Mobile vehicles are becoming increasingly complex. With the demand to offer improved performance, reduced wiring, superior diagnostic capabilities, and increased uptime, the functional requirements of a mobile vehichle are higher than ever. In addition, mobile vehicles are continually challenged by the extreme outdoor elements in which they must perform.
The rugged terrain and harsh elements found in the forestry industry is one of the most difficult environments for mobile vehicles – and their electronc controls. The machine builder HSM Honenloher relies on the 32-bit Classic Controller from ifm to meet the needs of their machines. The powerful CR0032 controller with a 32-bit processor features a large program memory that allows the processing of complex application programs. Set-up of the control system
 In the past, different control modules were used in the various vehicle platforms. Now, the different tasks can all be performed by ifm’s single, 32-bit Classic Controller. The controller processes all sensor, actuator, and controls signals via the CAN bus using decentralized input/output modules for the individual machine parts. The controller has 16 multifunctional inputs and 16 multifunctional outputs. The inputs can be configured as digital, frequency or analog with diagnostic function. The outputs can be configured as digital or PWM with diagnostic capapbilities with or without current control. Despite the size of the application program and its complex logic, the PLC cycle time is so short that four independent CAN interfaces can be read and processed in parallel. CAN Interface 1 is responsible for the communication with CAN joysticks and the decentralized I/O modules using the CANopen protocol. CAN Interface 2 handles the exchange of data with the central display. The display allows the vehicle to be adjusted to the unique requirements of up to 5 different operators while at the same time providing both diagnostics and machine calibration options. CAN Interface 3 manages the engine. Here the data is transferred using the standard SAE J1939 protocol. Engines feature both the tier 3 and the latest tier 4 emissions standards using this protocol. The harvester uses CAN Interface 4 for control data exchange. The integrated diagnostic functions allow the monitoring of all signals to further ensure operating integrity. For example, a short circuit or wire break in an actuator cable is detected, evaluated and immediately transferred to the control system. The response that occurs depends on the I/O configuration while fault messages are indicated on the display. Electronic requirements for harsh outdoor environments
 Vehicle controls are exposed to extreme temperature fluctuations – from the high heat of the diesel engine during operation to the extreme low temperatures of northern climates when the equipment is not running. The 32-bit Classic Controller’s electronic components are designed and tested for the extreme mechanical stress caused by physical impacts and vibration. These components can withstand elevated temperatures, dirt, moisture, and feature a high IP rating and a metal housing to ensure reliable function.
In addition, the Controller’s wide voltage range and additional protective circuitry insure reliable operation even in cases with large voltage fluctuations from the battery/generator supply and the high conducted and radiated interference. Application software for reliable operation
For HSM, the flexibility of the programming software is another important feature for the control concept. Without software specifically tailored to the respective machine, none of the installed components will work. The programming system CoDeSys features the programming standard IEC 61131. The software features different languages including Function Block Diagram, Ladder Diagram, Sequential Flow Chart, Continuous Function Chart, Structured Test and Instruction List. In addition to the software design, it is also possible to manage the projects and to store software functions for multiple use in libraries. A powerful visualization module for graphic representation of the machines functions completes the package. The visualization can be created as a service tool for local enginers to assist with troubleshooting machine functions while preventing unauthorized access to the software code.
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