UNIVERSITI TEKNOLOGI MARA SOFTWARE DESIGN AND DEVELOPMENT FOR AUTOMOTIVE ONLINE MONITORING SYSTEM

Transcription

1 UNIVERSITI TEKNOLOGI MARA SOFTWARE DESIGN AND DEVELOPMENT FOR AUTOMOTIVE ONLINE MONITORING SYSTEM NOOR HAFIZI BIN HANAFI Thesis submitted in fulfillment of the requirements for the degree of Master of Science Faculty of Electrical Engineering May 2011

2 Candidate's Declaration I declare that the work in this thesis was carried out in accordance with the regulation of Universiti Technologi MARA. It is original and is the result of my own work, unless otherwise indicated or acknowledged as referenced work. This topic has not been submitted to any other academic institution or non academic institution for any other degree or qualification. In the event that my thesis be found to violate the conditions mentioned above, I voluntarily waive the right of conferment of my degree and agree be subjected to the disciplinary rules and regulations of University Teknologi MARA. Name of Candidate Candidate's ID NO. Programme Faculty Thesis Title Signature of Candidate Noor Hafizi bin Hanafi Master of Science in Electrical Engineering Electrical Engineering Software Design and Development for Automotive Online Monitoring System. m/ Date ii

3 ABSTRACT An online monitoring system is an electronic system that collects data over time or in relation to location either with a built in instrument or sensor or via external instruments and sensors. An electronic online monitoring has replaced chart recorders in many applications. The vehicle online monitoring records the status data related to the security performance of automobile and integrate them, which can implement a real-time monitoring and diagnosis for the vehicle safety state. The Data acquisition can be classified three types: analogue quantity, switching value and instantaneous quantity. The goal of this research is to help scientist and engineers to more quickly and effectively extract important information from experimented car. The amount of data recorded can be overwhelming, which can restrain the effectiveness of the data. The purpose of this research is to increase the usefulness of the data through organizing, summarizing and analyzing. A computer program will be developed and written to implement more sophisticated data viewing methods. The online monitoring data functionalities is to record the speed of vehicle, engine revolution (rpm), engine temperature, fuel volume and distance. All values such as tyre sizes (to determine speed), fuel sender (to determine fuel volume in litre) and temperature sender (to determine engine temperature in Celsius) is downloaded to EEPROM. All the recorded information is saved in RAM of Microprocessor, which can be reset after load the information to the PC using serial communication (UART). The V-model technique is very helpful for the software development. The NEC microcontroller can support for other application likes CAN Bus, LIN Bus and Serial communication likes Manchester code. The microcontroller has reserved more memory space for expend the application. The online monitoring data can save a lot of money and time to measure the data from the sensors. The behavior of the sensor input can be monitored by using the online monitoring data. The existence of the online monitoring system has an advantage for the vehicle consumers. Since the system could retrieve accurate signals such as the fuel volume with resolution 0.01 litre and the traveling distance in meter with resolution 100m, actual speed in km/h with resolution 0.1 km/h and actual revolution. Using the online monitoring data the driver can also detect the defective sensor when the sensor input remain at certain value or zero during car moving. The driver could realize the fuel consumption in seconds and can optimized their driving maneuver. The retrieved data from the sensor can be studied and analyzed for further improvement of the vehicle. iii

4 ACKNOWLEDGEMENT IN THE NAME OF ALLAH, (AL MIGHTY) THE GRACIOUS, THE MOST MERCIFUL Alhamdulillah, with His willing has allowed me to complete this research. First and foremost, I would like to express my special gratitude to my principal supervisor, Encik Zuraidi bin Saad for his guidance, advice, co-operation, useful ideas and encouragement in order to complete this research. I would like to dedicate a deep appreciation to my co-supervisor, Associate Professor Dr. Hj Mohd. Asri Bin Mansor who had given very good technical guidance, valuable suggestions and moral support throughout the completion of this research. My appreciation also goes to the Coordinator of Master of Science (Faculty of Electrical Engineering) (by Research), Associate Professor Dr. Mohammad Nawawi Seroji, and Associate Professor Dr. Mohd Hezri Fazalul Rahiman for their effort to ensure her students are always comfortable with the research environment. Special thanks, as always, are reserved for my loving parents, who have given their unfailing inspiration, love and understanding throughout all these years. I am also grateful to my wife and my lovely kids, who always pray for my success in my studies in UiTM. Not to forget, special thanks to lecturers and to all my friends for their support and those who were involved whether directly or indirectly in helping me to finish this research. Noor Hafizi Bin Hanafi May iv

5 TABLE OF CONTENTS Contents TITLE PAGE AUTOR'S DECLARATION ABSTRACT ACKNOWLEDGEMENT TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF ABBREVIATIONS Page ii iii iv v x xi xiii CHAPTER I: INTRODUCTION 1.1 Introduction Problem Statement Significance of the Research to Body of Knowledge Project Objectives Scope of the Research Dissertation Layout of the Thesis 4 CHAPTER II: LITERATURE REVIEW 2.1 Introduction of Literature Review Hardware Implementation in Data Acquisition System Software Implementation in Data Acquisition System Summary of Literature Review 22 v

6 CHAPTER III: HARDWARE/SOFTWARE METHODOLOGY FOR AUTOMOTIVE ONLINE DATA MONITORING DESIGN 3.1 Introduction Methodology of Hardware Development Microcontroller Hardware Design Design Procedure of Microcontroller System for Automotive 26 Application Microcontroller Configuration Base on Result from Design 28 Procedure In-car sensors/ecus network topology Hardware from Vehicle to Microcontroller Interfacing 34 Circuit Speed Tacho (Revolution) Fuel Temperature of Engine Coolant Methodology of Software Development Introduction Software Methodology V-Model Verification Phases Requirement Analysis System Design Architecture Design Module Design Validation Phase Module Test Phase Integration Test Phase System Test Phase Programming Technique Single Loop Operation 43 vi

7 Naming Convention Software Testing Technique Bench Test Vehicle Test System Architecture Static Structure Communication Function Coupling Global Data System States Container Module Writing Data Storage Time Synchronization Interface Description of System Container Event Routine Routine SYCONsrEventStandby Routine SYCONsrActionReset Routine SYCONsrActionStandby Routine SYCONsrActionActive Routine SYCONsrActionOn Routine SYCONsrActionStandbyActive Routine SYCONsrActionActiveStandby Routine SYCONsrActionActiveOn Routine SYCONsrActionOnActive Routine SYCONsrActionStandbyOn Interaction between System Kernel and System Container System Kernel Module Interface Description of System Kernel Function SYKERsrMain Port Analogue Module Dynamic Description of Port Analogue Module Structure Description of Port Analogue Module vii

8 Data Interface Basic Function in Port Analogue Module Port Digital Module Dynamic Description of Port Digital Module Structure Description of Port Digital Module Data Interface Basic Function in Port Digital Module Velocity Module Dynamic Description of Velocity Module State Interrupt Structure Description of Velocity Module Data Interface Basic Function in Velocity Module Revolution Module Dynamic Description of Revolution Module State Interrupt Structure Description of Revolution Module Data Interface Basic Function in Revolution Module Tank Input Module Dynamic Description of Tank Input Module Structure Description of Tank Input Module Data Interface Basic Function in Tank Input Module Coolant Temperature Input Module Dynamic Description of Coolant Temperature Input Module Structure Description of Coolant Temperature Input Module Data Interface Basic Function in Coolant Temperature Input Module Monitoring Module Structure Description of Monitoring Module 92 Vlll

9 Data Interface Dynamic Description Traveling Distance (Odometer) Calculation Module Dynamic Description of Odometer Module Structure Description of Odometer Module 103 Basic Function of Odometer Module Software Computer Interface Software Flashing 104 CHAPTER IV: BENCH TEST AND VEHICLE TEST 4.1 Bench Test Introduction Setting Parameter Vehicle Test Introduction Setting the Online Monitoring System inside the Target 109 Vehicle 4.3 Uitm Pulau Pinang Campus Road as the Testing Track Field Test Result Field Test Result in Term of Velocity, Revolution, Fuel Volume and 111 Trip 4.6 Data Analysis and Data Validation 116 CHAPTER V: DISCUSSIONS, CONCLUSION, AND SUGGESTIONS 5.1 Introduction Discussions Finding of Project Objective Conclusion Suggestions 123 BIBLIOGRAPHY 124 ix

10 TABLE OF CONTENTS Contents TITLE PAGE AUTOR'S DECLARATION ABSTRACT ACKNOWLEDGEMENT TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF ABBREVIATIONS Page ii Hi iv v x xi xiii CHAPTER I: INTRODUCTION 1.1 Introduction Problem Statement Significance of the Research to Body of Knowledge Project Objectives Scope of the Research Dissertation Layout of the Thesis 4 CHAPTER II: LITERATURE REVIEW 2.1 Introduction of Literature Review Hardware Implementation in Data Acquisition System Software Implementation in Data Acquisition System Summary of Literature Review 22 v

11 CHAPTER III: HARDWARE/SOFTWARE METHODOLOGY FOR ONLINE DATA MONITORING DESIGN 3.1 Introduction Methodology of Hardware Development Microcontroller Hardware Design Design Procedure of Microcontroller System for Automotive 26 Application Microcontroller Configuration Base on Result from Design 28 Procedure In-car sensors/ecus network topology Hardware from Vehicle to Microcontroller Interfacing 34 Circuit Speed Tacho (Revolution) Fuel Temperature of Engine Coolant Methodology of Software Development Introduction Software Methodology V-Model Verification Phases Requirement Analysis System Design Architecture Design Module Design Validation Phase Module Test Phase Integration Test Phase System Test Phase Programming Technique Single Loop Operation 43 vi

12 Naming Convention Software Testing Technique Bench Test Vehicle Test System Architecture Static Structure Communication Function i Coupling Global Data System States Container Module Writing Data Storage Time Synchronization Interface : Description of System Container Event Routine Routine SYCONsrEventStandby Routine SYCONsrActionReset Routine SYCONsrActionStandby Routine SYCONsrActionActive Routine SYCONsrActionOn Routine SYCONsrActionStandbyActive Routine SYCONsrActionActiveStandby Routine SYCONsrActionActiveOn Routine SYCONsrActionOnActive Routine SYCONsrActionStandbyOn Interaction between System Kernel and System Container System Kernel Module Interface ; Description of System Kernel Function SYKERsrMain Port Analogue Module Dynamic Description of Port Analogue Module Structure Description of Port Analogue Module Vll

13 Data Interface Basic Function in Port Analogue Module Port Digital Module Dynamic Description of Port Digital Module Structure Description of Port Digital Module Data Interface Basic Function in Port Digital Module Velocity Module Dynamic Description of Velocity Module State Interrupt Structure Description of Velocity Module Data Interface Basic Function in Velocity Module Revolution Module Dynamic Description of Revolution Module State Interrupt Structure Description of Revolution Module Data Interface Basic Function in Revolution Module Tank Input Module Dynamic Description of Tank Input Module Structure Description of Tank Input Module Data Interface Basic Function in Tank Input Module Coolant Temperature Module Dynamic Description of Coolant Temperature Input Module Structure Description of Coolant Temperature Input Module Data Interface Basic Function in Coolant Temperature Input Module Monitoring Module Structure Description of Monitoring Module 92 viii

14 Data Interface Dynamic Description Traveling Distance (Odometer) Calculation Module Dynamic Description of Odometer Module Structure Description of Odometer Module 102 Basic Function of Odometer Module Software Computer Interface Software Flashing 104 CHAPTER IV: BENCH TEST AND VEHICLE TEST 4.1 Bench Test Introduction Setting Parameter Vehicle Test Introduction Setting the Online Monitoring Data inside the Target Vehicle Uitm Pulau Pinang Campus Road as the Testing Track Field Test Result Field Test Result in Term of Velocity, Revolution, Fuel Volume and 111 Trip 4.6 Data Analysis and Data Validation 116 CHAPTER V: DISCUSSIONS, CONCLUSION, AND SUGGESTIONS 5.1 Introduction Discussions Finding of Project Objective Conclusion Suggestions 123 BIBLIOGRAPHY 124 ix

15 Figure No. Table 3.1 Table 3.2. Table 3.3 Table 3.4 Table 3.5 Table 3.6 Table 3.7 Table 3.8 Table 3.9 Table 3.10 Table 3.11 Table 3.12 Table 3.13 Table 3.14 Table 3.15 Table 3.16 Table 3.17 LIST OF TABLES Name of Table Spending Cost for Hardware Microcontroller Comparison Speed Characteristic -km/h Scales Revolution Characteristic Fuel Level Characteristics Sender Value of Temperature Interface Description Data Interface Description Data Interface Description Data Interface Description Data Interface Description Data Interface Description Data Interface Description State Transaction Event Parameter Used in Odometer Module Page No X

16 LIST OF FIGURES Figure No. Name of Figure Page No Figure 3.1 Hardware methodology Process 25 Figure 3.2. Data logger in-car network topology 30 (with conventional network) Figure 3.3 Data logger in-car with CAN network topology 31 Figure 3.4 System architecture of the data logger 32 Figure 3.5 Circuit diagram design of the data logger 33 Figure 3.6 Speedometer connection diagram 34 Figure 3.7 Tacho connection diagram 36 Figure 3.8 Fuel sender connection diagram 37 Figure 3.9 Temperature sender connection diagram 38 Figure 3.10 V-Model diagram 40 Figure 3.11 Parameter transfer data source transfers data to data sink 51 Figure 3.12 Parameter transfer data sink fetches data from data source 51 Figure 3.13 Data coupling with a data source 52 Figure 3.14 Schematic drawing of system states and their relations 53 Figure 3.15 Schematic drawing of the time synchronization 57 Figure 3.16 The port analogue module interface 65 Figure 3.17 Dynamic state of port analogue module 66 Figure 3.18 Structure description of port analogue module 67 Figure 3.19 Dynamic chart of port digital module 69 Figure 3.20 Structure description of port digital module 71 Figure 3.21 Velocity interface 72 Figure 3.22 Dynamic description of velocity module 73 Figure 3.23 Interrupt windows for frequency input 74 Figure 3.24 Structure description of velocity module 76 Figure 3.25 Revolution interface 78 Figure 3.26 Dynamic description of revolution module 79 Figure 3.27 Interrupt windows for frequency input 80 Figure 3.28 Structure description of revolution module 81 XI

17 Figure 3.29 Tank interface 83 Figure 3.30 Dynamic description of tank module 84 Figure 3.31 Structure description of tank module 85 Figure 3.32 Data interface of coolant temperature module 87 Figure 3.33 Dynamic description of coolant temperature module 88 Figure 3.34 Structure description of coolant temperature module 89 Figure 3.35 Structure description of online monitoring module 92 Figure 3.36 Dynamic state diagrams 93 Figure 3.37 Travel distance related parameter 101 Figure 3.38 Dynamic description of odometer module 101 Figure 3.39 Structure description of odometer module 103 Figure 3.40 The setup of software flashing 104 Figure 4.1. PC interface software 106 Figure 4.2 UART interface circuit 108 Figure 4.3 Car meter removed to plug in the online monitoring device 109 to sensor outlet Figure 4.4 The device is connected to car sensor via sensor outlet 110 Figure 4.5 Roadmap from satellite image on Uitm Pulau Pinang 110 Figure 4.6 Velocity versus Time (with air-condition on) 111 Figure 4.7 Revolution versus Time (with air-condition on) 112 Figure 4.8 Trip versus Time (with air-condition on) 112 Figure 4.9 Fuel Volume versus Time (with air-condition on) 113 Figure 4.10 Fuel Volume versus Trip (with air-condition on) 113 Figure 4.11 Velocity versus Time (with air-condition off) 114 Figure 4.12 Revolution versus Time (with air-condition off) 114 Figure 4.13 Trip versus Time (with air-condition off) 115 Figure 4.14 Fuel Volume versus Time (with air-condition off) 115 Figure 4.15 Fuel Volume versus Trip (with air-condition off) 116 xii

18 ABBREVIATION ADC CAN EEPROM ID LIN PC PCB PWM RAM ROM UART Analogue Digital Converter Controller Area Network Electrically-Erasable Programmable Read-Only Memory Identifier Local Interconnected Network Personal Computer Printed Circuit Board Pulse Width Modulation Read Access Memory Read Only Memory Universal Asynchronous Receiver and Transmitter xiii

19 CHAPTER 1 INTRODUCTION 1.1 Introduction An online monitoring system is an electronic system that collects data over time or in relation to location either with a built in instrument or sensor or via external instruments and sensors. Increasingly, but not entirely, they are based on a digital processor (or computer). They generally are small, battery powered and portable. Online monitoring varies between general purpose types for a range of measurement applications to very specific devices for measuring in one environment only. It is common for general purpose types to be programmable however many remain as static machines with only a limited number of variable parameters. An electronic online monitoring has replaced chart recorders in many applications. The vehicle online monitoring records the status data related to the security performance of automobile and integrate them, which can implement a real-time monitoring and diagnosis for the vehicle safety state. The Data acquisition can be classified three types: analogue quantity, switching value and instantaneous quantity. The collection of analogue quantity such as water temperature, oil temperature, fuel capacity, oil pressure and engine speed. The switching value mainly includes brake, headlights, turns right and left light, ignition, high beam, ignition, front door and brake pressure and hand braking. The instantaneous quantity includes speed and mileage. The travelling recorder consists of predictive failure and diagnosis system to the traditional system. It can give the reasonable suggestion to the driver by comparing the parameters to the normal parameters. The goal of this research is to help scientist and engineers to more quickly and effectively extract 1

20 important information from experimented car. Modern cars employ data acquisition systems that record many aspects of vehicle behaviour. The amount of data recorded can be overwhelming, which can restrain the effectiveness of the data. The purpose of this research is to increase the usefulness of the data through organizing, summarizing and analyzing. A computer program will be developed and written to implement more sophisticated data viewing methods. The program will utilizes a new framework based on track segmenting to better organize data, instantly provides summaries of segment data and attempts to better display the driving performance. A special purposes online monitoring data for vehicle will be developed. The online monitoring data functionalities is to record the Speed of vehicle, engine revolution (rpm), engine temperature, fuel volume and distance. All values such as tyre sizes (to determine speed), fuel sender (to determine fuel volume in Litre) and temperature sender (to determine engine temperature in Celsius) is downloaded to EEPROM. All the recorded information is saved in RAM of Microprocessor, which can be reset after load the information to the PC using serial communication (UART). 1.2 Problem Statement An online data collection system (vehicle data logger) from general vehicle currently is not available in the market. Only vehicle manufacture has a tool to access the engine ECU to monitor the vehicle data. Current available automotives meter are not accurately display the speed, engine revolution, fuel and temperature. 1.3 Significance of Research to Body of Knowledge Outcome of the research is a vehicle electronic system that can detect the malfunction of the sensor. Incase of malfunction of the sensors the related data will remain zero meaning that 2

21 no input from the sensor. Besides logging the data from the sensor the system can detect the malfunction of the sensors such as speed sensor, engine sensor, engine temperature sensor, fuel sender sensor and voltage of battery. The engine tuning can be done base on the revolution data collection from the vehicle. Basically the engine tuning is done base on the engine idling condition. 1.4 Project Objectives The main objective of this project is to develop a fast, reliable with high accuracy and sensitivity of automotive data logger using microcontroller. The detail objectives of the research are as follows: 1. To study and select a suitable microcontroller for automotive data logging purposes. 2. To design and developed a new microcontroller programming technique for automotive data logging purposes. 3. To identify and implement data logging techniques to extract important information from experimented car. 4. To validate the logged data from the data logger. 1.5 Scope of the Research The research scope involves the following key tasks: 1. Study and select a suitable microcontroller for automotive data logging purposes. 2. Preparation of car data specification in normal condition from target car will be obtained from automotive trader and automotive part specification. See Appendix 1 for detail car specification. 3. Hardware Development 3

22 The hardware is developed for the automotive system that can collect data from vehicle sensors via UART. The system consists of a microcontroller that will read the rpm, speed, battery voltage, trip, engine temperature and etc. from the car sensor. 4. Software Development Design and developed a single loop microcontroller programming technique for automotive data logging purposes. The single loop programming technique is meaning that the system has cyclic main loop which is called for every 25ms. The detail explanation is in chapter System State Container Module. 5. Laboratory Testing The functionality test of data logger will be carry out in the laboratory to verify the stability of the integrated system. 6. Validation of the data logger The accuracy of collected data from data logger of the systems will be compared to the theoretical result that is done by mathematical calculation. 1.6 Dissertation Layout of the Thesis In general this thesis consists of 5 chapters. First chapter described an introduction of thesis correlating to the input triggering and data acquisition to be collected and analyzed, the availability of data acquisition in the market, objective of the thesis need to be achieved, scope of thesis and the last once the Dissertation Layout is described in this chapter as well. Chapter 2 describes the related topic of literature review based on Data acquisition system. The method and technique of Software and Hardware development are described. In this chapter most of the researchers are focus on the accuracy of the devices, stability, timeline and cost for the development. The famous communication techniques are CAN and UART for the data logging or collection. The MAX 232 serial interface chip for UART 4

23 communication is incorporated in the detached module, which acts as a data transfer interface between the data acquisition system and the computer. The acquisition data will retrieve from the EEPROM or Computer for analyzing. In the third chapter the Hardware and Software methodology are described. The Hardware interface for the online monitoring data are shown in detailed, where the data inputs are triggered and calculated. The analogue data are supplied to the analogue port of microcontroller and converted to the digital value (ADC) and frequency inputs triggered by the interrupt port for the time calculation. The software methodology described the method of software development using V-Model concept. The single loop method with 25ms every loop is called for the data calculation. The state transitions are also shown in this chapter. The vehicle test was performed using a Perodua Kancil 850cc and result was analyzed in the chapter 4. The driving style was performed with different condition during data collection. The driving test was conducted in Uitm P.Pinang. The speed, revolution and distance are successfully measured using the online monitoring devices. Finally the conclusion of the online monitoring results will be published in Chapter 5. Future suggestions that were obtained from the research will be summarized and included in this chapter. 5

24 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction of Literature Review This chapter will describe the literature review from other researchers. The literature review will be divided to two parts. First part explained about the software development including method used and the second part explained hardware development, example what kind of microcontroller is used for the data acquisition system and what is the important criteria of the microcontroller. Most of the researcher considers the cost effective, time consuming in product development and capability of microcontroller. Time and cost are very important to consider the right component in order to speed up the product into the market. This is due to compete with another competitors' in the same electronic company that produce the same product. Stability and robustness of the system are the main significant criterion for the software in the product development to ensure the product is marketable. 2.2 Hardware Implementation in Data Acquisition System Qiang et al (2009) have developed the data collected for DPF (Diesel Particulate Filter) from vehicle using microcontroller C8051F340. The collected Data's are vehicle speed, vent-pipe temperatures and counter pressure in the pipe. The data will be sent to the PC by serial port (USB) for analysis. The interval of detection is every 0.5 seconds. The results is shown that a scientific and reasonable basis for the upgrade of the relevant parts of vehicle and important parameter for technical support of installation of DPF. The Data recorder can also be used for the evaluation of extent of vehicle emissions. 6