABS system was desired it could be created as well. This would be a bit more challenging in order to hide all the components of the ABS system.

Economic Consideration

The cost of the mounting brackets and supplies has not been accounted for in this report. Most of the material and fasteners needed for manufacturing mounts, trays and brackets is already in inventory along with the tooling. There are also several components that need to be quoted directly from the manufacturer or wholesaler. Beyond these exceptions the remainder of the

Required WireType Length (ft)

22 gauge 505.5Can wire 3.083

Nut PlatesLocation Nutplate Number Price

Engine Bulk Head Connector ATM396-24 TBDRear Bulk Head Connector ATM396-20 TBD

system cost is reflected in the table below. Individual component prices can be seen in the Appendix.

Sources

1. Figure 1

ADL3 data logger [Digital image]. (n.d.). Retrieved October 11, 2016, from http://www.bimmerforums.com/forum/archive/index.php/t-1579010.html

2. Figure 8ARB Drop Link Force [Digital image]. (n.d.). Retrieved October 11, 2016, from http://www.pistonheads.com/gassing/topic.asp?t=1131871

3. Figure 5Damper Travel [Digital image]. (n.d.). Retrieved October 11, 2016, from http://www.fsae.com/forums/archive/index.php/t-5776.html?s=2f4ac3793225a1cc9fb6f05198249449

Component Cost Quantity TotalMotec ADL3 $ 8,040.00 1 $ 8,040.00

VIM Expander $ 3,400.00 1 $ 3,400.00 Sensor Package $ 16,115.21 1 $ 16,115.21

Raychem Transitions $ 641.02 1 $ 641.02 Raychem $ 94.22 1 $ 94.22

Raychem Boots $ 196.41 1 $ 196.41 Connectors $ 816.20 1 $ 816.20 CAN Wire $ 1.54 1 $ 1.54

22 Gauge Wire $ 141.54 1 $ 141.54

Total before TBDs $ 29,446.14

http://www.fsae.com/forums/archive/index.php/t-5776.html?s=2f4ac3793225a1cc9fb6f05198249449

http://www.fsae.com/forums/archive/index.php/t-5776.html?s=2f4ac3793225a1cc9fb6f05198249449

http://www.pistonheads.com/gassing/topic.asp?t=1131871

http://www.bimmerforums.com/forum/archive/index.php/t-1579010.html

4. Figure 3Wheel Speed Sensor Mounting [Digital image]. (n.d.). Retrieved October 11, 2016, from http://www.aa1car.com/library/diagnosing_abs_wheels_speed_sensors.htm

5. Figure 4Trigger Wheel and Hub [Digital image]. (n.d.). Retrieved October 11, 2016, from http://www.americanmuscle.com/mustang-frontwheel-hub-bearing-9404.html

6. Figure 6Load Cell [Digital image]. (n.d.). Retrieved October 11, 2016, from http://www.raetech.com/Instrumentation/images/Coil-over-Installation-400x533.jpg

7. Figure 7Load Cell [Digital image]. (n.d.). Retrieved October 11, 2016, from http://www.interfaceforce.com/index.php?&mod=applications&show=24

http://www.interfaceforce.com/index.php?&mod=applications&show=24

http://www.raetech.com/Instrumentation/images/Coil-over-Installation-400x533.jpg

http://www.americanmuscle.com/mustang-frontwheel-hub-bearing-9404.html

http://www.aa1car.com/library/diagnosing_abs_wheels_speed_sensors.htm