Ergoracer Car Simulator

Kettler Ergoracer SW Kettler Ergoracer Emergency stop Interface box
Wheel pulse signal Brake signal Motor revolutions pulse signal

Inductive Pick-up

Fuel flow signal

Eddy current brake

Digital signals Fuel flow signal cruise signals
speeder signal transformer + on/off signal
Digital signals to DevKit8000: Brake, Clutch, Gear (7bits), Tacho (pulses), Wheel (pulses).
User guide and Technical documentation

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Cruise control

Devkit80000 Add On board

Table of contents
Introduction.... 2 System block description... 3 Bike autopilot interface box... 3 Frequency converter Lenze 8200 vector (E82EV152 K2B200).. 5 Motor EN60034 - IP55... 5 Tachogenerator ITD21 TTL... 6 Inductive pick-up (wheel sensor) EI0801PPOS (carlo gavazzi).. 6 DevKit8000 (+IHA expansion board)... 6 Start-procedure.... 7 Kettler Ergoconcept (PC program)... 8 Appendix List: Appendix 1 Functional Diagram... 9 Appendix 2 DIN connector pinouts... 10 Appendix 3 Interface Box Schematics... 11 Appendix 4 Interface Box PCB... 13 Appendix 5 LENZE Frequency converter signal flowcharts.. 14 Appendix 6 Tacho documentation... 17 Appendix 7 Inductive pickup datasheet (EI0801PPOS).. 20 Appendix 8 Ergoracer parts list (german)... 21

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Introduction
The Bike Autopilot Interface Box for DevKit8000 is used to condition the various signal levels used to control the Ergoracer car-simulator setup. It also provides basic hardware based speed and brake controls using a potentiometer and a push-switch. Several kinds of measurement data are relayed back to the DevKit8000 through the Interface Box, these are: Motor revolutions, motor fuel flow and wheel revolutions. The Kettler ergoracer bike is equipped with an RS232 port to interface with a simulation-program supplied with the bike. This program can vary the resistance of the eddy current brake (Danish: hvirvelstrmsbremse), to simulate riding uphill on a real bike. See page 8 for an introduction to the Kettler Ergoracer program. A motor has been attached to drive the main wheel of the bike, the motor is controlled by a frequency transformer, which in turn is controlled by the Bike Autopilot Interface Box. The speed of the motor can also be controlled by an analog output from the DevKit8000. This signal is passed through the interface box to be conditioned to the proper voltage level. The interface box passes the highest voltage (either the potentiometer signal or the DevKit8000 signal) to the frequency transformer. This document will describe the building blocks of the system and how the various signals are conditioned to match the I/O requirements of both the DevKit8000 and the Ergoracer setup. A startup procedure is also described. The appendix section contains relevant data and diagrams needed to perform service operations on the Ergoracer car-simulator setup. Appendix 1 Functional diagram on page 9 is recommended as a quick reference to signal levels and I/O addresses.

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System block description
See the front page for a visualization of the systems connections. The Ergoracer setup consists of several independently controlled pieces of hardware, Signal levels, and I/O pins are described, for each block. A complete overview of signal levels, and I/O addresses can be found in appendix 1: functional diagram (p.9)

Bike autopilot interface box
The primary purpose of the interface box is to condition the different signal levels between the DevKit8000 and the rest of the system: Signal levels: Signal levels on the Ergoracer (bike) side of the interface box Analog: 0-10V Digital: Tacho: 0V low , 5V high Inductive (wheel) sensor: 0V low , 12V high
Signal levels on the DevKit8000 side of the interface box: Analog: 0-2V Digital: 0V low, 3,3 V high The bike autopilot interface box requires two separate 12V supplies. This is because the tacho generator interface is galvanically separated from the rest of the system, and thus requires a unique power supply. The bike autopilot box also has basic controls of the motor speed, brake and motor on/off, and also outputs autopilot relevant signals to the DevKit8000

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Controls on the interface box: The front panel of the interface box has clearly marked controls. The Motor on/off switch enables/disables the frequency converter and must be set to ON for the motor to run. It has no output to the DevKit8000. The Brake switch enables the bikes built in eddy current brake, and sets an output to the DevKit8000 high (3,3V). Brake switch signal (digital): I/O pin on DevKit8000 GPIO1 Bit 1 Direction (seen from Devkit800) Input
The Clutch switch has no active function in relation to the bike. It sets an output to the DevKit8000 high (3,3V). Clutch switch signal (digital): I/O pin on DevKit8000 GPIO1 Bit 0 Direction (seen from Devkit8000) Input
The Motor potentiometer sets the output voltage for the FRQ converter to between 0 and 10V. This voltage is also divided down to a 0-2V range and output to the DevKit8000: Interface box (potentiometer) motor control signal (analog): I/O pin on DevKit8000 AIN0 Direction (seen from Devkit8000) Input The Motor on/off switch enables/disables the potentiometer output. At the off position the output is tied to 0V. The switch does not affect the speeder signal from the DevKit8000.

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The gear switch has no active function in relation to the bike. It sets one of six outputs to the DevKit8000 high (3,3V), depending on the chosen gear. Gear signals (digital): Direction (seen from Devkit8000): Input. GPIO2 bit: Reverse 1. Gear 2. Gear 3. Gear 4. Gear 5. Gear Neutral 1 0
Frequency converter Lenze 8200 vector (E82EV152 K2B200)
The FRQ converter, is needed to regulate the asynchronous motor, so that its speed can be varied. The FRQ converter translates the speeder signal from the control box from a 0-10V DC voltage into an appropriate drive signal for the motor. It also outputs a fuel flow signal from 0V to10V which is proportional to the current consumption of the motor, this signal is divided down by the interface box and then output to the DevKit8000 to simulate the engines fuel consumption Fuel flow signal (analog*): I/O pin on DevKit8000 Direction (seen from Devkit8000)

AIN1 Input

*The theoretical voltage range of the flow signal is 0-5V, but no readings above 2 volts occur, since the motor never operates at full power. (Tested with brakes on, at startup from 0 RPM to max RPM)

Motor EN60034 - IP55

A 220V asynchronous motor drives the bike through a gearbox and a clutch to the bikes pedalling axis. The speed of the motor is controlled by the frequency converter

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Tachogenerator ITD21 TTL
The motor has a built in tacho generator, which provides a pulse-signal proportional to the revolutions of the motor. To suppress noise from the motor and the FRQ translator, the tachogenerator is supplied from its own power source in the bike autopilot box, and the signal is galvanically isolated from the rest of the system using an optocoupler The signal is used to simulate engine revolutions. The users DevKit8000 programming should consider the position of the gearchooser when translating the Tacho signal. Tacho signal (digital): Frequency range KHz I/O pin on DevKit8000 GPIO1 Bit 2 Direction (seen from Devkit8000) Input
Inductive pick-up (wheel sensor) EI0801PPOS (carlo gavazzi)
Wheel revolutions are measured by an inductive pick-up, which gives out a signal every time an iron block is passed. 2 pulses are output pr. rotation Wheel sensor signal (digital): Frequency range Hz I/O pin on DevKit8000 GPIO1 Bit 3 Direction (seen from Devkit8000) Input
DevKit8000 (+IHA expansion board)
The DevKit8000 runs the users autopilot/cruise control software. A speeder signal can be output to control the speed of the motor. The interface box is configured to output the highest available speeder signal, (potentiometer vs. Devkit speeder signal.)
DevKit8000 Speeder signal (analog): I/O pin on DevKit8000 AOUT0 Direction (seen from Devkit8000) Output

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Start-procedure
1. 2. 3. 4. Make sure the Motor switch on the interface box is set to OFF Plug the main cable into a grounded outlet Release the emergency stop button (if it is activated) Check that the brake switch on the interface box works. (It makes the brake relay click - this should be quite easy to hear) Turn on the DevKit8000 Switch the motor on Have fun!

5. 6. 7.

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Kettler Ergoconcept (PC program)
PC log on information: Username: Password: Log on to this workstation only: cruise iha check
Start the Ergoconcept program using the Konzept shortcut on the desktop. The standard password is iha Type this in every time the program asks for a password. Choose start of training Choose a user profile to get to the main menu It is also possible to create a new user profile if this is desired. At the main menu there are 4 options. For running simulations it is appropriate to choose either Cruise Test or Cruise Animation In Cruise Test it is possible to see the load on the eddy current brake In Cruise Animation the user can change gear on the bike (the load on the eddy current brake) using the up and down arrow keys (in an intersection, the user can choose a direction using the left and right arrow keys)

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Appendix 1 Functional Diagram
Mains transformer (primary) 12V
Mains transformer (tacho) 12V

FRQ translator

Grey Flow DC 0-10V 28V!! Blue Black Green

Seperate tacho supply

Motor (+Tacho)
Inductive Rotation Sensor

3 wires (12V, GND, Data)

Tacho Signal TTL 5V high 3,3V Rotation 12V High

Brake Box

Speeder DC 0-10V Max 8mA
Galvanic Separation (optocoupler) N.C. Tacho 3,3V high

(Rev, 1, 2, 3, 4, 5, N)

Pullldown

Motor on/off (SW)

Voltage Divider: 0-5V output 12V Clutch (push) Brake (push)

divider

Speeder on/off (SW)

Oversteering comparator

6 bits
Voltage Divider: 0-2V output
Voltage Divider: 3,3V output
FRQ Divider: 1:200 (74HC40103)

Amplification to 0-10V

Speeder

Pulldown Pulldown

(Pot) Brake 3,3V high Speeder out DC 0-2 V Speeder in DC 0-2 V Tacho 1:200 3,3 V high 0-15Hz Tacho 1:1 3,3V high 0-3KHz Gear 6x 3,3V high
Left and Right shorted through 10KO

Flow DC 0-5V

Clutch 3,3V high (Bit0)

Stereo Jack

Rotation 3,3V high 0-40Hz Devkit 8000 connections:
(Bit1) DevKit8K AIN0 (0-2Volt) DevKit8K AOUT0 (0-2Volt) DevKit8K GPIO1 (bit4) (3,3V high) DevKit8K CPLD: GPIO1 (bit2) (3,3V high) DevKit8K GPIO2: Bit0-5 (3,3V high) Devkit8K Audio Jack DevKit8K GPIO1 Bit3 (3,3V high)
DevKit8K AIN1 (0-5V) DevKit8K GPIO1 (bit 0:1) (3,3V high)

ADC/DAC

GPIO1 GPIO2
Theoretical maximum voltage of the flow signal to Devkit8K is 5V, but no readings higher than 2V occur at maximum motor load. So ADC range can safely be set to 0-2V
Tacho 1:200 output signal is Not yet implemented.

Audio Jack

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Bike Autopilot Interface Box
Appendix 2 DIN connector pinouts
Female DIN Solder side TACHO DIN3

FRQ. Transformer DIN6

GND Closed = motor on
Inductive wheel sensor DIN 3
GND 1 Yellow Signal 2 Green
5V 3 Brown Flow Feedback signal

1 Brown

N.C. 6
12V 5 Blue 4 Green Speeder Signal 1 Brown GND 2 Blue

Signal 3 Black

2 Grey GND 3 Yellow
Colors are cables inside DIN connectors

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Appendix 3 Interface Box Schematics

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Appendix 4 Interface Box PCB

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Appendix 5 LENZE Frequency converter signal flowcharts

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Appendix 6 Tacho documentation

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Appendix 7 Inductive pickup datasheet

(EI0801PPOS)

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Appendix 8 Ergoracer parts list (german)

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