Humanetics HITECSENSORS 01184 User manual

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IR TELEMETRY
STEERING EFFECT
SENSOR
(MODEL 01184)
OPERATING MANUAL

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CONTENTS
Introduction 3-4
System Overview 3
System Components 3-4
Installation 5-7
Installing The System 5-7
Operating The System 8
Calibration 8
Collecting Data 8
Overview Of System Electronics 9-13
Infra-Red (IR) Transmitter 9
IR Receiver/Encoder to Analog Converter 10
CAN Output (Optional) 11
Appendix 14-17
Specications          14-16
ServiceWarranty         16
Repair Services 17
15July2021_OM04/1

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SYSTEM OVERVIEW
HITEC Sensor Developments IR Telemetry Steering Effort Sensor (Model 01184) is designed to measure the amount
of effort needed to turn the steering wheel and the angular position of the steering wheel.
This system provides:
• A 10 in. through-hole for uninhibited deployment of an air bag without the danger of the sensor being projected at
the driver.
• A low mass-moment of inertia.
• Dual resolution for angular measurement (0.2º or 0.05º), and
• Non contacting torque signal transmission which permits unlimited wheel rotation
SYSTEM COMPONENTS
The system consists of the following:
• A steering effort sensor with.
• An Infra-Red (IR) telemetry transmission system
• An angular position sensor, and
• An analog converter
The Steering Effort Sensor
The steering effort sensor is an auxiliary steering wheel with 12 in. OD. The sensor mounts to the vehicle’s steering
wheelwithfourcableties.Thesensorhasfouradjustablemountingplatestotsteeringwheelsfrom14.5-16in.
OD.Thesensorhasa2.6in.offsetfromthesteeringwheel.(Seeillustrationonnextpage.)
The IR Telemetry Transmission System
The non-contact data coupling system consists of the IR transmitter (built into the steering sensor), a near-by
IR detector (mounted on the encoder housing), and the receiver. Power to the transmitter is supplied by a 9 Volt
battery.Thereceiverispoweredby11-16VDCvehiclepower.
Note: HITEC Sensor Developments recommends replacing the transmitter battery at the beginning of each test day.
INTRODUCTION

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The Angular Position Sensor
The angular position sensor is an optical encoder mounted on the inside of the front windshield. A drive train
assembly rotates the drive shaft attached to the encoder as the steering wheel sensor is turned. When the chain is
installed, and both gears are properly aligned, the IR emitters in the sensor are also properly aligned with the IR
detector mounted to the encoder housing.
The receiver (Figure 3) produces analog outputs from both the torque sensor and the encoder.
Figure 3: The IR Receiver/Encoder to Analog Converter
Figure 2: Angular Position Sensor

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INSTALLING THE SYSTEM
To install the system:
Step 1: Mount the steering effort sensor to the vehicle’s steering wheel.
A. Position the sensor so that it rests rmly against the front of the steering wheel.
B. Adjust all four mounting brackets for the proper t. Make certain to adjust all four brackets symmetrically.
C. Tie the steering effort sensor to the steering wheel using one cable tie for each of the four mounting brackets.
D. Pullthecabletiesrmlytotighten,andthentrimtheties.(Ifnottrimmedthetiesmayinterferewiththe
drive train.)
Step 2: Mount the angular position sensor to the inside of the windshield.
A. Push the gear all the way up the linear ball slide, and place the positioning pin through the holes in the front
and rear of the optical encoder to limit its travel to the midpoint.
INSTALLATION
Figure 4: Step 1B - Mounting brackets
Figure 5: Step 2A - Optical encoder

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B. Place the drive chain around the gear of the steering effort sensor.
C. Position the angular position sensor on the windshield so that:
• The angle encoder is NOT in the drivers direct line of vision
• The drive chain is taut
• The encoder gear is in the same plane as the gear on the steering wheel
D. Attach the angular position sensor to the windshield by pumping the suction cup’s plunger. Pump it until
the red stripe is no longer visible.
E. If necessary, adjust its position by loosening the knobs and sliding the bracket to the correct position
(see gure2).
F. Adjust the angle of the encoder so the arrow on its label is pointing directly toward the center of the
steering wheel by loosening and the tightening the ball and socket joint.
G. Remove the positioning pin from the front and rear holes of the angular position sensor, and place it
through the side holes.
H. Rotate the steering wheel to ensure that the encoder (on the angle position sensor) can travel along the
linear ball slide without restriction.
The IR telemetry emitters and detector are now properly aligned as well.
Figure6:Step2C-Positioningtheangular position sensor

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Step 3: Connect the angular position sensor (encoder) to the receiver. The IR detector’s power and digital data
signals are also carried through this cable/connector.
Step 4: Connect the encoder signal outputs of the receiver to the data acquisition system.
Step 5: Connect the torque sensor signal outputs of the receiver to the data acquisition system.
Step 6: Connect a 9V alkaline battery to the sensing element. Use the power switch to control power to the
transmitter.
Note: HITEC Sensor Developments recommends installing a new battery at the beginning of each test day.

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OPERATING THE SYSTEM
CALIBRATION
This unit was calibrated at the factory. Calibration sheets have been provided with the unit specifying what each output
will provide for a given input. The calibration on the torque output can be measured very accurately using the shunt cal.
Refer to Figure 7 for location of the shunt button. When the shunt button is pressed, a resistor is placed across a leg of
the bridge, which produces a very repeatable simulated torque on the sensor. The shunt button is a momentary type
button and will release the shunt when the button is released.
To calibrate the torque sensor to the data acquisition system:
Step 1: Place the steering effort sensor at the desired neutral position.
Step 2: Adjust the “zero” potentiometer until the output voltage is 0 volts.
Step 3: Zero/tare the data acquisition system.
Step 4: Press the shunt calibration button on the sensing element and measure the simulated output produced. The
 outputshouldreectthenumberonthedatasheetprovidedbythemanufacturer.
Step 5: Input the simulated torque value to the data acquisition system.
Step 6: Alternate... use the capacity and full scale output numbers provided on the data sheet for the values entered into
the data acquisition system. Use the shunt to verify cal.
Theangleoutputsdonothaveasimplemethodofverifyingcalibration,andifmorethana“ballpark”vericationis
needed,ananglexturewillberequired.
To calibrate the angle outputs to the data acquisition system:
Step 1: Place the steering effort sensor at the desired zero position.
Step 2: Momentarily press the encoder zero button on the receiver. See Figure 9 for location of this button.
Step 3: Zero/tare the data acquisition system on each encoder channel.
Step 4: Enter into the data acquisition system the range and output values from the data sheet provided with the sensor.
COLLECTING DATA
Torque and position data are transmitted automatically and continuously when the system is powered up.

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OVERVIEW OF SYSTEM ELECTRONICS
INFRA-RED (IR) TRANSMITTER
Thetransmitterconsistsofastraingageamplier,a4polelowpassbutterworthlter,analogtodigitalconverter,
controlelectronics,andanarrayofIRLED’s.Thebasicoperationisthat,whenpoweredup,thetransmitterampliesthe
signalfromthetorquesensor,ltersit,digitizesitandsendsitoutbypulsingtheIRemitterstotransmitthecode.
Under normal operation, the power indicator (see Figure 7) will blink indicating that the unit is powered up and
transmitting normally. The power switch (Figure 7) controls power to the unit.
The shunt button is used to verify calibration of both this sensor, and any subsequent data acquisition system. It is a
momentary switch that, when pressed, applies a shunt resistor to the sensor bridge. This has the effect of producing
a simulated output from the sensor, and likewise, a signal will be produced at the receiver’s output. The shunt is very
repeatable and calibration information for its effect is documented in the calibration data provided with the sensor.
All data sent from the transmitter are encoded with a CRC. This is an error detection scheme that is used by the receiver
to tell if the received data was good. When the transmitter’s battery gets low, the transmitter will intentionally corrupt
the CRC before sending it. The receiver will continually see the transmission as in error. In addition, the transmitter’s
powerindicatorwillstopashing,turningsolidred.Replacethetransmitter’sbatterywhenthisoccurs.
Figure 7: Infra-Red (IR) Transmitter

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IR RECEIVER/ENCODER TO ANALOG CONVERTER
The receiver consists of an Infra-Red detector unit (mounted at the encoder), control electronics, digital to analog (D/A)
convertersandbuffer/lters.Basicoperationis:
Step 1: Connect to the required signal outputs as shown in Figure 8a or 8b.
Step 2: Connect the encoder as shown in Figure 9.
Step 3: Connect power to the power input pins as shown in Figure 9 and turn on the power switch.
Figure 8a: IR Receiver PT Style Connections, Side 1
Figure 8b: IR Receiver Optional BNC Style Connections, Side 1
Figure 9: IR Receiver Connections, Side 2

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The unit will receive a digital signal from a near-by transmitter. When this happens, the green “good data” indicator
will light showing that the digital data was recovered without error. The good data is then fed to the Digital to Analog
converter,andontotheanalogoutput.Theanalogoutputisbufferedandltered.Thelteristheretosmooththesteps
that are inherent in the output of the D/A converter. In the event that the data is found to be in error, the good data
light will go out, a beeper will sound a short tone and the good data relay contacts will open. In the event that the unit
loses power, the relay contacts will rest in the open position, indicating an error. The contacts are available at the power
connector as shown in Figure 9. Note that the beeper can be disabled by opening the enclosure and moving the jumper
next to the beeper to the “disabled” location.
The encoder’s position and rate of change are available at the encoder output connector. As with the sensor output,
theencoderoutputsarebufferedandltered.Sincetheencoderinputiscompatiblewithincrementalencodersonly,
the position output must be zeroed. To do this, position the encoder to the desired zero position, and press the “zero
encoder” button. See Figure 9. The zero value will be lost if power is removed. The encoder’s output connector provides
2positionsignals,thusproviding2availableresolutions.Refertopages13&14ofthisdocumentforspecicationson
resolution and rate.
This unit comes with adjustments for zero, along with a span adjustment for the meter. The signal output span
adjustments have been set at the factory and are not user adjustable. The meter is simply a voltmeter connected to the
sensor output signal. The meter has a span adjustment range that covers 0 to 2000 counts with a decimal point that is
factoryset.With5voltsatthesensoroutput,unitsthathavethemeterconguredforvoltagewillbeadjustedtoshow
5.00counts.Unitsthathavethemeterconguredforengineeringunitswillshowthoseunitsinaunitthatbesttsthe
display. For example, if the sensor capacity was 7000 pounds, the meter would display 7.00 and the units would be
understood to be in 1000’s of pounds.
When measuring the signal outputs, note that the signal ground is isolated from the power supply ground to prevent
ground loops. Measurements must be taken with respect to the signal ground and not the power ground. The signal
ground is common for all output signals. The signal ground may be connected to the power supply ground without
damaging the unit. Some applications may require that they be connected. For example, when using a DAQ system with
differential inputs to read these signals, it is important to ground the negative signal input on the DAQ system to provide
an absolute point of reference for the input. Without such a connection, erroneous data may be collected. For DAQ
systems with grounded single-ended inputs, this is not an issue.
CAN OUTPUT (OPTIONAL)
HITEC Sensors provides the 01184 Steering Effort sensor with an optional CAN output. See Figure 10.
Figure 10: Steering Effort

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The CAN output is designed to connect directly to a differential CAN bus, and supports the CAN 2.0B standard. The
01184 allows the user to select, via a USB Setup program (install from supplied CDROM), which items will be placed
onto the CAN bus. See Figure 11.
The three items measured by the 01184 are Torque, Angle and Rate. Each item may be placed on the CAN bus as an
individualmessage.Eachmessageismadeupofeightbytes.Therstfourbytes(bytes0-3)arethe32bitIEEEsingle
precisionoatingpointrepresentationoftheitembeingmeasured.Theyarestoredlittleendian,withthelowbyteof
thesignicand,ormantissa,intherstbyte(D0).Theremaining4bytes(bytes4-7)areASCIIcharactersthatcontain
engineering units. Units that use less than 4 bytes will be completed with ASCII space characters. For example, consider
adatapacketreceived,fromD0-D7,thatcontains0x27A00341696E6C62.Therstfourbytes,0x27A00341,arethe
oatingpointportion.0x27isthelowestbyteand0x41isthehighestbyte.Aconversion,orre-typing,ofthesebytes
frombinarytooating,pointrevealsthatthevalueis8.2266.Thenextfourbytes,0x696E6C62areASCIIcodesfor‘i’,
‘n’,‘l’and‘b’respectively,or“inlb.”
EachitemmeasuredcanbespeciedwithaStandardIdentierandanoptionalExtendedIdentier.TheExtended
Identiermaybeenabledordisabledbyclickingthebuttonnexttoit.It’sworthnotingthatthelowerthevalueofthe
Identier,thehigherthepriorityoftheCANmessage.Also,inthespecialcaseoftwomessagesthatsharethesame
StandardIdentier,butonemessageisstandardandtheotherisextended,thestandardmessagewillhavepriority.
StandardIdentiervalues0x7F0-0x7FFarereserved.Pleasedonotusethem.
The speed of the CAN bus can be selected, with values from 125k to 1Mbaud supported. In order to lower the amount
ofbustrafc,theusermayopttosendlessthanthefullamountofdatathattheIRReceiverhascollected.Thisisdone
usingtheDecimate/Averageselection.Notethatifan‘average’selectionischosen,onlyTorqueisaveraged.Angleand
Rate are not averaged tofurtherreducebustrafc,theusermayopttoturnunwantedoutputsoff.Thisisdoneby
clicking the Send Torque, Send Angle and Send Rate buttons, to enable/disable them.
Figure 11: USB Setup program

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The user may zero the Torque and/or the Angle using the Zero Torque and Zero Angle buttons. These values are
recorded/saved immediately when the button is pressed. There is no Zero Rate, as Rate is inherently zero when the
sensor is not in motion.
The Live update on the screen shows real time data in the engineering units shown above the Live display.
The Engineering Units may be changed by using the selections to the right of the Zero buttons, but these selections will
not take effect until they are saved to the device. Engineering Units for Rate correspond to those of Angle. For example,
if Angle is degrees, Rate is Degrees/Second.
Unsavedchangesmaybediscardedbyclicking‘ReadSettingsfromDevice’.
Whenallselectionshavebeenmade,click‘SaveSettingstoDevice’.
The‘Help’buttonlaunchesthismanual.
Whensetupiscomplete,click‘Exit’toclosetheprogram.
CAN bus termination is available by opening the receiver and turning on the dip switches labeled S2. Both switches
must be turn on to enable termination. Likewise, both switches must be off to disable termination.

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SPECIFICATIONS
TORQUE TRANSDUCER DATA
Capacities (in-lbs) 200, 500, 1000
Output at Full Scale (nominal) (V) ±5
Optional Output at Full Scale (nominal) (V) ±10
Optional Output at Full Scale (nominal) (V) +2.5 ±2.5
Overload Capacity (%) 150 of FS
Hysteresis (%) 0.25 of FS
Non-linearity (%) 0.25 of FS
Mass moment of inertia (calculated) (in-lbs) 0.20 sec2
Resolution (bits) 16(15+sign)
Sample rate (second) 2000 samples
Lowpassanti-aliasinglter 4pole@600Hz
Power supply input (VDC) 6.5-15
Power supply current (mA) 30
Recommended battery (V) 9 Alkaline
Approximate battery life with recommended
battery
8 Hours
SECONDARY STEERING WHEEL
OD (in) 12
Offset (in) 3.5
APPENDIX

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IR TRANSMISSION SYSTEM
Analog Output (nominal) (V) ±5
Optional Analog Output (nominal) (V) ±10
Optional Analog Output (nominal) (V) +2.5 ±2.5
Outputlowpasslter 2 pole @ 1000Hz
Resolution (%) 0.005 of FS
Transmitter (V) 9 battery
Receiver (VDC) 10 - 28
Transmitting range (in) 2 - 10
POSITION/VELOCITY SYSTEM
Encoder (ppr) 7,200
Low resolution Output
Resolution (degrees) 0.20
Maximum Range (degrees) ±1638.4
Output at maximum range (VDC) ±5
Optional Output at maximum range (VDC) ±10
Optional Output at maximum range +2.5V ±2.5VDC
Update rate (second) 2000 updates
Low pass lter 2 pole @1000Hz
High Resolution Output
Resolution (degrees) 0.05
Maximum Range (degrees) ±409.6
Output at maximum range (VDC) ±5
Optional Output at maximum range (VDC) ±10
Optional Output at maximum range + 2.5 V ± 2.5VDC
Update rate (second) 2000 updates
Low pass lter 2 pole @1000Hz

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Rate Output
Resolution (degrees) 0.20
Maximum Range (degrees) ± 1638.4
Signal Output at maximum range (VDC) ±5
Optional Signal Output at maximum range (VDC) ±10
Optional Output at maximum range +2.5V ±2.5VDC
Update rate (second) 2000 updates
Low pass lter 2 pole @1000Hz
POWER REQUIREMENTS FOR IR RECEIVER
Voltage range (VDC) 10 - 28
Voltage range (mA) 300 max.
SERVICE WARRANTY
HITEC Sensor Developments warrants its products to be free from defects in material and workmanship for a period of
one year from shipment from our factory. In that period we will, at our option, repair or replace a defective component or
entire product which has been submitted for our examination. This is our sole obligation. We are not responsible for any
costs or liabilities arising from but not limited to de-installing, consequent or collateral damage, delays, loss of use, re-
installing, or any others. The warranty is in effect provided the component or product is properly used in the application
forwhichitisintended.ProductswhichhavebeenmodiedwithoutHITECSensorDevelopmentsapproval,onwhich
repairshavebeenattemptedbynon-qualiedpersons,whichhavebeensubjectedtophysicalorelectricalstress
beyond our ratings, or which have had their identifying marks removed or altered are not covered by this warranty.
In cases of incorporation of a product by the user in a larger system provided by a third party or sold on to a third party,
wemakenowarrantiesexceptthoseabove.Weassumenoresponsibilityfortnessforpurposeinthesecircumstances.
Warranty returns must be authorized by us and shipped prepaid to us. Our return authorization number must appear
on the packaging and any correspondence. We will return the goods prepaid. Products, which have been exposed to
hazardous materials, will not be accepted unless they have been properly decontaminated. HITEC Sensor Developments
reserves the right to refuse any shipment which it believes may create a physical or health hazard to our employees.
Products returned out of warranty for repair are subject to a minimum inspection fee. The fee is waived if the repair is
authorized. It is also waived if the product is un-repairable and/or a replacement is purchased.

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REPAIR SERVICES
HITEC Sensor Developments products requiring repair should be returned freight prepaid to:
Attention - Service Department.
Information should be included stating what is wrong with the item(s) returned and name of contact.
No item shall be returned for repair which has been exposed to hazardous materials without suitable decontamination.
Hazardous materials include, but are not limited to: poisons, materials capable of producing toxic fumes, radioactive
waste materials which can spread viral or other diseases and materials which pose hazards by airborne ingestion, such
as asbestos. HITEC Sensor Developments reserves the right to refuse and/or return any shipment which it believes
poses any health risk to its employees. Unless the repair is covered under the terms of HITEC Sensor Developments
warranty, there will be a minimum inspection and evaluation fee for each item returned. This fee may be waived if the
item proves non-repairable, and a comparable replacement is ordered.