Introduction

• Data acquisition systems are the backbone of

modern car testing.
• Crucial to measure and analyze critical vehicle
safety and performance parameters accurately.
• Key component of performance testing.
• Sensors are used to collect important information.
• Microcontrollers and process analyze data from
sensors.
• Data is stored to analyze trends.
• Wireless data transmission allows Real-Time
monitoring.
 Flowchart Of Our Work

Selection Of Prioritize
Research on how
Parameters to be parameters on basis Selection of a
to measure said
measured/validated of importance and method.
parameters.
/tested. need.

Sensor calibration, Sensor interfacing

Sensor Selection
mounting, testing and program Market Survey
and research.
and monitoring. debugging.
 Objective and importance of our Project.
1. Performance Evaluation: Assess and evaluate the overall performance of vehicle under various conditions, including
acceleration, braking, cornering, and stability.
2. Data Collection: Collect and record a wide range of vehicle parameters and sensor data in real-time to create a
comprehensive dataset for analysis.
3. Component Analysis: Analyse the performance of individual vehicle components, such as the engine, brakes,
suspension, and transmission, to identify areas for improvement.
4. Driver Behaviour: Understand how driver behaviour affects vehicle performance and safety. This can include studying
driver actions during aggressive driving, panic braking, and other scenarios.
5. Comparative Analysis: Compare the performance of the tested vehicle to similar models or competitors to determine its
relative strengths and weaknesses.
6. Validation of Theoretical Models: Verify the accuracy of theoretical models and simulations through practical testing and
data comparison.
7. Optimization: Identify areas where vehicle performance can be optimized for better efficiency, safety, and customer
satisfaction.
8. Documentation: Create a comprehensive report that documents the entire testing process, including methodologies, results,
and recommendations.
9. Safety Enhancement: Identify potential safety enhancements or modifications based on real-world performance data.
 Selection of criteria.
1. ESP32 3. S – type Load cell:-
▪ Higher flash memory. 2. MPU 6050:- • High load capacity.
▪ Higher operating frequency. • Compact packaging • Low voltage.
▪ More RAM. • 3-axis Gyroscope • Easy interfacing
▪ Lower operating voltage. • 3- axis accelerometer with
▪ Additional analog and input • Low voltage microcontrollers.
pins • Low cost • Low error
▪ Lower cost • Versatile percentage.
▪ WiFi and Bluetooth • Simple mounting.
connectivity

5. Temperature Sensor:-
4. HW477 sensor:-
• K – type Thermocouple:-
▪ Easy interfacing with
➢ Appropriate temperature range.
microcontroller.
➢ Chemically compatible.
▪ Low cost.
➢ Easy mounting.
▪ Compact size.
▪ Simple connections and
• DHT 22 ( non contact type):-
mounting.
➢ Appropriate temperature range.
▪ Digital output.
➢ Easy interfacing with microcontroller.
▪ Low error percentage.
➢ Humidity measurement possible.
 Overview of components
ESP32 Microcontroller

• Memory:
➢ RAM: Up to 520 KB of SRAM.
➢ Flash Memory: Up to 16 MB

• Connectivity:
➢ Wi-Fi: Supports 802.11 standards.
➢ Bluetooth: Includes Bluetooth 4.2 and BLE 5.0.

• Low Power Consumption

• GPIO Pins:
➢ Up to 36 GPIO pins, configurable for various functions such as PWM, ADC,
DAC, and touch sensors.
➢ Analog Interfaces: 12-bit ADC channels & two 8-bit DAC channels.
➢ Digital Interfaces: I2C, SPI, UART, I2S, CAN, and Ethernet,
 Accelerometer sensor S – Type Load Cell

S-Shaped Design:
• Tri-Axis (3D) Accelerometers: The load cell is named for its distinctive S-shaped structure,
Measure acceleration along three perpendicular axes: X, Y, which consists of a central body with two arms extending
and Z. outwards in opposite directions.
Strain Gauges:
• Force Sensing:
Inside the load cell, strain gauges are bonded to the metal
When the accelerometer experiences acceleration, the inertial
structure. The strain gauges measure this strain and convert
forces cause these structures to move relative to the sensor it into an electrical signal.
frame.
Wheatstone Bridge Configuration:
• Measurement: The strain gauges are typically arranged in a Wheatstone
Changes in the position of these structures are measured using bridge configuration, which allows for precise
various methods, such as capacitance changes, piezoelectric measurement of small changes in resistance caused by the
effects, or changes in resistance. applied force.
 Hall Effect Sensor Temperature sensor

• Hall Voltage: • DHT 22:

When a magnet is placed near the hall effect sensor a voltage is Non-contact type digital temperature and humidity
induced indicating detection of the magnet. sensor utilizing a capacitive humidity sensor and a
thermistor to measure humidity and temperature,
• Directionality: respectively
The polarity of the Hall voltage depends on the direction of the
magnetic field relative to the direction of current flow.
• K-type thermocouple:
• Output Signal: Contact Type digital temperature which uses two
Hall effect sensors output voltage or current can be proportional different metal alloys joined together at one end,
to the strength of the magnetic field being detected. forming what's known as the sensing junction
 Block diagram of Vehicle Data Acquisition System

ESP 32 Dev
Accelerometer
sensor
kit V1
Final
RPM Result
Sensor

Temperature
Sensor
Serial Monitor
M-BAJA Vehicle S - type Load
Cell

*completed work of sensor is highlighted by green.

Circuit Diagram for Accelerometer sensor
Accelerometer pins ESP 32 Pins

VDD 3V3

GND GND

SCL 22

SDA 21

Specifications:-
MEMS 3-axis accelerometer and 3-axis gyroscope values
combined
Power Supply: 3-5V
Communication : I2C protocol
Built-in 16-bit ADC provides high accuracy
Mounting: Driver’s Chest
Circuit Diagram for S – Type Load cell
S – type load cell ESP 32 Pins
amplifier pins
VDD 3V3

GND GND

CLK 0

DATA 2

Specifications:-
Capacity:- 10kN
Sensitivity:- 2mV/V
Model:- S5kN
Mounting: Suspension arm
Circuit Diagram for Hall effect sensor
Hall Effect Sensor Pins ESP 32 Pins

VCC 3V3

GND GND

Vout 12

Specifications:-
Voltage- 5V DC
Model – HW477
Mounting: CVT casing’s Engine Side plate
Magnet mounting: CVT
Circuit Diagram for Temperature Sensor

Temperature Sensor Pins ESP 32 Pins

VDD 3V3

GND GND

DATA 0 and 10k ohm resistor

to 3V3.

Specifications:-
Temperature Range - -40 – 1250C
Voltage- 3 – 5 V
Humidity- 0 – 100%
Circuit Diagram for K-type thermocouple

Temperature Sensor Pins ESP 32 Pins

VCC 3V3

GND GND

SCK 14

CS 15

Specifications:-
Temperature Range - -ve 50 – +ve1500C
Voltage- 3 – 5 V
Humidity- 0 – 100%
 Accelerometer MPU6050 application and mounting

• Mounting: Driver chest.

• Application: Measurement yaw, pitch and roll angles with accelerations in x, y & z directions.
• Other Applications: Measurement of vibrations of components.
• Outcome: Quantification of yaw, pitch and roll angles with lateral and longitudinal
acceleration to analyse different suspension setups and design validation.
Accelerometer MPU 6050 connections.
 S-type loadcell application and mounting

• Mounting: Suspension arms.

• Application: Measurement of compressive and tensile loads on suspension arms under
various dynamic conditions.
• Outcome: Quantification of loads on suspension and validating the design.
 Hall effect sensor application and mounting

• Mounting: CVT casing.

• Application: Measurement of CVT’s RPM of Primary and Secondary sheaves.
• Other applications: Measurement of Actual RPM of motor in EV’s.
• Outcome: Performance Analysis of CVT with variation in flyweights and different
spring preloads.
 DHT-22 application and mounting

• Mounting: CVT casing.

• Application: Measurement of CVT casing’s internal temperature.
• Other applications: Measurement of internal temperature of Battery or motor in EV’s.
• Outcome: Performance Analysis of CVT with variation in temperature.
 K-type thermocouple application and mounting

• Mounting: Transmission gearbox.

• Application: Measurement of gearbox fluid temperature.
• Other applications: Measurement of brake fluid temperature.
• Outcome: Performance Analysis out of component with variation in temperature
K-type thermocouple calibration and results
Accelerometer MPU 6050 Result
S-type Loadcell Result
S-type Loadcell Result
S-type Loadcell Result
HW477 Result
DHT-22 Result
 Future Scope
1. Advanced Real-Time Monitoring and Analysis 6. Enhanced User Experience
➢ Enhanced Sensors ➢ Augmented Reality (AR)
➢ Edge Computing ➢ User-Friendly Interfaces

2. Predictive Maintenance and Diagnostics 7. Sustainability and Energy Efficiency

➢ AI and Machine Learning ➢ Fuel Efficiency
➢ Automated Diagnostics ➢ Electric and Hybrid Vehicles

3. Performance Optimization 8. Regulatory Compliance and Standardization

➢ Data-Driven Tuning ➢ Compliance Monitoring
➢ Adaptive Systems ➢ Standardization

4. Safety Enhancements 9. Educational and Research Applications

➢ Real-Time Alerts ➢ Research and Development
➢ Collision Avoidance Systems ➢ Educational Tools

5. Data Integration and Connectivity 10. Custom Applications and Innovations

➢ IoT Integration ➢ Custom Tuning
➢ Vehicle-to-Everything (V2X) Communication ➢ Innovation Platform
 Conclusion

• Coming to the conclusion after employing/integrating all sensors to the vehicle by

connectivity of sensors like S – type load cell, Hall effect sensor, Temperature
Sensor, Accelerometer Sensor with ESP 32 Dev kit 1 (WiFi module).
• By this all connectivity get a remotely stored database which is displayed on the
webpage on the device (mobile through Wifi) and in the serial monitor.
• Parameters like Speed, acceleration, temperature, suspension tension can be
displayed and viewed real time.