Project Overview
As part of the UT25 FSAE vehicle development, I designed and built a custom drivetrain datalogger system to capture cooling and strain gauge data during testing days on the 2024 car. This project was crucial for gathering real-world performance data to inform 2025 vehicle development, with all programming and circuitry handled personally.
System Architecture
The datalogger was built around a Teensy microcontroller with onboard SD card storage:
Teensy Microcontroller
Programmed the Teensy to handle multiple sensor inputs and SD card data logging
Onboard SD Card Storage
Implemented reliable data storage for extended testing sessions without data loss
Circuit Design & Wire Harnessing
I personally handled all aspects of the electrical system implementation:
- Molex Wire Crimping: Learned professional wire termination techniques for reliable connections
- Wire Harnessing: Designed and installed comprehensive wire routing throughout the vehicle
- Circuit Integration: Wired up complete sensor circuits for cooling and strain gauge data acquisition
Data Acquisition Capabilities
The system was designed to capture critical vehicle performance data:
Cooling System Monitoring
Temperature sensors throughout the cooling loop to validate thermal performance
Strain Gauge Data
Real-time structural load monitoring from tie rods and motor mounts
Integration with Strain Gauge Testing
This datalogger system directly supports the strain gauge testing and load analysis work by providing the hardware platform to capture calibrated strain measurements during actual vehicle testing conditions.
Custom-built datalogger with Teensy microcontroller and SD card storage
Data Analysis & Simulation Correlation
The collected data serves multiple purposes in vehicle development:
- Force Analysis: Correlating measured loads with simulation predictions for improved accuracy
- Thermal Validation: Comparing cooling system performance with CFD models
- Design Optimization: Using real-world data to refine component specifications
Technical Achievements
Key technical milestones achieved in this project:
Hands-On Electronics
Complete system design from concept to implementation
Wire Harnessing Skills
Professional-grade wire management and termination
Future Applications
This datalogger establishes the foundation for comprehensive vehicle telemetry systems, enabling data-driven development across multiple engineering domains for future FSAE competitions.
Related FSAE Projects
Integrated MATLAB Simulink Lap Simulation
2025Led development of integrated MATLAB Simulink framework advancing from steady-state to transient simulations, collaborating with powertrain and vehicle dynamics teams to integrate existing models and implement comprehensive multi-physics modeling with Vi-grade and Adams integration.
Impact: Established transient simulation capabilities enabling real-time analysis of complex vehicle dynamics, electrical systems, and thermal management interactions
Radiator Characterization & Testing
2024Designed and built UTFR's first comprehensive radiator characterization test bench with custom circuit board for data acquisition, featuring 1 flow rate sensor, 2 pressure sensors, 2 water temperature sensors, 2 air temperature sensors, and hot wire anemometer - all logged directly to computer. This marked the first experimental radiator testing in team history and generated valuable thermal performance data.
Impact: Established experimental thermal testing capabilities and generated comprehensive radiator performance database for CFD validation and cooling system design
HV Box
2022Designed and manufactured the waterproof high voltage electrical enclosure for the team's first electric FSAE vehicle, focusing on manufacturable sheet metal design and precision assembly techniques.
Impact: Developed manufacturable enclosure design
