Kistler 5612A Series User 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.
© 2019 Kistler Group. Kistler Group products are protected
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. [phone]
[e-mail]
Kistler Instrumente GmbH
Automotive Research & Test Division
Charlotte-Bamberg-Str. 12
35578 Wetzlar
Germany
Phone [phone]
[e-mail]
www.kistler.com
Foreword
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:
[phone]
[e-mail]
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 interchangeable 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.