Control System 1
rev1 03.06 MY
Control system
Display
ECM
Middle
Module
Front
Chair
Module
Module
Can bus
J1939
Sandvik Mining and Construction
Control System 2
rev1 03.06 MY
Main components
DISPLAY
Presents information from machine
and control system.
CONTROL MODULE (IO-module)
Controls machine movements and
operations
IO= input/output
Sandvik Mining and Construction
Control System 3
rev1 03.06 MY
Abbreviations
CAN Controller Area Network
Described by ISO 11898 : Year 1993Road vehicles -- Interchange of digital information --
Controller area network (CAN) for high-speed communication CAN consist of different
protocols e.g. CAN open and SAE J1939
CANopen CANopen profile family specifies standardised communication mechanisms and device
functionality Components and sensors from different manufacturer can be used. CANopen
was originally designed for motion oriented industrial control systems , such as handling
systems. But CANopen networks are also used in other application fields, e.g. public
transportation, off-road vehicles and building automation
SAE J1939 Another CAN protocol which is used to communicate with ECM (Engine Control Module)
Sandvik Mining and Construction
Control System 4
rev1 03.06 MY
Traditional vs. CAN bus
24V
Traditional S1 S3 S5
wiring
S2 S4 S6
K1 K2 K3
Y1 Y2 Y3
0V
Y1 Y2 Y3
24V S1 S2 S3 S4 S5 S6
CAN bus
system Front module
GND
GND
CAN bus
24V
GND 24V Chair module
Sandvik Mining and Construction
Control System 5
rev1 03.06 MY
Control system principle
Display-module on dashboard
Chair and Middle-modules in
the dashboard
J1939 cable between Engine Control
Module (ECM) and chair module
CAN bus between modules
Wiring harnesses from IO modules to
sensors and actuators Front module in connection box
Sandvik Mining and Construction
Control System 6
rev1 03.06 MY
Control system principle
24 v
Gnd Can High
Can Low
Engine
J1939
Control
Module
Chair Module Middle Module Front Module Display
-Solenoids -Solenoids
-Joysticks -Lights -Lights
-Lights -Speed sensors -Limit swithes
-Swithes -etc. -etc.
-etc.
Sandvik Mining and Construction
Control System 7
rev1 03.06 MY
Signal types
PWM Pulse Width Modulation, output signal
- e.g boom/bucket control main valve.
FB Feed back, control signal is read back to module from proportional valve.
- e.g control valve in a piston type pump
DO Digital Output, 24 V.
- e.g signal lights
DI Digital Input, is used to read signal from switch (Typically 24VDC or 0 VDC). fn< 750 Hz
- e.g door limit switch
PI Pulse input, it is like DI input but is capable to read high frequency signal from sensor
- e.g. speed sensor). fn< 10 KHz
AI Analog input, is used to read analog signals from sensors.
-Temperature and pressure sensor
Sandvik Mining and Construction
Control System 8
rev1 03.06 MY
Principle of Can Bus - control system
Module controls its outputs according to information the module has get from:
- Input/output-pins. (I/O-pins)
- Other modules via CAN-bus.
- CAN sensors via CAN-bus.
- ECM (Engine Control Module) unit via Chair module’s dedicated CAN-bus (SAE J1939)..
Boom control example:
- Chair module measures joystick position.
- Joystick position is transferred to front module.
- Front module controls proportional valve with PWM output.
- Front module can restrict boom movement and speed.
- The state of the boom control output can be seen in the display, in special diagnostic window (except PWM).
0….27V
PWM
Chair Front
Display
Module Module
0….5 VDC 00101100 0….1000mA
Voltage signal Can message Current feedback
Sandvik Mining and Construction
Control System 9
rev1 03.06 MY
Troubleshooting
Related interlocks
Diagnostics display for
Boom
Bucket
Steering
Boom joystick voltage
CAN bus signal
Program status for the
valve control
0 = Off
1 = On Pump control current Valve feedback current
Sandvik Mining and Construction
Control System 10
rev1 03.06 MY
Troubleshooting
Related interlocks
Diagnostics display for
Boom
Bucket
Steering
Boom joystick voltage
CAN bus signal
Program status for the
valve control
0 = Off
1 = On Pump control current Valve feedback current
Sandvik Mining and Construction
Control System 11
rev1 03.06 MY
Troubleshooting
Related interlocks
Diagnostics display for
Boom
Bucket
Steering
Boom joystick voltage
CAN bus signal
Program status for the
valve control
0 = Off
1 = On Pump control current Valve feedback current
Sandvik Mining and Construction
Control System 12
rev1 03.06 MY
Warnings/alarms
Warning pop up at 105
Warnings and alarms for:
Engine alarms from Engine Control Module (ECM)
according to J1939 standard SPN/FMI
Temperatures and pressures
Oil levels
Central lubrication failures
Control system component failures
Connection failures
Sensor failures
Filter blocking
All stored in log file Alarm pop up at 110
Browsing on display
Downloading with standard laptop
Downloading with Program Downloading Tool
Sandvik Mining and Construction
Control System 13
rev1 03.06 MY
CAN high/CAN low
3,75
V
2,5
V
1,25
0 0 1 0 1 0 1 0 0 1 1 0 1 0
V
CAN High
120Ω
120Ω
Bus termination Bus termination
resistor resistor
CAN Low
Front module Chair module Middle module Display
Sandvik Mining and Construction
Control System 14
rev1 03.06 MY
Principle of closed electrical circuit
- Electrical circuit which is connected to a module has to be in a closed circuit.
- Closed circuit means e.g. DO outputs are connected to the valve. This valve is grounded in module ground pin.
- This kind of circuit minimize the risk of module input damage which is caused by e.g. earth current during
welding.
- Another example is a light switch. Power supply for the switch is connected to module’s DO output. Signal pin
for Switch is connected to the module’s DI pin which observe the current state of the switch.
Sandvik Mining and Construction
Control System 15
rev1 03.06 MY
Analog input
An analog input can be used in voltage or current mode. The mode is selected by the programmer /
factory according to the sensor type.
Voltage mode:
- Measure range is 0 to 5 V.
- Absolute maximum input voltage is 30 V.
In this mode, analog inputs can be used with all voltage sensors which operate in range 0 to 5 volts. The picture
below represents the basic connection for a sensor. In e.g. sensors named in picture, can be used in this input
type.
Temperature sensor
Joystick measuring sensor
Sandvik Mining and Construction
Control System 16
rev1 03.06 MY
Analog input
Current mode:
- Measure range is 0 to 22,7 mA.
- In current mode, absolute maximum input voltage is 15 V.
In this mode, analog input can be used with all current sensors which operate in range 0 to 22,7 mA. The
picture below represents the basic connection of the sensor. In e.g. sensors named in picture can be used in
this input type.
Temperature sensor
Pressure sensor
Steering sensor
Current measure sensor
Sandvik Mining and Construction
Control System 17
rev1 03.06 MY
Digital input
-The digital input can regocnize two different state: Voltage high or voltage low.
-Voltage is high (=input on) when voltage is above set limit
(between 2,0 V to 4,8 V depending on the pin)
-Voltage is low (=input off) when voltage is under set limit.
(between 0V to 4,2 V depending on the pin)
- Absolute maximum input voltage to pin is 30 V.
The most common application of digital inputs:
- Reading the state of buttons and switches (e.g. light switches)
- Joystick direction switches
- Limit switches
- Pressure switches (e.g. brake pressure, filter diagnostic)
Sandvik Mining and Construction
Control System 18
rev1 03.06 MY
Digital output
There are two kind of digital outputs, current sourcing and sinking.
Current sourcing type:
- Current sourcing output is the most common used pin type.
- Current sourcing output connect the load to the positive supply voltage.
- Output maximum current is 3 A.
E-Stop circuit supply
Sensor supply
Light control
etc..
Sandvik Mining and Construction
Control System 19
rev1 03.06 MY
Digital output
Current sinking type:
- Current sinking output connect the load to the ground.
- Current sinking output is used in very carefully considered implementations.
- Output maximum current is 3 A.
Sandvik Mining and Construction
Control System 20
rev1 03.06 MY
PWM output
- Pulse width modulated (PWM) output is used to control hydraulic proportional valves.
- When PWM output is connected so that the return path is feedback pin, the current can be controlled.
- Frequency of PWM output can be adjusted from 40 to 2550 Hz.
- Maximum current is 3A.
- Maximum current with Feedback input is 1,0A.
0….27V
PWM
Front
Module
0….1000mA
Current feedback
Sandvik Mining and Construction
Control System 21
rev1 03.06 MY
Feedback
- Feedback pin is normally used as return path for PWM output.
- The pin has a ability to measure the current flowing through it. The most common purpose of
this pin is to measure the current of electrically controlled hydraulic proportional valves.
- The maximum input current is 1.0 A.
Sandvik Mining and Construction
Control System 22
rev1 03.06 MY
Cyclical program execution
Read inputs
CAN Bus
Execute program
set outputs
Execution time is 10ms, so this is done 100 times in one second
Sandvik Mining and Construction
Control System 23
rev1 03.06 MY
What the modules include?
Display
Module
- Alarm log -Program
-Input/output defining
- Backup storage for module parameters
-Parameter defining
-Installation package -CAN Bus defining
-Display program -Actual program
-Module programs
-Module parameters
-Machine type parameter files
-Parameter adjusting files
-Lanquage files
Sandvik Mining and Construction
Control System 24
rev1 03.06 MY
Program downloading
By using Program Downloading Tool
Can cable
Program Control
Downloading System
Tool in
Toro
Sandvik Mining and Construction
Control System 25
rev1 03.06 MY
Program downloading
By using Program Downloading Tool - application on PC
Can cable
CAN-
interface
Control
System
Program
in
downloading tool -
Toro
application
Sandvik Mining and Construction
Control System 26
rev1 03.06 MY
Making a Program Downloading Tool
By using Program Downloading Tool - application on PC
Can cable
CAN-
interface
Program
downloading tool -
application Display
Module
24V Power
supply
Sandvik Mining and Construction
Control System 27
rev1 03.06 MY
Making a Program Downloading Tool
By using Program Downloading Tool
Can cable
Program
Downloading
Tool
Display
Module
24V Power
supply
Sandvik Mining and Construction
