Electronic control system redesign

Frank Tegtmeier - Electrical Engineering Terex O&K

Current configuration of the control system

Board Control System
BCS

CAN Bus II
CAN Bus I

J1939

Data
Aquisition
Processor
DAP

Pump Management System

LH engine
PMS

J1939

Programmable
Logic Control
PLC

Data
Aquisition
Processor
DAP

Pump Management System

RH engine
PMS

Central Management
CMS

Goals / Advantages of the new control system

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

New control system

BCS

CAN bus II
CAN bus I

J1939

Drive controller LH

J1939

Motion Management

Auxiliaries

Drive controller RH

New Board Control System (BCS) Hardware

Faster CPU (400 MHz)

Advanced temperatur
range (-40C - 55C)
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

July 2007
Software

December 2007
October 2007

3rd quarter 2008

Development
BCS
Controller
module test
Software
Development
Controller

Prototype
installation
at factory

Prototype machine
to selected client

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

Advanced fault storage / Example

Fault
code

123

Description

LH pump drive temperature

high

Alarm
condition

Temp. > 70C

for 15 sec.

Sensor
code

B1

Temp. < 65C

for 2 min.

LH pump drive
gearbox temperature

Start time and date

Machine hour at start

Duration of fault

13:27:15 15.8.2006

2340

00:15:23

Component serial
number

Time and date of

installation

xxyyzz

13:27:15 15.8.2006

Alarm limit

Time of occurrence

Related info from continuous logging

LH engine speed

LH engine load factor

Component Management Info

Fan motor
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

Pump drive gearbox

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

Engine coupling
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

Engine
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

Fan motor
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

radiator
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

Fan motor
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

Oil cooler
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h
Oil cooler
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h
Rotor
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

Fan motor
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

Swing gearbox RH
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h
Swing gearbox LH
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

Pump drive gearbox

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

Engine coupling
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

Engine
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

radiator
date of inst. : 2.2.2006
S/N: xxyyzz
oper hour: 345 h

On board documentation

On board documentation
electrical schematic
technical handbook
operator handbook

Dealer Days 06

Thank you !