Electronic control system redesign

Frank Tegtmeier - Electrical Engineering Terex O&K

Current configuration of the control system

Pump Management SystemRH enginePMS

Central ManagementCMS

ProgrammableLogic ControlPLC

Board Control SystemBCS

CAN Bus I

DataAquisitionProcessorDAP

CAN Bus II

J1939

Pump Management SystemLH enginePMS

DataAquisitionProcessorDAP

J1939

• One type of controller for all automation functions

• Less different parts to be kept

• Reduced number of controllers in the new system

• Only one programming tool for reprogramming

• Controller can be programmed through BCS

• Advanced trouble shooting and self diagnostic functions

Goals / Advantages of the new control system

New control system

Drive controller LH Motion Management

CAN bus I

CAN bus II

BCS

J1939 J1939

Auxiliaries Drive controller RH

New Board Control System (BCS) Hardware

• Faster CPU (400 MHz)

• Advanced temperatur range (-40°C - 55°C)

• Larger display (12” / 800 x 600 pixel)

• Additional keys and touch screen for better navigation

• Operating system Win XP embeded

• Compact Flash card and USB port for software updates

Development timeline

Software

Development

BCSController

module test

Prototype

installation

at factory

Prototype machine

to selected clientSoftware

Development

Controller

July 2007

October 2007

December 2007

3rd quarter 2008

New BCS functions

• Integrated engine interface via J1939 data bus

• Engine fault code information is available

• All controllers can be configured and programmed through the BCS

• No additional service tool is required.

• Service laptop can be connected using wireless network access.

• Service software will be identical with BCS software

• Operators and service personell will have different access levels

Time of occurrenceAlarm limit

Related info from continuous logging

LH pump drivegearbox temperature

LH engine speed

LH engine load factor

Faultcode

123

Description LH pump drive temperaturehigh

Alarmcondition

Temp. > 70°Cfor 15 sec.

13:27:15 15.8.2006

Start time and date Machine hour at start

2340

Duration of fault

00:15:23

Sensorcode

Advanced fault storage / Example

Temp. < 65°Cfor 2 min.

B1

Component serialnumber

xxyyzz

Time and date ofinstallation

13:27:15 15.8.2006

Enginedate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

radiatordate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Fan motordate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Engine couplingdate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Pump drive gearboxdate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

radiatordate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 hEngine coupling

date of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Pump drive gearboxdate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Fan motordate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Fan motordate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Fan motordate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Oil coolerdate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Oil coolerdate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Rotordate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Swing gearbox RHdate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Swing gearbox LHdate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

Component Management Info

Enginedate of inst. : 2.2.2006S/N: xxyyzzoper hour: 345 h

On board documentation

electrical schematic

technical handbook

operator handbook

On board documentation

Thank you !

Dealer Days ‘06