Electronic automation for mobile machinery

Electronic controls are now a standard feature in modern vehicles and mobile machinery. Without the application of sophisticated electronics, the present-day demands on machinery could never be fulfilled.
The demands placed on the electronic automation (total control) of mobile machinery, contrary to control systems of static industrial machines, are enormous.

Demands on electronics

Extreme mechanical stresses caused by sudden impacts and high peak loads, as well as applications at very high ambient temperatures, can only be overcome by innovative design measures and the meticulous selection of ideal components. A high protection rate against dirt, humidity and salt water can only be achieved by stringent development stages and the careful choice of electronic components for outdoor use.

External electrical interference that could have an effect on individual units or the total control system must be effectively safeguarded. Extreme fluctuations of the internal power supply can also occur in mobile machinery due to their on-board battery/generator systems. Such negative influences can only be combatted by a sophisticated power supply and specific safeguarding measures to ensure reliable machine operation.
An additional technical hurdle is that mobile machinery must be reliably protected against external interference to ensure a high rate of electro-magnetic compatibility.

Demands on hydraulics

Mobile machines are generally hydraulically driven. Their hydraulic drive systems are controlled and governed by special automation systems for mobile machinery which must be capable of adapting and actuating proportional hydraulic valves of various specifications from different manufacturers.

Their programmable function-dependent logics enable hydraulic movements not only to be actuated but also to be controlled, which is not possible with standard hydraulic systems. This, among others, is the reason for the rapidly increasing popularity of outdoor electronics.

Demands on wiring

Due to the size of mobile machinery, the expense incurred for electrical wiring cannot be disregarded. Today, special bus systems are generally used instead of cable bundles to cope with the tough demands on mobile machinery applications.
The CAN bus has proved itself during the past years as an effective method of connecting various electronic units. Contrary to the automotive industry, where cars are mass produced and optimised according to precisely defined protocols, the CANopen protocol cannot be dispensed with for mobile machinery.

This bus system enables a decentralised configuration of high-performance input and output modules located extremely close to the sensors and actors. Installation is carried out exactly where the data signals occur or are required. These components must also be located where they are simple to install and must be easily accessible in the event of a service requirement. This task is achieved by their convenient mechanical design and their simple integration in a system during programming.

Last but not least, the applied components and units must be able to withstand all mechanical, climatic and electrical demands while reliably functioning over extremely long periods. All these demands result in a mutual task: the development of reliable, economical and therefore competitive machinery.

Demands on diesel engines

The present-day demands on emission control of combustion engines could never be achieved without the assistance of electronics.
Modern diesel engines for mobile machinery are also equipped with electronic controls. These electronic controls possess a CAN bus with a protocol according to American SAE standard J1929. Gateways allow the connection of manufacturer and application-specific protocols to a machine process, such as engine diagnostic data according to SAE J1939, or a bus system (ISO bus) which is frequently used in agricultural vehicles, or the truck-to-trailer interface of commercial trucks. Inter Control have developed all necessary tools to fulfil these tasks.

The automation system digsy Compact from Inter Control is equipped with 2 CAN controllers with an integral process interface. This feature enables different CAN protocols to be operated and data exchange to be carried out with just one unit. Engine condition data, such as operating temperature, oil pressure, torque or speed can be filtered out for processing or visualisation by the control programme.

Demands on visualisation

Mobile machinery of the new generation is complex and offers a multitude of functions. The operator is therefore dependent on the latest operational status and machine condition data. Reliable and adapted data of the machine's condition will assist the operator enormously thereby prevent the risk of incorrect operation. This necessary data can be seen on extremely sturdy displays that can be read at a glance - even in direct sunlight.

All operation data and system conditions must be stored via a save feature for statistical and documentation purposes.