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NuVici Developer's Kit User Manual

1. MuVinci NuVinci CVP AS Developer Kit User Manual FALLBROOK TEC AWOL amp le Ss Table of Contents Mc B ew 072 Vd 2 ei ene eee rete ee eae ear cere Mee Sc erence ce ee eee ene eee ae ey Oe pO Mere ee Pee 3 A 8 beeen rameter teen tere te te er el eee eee en ee ge ern ae ere eee 3 2 GV P Developer INIT OD CATO Ni te NA 4 To System POWER dois 5 1 4 System Capabilities ic cau glad tan eat ee A eee E ected alata 6 1 5 Product Development OptiONS cocccccocnccoccnccncnnococononononononncnonnnononnnonnnnnnnnnnonnnnnnnnnnnonnnnnnnnnnnnnnnnonanenes 6 1O Warnanya E EE 6 2 Hardware Details amp InstallatiON ooocccconcncconnnoconnnoconnnconnnonoconononnnnnnnnonanononannonannnnnnnnnnonannnnananenanos T 2 1 Wheel Duilding Lacing Of the CVP ii E E Soawie tad emanated T 2 2 S DOCKO S I Gadir ae ec Tl aNd E Roe tonb ade T 223 CONTO Ia a S 8 Z 4 Wal VVIGING Ha Ness isa a 9 2 9 Installation of CVP and Speed SENSO ui A ac ieades 9 ZO SAM ACUO Instalado de aie 11 Zi VINO PIO a en a a a a E ania aialyns 12 3 NuVinci Desktop Application Installation amp Operation oocccconcnccccnncconnncconnnconnnnonacnnonnnnnnnnnnnonononononnnos 13 Ai OO O A A aN 13 32 mstallatioh anda Configuration is n a ea sdasuiad oPesutadsas abe a a a las 13 3 3 NuVinci Desktop Application Installation cooocccoccccocncnocnccocnconnnonononanononnnnnnnonnnnon
2. To view any subfolders click a plus sign above res The Hardware Update Wizard will load the driver for the Controller You will have to repeat this for the second USB Serial B It may also be necessary to unplug and reinstall the USB cable to recognize the Controller Conflict with another Serial Device such as a modem Another serial device in your system may erroneously be recognized as a Controller This is not an installation issue with the Controller itself as it may not even be connected If your application is detecting a NuVinci Controller but it is not responding to commands note the COM port that the application detected as your Controller NuVinci CVP Developer Kit Manual Page 44 LEY fevers Kal Ikeda e A A AO Nuvine Controller found or COME FALLBROOK Select Command Check this COM port against the COM port assignments in Device Manager If they are different another device is being detected as your Controller Disconnect your Controller until the problem is resolved Browse through the Device Manager and try to find the COM Port that is being falsely detected If it is a device that is not in use you may disable it from within Device Manager by right clicking on it and selecting Disable The disabled device will have a red X across Its icon g Device Manager Eifel Eq File Action View Help EA ETE E 4 Intel R 82801GBM ICH 7 M LPC Interface Controller 27B9 Intel
3. The Vehicle Speed Capability section includes the maximum possible speed for the vehicle in miles per hour This value will be used to determine the Shift Map speed increment size in mph The NuVinci Configuration Editor will provide 64 data entries equally spaced across the vehicle speed range Thus for each Shift Map there will be 64 Shift Position values associated with 64 Vehicle Speeds NuVinci CVP Developer Kit Manual Page 25 NuVinci CVP Model 1 Square shift rod end 4 turns 2 Splined shift rod end 2 turns The NuVinci CVP Model section requires selection of the model CVP that is being used for the application CVPs with a square shift rod end allow four 4 turns of the Shift Rod to span the ratio range of the CVP while CVPs with a splined shift rod end allow two 2 turns of the Shift Rod to span the same ratio range CVP Ratio Calibration only modify if necessary Shift Pos A In Speed Ratio B Shift Calibration A value Shift Calibration B value Minimum CVP Shift Position Maximum CVP Shift Position Minimum CVP Speed Ratio Maximum CVP Speed Ratio calculated calculated calculated calculated The CVP Ratio Calibration section is only to be changed by experienced developers who are prepared to calibrate their particular NuVinci CVP The CVP speed ratio is varied by rotating a shift rod on the input right side of the transmission The speed ratio is dependent on
4. 50 55 atesat tentes 00 r ost res 120 125 19019140150 reef anes OTH 4 NameO3 1 1 1 45 Josj 64 Of OT ojopojoptotototojofojofafofafofofofofofofoto AAA ee atatoa oteren oare aT 6 Nameos 1 1 1 45 J0s46 64 ojojojojojojojojaoajojojojojojojofjojaoajojojojaoajojojojfjof z Named 1 1 1 45 046 es ojojojofjojojojojojojojojojojojojojojojojojojojojofo 8 Nameoz_ 1 1 1 45 Jo0sr6 6e ojojofjofjojojofjojojofjofjofjofjojojofjojojfjojofjojojfjofjofofo S Named 1 1 1 45 Josej es ojojojofojojofjofjojaojofjojofojojojofjojojofofjojfjojofofo 10 Nameog 1 1 1 45 J0s6B es ojojojofjojojojofjojojofjojofojojojofjojojofjofjojojofofo E AA A a tt tb Manual ES PA E E The selected file type does not support workbooks that contain multiple sheets A To save only the active sheet cick OK To save all sheets save them individually using a different file name for each or choose a file type that supports multiple sheets Ca Cea Developer Kt Shift Table Entry Tool Beta 10 csv may contain features that are not compatible wth CS M5 DOS Do you want to keep the workbook in this format e To keep this format which leaves out any incompatible features dick Yes e To preserve the Features dick No rae Save co tse EEA Bical RR To see what might be lost click Help 12 13 15 16 18 19 20 21 Ee 23 24 25 26 28 29 30 31 32 33 34
5. Port Settings Bits per second 115200 Data bits 8 Parity None Stop bits 1 Flow control None v Restore Defaults Disconnected Auto detect Auto detect NOTE Often on the first attempt to open the PC Terminal connection to the Controller an error may occur stating that the port was unable to be opened Hyper Terminal If this happens select OK and then within HyperTerminal go to the Call menu and select Call or click the telephone icon Once the connection is established and saved it should open immediately upon future sessions Saved HyperTerminal session files can be saved to your desktop for easy execution NuVinci CVP Developer Kit Manual Page 36 PC Terminal Display Typically the lower COM port value will be the PC Terminal Display connection Once connected information should appear in HyperTerminal as Display Hyper Terminal File Edit View Call Transfer Help VDC 38 6 Spd 8 6 Actuatorl 0 78 T A Pos 339 445 ShiftMap FiveSpeed This display is explained in the previous section for the optional NuVinci Display Interface In addition to the display function there is also a user interface to communicate with the Controller through the USB connection When the terminal application is active typing the following keys will have the following function When operating from a Shift Map ShiftMap Manual e 1 keystroke Will go to the next h
6. v Nuvinci Desktop Controller Revision Information HARDWARE FIRMWA E FIRMWARE Primary Rey ii Alternate Rey Minor Rey Shift FALLBROOK 0 a Select Command NOTE If there is an error upon selecting Controller Information the NuVinci Desktop application is likely mistaking another piece of hardware in your PC for the Controller This is very common if a modem is installed on the PC It is likely that this conflicting hardware will need to be disabled as described in Appendix I NuVinci CVP Developer Kit Manual Page 16 3 3 4 Sending Tables to the Controller When the NuVinci Desktop application has successfully located the Controller click on the Select Command drop down menu and choose either Send Shift Table or Send Configuration Table reference the NuVinci Configuration Editor section of this User Manual for how to create Configuration Tables and Shift Tables The program will ask you to locate the file you want to send on your PC and will perform the communication between the PC and the Controller The Controller can hold only one Shift Table and one Configuration Table at a time so this procedure will overwrite the Shift Table or Configuration Table on the Controller with the one from your PC Select Shift Table O Shift 8 Config Table Tools amp Files O egan E config_RefvoltShift E DCoper Kit Shift amp Developer Kit Shift i El Config_1_00_24 csv El otherCS
7. Config cs El Config_1_00_36 csv El random_shift cs BL Config_1_00_48 csv BL shift_1_O0 csv Ed Config_AutoShift_1_00_12 csv E Shift Currie _00 csv Ed config_AutoShift_1_00_12Y_harmon y Csy Eb Shift_Giant_Harmor E Config_AutoShift_1_00_24Y csw Ed shift_Sample_Excel El Config_AutoShift_1_00_36 csv El shiftTable csv Ed Config_AutoShift_1_00_48 csv Ed Config_Giant_Harmony_36 18 csw EL Config_RefYoltShift_1_00_12W csw E Ed Config_Ref oltShift_1_00_24 csv Ed config_RefvoltShift_1_00_36Y csw File name Config_1_00 12 csv Files of type Comma Separated Values csv NOTE If there is an an error when sending a Configuration Table or Shift Table to the controller the data will not transfer to the controller and the system will not function as intended After an error communication will often be compromised If this occurs close the NuVinci Desktop application and unplug and reconnect the USB cable to the Controller before attempting again Reference Appendices A and B to ensure the Configuration Table and Shift Table are in the correct format and entries are within limit values 3 3 5 Receiving Tables from the Controller When the NuVinci Desktop application has established communication with the Controller click on the Select Command drop down menu and choose either Receive Shift Table or Receive Configuration Table The Controller can only hold one Shift Table and one Configurat
8. DEMANDS OR ACTIONS ARISING OUT OF OR RELATING TO THIS AGREEMENT SHALL NOT EXCEED THE AMOUNTS PAID TO FALLBROOK TECHNOLOGIES BY THE PURCHASER UNDER THIS AGREEMENT IN NO EVENT SHALL FALLBROOK TECHNOLOGIES BE LIABLE FOR ANY INDIRECT INCIDENTAL CONSEQUENTIAL SPECIAL OR EXEMPLARY DAMAGES OR LOST PROFITS EVEN IF FALLBROOK TECHNOLOGIES HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES Notwithstanding the foregoing Fallbrook Technologies may at its sole discretion replace kits that it determines have manufacturing or material defects If you believe your product has manufacturing or material defects notify Fallbrook Technologies and do not install or use the kit NuVinci CVP Developer Kit Manual Page 6 2 Hardware Details amp Installation 2 1 Wheel building Lacing of the CVP The NuVinci CVP is intended to be laced into a 36 spoke bicycle wheel The N17X series NuVinci CVP has successfully been laced into 20 24 26 inch and 700c wheels wheel diameters smaller than 26 inch sizes may require custom length spokes A Truing Stand Adapter is included to install over the left axle to provide equal diameter contact points for a wheel truing stand Wheel building and lacing tips can be found in the NuVinci Technical Manual available in the Bike Tech Data section of the NuVinci website www fallbrooktech com Other wheel or jackshaft configurations for the NuVinci CVP are possible which may require custom components output
9. determine final vehicle gearing Configuration amp Shift Tables CSV NuVinci Desktop Application Install NuVinci Desktop Application Establish Controller Connection Send Configuration Table amp Shift Table Files to Controller Figure 5 NuVinci CVP Developer Kit System Flowchart NuVinci CVP Developer Kit Manual Page 5 1 4 System Capabilities The electronic components of the NuVinci CVP Developer Kit are compatible with a power supply of 12 to 48 Volts direct current VDC The NuVinci CVP transmission included with the CVP Developer Kit offers a nominal 350 ratio range from a speed ratio of 0 5 underdrive to 1 75 overdrive As with any transmission device there are limits to torque power and speed The NuVinci CVP is a production bicycle drivetrain that has proven to be extremely robust in bicycle and light electric vehicle applications Firm performance limits for vehicles other than bicycles are being developed but Fallbrook Technologies recommends the following limits e Maximum Sustained pulse free Input Torque 65 Nm 48 Ib ft e Maximum Instantaneous spike Input Torque 130 Nm 96 Ib ft e Maximum Sustained Input Power 5 kW 7 hp e Maximum Input Speed 1000 RPM e Maximum Output Speed 1000 RPM e CVP Orientation Main Shaft Horizontal to Ground Operation at these torque and power conditions is not recommended for extended durations and durability is heavily dependent on d
10. 35 36 Ec 39 14 Mp p i Draw yz AutoShapes N dM JO J A xs El La Oe NOTE There are a number of other parameters that are contained in the Shift Table but function and durability of the system may be compromised if they are modified Therefore it is critical that the user not modify any of the other values in the Shift Table unless instructed by Fallbrook Technologies Customer Support NuVinci CVP Developer Kit Manual Page 32 Appendix D Alternative Shift Methods The default mode of operation for the CVP Developer Kit is automatic shift control based on speed measurement of the NuVinci CVP Any Shift Maps that are programmed are used for this type of operation only Reference section 4 2 1 Actuator Control Mode 0 This default mode also supports manual shifting in 50 Shift Position steps through the Display Interface and PC Terminal Display connections as detailed in Appendix F There are two other ways to control Shift Position for the NuVinci CVP Developer Kit Analog Input Control This shift method forgoes Shift Maps and allows the developer to simply apply a reference voltage to the Controller to accurately control shifting The resulting Shift Position will be determined by the direct current voltage applied 0 to 5 VDC To enable this shift method 1 Set Shift Method to 1 in the NuVinci Configuration Editor or manually set the Actuator Control Mode parameter to 1 in
11. A A T established Step 1 create Shift Maps Minimum Shift Position 23 manually or with Target Source RPM too Maximum Shift Position 977 NOTE Only Shift Map 21 will be accessible unless if you want the CVP to you have a mode switch or controvdisplay interface maintain a constant power z source RPM cadence Shift Maps motor speed etc enter the speed here and this Shit Map Name 3 Characters No Spaces will calculate the proper Source Shift Position below Entered Source Entered Source Calc Shift RPM Vehicle Position Result Speed 0 1000 rom rm ern E Copy this column and use 23 e Paste Special Values to zan transfer them to an ORANGE Shift Map column to the right The NuVinci Configuration Editor is intended to be a relatively simple interface for a feature rich system allowing the developer to customize the NuVinci CVP control to their application By inserting configuration information into the orange fields and creating Shift Maps the NuVinci Configuration Editor will allow the developer to export the Configuration Table and Shift Table that will be sent to the Controller via the NuVinci Desktop application Detailed instructions for exporting the Configuration Table and Shift Table files are included on the NuVinci Configuration Editor on their respective worksheets Export Config Table and Export Shift Table These tables are required for operation of the NuVinci CV
12. CVP Developer Kit Manual Page 12 3 NuVinci Desktop Application Installation amp Operation 3 1 Introduction The NuVinci CVP Developer Kit is a powerful transmission and electronic control system that allows a developer to customize the NuVinci CVP to their particular application The drivetrain can be custom tuned allowing maximum flexibility for the designer In order to interface with the NuVinci Controller the NuVinci Desktop application must be installed on a PC operating Microsoft Windows XP or Vista 3 2 Installation and Configuration The NuVinci CVP Developer Kit CD includes the NuVinci Desktop application and National Instruments NI LabVIEW Runtime Engine 8 2 1 If you already have LabVIEW or other NI software installed on your PC the installer will not overwrite or otherwise interfere with normal operation of your currently installed software 3 3 NuVinci Desktop Application Installation Close all other open programs and then run setup exe if the installation does not automatically begin from the NuVinci CVP Developer Kit CD Select the destination directories to which you wish to install the application components and select Next to continue E Nu inci PC Application E NuYinci PC Application Destination Directory Select the primary installation directory Welcome to the NuVinci PC Application 1 0 Setup Wizard This wizard will guide you through the installation of the Nuvinci PC Applicati
13. Interface Integrated Into a Light Electric Vehicle eGo NuVinci CVP Developer Kit Manual Page 4 1 3 System Flowchart The NuVinci CVP Developer Kit contains three separate sub systems that allow the user to customize the transmission and control system to a particular vehicle or application e Hardware All mechanical and electrical components of the system Reference Figure 1 e NuVinci Configuration Editor Microsoft Excel spreadsheet template that allows the system configuration to be established and Configuration Table and Shift Table to be exported for the Controller e NuVinci Desktop Application Software application that enables communication between a PC and the NuVinci Controller to transfer Configuration and Shift Table files Hardware Specify and Build CVP Wheel for Vehicle Determine CVP Wheel and System Configuration Data Install Final Configuration Hardware Gearing etc Install Controller Operate NuVinci CVP Developer Kit Wheel Rolling Circumference System Voltage Shift Mode etc Source Sprocket and CVP Sprocket Gearing Open Excel Template from CD amp Save Local Copy Input Vehicle Configuration Parameters Gearing Top Speed etc Create amp Analyze Shift Maps for Vehicle Application Determine Final Configuration Gearing Shift Maps etc Export Configuration Table amp Shift Table CSV Files Configuration amp Shift Tables Iterate to
14. R 82801GBM GHM ICH M Family Serial ATA Storage Controller 27C4 4 Microsoft UAA Bus Driver For High Definition Audio A Conexant HDA D110 MDC 92 Modem SigmaTel High Definition Audio CODEC 4 Mobile Intel R 945GM PM GMS 940GML and Intel R 945GT Express Processor to DRAM Controller 27 4 Mobile Intel R 945GM PM GMS 940GML and Intel R 945GT Express PCI Express Root Port 2741 4 System board 9 System board Y System board Audio Codecs 0 Legacy Audio Drivers Legacy Video Capture Devices Media Control Devices 1 Microcode Update Device If possible turn local echo for the device off This may make it unnecessary to disable the device Another possible option is to reorder the devices in order to allow the NuVinci Desktop application to find the NuVinci Controller before the conflicting device It is a function of the NuVinci Desktop application to scan each detected COM Port in order detected for a NuVinci Controller until it encounters one The application will not scan beyond that point It is not necessarily true that the detected COM Ports are in sequence from lowest to highest so reordering COM port assignments is not a foolproof method Reorder the COM Port assignments by removing and reinstalling the devices in different order Disable everything and then enable the NuVinci Controller first so that it moves up the list Enable the other devices after the NuVinci C
15. System Clock System time count Seconds System Voltage System voltage to the NuVinci Controller volts Drive Motor Current not utilized Shift Actuator Current Current supplied to Shift Actuator Amps Throttle Position In not utilized AS NS NuVinci CVP Developer Kit Manual Page 37 6 Throttle Position Out not utilized 7 Shift Actuator Actual Position Actual Shift Position 0 1000 8 Shift Actuator Target Position Target Shift Position 0 1000 9 Vehicle Speed Measured from speed sensor mph 10 Drive Motor RPM not utilized 11 Shift Actuator PWM Pulse width modulation of Shift Actuator 12 Drive Motor PWM not utilized 13 Main Loop Count not utilized 14 Analog to Digital Loop not utilized 15 Drive Motor Power not utilized 16 Economy not utilized 17 Shift Mode 0 is Shift Map 1 1 is Shift Map 2 etc 18 Brake Interrupt not utilized This data can be viewed in the HyperTerminal window in real time or can be saved to a data log The data will look like this in the raw format Debug HyperTerminal File Edit View Call Transfer Help 70 201 38 688 0 000 0 000 0 000 0 93 104 53 644 0 1 1 1008 0 0 0 0 0 0 221 38 688 0 000 0 000 0 000 0 93 111 9 6 0 1 1 1008 0 0 0 0 0 70 241 38 688 0 000 0 000 0 000 0 93 104 53 644 0 1 1 1008 0 0 0 0 0 0 261 38 688 0 000 0 000 0 000 0 93 104 5 644 0 1 1 1008 0 0 0 0 0 0 281 38 688 0 000
16. cuon cocino a dead Gas eee ses 36 PCPS iri NOS Aye seccatrcan tas E d 37 ESTE mia DEDUd eiii dt taa ii icon 37 Appendix G Controller Connections amp Capability oocooocccccoccncconcnoconononacononononononononcnononononononcnnnos 39 Appendix H Speed Ratio Shift Position CalibratiON cocooccccccnnccccnnconnnononononononononnnonacnnnnnnncnnnnos 40 Appendix NuVinci Desktop Application Troubleshooting coooccccocncoccnconcnnccnconcnoncnconcnonnnnnnanonnanonnnnss 41 A y ec ee eee 41 A PP es ee eee eee ere 41 Hardware Dee e e oA a do i 42 Appendix J Support and SEVA eidss 46 NuVinci CVP Developer Kit Manual Page 2 1 Product Overview 1 1 Included in the Box The following components should be included in the NuVinci CVP Developer Kit as shipped from Fallbrook Technologies CD INCLUDES 1 NUVINC CONFIGURATION EDITOR 2 NUVINCI DESKTOP SOFTWARE Figure 1 Contents of NuVinci CVP Developer Kit NuVinci CVP Developer Kit Manual QT Y DESCRIPTION TRUING STAND ADAPTER SOCKET HEAD CAP SCREW M5 x 14 SOCKET HEAD CAP SCREW MS x 5 DECAL NUVINCI JAM NUT MI2 x 1 75 DISPLAY MODE WIRING IGTAIL MAIN WIRING HARNESS WASHER FLAT W5 WASHER LOCK SPLIT M5 LH WASHER NO TURN NJT ACORN o 0 Page 3 1 2 CVP Developer Kit Operation The NuVinci CVP Developer Kit is a flexible and adaptable electronically controlled continuo
17. device What do you want the wizard to do No not this time I ni O Install from a list or specific location Advanced Click Next to continue Click Next to continue Cancel The Found New Hardware Wizard will search the Internet for a period of time sometimes 60 seconds or more for the appropriate drivers from the manufacturer When the appropriate driver has been found a message will be displayed showing software has been installed for USB Serial Converter A as shown below Found New Hardware Wizard Found New Hardware Wizard Please wait while the wizard searches SS Compl etin g the Found New Hardware Wizard S The wizard has finished installing the software for 2 USB Serial Converter 4 2 Dual RS232 Click Finish to close the wizard Next Cancel NuVinci CVP Developer Kit Manual Page 14 Following the successful USB driver installation a message will pop up stating Found New Hardware Your new hardware is installed and ready to use The same setup will repeat for USB Serial Converter B and should be executed in the same fashion as above i Found New Hardware Your new hardware is installed and ready to use IA 3 11PM NOTE If there is no active connection to the Internet please reference Appendix section titled Manually Installing USB Device Drivers This will desc
18. includes information such as system voltage speed measurement parameters shift control modes and Shift Actuator performance parameters The Configuration Table is a comma delimited csv or comma separated values file with all information in a simple text format separated by commas Reference Appendix A for further details and structure of the Configuration Table 4 1 2 Shift Table The Shift Table includes all shift information for automated shifting of the NuVinci CVP Shift Maps are created for a range of vehicle speeds which the Controller will reference to control the speed ratio of the CVP Shift Positions are normalized from O to 1000 across the speed ratio of the NuVinci CVP The values correspond to the rotational position of the Shift Rod and not directly to speed ratio reference Appendix H Up to 10 Shift Maps can be sent to the Controller in the existing Shift Table format though the system can be configured to accommodate more In addition to Shift Map information the Shift Table includes other information such as software speed limiting speed step size and Shift Map table length The Shift Table is also a comma delimited csv or comma separated values file Reference Appendix B for further details and structure of the Shift Table 4 2 Define your Application Parameters The best way to create and customize your Configuration Table and Shift Table is to use Microsoft Excel and the NuVinci Configuration Editor Templ
19. option allowing easy sprocket installation and removal NuVinci CVP Developer Kit Manual Page 7 2 3 Controller The NuVinci CVP Developer Kit is delivered with an electronic shift Controller that can operate over a wide range of system voltages The Controller has a powerful 32 bit microprocessor and advanced capabilities There are six primary connections provided on the CVP Developer Kit Controller as shown in Figure 7 NOTE The Controller printed circuit board and components are covered with a protective coating that will protect against some amount of contact conduction condensation and corrosion If harsh environments are expected the Controller may require non conductive potting POSITIVE amp NEGATIVE POWER LEADS MINI USB JTAG Figure 7 NuVinci Controller and Connector Locations e Positive amp Negative Power Leads Provided bare for the developer to use their preferred connection The system is designed to operate on 12 to 48 Volts DC While some protection is provided please note that the Controller may be permanently damaged by reverse polarity NOTE It is recommended to place a 5AMP fuse in line on the positive red wire This will help to protect the vehicle application electrical system from excessive current should any failures or surges occur e Mini USB connector Connector used for communicating between a PC and the Controller including Shift Table and Configuration Table send and receive
20. that can be copied to a Shift Map Legend Calculated Values do not change Instructions or Data to be Copied There are multiple worksheets in the NuVinci Configuration Editor noted by the tabs at the bottom of the Excel document These worksheets are intended to be completed from left to right The first is the Inout Parameters worksheet where basic configuration information will be inserted by the developer and is shown in the above screen shot NOTE Shift Map information should only be entered after appropriate entries are made on the Input Parameters worksheet NuVinci CVP Developer Kit Manual Page 19 The second worksheet is titled Create Shift Maps which has tools to help create Shift Maps for the intended application vu yu 6 2 gt yl SPEDEIITHIEIEIGIEIGIEIGIEIEE 0 95 67 75 67 PEHNEHEIEHHEEE M 4 M Input Parameters Create Shift Maps Chart Position Chart Source RPM Export Config Table Export Shift Table lt gt Drawv 13 AutoShapes MOJO 44 Ai al gt gt dr Ar 3 349 w Bik AEH File Edit View Insert Format Tools Data Window Help Adobe PDF Type a question for help X TO EIA EF AMAIA LZ ll 0 00 lt 00 gt 0 152 A B C D 3 G H J K IR S NuVinci Configuration Editor wersion 1 01 Unhide additional Shift Maps gt Legend Create Shift Maps Step 2 After Input Paremeters are aS Spay A
21. the rotational position of the shift rod which is controlled by the Shift Actuator and Controller These calibration values allow you to custom calibrate your CVP speed ratio The factory settings should be accurate enough for most applications If you need custom calibrations reference Appendix H Create Shift Maps Worksheet There are two distinct ways to create Shift Map values using the NuVinci Configuration Editor One method is to simply enter Shift Map values manually and the other method is to calculate constant Source RPM Shift Maps NOTE The calculations to create Shift Maps depend on the data from the Input Parameters worksheet therefore accurate information should be entered prior to creation of any Shift Maps Manual Entry The Shift Maps are shown in the following basic configuration columns truncated for display on this page Up to ten separate Shift Maps are supported with the NuVinci Configuration Editor though only the first Shift Map is accessible without a mode switch Display Interface or PC Terminal connection reference Appendices E and F To view the Shift Maps in hidden columns L through Q select the top column headers labled K and AB right click and select Unhide as illustrated below The Vehicle Speed column is automatically calculated using the previously input Maximum Possible Vehicle Speed For each Vehicle Speed value there will be an associated trans
22. the Configuration Table 2 Apply the 0 to 5 VDC reference voltage to the HDR4 connector via the Shift Reference Wiring Pigtail Positive voltage is applied to the White pigtail wire and the brown pigtail wire should be grounded reference Appendix G 3 The Oto 5 VDC reference voltage is proportional to the normalized Shift Position values of O to 1000 e g a value of 2 5 VDC correlates to a Shift Position of 500 Maximum and Minimum Shift Position values are still in effect as noted in Appendix C NOTE Speed Ratio is not directly proportional to voltage or Shift Position for the NuVinci CVP reference Appendix H Command Interface Control Unsupported This shift method forgoes Shift Maps and allows the developer to simply command the Shift Position 0 1000 directly to the Controller Maximum and Minimum Shift Position values are still in effect as noted in Appendix C This _ shift method _is currently under development and _is unsupported by Fallbrook Technologies NuVinci CVP Developer Kit Manual Page 33 Appendix E Mode Switch Capability The NuVinci CVP Developer Kit supports a dual control mode that is operated by a switch Effectively when the switch is open the Controller will reference Shift Map 1 If the switch is closed the Controller will reference Shift Map 2 This provides immediate flexibility between two different Shift Maps for the target application One possible use could be an eas
23. 0 000 0 000 0 93 111 5 9 6 0 1 1 1008 0 0 0 0 0 70 301 38 688 0 000 0 000 0 000 0 93 104 53 644 0 1 1 1008 0 0 0 0 0 70 321 38 688 0 000 0 000 0 000 0 93 104 5 644 0 1 1 1008 0 0 0 0 0 When imported into a spreadsheet the data can be documented and used for analysis grey columns are not applicable for the NuVinci CVP Developer Kit Current In A O ee ee 63 601 38 378 O 074 O O 283 267 6 64 63 621 38 316 0 084 0 280 257 265 l Shift Shift Shift l l Pae Throttle Throttle Actuator Actuator Shift Brake Motor Actuator Position Position ae a Power Economy Voltage Current Out Position Position Mode Interrupt 63 661 38 378 0 032 0 272 257 63 681 38 378 0 018 0 0 0 268 257 63 701 38 502 0 6 64 0 1 1 50432 9 0 0 2 0 AS E po o 2 o po o y 2 0 63 641 38 316 0 084 0 275 257 IN 2 MA po 2 0 po o 2 o NuVinci CVP Developer Kit Manual Page 38 Appendix G Controller Connections amp Capability HDR2 Display Mode Wiring Pigtail This connector is capable of performing two functions A mode switch can be connected to the Yellow and Black wires to provide a quick method of switching between Shift Map 1 and Shift Map 2 see Appendix E Alternatively all four wires can be used to interface with the optional NuVinci Display Interface see Appendix F HDR2 Display Mode Wiring Pigtail Red 5V sup
24. 12 Next slide the RH No Turn Washer over the Main Shaft the bent tab should point toward the CVP and thread the Shift Rod Retaining Nut onto the Main Shaft along with the RH Main Shaft Nut reference Figure 13 Ensure that the RH Main Shaft Nut is not tightened against the No Turn Washer at this time and torque the Shift Rod Retaining Nut with the thin hexagonal flange to the value in Table 1 With the RH No Turn Washer outside of the dropout and the drive chain belt loosely installed slide the CVP into the frame fixture Locate the Speed Sensor on the non drive side of the CVP against the inside of the frame The sheetmetal enclosure is intended to locate the Speed Sensor within a nominal distance of 2 mm 0 080 inch to the 6 ferrous disk brake mounting bolts These bolts function as the pick ups for the Speed Sensor reference Figure 10 NOTE The Speed Sensor in the CVP Developer Kit is not a standard Hall Effect sensor The signal to the Controller varies between 0 7 and 1 4 volts to designate a ferrous bolt passing by the sensor Fallbrook Technologies does not recommend using a different Speed Sensor Speed Sensor voltages higher than 3 3 volts can cause permanent damage to the Controller NuVinci CVP Developer Kit Manual Page 10 SHIFT ROD RETAINING NUT TIGHTENED RH MAIN SHAFT NUT TIGHTENED Figures 12 8 13 Seating the Shift Rod Fully Into the CVP Shift Rod Retaining Nut and RH MainShaft Nut Tightening Order O
25. A and USB Serial Converter B This is found by right clicking the USB Serial Converter entries and selecting Properties and selecting the Advanced tab USB Serial Converter A Properties General Advanced Driver Details gt USB Serial Converter 4 Configuration Use these settings to override normal device behaviour NuVinci CVP Developer Kit Manual Page 42 If you do not find your Controller as a USB Composite Device look for unrecognized device types under Other devices as on the left below The Controller may be recognized as USB device but as an unrecognized type or possibly with no COM ports assigned as on the right below Device Manager Oy E3 File Action view Help e MES 2 a lt mA 4 SPARKE LTOP Batteries Bluetooth Radios Computer A a PCMCIA adapters Hs Disk drives x H E Display adapters Ports COM amp LPT 4 4 DYD CD ROM drives Processors g Human Interface Devices ZE Smart card readers H IDE ATA ATAPI controllers 8 Sound video and game controllers gt Keyboards gt lt i f System devices Mice and other pointing devices E Modems Universal Serial Bus controllers ik Conexant HDA D110 MDC 92 Modem H Monitors Generic USB Hub 88 Network adapters Generic USB Hub E 4 Other de
26. Be sure to get the Virtual COM Port VCP and not Direct D2XX version latest version as of this User Manual release is 2 04 16 released February 25 2009 What is the LabVIEW Run Time Engine The NuVinci Desktop application requires National Instruments LabVIEW Run Time Engine LVRTE version 8 2 1 If you already have this version of the LVRTE or the LabVIEW development environment it will not be installed If you have another version on your system later or earlier LVRTE 8 2 1 will be installed with it and will not interfere with the other version Errors Unable to find required support libraries When the application first starts it self checks the system for required components If any components are missing or corrupted it will return Unable to find required support binaries CODE 25 and inform you that the application will exit Your application will need to be uninstalled and reinstalled to recover them No serial ports found After the application starts it checks the system for available COM ports If no COM ports are found a dialog will inform you that the application will exit Even if you do not have a NuVinci Controller installed most PCs will have at least one COM Port that the application will detect Check your system configuration for the existence of any COM ports If you do have one or more COM ports and the application fails to detect them contact Fallbrook Technologies for technical assistance If you do n
27. Calibration do not change Click on the Create Shift Maps worksheet and type 70 into the Target Source RPM Tool orange entry box Copy the calculated Shift Map column 64 values highlighted in yellow boxes to the Shift Map 1 orange entry fields as the instructions state on the worksheet Name Shift Map 1 70 RPM optional View the Shift Map characteristics by clicking on the Chart Position and Chart Source RPM worksheets and graphs Click on the Export Config Table worksheet and follow the instructions to export and create the Configuration Table CSV file Click on the Export Shift Table worksheet and follow the instructions to export and create the Shift Table CSV file Use the NuVinci Desktop application to connect to the PC and then individually send the Configuration Table and Shift Table files to the Controller This concludes the basic User Manual for the NuVinci CVP Developer Kit Please reference the Appendices for more detailed information and instructions Fallbrook Technologies looks forward to the applications that will result from this product NuVinci CVP Developer Kit Manual Page 21 Appendix A Configuration Table Format The Configuration Table is a comma delimited file with entries separated by commas and line Spacing There are 64 lines in the Configuration Table and 2 columns The first column is a description and the second column is the configur
28. P Developer Kit If further details are required for the NuVinci Configuration Editor please reference Appendix C which details each step and worksheet involved with creating and exporting Configuration and Shift Tables NuVinci CVP Developer Kit Manual Page 20 4 3 Example Application Suppose the target application is a pedal assist bicycle with the motor in the front wheel hub The goal for the NuVinci CVP Developer Kit application is to allow the rider to operate at a constant pedal cadence of 70 RPM when within the speed ratio range of the transmission The vehicle has the following attributes 700c road wheels with a rolling circumference of 84 8 inches Front chain ring of 33 teeth Rear sprocket of 17 teeth Top speed of 40 mph 48 volt battery system Disk brakes with speed sensor in standard location on 6 ferrous bolts The NuVinci Configuration Editor process would follow these steps 1 2 Open the NuVinci Configuration Editor template and save locally to your system Input the following values on the Input Parameter worksheet a Application System Voltage 48 volts b Shift Method 0 automatic using Shift Table c Power Source Sprocket 33 pedal crank teeth d CVP Sprocket 17 sprocket teeth e Output Wheel Circumference 84 8 inches f Speed Pulses per Revolution 6 ferrous bolts g Maximum Possible Vehicle Speed 40 mph h NuVinci CVP Model 1 square shift rod end CVP CVP Ratio
29. SV Comma delimited csv file and name it descriptively and in a location you will remember so you can locate it with the NuVinci Desktop application and send it to the Controller ES Microsoft Excel NuVinci Configuration Editor 2009 07 14 xls Ema fx E File Edit View Insert Format Tools Data Window Help Adobe PDF Type a question for help f X 0 00 iF gt 60 gt 0 z ES iiu 1 opuso atomica Display Update Period in millisecs oo a E 5 Debug Output Period in millisecs 20 6 Speed Measure Pulse Per Rotation 6 7 Wheel Circumference n mili inches 64400 8 DetectLossofEncoder_____ 1000 O o O The selected file type does not support workbooks that contain multiple sheets A To save only the active sheet cick OK To save all sheets save them individually using a different file name for each or choose a file type that supports multiple sheets P19 ECT C 22 Actuator Control Mode ME u will then get the following message from re 25 26 Reserwe 0 27 Reserwe Oo rot a mAy Coreen foment iss ere oak compete it CY PODS Do you want to heep the y encia which leaves out any incompatible features dick Yes features ich No Then save a copy in the latert Excel format S To as abet rahe belo dick Help EJ 29 Reserve a0 Reserve SSCS _ u TTEN 36 Reseve SSCS 37 Resewe oooi U 38 Reserve fo P 4 TN Input Parameters Create Shift Maps Chart Positi
30. ate This file is located in the Developer Tools directory on the WNuVinci CVP Developer Kit CD Visit http www fallbrooktech com DevTech for new releases of the NuVinci Configuration Editor If you do not have Microsoft Excel or a compatible spreadsheet tool you can still modify the Configuration Table and Shift Table files using any simple text editor such as Microsoft Notepad The entries are separated by commas and you must manually change the values and enter the appropriate data There is also a free spreadsheet application available at www openoffice org although Fallbrook does not recommend any particular application and is not responsible for any damage any other company s software may cause Configuration Table and Shift Table sample files are also provided on the NuVinci CVP Developer Kit CD These are also located in the Developer Tools directory on the CD For more information on Configuration Table and Shift Table format reference Appendices A and B NuVinci CVP Developer Kit Manual Page 18 The NuVinci Configuration Editor is intended to simplify Configuration Table and Shift Table creation This is how the document should appear when you first open it in the spreadsheet editor ES Microsoft Excel NuVinci Configuration Editor Beta 41 xls Eu File Edit View Insert Format Tools Data Window Help Adobe PDF A ENS RA EF EA 2 10 BL SEAS 2 142 M fe B C D ALA E lt CO w00 oo h
31. ation value There are limits to the values some of which are displayed in the following representation note that this is what the NuVinci Configuration Editor will create and format for the developer Parameter Value Min Max Description Column A Column B Line 1 10 10 000 Update period for display output in milliseconds NA 100 Do not modify OS 4 10 000 Do not modify CA E 1 1 000 Do not modify 5 10 10 000 Update period for debug output stream to COM port in milliseconds 6 Speed Measure Pulse Per Rotation 6 0 100 Number of speed sensor pulses per rotation of the CVP output wheel 7 1 000 125 000 Wheel rolling circumference in milli inches distance per rotation 8 0 1 000 000 Deactivate system if actuator errors 0 for inactive 1 for active 9 AR 10 000 53 000 Unused 10 SS 1 000 50 5500 Unused no AT 50 5 500 Unused 2 SSS 2 800 2 400 60 000 Unused 1 SSS 2 500 2 400 60 000 Do not modify 10 2 0 1 000 Unused 7 O 0 1 Unused 16 7 000 53 000 Default system battery voltage in millivolts 7 18 000 0 42 000 Do not modify 18 TG 100 10 000 Unused 19 TG 100 10 000 Unused 20 PJ 292 2 10 000 Do not modify 21 2 1 000 000 Revolutions of total mechanical travel for actuator in milli revolutions 22 Actuator Control Mode 0 0 2 0 for Automatic Shift 1 for Analog 0 5VDC Input Control 2 for Command Interface a AR 50 1 000 Donot modify 24 10 20 000 If auto
32. d to your NuVinci Controller To open the Device Manager go to Start Menu gt gt right click on My Computer select Properties select the Hardware tab and select Device Manager To see the COM Port assignments for your Controller select View gt gt Devices by Connection Expand each USB Universal Host Controller entry until you find USB Composite Device with components USB Serial Converter A and USB Serial Converter B Each entry should show the Serial port assigned to that device If you see the resources assigned as below then your device is properly installed and ready to use System Properties HEI A Device Manager Ox z File Action Yiew Hel System Restore Automatic Updates Remote ae General Computer Name Hardware Advanced e 32 A E i PCI bus E Intel R 82801 PCI Bridge 2448 M Device Manager gt The Device Manager lists all the hardware devices installed on your computer Use the Device Manager to change the properties of any device Device Manager Driver Signing lets you make sure that installed drivers are compatible with Windows Windows Update lets you set up how Windows connects to Windows Update for drivers Driver Signing Windows Update m Hardware Profiles 4 Intel R 828016 ICH Family PCI Express Root Port 27D0 4 Intel R 828016 ICH Family PCI Express Root Port 27D2 4 Intel R 828016 ICH Family PCI Express Root Po
33. dows Update Web site with your permission Read our privacy policy USB Serial Converter A If your hardware came with an installation CD Can Windows connect to Windows Update to search for 2 or floppy disk insert it now software O Yes this time only Yes now and every time connect a device What do you want the wizard to do C Install the software automatically Recommended IA a AAA A A Click Next to continue lt Back Cancel Click Nest to continue The operating system will then allow you to choose where to search the local system for the appropriate drivers Select the following options before selecting Next NuVinci CVP Developer Kit Manual Page 43 Hardware Update Wizard Please choose your search and installation options SS Y Search for the best driver in these locations Use the check boxes below to limit or expand the default search which includes local paths and removable media The best driver found will be installed IV Include this location in the search CA y Browse C Don t search will choose the driver to install Choose this option to select the device driver from a list W indows does not guarantee that the driver you choose will be the best match for your hardware onea Select Browse and navigate to the drivers folder shown below left The search path is now the drivers folder in the installat
34. e ability to manually control the Shift Position in increments of 50 A general equation can be used for approximating the NuVinci CVP Speed Ratio to the Shift Position The Speed Ratio is not directly proportional to the Shift Position especially towards the ratio extremes at full underdrive and full overdrive For the NuVinci CVP Developer Kit the approximate relationship can be accurately estimated by Shift Position A In Speed Ratio B For initial operation the following values can be used A 731 B 539 The above default A and B values are used in the NuVinci Configuration Editor spreadsheet to calculate Shift Maps If your specific hardware is determined to need more accurate control the calibration procedure described below can be used to arrive at more specific A and B values for a particular CVP 1 Interface with the Controller via the USB to PC Terminal connection or the optional NuVinci Display Interface reference Appendix F 2 Switch to Manual shift mode by pressing 5 PC Terminal Display or lt NuVinci Display Interface once 3 In Manual mode use the 1 and 3 keys PC Terminal Display or A and Y buttons NuVinci Display Interface to shift the CVP to different Shift Positions noting the Actual Shift Position value approximately 20 different Shift Positions are possible due to the Manual mode Shift Position increments being approximately 5 4 When operating
35. for communicating with the Controller e Exit Button At the lower right side of the window this will exit the application NuVinci CVP Developer Kit Manual Page 15 If the NuVinci Desktop application is not able to locate the Controller the following status message will display allowing you to re scan for the Controller or to exit the application No controllers found No controllers found FALLBROOK Retry or Exit If you receive the No controllers found message disconnect and reconnect the Controller to the PC with the supplied USB cable and Rescan for the Controller after approximately 5 seconds If the Controller is still not recognized refer to Appendix for troubleshooting tips Visit http Awww fallbrooktech com DevTech for new releases of the NuVinci Desktop application 3 3 3 Controller Information When the NuVinci Desktop has successfully located the Controller click on the Select Command drop down menu and choose Controller Information v Nuvinci Desktop Nuvinci Controller found on COM6 A Pa 2 Select Command Send Shift Table Send Configuration Table Receive Shift Table Receive Configuration Table Safe Mode Controller Information Copyright Information Controller revision information will be displayed that will reveal the hardware and firmware revisions for the particular Controller This information can be useful for support from Fallbrook Technologies
36. format The NuVinci Configuration Editor allows you to automatically view the Shift Maps you have programmed in two fashions The Chart Position worksheet is the third worksheet in the NuVinci Configuration Editor which graphs the Shift Position versus Vehicle Speed M 4 M Input Parameters Create Shift Maps Chart Position Chart Source RPM Export Config Table Export Shift Table lt gt This shows what the Shift Position is for each Vehicle Speed as was entered in the Create Shift Maps worksheet tab It is good practice to view this prior to exporting your Shift Table to ensure that your Shift Maps are correct Shift Position vs Vehicle Speed 75_RPM 6 Speed Empty_03 Empty_04 S o o Li e lt O Y O ou YN Empty_05 15 20 Vehicle Speed mph NuVinci CVP Developer Kit Manual Page 29 Chart Source RPM Worksheet The Chart Source RPM worksheet is the fourth worksheet in the NuVinci Configuration Editor which graphs the Source RPM versus Vehicle Speed M 4 ah Input Parameters Create Shift Maps Chart Position _ Chart Source RPM Export Config Table Is Drawr h AutoShapes Y MOJO 4 Al ct is cl or dr A This shows what the source RPM motor engine cadence etc should be for all vehicle speed ranges It is good practice to view this prior to exp
37. functions Reference Appendix F for additional USB functionality NOTE If the USB connection to a PC is active a CVP Developer Kit in the off state will not be able to initialize and shift properly If USB functionality is desired during CVP Developer Kit normal operation shifting measuring speed etc the USB cable must be connected after the CVP Developer Kit is turned on and initialized See Appendix F for further information and USB capabilities e HDR1 Main Wiring Harness connector Primary connection for operation of the CVP Developer Kit This allows the Controller to receive Vehicle Speed and Shift Position information as well as command and power the Shift Actuator e HDR2 Display Mode Wiring Pigtail connector Can accommodate a user supplied Mode Switch or a NuVinci Display Interface reference Appendices E F and G e HDR4 Shift Reference Wiring Pigtail connector Can accommodate a reference voltage signal for manual shifting as well as other features reference Appendices D and G NuVinci CVP Developer Kit Manual Page 8 NOTE The HDR1 HDR2 and HDR4 connections are not intended to be connected and disconnected repeatedly over the life of the product Use care when installing or removing connectors from the Controller e JTAG firmware programming connector lf firmware changes are required or updates become available this connector can be used by Fallbrook Technologies to flash new firmware to t
38. he Controller Do not modify or attempt to utilize this connector 2 4 Main Wiring Harness The NuVinci Controller communicates with CVP Developer Kit components through the Main Wiring Harness The Main Wiring Harness includes three components e HDR1 Connector Attaches to the Controller e Speed Sensor Attaches at the NuVinci CVP left axle and uses 6 ferrous bolts to register a speed signal for the Controller e Shift Actuator Connector Automotive quality sealed connector that attaches to the Shift Actuator There are two locking features on this connector a red locking tab and a black press to release tab as shown in Figure 9 When removing ensure the red locking tab is extended as shown and press the black tab La ni ZA a MAN lt E E puan m eo MS HORT W connector e EE J a ee 4 55m ae A y lt A f X Sy ae a z E eh o e 2 gt 5 j E oe i TTR H SHIFT i Be Hees hat Spal aah ae z A sae CONNECTOR ACTUATOR pas ae gt O sie ES eee ze a as LOCKING TAB RED CONNECTOR a has E ee Figures 8 amp 9 Main Wiring Harness and Components Shift Actuator Connector 2 5 Installation of CVP and Speed Sensor The NuVinci CVP was designed to be installed into a 135mm width dropout of a typical bicycle as shown in Figure 10 Reference http www fallbrooktech com DevTech for CAD geometry and dimensions of select components of the NuVinci CVP Developer Kit The p
39. i CVP Developer Kit Manual Page 13 NOTE To use the NuVinci Desktop application with the Controller it is not necessary to supply external power to the Controller The USB connection provides power to enable communication but not for shift operation The first time the NuVinci Controller is connected to a Windows PC via the USB connector cable Windows will recognize new hardware and attempt to load the appropriate drivers i Found New Hardware Dual R5232 A 3 06 pm The Found New Hardware Wizard will guide the user to select appropriate drivers for the NuVinci Controller If you have an active connection to the Internet choose Yes this time only when asked to connect to Windows Update to search for software see note at the end of this section if there is no active connection to the Internet Choose Install the software automatically Recommended as shown below Found New Hardware Wizard Found New Hardware Wizard Welcome to the Found New Hardware Wizard Windows will search for current and updated software by looking on your computer on the hardware installation CD or on the Windows Update Web site with your permission This wizard helps you install software for Dual AS232 head Our pivacy POC If your hardware came with an installation CD Can Windows connect to Windows Update to search for OOP cs Happs dicks maine software Yes now and every time connect a
40. igher Shift Map stopping at Shift Map 10 e 3 keystroke Will go to the next lower Shift Map stopping at Shift Map 1 e 5 keystroke Will switch between Shift Map operation and Manual shift operation When operating in Manual shift mode ShiftMap Manual e 1 keystroke Will increase Shift Position by 50 e 3 keystroke Will decrease Shift Position by 50 e 5 keystroke Will switch between Shift Map operation and Manual shift operation As with the optional NuVinci Display Interface the user interface nature of the USB to PC Terminal connection is quite powerful The PC Terminal connection allows full use of different Shift Maps as well as manual shifting without having to supply a 0 5 V reference signal as with Actuator Control Method 2 see Appendix D NOTE The PC Terminal Display connection is only functional if the USB connection is made after the CVP Developer Kit system is turned on and initialized If the CVP Developer Kit is off and the USB cable is connected to a computer that is on the CVP Developer Kit will not initialize and will remain in a Hardware Safe mode PC Terminal Debug For advanced developers the second COM port usually one higher than the PC Terminal Display COM port will be a running stream of debug output typically sent at a rate of 50 Hz This will include the following information in comma delimited format with 18 entries on each line
41. in Manual mode at multiple Shift Positions between O and 1000 accurately measure the input and output speeds or number of relative rotations of the NuVinci CVP in order to calculate the speed ratio at each condition These values can then be used to estimate a new relationship using the equation above Output Speed Speed Ratio Input Speed NOTE For even higher accuracy and flexibility with this calibration it is possible to use Analog Input Control reference Appendix D along with the NuVinci Display Interface or PC Terminal Display connection to more finely control Shift Position with a 0 5 VDC reference signal NuVinci CVP Developer Kit Manual Page 40 Appendix NuVinci Desktop Application Troubleshooting FAQ Does the NuVinci Desktop need to be running to detect my NuVinci Controller No Your device will be detected and configured by the operating system when you have the appropriate drivers are installed What drivers do need to communicate with the NuVinci Controller The drivers required for communication with your NuVinci Controller are provided by Future Devices International Ltd The latest driver available at the time of this release is included with the installation and can be found in the Program Files Fallbrook Technologies NuVinci Developer Kit Drivers directory see Manually Installing USB Device Drivers below You may obtain the latest drivers from FTDI at http www ftdichip com Drivers VCP htm
42. inci Display Interface NuVinci CVP Developer Kit Manual Page 35 USB to PC Terminal Connection The NuVinci CVP Developer Kit Controller offers significant capabilities through the use of the USB connection protocol Upon successful connection to a PC two separate COM ports will be assigned Both COM ports are accessible through a terminal application such as HyperTerminal Start gt gt All Programs gt gt Accessories gt gt Communication gt gt HyperTerminal NOTE HyperTerminal was included with Windows operating systems prior to Windows Vista HyperTerminal is available for Microsoft Vista from the original manufacturer www hilgraeve com hyperterminal html although there are free terminal emulators available elsewhere NOTE The USB to PC Terminal connection will not function while the NuVinci Desktop application is running Conversely the NuVinci Desktop application will not function while the PC Terminal connection is active This is due to the fact that both these programs attempt to use the same COM ports NOTE If using the optional NuVinci Display Interface the USB to PC Terminal connection will support only the PC Terminal Debug connection and not the redundant PC Terminal Display connection The following connection settings are required for both COM ports 175200 Bits per second 8 Data bits No Parity 1 Stop bits No Flow control e New Connection HyperTerminal z COM3 Properties Dae 8 aD Y
43. ion Table at a time so the NuVinci Desktop application will automatically read the appropriate information from the Controller and ask you to locate and name the Configuration Table or Shift Table on your PC These files will be in the standard comma delimited csv format and can be viewed by Microsoft Excel or any basic text editor 3 3 6 Safe Mode If you would like to reset the Controller to the default settings click on the Select Command drop down menu and choose Safe Mode This will overwrite the Configuration Table and Shift Table with default values from within the Controller firmware These tables will then need to again be modified for the current application but will provide basic values for reference NuVinci CVP Developer Kit Manual Page 17 4 NuVinci Configuration Editor 4 1 Setting up your Application The NuVinci CVP Developer Kit is designed to allow custom tuning of the NuVinci CVP drivetrain control for a variety of applications This is accomplished by creating and sending two separate reference tables to the NuVinci Controller a Configuration Table and a Shift Table 4 1 1 Configuration Table The Configuration Table includes important information for the general setup and operation of the NuVinci CVP Developer Kit The NuVinci Controller is a flexible tool with multiple functions and capabilities most of which are enabled and configured through the Configuration Table The Configuration Table
44. ion directory for the NuVinci Desktop application Browse For Folder 1x Select the Folder that contains drivers For your hardware Desktop B My Documents E 4 My Computer S Local Disk C O Config Msi gt DELL O Documents and Settings B IOGEAR GUC2324 O M50Cache 5 National Instruments Downloads O Program Files 5 Adobe O Apple Software Update O Broadcom O BUFFALO Hardware Update Wizard O CCleaner Common Files Please choose your search and installation options SS 9 Conduit SY 9 CONEXANT 3 configSd O Daytronic 7 e 3 Dell Use the check boxes below to limit or expand the default search which includes local e paths and removable media The best driver found will be installed E 1 Search for the best driver in these locations Desktop Activity Recorder 5 Fallbrook Technologies a Search removable media floppy CD ROM O Nuvinci PC Application O documentation V Include this location in the search C Program Files Fallbrook Technologies NuVinci P y Browse O amd64 1386 C Don t search will choose the driver to install O support Choose this option to select the device driver from a list Windows does not guarantee that 3 IAR Systems y the driver you choose will be the best match for your hardware
45. ized when connecting components Attach the Shift Actuator Shroud and secure the components with the three M5x50 fasteners and their associated washers and lock washers Torque values are shown in Table 1 Once the installation orientation is finalized it is recommended to use a thread locking compound that allows disassembly without extreme measures on the M12 Jam Nut and the M5 Button Head Cap Screw fasteners The Speed Sensor and Shift Actuator connector should now be installed so the remainder of the Main Wiring Harness can be routed to the Controller location If extensions are required for any of the wires use similar gage wire and fully insulate and protect the wiring Table 1 Torque Specifications for Dry Threads Shift Rod Retaining Nut Acorn Nut RH Mainshaft Nut Jam Nut M12 x 1 75 Mount plate M5x50 button head cap screw Actuator shroud M5x10 button head cap screw Secondary bracket 2 7 Wiring Pigtails Two additional wiring assemblies are included with the NuVinci CVP Developer Kit These connect to the Controller and provide colored leads for additional functionality When connecting to these wire leads use similar gage wire and fully insulate and protect the wiring The Display Mode Wiring Pigtail and Shift Reference Wiring Pigtail are described further in Appendix G These connection pigtails support future products from Fallbrook Technologies as well as third party accessories NuVinci
46. le and save it for future reference After the Shift Table is exported you will close the NuVinci Configuration Editor without saving After saving the spreadsheet file the Shift Table worksheet has instructions that walk through the process of creating a CSV file for the Shift Table Follow those instructions to save the active worksheet as a CSV Comma delimited csv file and name it descriptively and in a location you will remember so you can locate it with the NuVinci Desktop application After saving the Shift Table the entire Excel spreadsheet not just the active worksheet will assume it has been renamed to the name you selected for the Shift Table only To keep things organized it is best to exit from the spreadsheet which should have been saved prior to exporting the Shift Table and not save it when prompted by the spreadsheet application ES Microsoft Excel NuVinci Configuration Editor 2009 07 14 xls E sul Edit View Insert Format Tools Data Window Help Adobe PDF Type a question For help 958 iB SE SE E F JH i s K LIM IN O Pla R s T uUjv w x Z AA ABI Ac Ad Ab AF AG 7 ee Shift Map N Ui d Ui d Speed Limit S diga e RE Pe Pue se aa sal ve es o Teo ee orf nf ve e oo oe we no 2 Nameot_ 1 1 1 45 0476 64 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 3 Named2 1 1 1 45 0476 64
47. lect the Paste Special command selecting Values from the option list this will maintain the orange formatting for the Shift Map input fields see spreadsheet for OpenOffice instructions NuVinci CVP Developer Kit Manual Page 28 NOTE Only Shift Map 1 will be accessible unless you have a mode switch or controvdisplay interface Shift Maps Paste Special Shit Map Name Paste Vehicle Entered Source Entered Source Shift RPM mph 0 1000 cpm 0 1000 rem lo Position Result Position Result amp Cut a Copy A Paste Paste Special Insert Delete all Formulas O Formats O Comments Operation e Mone O validation All except borders Column widths O Formulas and number Formats values and number formats O Multiply Clear Contents O add Divide Subtract o BAA Ld Insert Comment A Format Cells Pick From Drop down List C Transpose Add Watch C Skip blanks 5 BER Create List Hyperlink Table Fi This will locate the values in the appropriate Shift Map column You can then custom modify the Shift Map as you see fit Always name the Shift Map at the top of the column as shown above 55_RPM The name should be 8 or fewer characters Chart Position Worksheet Once Shift Maps have been created it can be helpful to view the maps in a graphical
48. ll register for one revolution of the output wheel The stock system uses 6 fasteners on the NuVinci Disk Brake Adapter to register with the speed sensor NOTE The following two data entries are in grey boxes meaning they are calculated values Typical operation of the NuVinci CVP consists of only two sprockets one for the source and one for the CVP However some applications will utilize multiple sets of sprockets prior to the CVP and may even use additional gearing after the CVP If your application is non standard you will need to replace the following data entries with your application speed ratios Speed Ratio is defined as Output Speed _ 1 Speed Ratio _____ Input Speed Gear Ratio e Speed Ratio to CVP Input f you do not have the simple case of a source and CVP sprocket only calculate your speed ratio from the source to the CVP This is effectively how many times the CVP input sprocket rotates divided by the number of times the source rotates e Speed Ratio from CVP Output If you are not using the NuVinci CVP as your output wheel but are using it in some other configuration jack shaft for example you will need to calculate your speed ratio from the CVP output to the output wheel This is effectively how many times the output wheel rotates divided by the number of times the CVP output rotates Vehicle Speed Capability Maximum Possible Vehicle Speed mph Table Step Size mph calculated
49. mission Shift Position entry The transmission absolute range is normalized between 0 and 1000 respectively A Shift Position of 0 is associated with the full underdrive stop for the CVP speed ratio 0 5 and 1000 is associated with the full overdrive stop speed ratio 1 75 NuVinci CVP Developer Kit Manual Page 26 The full 0 1000 range cannot be safely utilized without the possibility of hitting the mechanical stops inside the transmission so there is a small buffer at each end The actual minimum and maximum Shift Position values will be displayed on the Configuration Editor above the Shift Maps and will typically be the following Shift Position values below or above these will not be attempted by the Controller which will automatically stop at these limits SHIFT ROD NO SHIFT ROD dl oli M DEVELOPER KIT OF TURNS END STYLE SHIFT SHIFT POSITION POSITION N171B DEV 36S 1 SQUARE N171B DEV 368 2 SPLINED Shift Maps Shift te n _ __i Maz AC Position Position Unhide additional Shift Maps gt 0 1000 0 1000 Calculated Yalues Instructions or D Minimum Shift Position Maximum Shift Position de Cut 3 Copy NOTE Only Shift Map 1 will be accessible unieg you have a Mode Switch or Display User Interface _ FR Paste Shift Maps gt Paste Special Delete Entered Source Entered Source Clear Conte
50. mph entries ARMA 7 2 0470 a pofofofojofo espe 1 7 75 0476 04 60 60 60 00 60 00 Names 1 1 1 0476 se ofofofofofo Nme 1 1 1 7 0476 04 ofofofojofo Names 1 1 75 0476 04 ofofofofofo Namee 1 1 1 5 0476 es o o o o o o Nme 1 1 1 7 0476 es ofofofofofo Name 1 1 75 0476 s ofofofofofo Name 1 1 1 5 0476 es ofofofofofo Nme o 1 1 1 7 0476 pos fofofofofofo Manual 1 1 1 7 1 0 gt Line 1 oOo AN DA A W N Line 12 Additional information on Shift Table entries e Software Speed Limit mph This is an imposed speed limit for a particular Shift Map This value is set to 1 5 times the highest speed value on the Shift Map as a default effectively disabling it This feature has not been tested on a wide range of speeds or applications e Table Step Size mph For this release of the NuVinci CVP Developer Kit the maximum speed entered by the user on the NuVinci Configuration Editor is simply broken into 64 steps for each Shift Map in this example 64 evenly spaced steps from 0 to 30 0 mph is approximately 0 476 mph per step e Table Entry Length This is how many steps the Shift Map is segmented into 64 in this example e Speed Value Reference Line 1 starting in Column 8 is simply a reference value for the vehicle speed that the Shift Map relates to A representation of how the Shif
51. nce the Speed Sensor is located slide the LH No Turn Washer over the protruding LH end of the Main Shaft Set the chain belt tension and tighten the RH Main Shaft Nut and Acorn Nut to the values shown in Table 1 If the application dropout thickness is less than 7mm 0 25 in washers may be required to allow correct thread engagement on the Acorn Nut and RH Main Shaft Nut NOTE It is important to note that the No Turn washers are required for this design as there is significant torque reaction from the CVP main axle to the frame The tabs on these washers can point either forward or backward but must firmly engage the dropout slots of the frame fixture 2 6 Shift Actuator Installation Once the NuVinci CVP is installed in the vehicle application the Shift Actuator can be installed Angular orientation of the Shift Actuator is not critical though for this instruction manual it will be installed in a roughly vertical configuration Once the orientation is chosen the Shift Actuator Mount Plate can be installed over the Shift Rod Retaining Nut and secured by the Lock Washer and Jam Nut Torque values are provided in Table 1 A Shift Actuator Secondary Support bracket is also included though it may need to be modified for each particular application Use of this secondary support bracket is encouraged if your vehicle will see bump or vibration loads at the CVP location with the weight of the Shift Actuator the assembly can rotate arou
52. nd the Main Shaft if not secured adequately An example of the secondary support bracket is shown in Figure 15 for a light electric vehicle application With the Shift Actuator Mount Plate installed the Shift Actuator and Shift Actuator Shroud can be mounted Manually rotate the Shift Rod approximately one turn clockwise from its counterclockwise stop in order to have flexibility to mount the Shift Actuator to the Shift Rod Install the Shift Actuator over the square end of the Shift Rod aligning the male and female components Once mated rotate the Shift Actuator until the three mounting holes align with the extruded tapped holes in the Shift Actuator Mount Plate If resistance is felt when rotating the Shift Actuator do not force the assembly make sure that the Shift Rod is free to rotate fully NuVinci CVP Developer Kit Manual Page 11 SHIFT ACTUATOR MOUNT PLATE LOCK WASHER JAM NUT SECONDARY SUPPORT BRACKET Figures 14 8 15 Shift Actuator Mount Plate Installation Secondary Support Bracket Example Prior to mounting the Shift Actuator Shroud it may be easier to attach the Main Wiring Harness connector to the Shift Actuator and lock it in place with the red tab See Section 2 4 Main Wiring Harness NOTE Ensure the power supply is disconnected and the CVP Developer Kit is powered OFF prior to attaching the wiring harness Permanent damage can occur to the Controller and or Shift Actuator if the system is energ
53. nnncnnnnnnanonos 13 3 3 1 Connecting to the Controller via USB Cable ooocccccoconcncococnonoccncononononnonnononnonanennonancnnnnnnnonos 13 3 92 INUVINCK DESKTOP APPliCaNO Micinta a ea a a a e een tepaceds a ea 15 3 05 GCOMMONCKE INOMaUON ertai a a A e N 16 3 3 4 Sending Tables to the Controller ooccccocncocococnncocoononoconcnnnonanoncoannnonnnnnnnnnannnnnnnnnnnononannnss 17 3 3 5 Receiving Tables from the Controller ccoooococcccnconncconococonnncoconcnnconanoncnnannnnonannnnonnnnannss 17 SA A A hes ena 17 AAN VIC COMMOMPAMON EH CILON aia 18 A doetingd Up your ADDNCIUO M an a e dados 18 A E GON TIguatO dal irea e a a E a a E AE EE AE 18 A A E eee cms ae nas aetna ecioaee Suen eda 18 4 2 Define your Application ParameterS cccoccccconncocccnnoconncononnnononnnonnnononnnonnnnonnnnnonnnnnnnnnnnnnnnnnnnnnnenanos 18 AS EXA CsA MICA a ls do o e 21 Appendix A Configuration Table Formalt oocccconnccocnncccnnnoconnnonononononnnononononnnononnnonannnonannnonannononannonanos 22 Appendix B SAL Tale UM a a a 23 Appendix C NuVinci Configuration Editor Template cooooccccoccncccncncconnnnoncnnnonnnonncnnonannnnoncnononenononos 24 Input Parameters Worksheet occccoccccccnococcnnccccnnconnnoconononanononannnonnnnnnnnnnonnnnnonnnnnnnnnnonnnnonannnnnananenas 24 Create Shift Maps Worksheet coooocccocococococococonocononoconononacononacononnnnnnnnnnnnnnnnn
54. nnrnonnnnonnnnnnnnnnnonanenenos 26 Mangal ENUY oieee e a E tes 26 Constant Target Source RPM Calculator oocccccconcnccoccnnccnoncnconononnononconononcnnonnnencononrnnnnnnrnncnnanennss 28 Chart Position Worksheet cccccecccceececeesceceeeeeceeeeceeeceeessecesseeeessaeeeseaeeeseaeessaueessaseesseaeesesesseas 29 Chart Source RPM Worksheet ocoooccccccccccoccncoccnccoconoconononaconononnnonnnonnnnnonnnnnonnnnnnnnnnnnnnnnnnnnnnnennnnenas 30 Export Config Table Worksheet ccccccsssecccceseeeccesseecseseeecseuseecceuseesceaseeessaeeessaueeesseseesssansaeessaneees 30 Export Shift Table Worksheet ccooocccccccnccccnccoccnccoconocanononacnnononnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnananenos 31 Appendix D Alternative Shift Methods ooocccccocccocccococonococonoconcncconnnononnnonnnnonannnonannonannnonannnnonannonanos 33 Analog IN pUt C OMUOl sitos OS IS Ao de dis 33 Command Interface Control Unsupported ooccccccooccncccoccncconconconanonnononennnnnncononnnncnononcnnnnnnnnnnonanennnnnnors 33 Appendix E Mode Switch Capability oocccooccccoccncconcnccononoconononononononnnnnnnnnnnnnnonnnnnnonnnonnnnnnnnnnnnnnoos 34 Appendix F Display Interface Capabilities ooccccoccccccocncoconnccononononononnnnonnnnnnnnnnnnonnnononononononinonos 35 NUVincr Display IMG Ma CE A A a A hieleeds 35 USB to PC Terminal COnn
55. nship Reference Appendix D e Command Interface Shift Method 2 Currently unsupported Reference Appendix D NOTE If any Shift Method besides 0 is chosen the Shift Maps are not used by the Controller Red values will be displayed across the top of the Shift Map columns indicating this fact See Appendix D for more information on alternative shift methods Gearing and Wheel Circumference Data Power Source Sprocket teeth CVP Sprocket teeth Output Wheel Circumference inches peed Pulses per Revolution 6 stock Speed Ratio to CVP Input calculated Speed Ratio from CVP Output calculated NuVinci CVP Developer Kit Manual Page 24 The Gearing and Wheel Circumference Data section includes information for speed measurement for the Controller as well as calculations within the NuVinci Configuration Editor e Power Source Sprocket The number of teeth on the source of input power Examples include a front crank ring for bicycles motor sprocket for electric vehicles etc e CVP Sprocket The number of teeth on the sprocket connected to the NuVinci CVP e Output Wheel Circumference The circumference of the output wheel on the vehicle application This is used to calculate vehicle speed and should be a rolling circumference for the vehicle such that it is accurate for a loaded rolling vehicle e Speed Pulses per Revolution The number of encoder pulses that the speed sensor wi
56. nts Shift RPM Shift ar Format Cells Position Result Position Result 0 1000 rpm co 1000 com Column Width Po Hide TE Vehicle Speed Notice that there is a calculated white field directly to the right of each orange Shift Map entry These values estimate the Source RPM motor engine rider cadence or other power source for that Shift Position and Vehicle Speed This column uses the information from the NuVinci Configuration Editor Inout Parameters worksheet to estimate these values and provide the user an immediate reference To utilize Shift Maps 2 or higher reference Appendices E and F All ten Shift Maps are represented by the following screen shot Shift Maps 3 10 are empty Shift Maps are truncated for view on this page NuVinci CVP Developer Kit Manual Page 27 Shift Maps Shift Map 1 Shift Map 2 Shift Map 3 Shift Map 4 Shift Map 5 Shift Map 6 Shift Map 7 Shift Map 8 Shift Map 9 Shift Map 10 Entered Entered Entered Entered Entered Entered Shift Shift Shift Shift Shift Shift Shift Shift Shift Shift Position Position Position Position Position Position Position Position Position Position mph 0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 Vehicle Speed Constant Target Source RPM Calculator The Constant Target Source RPM entry tool allows you to create Shift Map
57. o am NuVinci Configuration Editor version 1 01 Input Parameters STEP 1 Establish sysfem configuration parameters prior to creating Shift Maps Step 2 System Voltage Application System Voltage Shift Method select one 0 Automatic Shift via Shift Maps f Analog Input Control 0 5 VDC ing and Wheel Circumference Data Power Source Sprocket teeth teeth inches Speed Ratio to CVP input gt oso calculated Speed Ratio from CVP Output 100 calculated Vehicle Speed Capabilit Maximum Possible Vehicle Speed mph Table Step Size mph calculated Calculated Values do not change Instructions or Data to be Copied NuVinci CVP Model f Square shift rod end 4 turns 2 Splined shift rod end 2 turns CVP Ratio Calibration only modify if necessary Shift Pos A in Speed Ratio B Do not change these values unless you are prepared to Shift Calibration A value map your specific NuVinci CVP to provide more clout accurate calibration eacute Reference Appendix H in the minimum CVP Speed Ratio 049 comunes MuVinci CVP Developer Kit 1527 caleueto User Manual NOTE Items in orange boxes are intended for information that the developer will enter for the intended vehicle application Items in white boxes are calculated values and are not to be modified unless instructed by Fallbrook Technologies Customer Support Items in light yellow boxes are instructions or data
58. on i Drawy Li AutoShapesy X a OO Ad d 23 a S Legend Calculated Values can be changed Value outside accepted range NOTE There are a number of other parameters that are contained in the Configuration Table but function and durability of the system may be compromised if they are modified Therefore it is critical that the user not modify any of the other values_in the Configuration Table unless instructed by Fallbrook Technologies Customer Support NOTE If any cell in column B is highlighted in red the value is outside of the accepted range for the Configuration Table and the table will not upload to the Controller If there are values out of range locate the cause and correct prior to exporting the Configuration Table Export Shift Table Worksheet When you are sure that your Create Shift Maps worksheet is correct you can export the Shift Table to a comma delimited CSV file that the NuVinci Desktop can send to your Controller To export your Shift Table click on the worksheet titled Export Shift Table NuVinci CVP Developer Kit Manual Page 31 M 4 M Input Parameters ens _ Chart Position Z Chart Source RPM_ Export Config Table Export Shift Table lt gt NOTE Prior to exporting the Shift Table it is very important to save the Excel workbook in its entirety if you plan to access the spreadsheet and entry values again Choose File gt Save As to rename the fi
59. on 1 0 It is recommended that you close all othere applications f A s 3 faa starting Setup PP All software will be installed in the following location s To install software into a different location s click the Browse button and select another directory M Directory for Nu inci PC Application C Program Files Fallbrook Technologies Please wait while the installer initializes M Directory for National Instruments products C Program Files National Instruments lt lt Back You must accept the end user license agreements from both Fallbrook Technologies and National Instruments to proceed with the installation Updated terms and conditions governing the installation and use under the license purchased with the software are available at the NuVinci website www fallbrooktech com Review the summary of components the installer will add and select Nexf to begin the installation which will take approximately 3 minutes to complete Successful installation will display the Read Me file included with the documentation 3 3 1 Connecting to the Controller via USB Cable After successful installation of the NuVinci Desktop application the correct USB device drivers must be installed in order to communicate between the PC and NuVinci Controller Connect the mini USB end of the connector cable to the Controller and connect the other end to any functional USB port on the PC NuVinc
60. ontroller gets its COM Port assigned NuVinci CVP Developer Kit Manual Page 45 Appendix J Support and Services Fallbrook Technologies Website www fallbrooktech com www fallbrooktech com DevTech Developer Kit technical data amp updates www fallbrooktech com 08 bike specs asp Bicycle technical data Fallbrook Technologies Customer Support Phone 888 NuVinci 888 688 4624 512 279 6200 outside the United States Fax 512 267 0159 Email developersupport fallbrooktech com Address Fallbrook Technologies Inc 505 Cypress Creek Suite C Cedar Park TX 78613 Hours 7AM 4PM Central Standard Time Fallbrook Technologies Headquarters Phone 888 NuVinci 888 688 4624 858 623 9557 outside the United States Fax 858 623 9563 Email info fallbrooktech com Address Fallbrook Technologies Inc 9444 Waples St Suite 410 San Diego CA 92121 E o O Novinei Microsoft Windows and Excel are the trademarks or registered trademarks of Microsoft Corporation Fallbrook NuVinci NuVinci Desktop and their stylized logos and elements are trademarks of Fallbrook Technologies Inc FALLBROOK TECHNOLOGIES All rights reserved O 2009 Fallbrook Technologies Inc Printed in USA NuVinci CVP Developer Kit Manual Page 46
61. orting your Shift Table to ensure that the source is within operation limits Power Source Motor Engine Cadence etc RPM vs Vehicle Speed 5 RPM gt Speed Empty_03 am X O pa 5 O YN Empty_04 Empty_05 15 20 Vehicle Speed mph Export Config Table Worksheet When you are sure that your Input Parameters worksheet is correct you can export the Configuration Table to a comma delimited CSV file that the NuVinci Desktop application can send to your Controller To export your Configuration Table click on the worksheet titled Export Config Table 40 Reserve SSS AL A Dacoargo n M 4 A Input Parameters Create Shift Maps Chart Position Z Chart Source RPM Export Config Table Export Shift Table lt NOTE Prior to exporting the Configuration Table it is very important to save the Excel workbook in its entirety if you plan to access the spreadsheet and entry values again Choose File gt Save As to rename the file and save it for future reference After the Configuration Table is exported you will close the NuVinci Configuration Editor without saving NuVinci CVP Developer Kit Manual Page 30 After saving the Excel spreadsheet see note above the Config Table worksheet has instructions that walk through the process of creating a CSV file for the Configuration Table Follow those instructions to save the active worksheet as a C
62. ot have any configured COM ports particularly if none are assigned to your NuVinci Controller refer to the Hardware Detection Troubleshooting section No Controllers found After all of the available COM ports on your system are identified each is scanned for the presence of the NuVinci Controller If none are found you will be prompted to rescan the ports or exit the application Make sure the Controller is connected with the USB cable and rescan If your Controller is not being detected or is being detected and no COM ports are being assigned to it refer to the Hardware Detection Troubleshooting section General communication errors If you receive an error message that starts with The following error occurred during the last operation it is usually indicative of a break in communication with the Controller You will be prompted to rescan the ports to check for the presence of a Controller If your Controller is not detected check the connection first by unplugging and reinstalling the USB cable Wait for the NuVinci CVP Developer Kit Manual Page 41 operating system to indicate it has detected and configured the new hardware and then select rescan If this does not work verify that the Controller is redetected and has COM ports assigned to it Refer to the Hardware Detection Troubleshooting section Hardware Detection Normal detection Device Manager is the primary tool to use for detecting and viewing the resources assigne
63. ply 2 Blue TXDO 3 Black Display_RXDO 4 Yellow GND HDR4 Shift Reference Wiring Pigtail This connector can perform multiple functions Primarily it will be used for reference voltage 0 5 VDC analog shift control see Appendix D Additional capabilities can include current signal measurement brake signal interrupt throttle position measurement and throttle position output HDR4 Shift Reference Wiring Pigtail Cavity Wire Color Function ______ Orange Analog Input 0 5VDC Current In Grey Brake Input White Analog Input 0 5VDC Shift Ref Purple Throttle Out 0 5VDC Gov Brown GND Red Black Throttle_ VCC 5V Yellow Black Throttle In Green Throttle GND NOTE Reference Figure 7 in the User Manual for mating connection points on the NuVinci Controller NuVinci CVP Developer Kit Manual Page 39 Appendix H Speed Ratio 4 Shift Position Calibration For automated shifting the CVP Developer Kit relies on Shift Maps defined by the user These Shift Maps relate a Shift Position to a corresponding CVP Speed Ratio The NuVinci Configuration Editor uses this relationship to generate accurate Shift Maps The NuVinci CVP Developer Kit normalizes Shift Position from O to 1000 This calibration procedure requires the optional NuVinci Display Interface or the USB to PC Terminal connection reference Appendix F These connections allow visual display of the actual Shift Position as well as th
64. referred mounting includes horizontal dropouts to allow for chain belt tension adjustment though vertical dropouts can be used with a chain belt tensioner not included In addition to the CVP installation instructions here bicycle installation instructions are available in the NuVinci Technical Manual within the Bike Tech Data section of the NuVinci website www fallbrooktech com The NuVinci CVP must be oriented in a position where the Main Shaft is approximately horizontal to the ground for distribution of internal lubrication Remove the protective clear cover on the Shift Rod threads and apply all purpose grease to the o ring and adjacent shoulder on the Shift Rod reference Figure 11 With the black Main Shaft lug oriented upward to reduce the chance of spilling internal traction fluid remove the rubber plug NuVinci CVP Developer Kit Manual Page 9 21 1 5 mm IO Ta TEATATI LN AA A eed J A a TETERA AAA EA aE Eq A a E ee ene 2 SEB Uses LI Figure 10 Standard Dropout Spacing of 135mm Clearance between the Speed Sensor and Disk Brake Bolts CVP Installation to Frame Ai a se i me W e p ae E io e ey eg Reyes a att AAA o ANA SHIFT PENES PROTECTIVE COVER REMOVE Figure 11 Shift Rod Cover and Main Shaft Plug both to be removed Insert the threaded end of the Shift Rod and rotate clockwise until the Shift Rod shoulder seats fully inside the Main Shaft counterbore see Figure
65. ribe how to locate and install drivers that were installed on the local system drive during the NuVinci Desktop installation 3 3 2 NuVinci Desktop Application Once the Controller is connected to your PC by the USB cable for approximately 5 seconds start the NuVinci Desktop application Start gt gt All Programs gt gt Fallbrook Technologies gt gt NuVinci Desktop If a Hyperterminal application is running and communicating to the Controller the NuVinci Desktop application will not locate the controller reference Appendix F The NuVinci Desktop application will launch and immediately attempt to locate the Controller The following status message should display when the Controller has established communication though your COM port number will likely be different than the number COM6 displayed below STATUS SELECT COMMAND MESSAGE MENU Nuvinci Desktop Nuvinci Controller found on COM6 w Y 2 lt gt y STATUS EXIT BUTTON BAR Notice that there are four main features to the NuVinci Desktop application e Status Message At the top of the window there is a text status message that will remain until another action is performed e Status Bar At the bottom of the window there is an orange graduated status bar that indicates the application is idle black or performing a task some level of orange e Select Command Menu At the right side of the window this is a drop down menu with selections
66. rt 27D4 Intel R 828016 ICH Family SMBus Controller 27DA E Intel R 828016 ICH Family USB Universal Host Controller 27C8 Intel R 828016 ICH Family USB Universal Host Controller 27C9 USB Root Hub E amp USB Composite Device 2 458 Serial Converter Y USB Serial Port COMB USB Serial Converter B 4 USB Serial Port COM9 Intel R 928016 ICH Family USB UpiverSal Host Controller 27C Intel R 828016 IC amily USB Universal Host Controller 27CB E Intel R 828016 ICH Family USB2 Enhanced Host Controller 27 CC 4 Intel R 82801GBM ICH M LPC Interface Controller 27B9 Intel R 82801GBM GHM ICH M Family Serial ATA Storage Controller 27C4 E 4 Microsoft UAA Bus Driver For High Definition Audio 4 Mobile Intel R 945GM PM GMS 940GML and Intel R 945GT Express Processor to 4 Mobile Intel R 945GM PM GMS5 940GML and Intel R 945GT Express PCI Express 4 System board Y System board z 4 Ooo gt Drivers Hardware profiles provide a way for you to set up and store zy different hardware configurations Hardware Profiles Controller not recognized as USB Serial Port Your Controller may be recognized as a USB Serial Converter A and USB Serial Converter B but may not have the Serial Ports assigned to it First check to see that the Load VCP box is checked on the Advanced tab for both USB Serial Converter
67. s as well as simplify the creation of accurate Shift Maps Each aspect of the NuVinci Configuration Editor is covered in this Appendix Visit http www fallbrooktech com DevTech for new releases of the NuVinci Configuration Editor Input Parameters Worksheet System Voltage Application System Voltage volts The System Voltage section defines the nominal system voltage that will be used to operate the NuVinci CVP Developer Kit the voltage applied to the positive and negative power leads from Figure 7 of the User Manual The system is designed to operate on 12 to 48 Volts direct current VDC If your system cannot provide voltage within this range it is incompatible with the NuVinci CVP Developer Kit and Controller Shift Method select one 0 Automatic Shift via Shift Maps 1 Analog Input Control 0 5 VDC The Shift Method section includes three methods for shifting the NuVinci CVP Developer Kit e Automatic Shifting Shift Method 0 The default shift method that automatically controls Shift Position based on Shift Maps Manual shifting in increments of 50 Shift Positions 5 of total range is available through the Display Interface or PC Terminal Display connection reference Appendix F e Analog Input Control Shift Method 1 An alternative method of shifting by sending an analog reference voltage signal of 0 5 VDC 0 VDC is O Shift Position 5 VDC is 1000 Shift Position linear relatio
68. s that will maintain a constant source RPM motor engine rider cadence etc throughout the ratio range of the NuVinci CVP This tool will create a Shift Map for a given target source RPM This Shift Map will be in yellow boxes and the calculated source RPM will be shown in white directly to the right The calculated values will be in a green font when it matches the target RPM 55 RPM in the following example The only orange box is the target source RPM which the developer enters If you want the CVP to maintain a constant power source RPM cadence RPM Tool motor speed etc enter the speed here and this will calculate the proper Shift Cale Shift SQUIce Position below Position 0 1000 rpm Copy this column and use EE Paste Special Values to 23 transfer them to an 23 ORANGE Shift Map column 23 to the right 7J EE EEES 2 ss NOTE The Calculated Shift Position values from this tool will not be automatically transferred to the Shift Maps The user must transfer them to the orange fields as described below In order to use the map that is calculated the user must copy the Shift Position yellow values to one of the orange Shift Maps The best way to do this as shown in the yellow instructions above is to select all 64 Shift Position values in the yellow column right click and select Copy Then select the first entry on an orange Shift Map entry column right click and se
69. sprocket assembly special frame mounting etc to be fabricated by the developer 2 2 Sprockets Gearing The NuVinci N17X series CVP is designed to transfer torque in one direction Facing the drive side of the NuVinci CVP the input torque direction must cause clockwise rotation as shown in Figure 6 Therefore the sprocket must be on the right side of the vehicle as in a typical bicycle design The NuVinci CVP in this production configuration will not transmit torque in the opposite direction it will freewheel Figure 6 Clockwise Torque Input Direction Sprocket shown for illustration purposes only The CVP Developer Kit does not include a sprocket for the NuVinci CVP as there are multitudes of gearing and drive chain belt possibilities The NuVinci Configuration Editor is a tool intended help the developer determine the correct gearing for their particular application A standard ISO 24 x 1 3 8 TPI threaded freewheel adapter is included which facilitates the use of many different freewheels and cogs Compatible sprockets and freewheels can be found at bicycle retailers electric scooter retailers e g www electricscooterparts com and several other hardware retailers If removal of a sprocket is required a NuVinci sprocket removal tool is available for purchase through Fallbrook Technologies Customer Support If regular use of multiple sprockets is desired additional freewheel adapters can also be purchased for each sprocket
70. t Table appears in a normal text editor follows E Shift Table Sample 10 Map csv Notepad File Edit Format View Help Name Unused Unused CUnused Software Speed Limit mph Table step size mph 476 64 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 12 476 64 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 1 476 64 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 0 476 64 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 476 64 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 476 64 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 476 64 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 476 64 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 476 64 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 Name 10 1 1 1 150 0 476 64 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 Manual 1 1 1501103759919 5 ss 3353 3333333339533 jay ats p pas iL Los pas l ply 1 ss 333333393993 Sample Shift Table files can be located on the NuVinci CVP Developer Kit CD in the Developer Tools directory NuVinci CVP Developer Kit Manual Page 23 Appendix C NuVinci Configuration Editor Template The NuVinci Configuration Editor is intended to help determine the vehicle application configuration parameter
71. tion of up to 10 Shift Maps displaying the current Shift Map name Display of the operating Shift Position vehicle speed and system operating conditions Any error messages or system function status Information provided on the display is as follows e VDC System measured voltage Volts e Spd Vehicle speed mph e Actuator Shift Actuator current Amps e T A Pos Target Shift Position 0 1000 Actual Shift Position 0 1000 e ShiftMap Name of the current Shift Map see note below NOTE The default Shift Map with the NuVinci Display Interface is Shift Map 2 This allows one map below the default Shift Map without a NuVinci Display Interface the default is Shift Map 1 When operating from a Shift Map Default ShiftMap Manual e A Will go to the next higher Shift Map stopping at Shift Map 10 e WV Will go to the next lower Shift Map stopping at Shift Map 1 e lt lt Will switch between Automatic shifting and Manual shifting When operating in Manual shift mode ShiftMap Manual e A Will increase Shift Position by 50 Y Will decrease Shift Position by 50 e lt Will switch between Automatic shifting and Manual shifting If your application requires this display functionality and the ability to switch between multiple Shift Maps contact Fallbrook Technologies Customer Support for further details price and availability of the NuV
72. usly variable transmission system The NuVinci bicycle CVP continues to win prestigious awards since its introduction in 2006 and the NuVinci system is now available in an automatic shifting version for bicycles light electric vehicles small internal combustion engine vehicles as well as many other applications The CVP Developer Kit consists of a NuVinci Continuously Variable Planetary CVP transmission an electronic Shift Actuator a Controller and all primary wiring and mounting hardware to install the system In addition software is provided to configure the system with a Windows PC The CVP Developer Kit functions by automatically controlling the transmission speed ratio based upon vehicle speed manual shift modes are also supported The NuVinci Controller monitors vehicle speed via a Speed Sensor and determines the appropriate Shift Position value based upon user derived uploaded Shift Maps The Controller then commands the Shift Actuator to arrive at the correct speed ratio for the NuVinci CVP Significant benefits can be realized with the CVP Developer Kit including increased acceleration top speed hill climb capability range and overall drivetrain efficiency Additional information and results can be reviewed at the NuVinci website www fallbrooktech com Some recent applications of the CVP Developer Kit by Fallbrook Technologies are shown below ERP Pos ata Figure 4 NuVinci CVP Developer Kit and NuVinci Display
73. uty cycle Use discretion and contact Fallbrook Technologies Customer Support for production application needs or customized configurations 1 5 Product Development Options Fallbrook Technologies is capable of configuring custom transmission designs specifically for production vehicles or applications For drivetrain configurations outside of the NuVinci CVP Developer Kit performance envelope please contact Fallbrook Technologies for other product possibilities 1 6 Warranty The NuVinci CVP Developer Kit is a development tool for applications that benefit from an electronically controlled continuously variable transmission Fallbrook Technologies has no control over the type or quality of installation for the kit application nor the performance characteristics of the electrical system that is powering the kit Because of the possible varied nature of the application and installation for this system the purchaser hereby acknowledges that the kit is a developmental unit provided for experimentation and is provided AS IS FALLBROOK TECHNOLOGIES MAKES NO REPRESENTATION OR WARRANTIES EXPRESS OR IMPLIED WITH RESPECT TO THE KIT OR THE USE THEREOF FALLBROOK TECHNOLOGIES DISCLAIMS ALL IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE AND NONINFRINGEMENT FALLBROOK TECHNOLOGIES CUMULATIVE LIABILITY TO THE PURCHASER OR ANY OTHER PARTY FOR ANY LOSS OR DAMAGES RESULTING FROM ANY CLAIMS
74. vices f Intel R 828016 ICH Family USB Universal Host Controller 27C8 Biometric Coprocessor Ual RS232 Intel R 828016 ICH Family USB Universal Host Controller 27C9 Dual R5232 Intel R 828016 ICH Family USB Universal Host Controller 27CA4 p PCMCIA adapters Intel R 828016 ICH Family USB Universal Host Controller 27CB Ports COM amp LPT Intel R 82801G ICH Family USB2 Enhanced Host Controller 27CC f 2 Birger d USB Composite Device Smart card readers 4 6 Sound video and game controllers USB Root Hub System devices USB Root Hub El Universal Serial Bus controllers USB Root Hub Manually Installing USB Device Drivers In either circumstance above the operating system was unable to associate a driver with Controller You may choose to allow Windows to search for the driver itself or get a specific driver from a location you specify It is recommended that you choose the valid tested driver that is included with each installation of the NuVinci Desktop application To do so Right click the first DualRS232 item and select Update Driver Select the following options at each prompt before selecting Next Hardware Update Wizard Hardware Update Wizard Welcome to the Hardware Update Wizard Windows will search for current and updated software by This wizard helps you install software for looking on your computer on the hardware installation CD or on the Win
75. y way to switch between performance and economy modes for a vehicle Any basic switch will work for this application and some examples from motorcycle electrical accessories can be found online at sites such as http trailtech net switches html as a sample is shown below for a handlebar mounted switch The switch will utilize the Yellow GND and Black Display RXDO wires on the HDR2 Display Mode Wiring Pigtail Simply connect the switch to these two wires and the functionality will be as follows Display Mode Wiring Pigtail e Yellow pigtail wire isolated from Black pigtail wire Switch Open Shift Map 1 will be active e Yellow pigtail wire connected to Black pigtail wire Switch Closed Shift Map 2 will be active NOTE The Mode Switch is not functional when a USB connection is made between a PC and the Controller Reference Appendix G for HDR2 connector and Display Mode Wiring Pigtail specifics NuVinci CVP Developer Kit Manual Page 34 Appendix F Display Interface Capabilities NuVinci Display Interface Fallbrook Technologies has made available a NuVinci Display Interface that allows system monitoring and interaction with the Controller This can be mounted onto a flat back plane or secured with included handlebar style mounts The NuVinci Display Interface provides the following advantages On the fly selection of Automatic shifting referencing Shift Maps or Manual shifting On the fly selec
76. zero has not completed in this time system will deactivate 2 0 100 50 000 Unused s C Rsm 0o Unused 2 C Rsm o Unused 2 ese o Unused E i e Tes Unused Line 64 __Resewe 0 Unused A representation of how the Configuration Table appears in a normal text editor follows E Config Table Sample csv Notepad File Edit Format wiew Help Display Update Period Cin millisecs 100 5 5 prang output Period in millisecs 20 Speed Measure Pulse Per Rotation 6 wheel Circumference Cin milli inches 84400 Detect Loss of Encoder 1000 D e Actuator Control mode 0 420 Actuator Autozero Time Cin ms 16000 50000 Reserve 0 Reserve O Sample Configuration Table files can be located on the NuVinci CVP Developer Kit CD in the Developer Tools directory NuVinci CVP Developer Kit Manual Page 22 Appendix B Shift Table Format The Shift Table is a comma delimited file with entries separated by commas and line spacing There are 7 lines in the Shift Table and 71 columns Line 1 is simply a header description Shift Maps are aligned horizontally in rows starting at Row 2 with the name in the first column note that this is what the NuVinci Configuration Editor will create and format for the developer Column 1 2 3 4 5 6 7 ETS 8 9 10 11 12 69 70 7 f Software Shit Map I Unused Unused Unused Speed Limit 12 Step Table Length o5 i10 14 19 24 29 0 29 5 30 0 Name mph Size

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