Control System Electronics - STW Technic · Control System Electronics Control System Electronics...

Cont ro l Sys tem E lec t ron icsContro l Sys tem E lec t ron ics

Excellence in mobile controllers and measurement technologies

02 02

Contents

03 GENERAL DESCRIPTION

05PROGRAMMING SIMULATION

06OVERVIEW IN- / OUTPUTS

07FREELY PROGRAMMABLE CONTROLLERS

11I / O MODULES

12TELESERVICE

14OTHER CONTROL SYSTEM PRODUCTS

16SOFTWARE

17HOUSING OVERVIEW

19FURTHER BUSINESS SEGMENTS

03 03

The application of electronic control units

in off-highway vehicles and mobile ma-

chines is rapidly increasing in importance.

There is a constant need for more capable

machines, with more safety and more com-

fort. At the same time there is ever increas-

ing pressure to optimize and reduce costs.

These goals lead to higher levels of automa-

tion, which in turn leads to a greater reliance

on electronics.

STW GmbH offers programmable control

units, I / O modules and teleservice units

based on powerful 16 and 32 bit proces-

sors. These control units are ideally suited for

the rough environment and extreme tem-

peratures (−40°C ... +85°C) of off-highway

vehicles and mobile machines.

All modules include protection against short

circuits and have in built diagnostics for all

inputs and outputs. The control units offer

digital and analog inputs and outputs, RPM

inputs, and pulse width modulation (PWM)

power outputs with current regulation.

Proportional valves can be directly driven

without additional amplifier or control

electronics. A safety relay provides a sec-

ond means of switching off the digital and

PWM outputs. Data exchange with other

intelligent units is made possible with CAN

(CAN 2.0 B) interfaces.

Robust cast aluminum housings (protection

class IP65, optionally IP67 / IP69k) offer a

high level of protection against electromag-

netic disturbances and mechanical protec-

tion.

Naturally, all units comply with the standards

required for CE conformance. Additionally

the control units satisfy the standards of

passenger, construction and agricultural ve-

hicles and machines.

For safety relevant applications, such as

platform lifts and refuse compaction, SIL2

(IEC 61508) / PLd (DIN EN ISO 13849) certi-

fied control units are available.

The freely programmable controllers of the

ESX®-family are working independently as

measuring, driving or controlling devices

for sensor actuator management and are

capable of executing a number of separate

or related tasks in real time.

General Description

04

Applications in vehicles: Electrohydraulic steering systems

(steer-by-wire)

Electronically controlled hydrostatic drives

(drive-by-wire)

Hydraulic functions

Engine management

Transmission control

Automatic levelling and positioning of

platforms

Expansion boardsElectronic controllers of the ESX®-family may

be expanded, using standard internal inter-

faces and various modules to provide addi-

tional input or output ports. The type of I / O is

not restricted. These modules may also include

further design features (e.g. real time clock)

making the ESX®-controllers ideally suited for

quick adaptation to customer demands.

Configuration, calibration and parameter settingCharacteristics, calibration data and criti-

cal parameters for sensor-actuator man-

agement as well as controller configura-

tion can all be stored in a non-volatile

FRAM / EEPROM. Using an editor software,

this data may be accessed via CAN bus or

the RS 232 interface.

Comprehensive external and internal error diagnosticsSTW offers a line of software tools for read-

ing the error buffer, system diagnostics, visu-

alization and maintenance or repair servic-

es. Communication is established using the

standard CAN-Bus or the RS 232 interface.

04

General Description

Inputs

ON-Signal(interruption input)

Memory

CAN interfaces

Serial interfaces

additional interfaces(e. g. for expansion boards)

PWM/PVG outputs

Analog outputs

Stabilized voltage outputs

05 05

Rapid software development with CoDeSys or CThe software can be programmed using

CoDeSys (IEC 61131-3) or C.

CoDeSys is based on a graphical develop-

ment environment with the following choice

of programming languages:

Function Block Diagram (FBD)

Ladder Diagram (LD)

Instruction List (IL)

Structured Text (ST)

Sequential Function Chart (SFC)

Continuous Function Chart (CFC)

CoDeSys can be used without previous

knowledge of any high level programming

languages.

Integrated Development Environments

(IDEs) are also available for programming

in C. The function library with ready-to-use

code blocks provide the possibility to quickly

and easily program application software,

with the sophistication and flexibility of a

high level programming language.

The software is downloaded into the flash

memory using either CAN or RS 232 inter-

face. STW has an extensive diagnostic li-

brary available that supports programming

and configuration functions including debug

and diagnostic tools. ESX®-KEFEX, STWs PC

based software, can be used to create stand-

alone diagnostic, service and „end of line”

configuration tools. Upon request STW can

develop complete software solutions for

customer applications.

Simulation of all inputs and outputsTo simulate the target vehicle in support

of the development process, STW offers

a test box with a connector for the ESX®-

controllers and monitoring and simulation

circuits for all inputs and outputs. The I / O

channels can be switched as required or

connected to external sensors and actua-

tors.

Programming and Simulation

06

Product Typ I / O I max. CAN RS 232 RTCSoftware

programmingFurther options Page

ESX®-3XL 32 bit 52, max. 136 90 A 4 1 CoDeSys, C SIL2 / PLd, expansion boards 07

ESX®-3XM 32 bit 23, max. 65 40 A 4 1 CoDeSys, C SIL2 / PLd, expansion boards 07

ESX® 16 bit 36, max. 48 30 A 1, opt. 2 1 CoDeSys, C SIL2 / PLd, expansion boards 08

ESX®-C 16 bit 36, max. 48 30 A 2 1 – CoDeSys, C – 08

ESX®-LT 16 bit 25, max. 29 20 A 1, opt. 2 1 – CoDeSys, C – 09

ESX®-LTplus 16 bit 32 30 A 2 – – CoDeSys, C – 09

ESX®-micro 16 bit max. 10 15 A 1, opt. 2 – CoDeSys, C Motor bridge 10

ESX®-IOXp 16 bit 26 11 A 2 1 – CoDeSys – 10

ESX®-DIOM 8 bit 24 70 A 1 – – Software configurable

I / O module

Layer 2, CANopen 11

ESX®-DIOS 8 bit 8 30 A 1 – – Software configurable

I / O module

Layer 2, CANopen 11

ESX®-IOX 8 bit 28 11 A 1 – – Software configurable

I / O module

Layer 2, CANopen 11

ESX®-C2C 16 bit 5 8 A 2 2 C Teleservice module, GPS,

GSM / GPRS, Bluetooth

13

ESX®-TC3 32 bit 2 – 2 1 C Linux based operating system, GPS, USB

GSM / GPRS, Bluetooth,Ethernet, WiFi,

13

ESX®-TC1 – 4 – 1

(for FMS)

1 Software

configurable

Teleservice module, GPS, GSM / GPRS, 12

Overview In- / Outputs

= Standard

= Optional

12

Teleservice

ESX®-TC1Interfaces Housing type: HP-1 29 pin automotive connector (Tyco / AMP)

I / Os| 4 digital / analog inputs

| 1 output

GSM MODEM | Quad band EGSM 850 / 900 / 1800 / 1900 MHz | GPRS Class 10

GPS | SiRFstarIII™ | 20 channel GPS receiver

CAN-Bus | 1 x CAN

ESX®-TC11

(FMS)1

4 IN

1 OUT– – 1 1 – – 1 min approx. 1 min Pyton Script 15 external no

ESX®-C2C 2 2 max. 5 – – 1 1 1 – 2 sec < 100 ms embedded C 64 external yes

ESX®-TC3 2 11 IN

1 OUT1 1 1 1 1 1 1 ms approx. 30 sec

embedded C

linux100

external /

internalyes

Prod

uct

CANRS 2

32

I / O WiFiEthe

rnet

USB Boot t

ime

GPS Typ.

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ount

Anten

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Blueto

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Syste

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Typ.

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and G

SM / G

PRS

Internet

Server

PC

PC BT, WiFi, USB

PC

GPS

GPRS

Gateway

GSM / GPRS, CSD

BT, WiFi, USB

Ethernet

14

Other Control System Products

ESX®-FLASHBOXProcessor System 12 pin M16, USB device socket, USB host socket


Flash | 128 MByte nonvolatile data memory

Interfaces

CAN-Bus | 2 x CAN

USB | USB 2.0

Operator interface | white LED B / W display (240 x 160) | 4 soft-keys

Dimensions (W x D x H) | approx. 4.72” x 4.65” x 1.46” (120 mm x 118 mm x 37 mm)

ESX®-LDMLoad-Dump-Impulse Blade terminals 6.3 mm

Amplitude | 200 V

Source impedance | 2 Ω

Impulse duration | 500 ms

Impulse count | 5

Repeat time | 25 s

System data

System voltage | 9 ... 32 V DC

Breakdown voltage | ≥ 33 V DC

Voltage limit | max. 51 V DC

Impulse duration | ≤ 300 ms

max. continuous current | 33 A (at voltage limit)

Peak current | max. 388 A (at 10 / 1000 µs)

Reverse voltage protection

Amplitude limit | ≤ –2 V

Short circuit current | ≤ 200 A

Impulse duration | ≤50 ms


The ESX®-FLASHBOX is a programming de-

vice for updating the software in ESX® family

control units. The ESX®-FLASHBOX is config-

ured and loaded with the necessary hex files

in the office using the supplied PC software.

The service personnel can then update con-

trollers in the field via a vehicle CAN port.

The rugged construction, ease of use and

vehicle power connection makes the ESX®-

FLASHBOX an ideal alternative to a note-

book with Winflash.

15

Other Control System Products

ESX®-µHMIProcessor System Blade terminals 6.3 mm


Interfaces

CAN-Bus | CAN


ESX®-MBOutput Blade terminals 6.3 mm

Permanent output current| 1.5 A | inverse-polarity protection | protection against thermal overload

| starting current up to 10 A


The ESX®-µHMI reads in CAN-Bus messages

and displays them for fast and easy diagno-

ses of system related hardware and software

states. Error codes and information codes,

defined during program development, can

The ESX®-C2Ulog CAN data logger is an

automotive memory device that can be

accessed via CAN and USB. Depending on

configuration, it records CAN messages with

be assigned to each machine and / or failure

mode. Two push buttons on the display al-

low the operator to scroll through messages

and implement simple system actions.

ESX®-C2UlogProcessor System 8 pin M9 and USB device socket, optional USB over M9 connector


Flash | 128 MByte | non-volatile data memory

Interfaces

CAN-Bus | 1 x CAN

Functions

| logging CAN messages with filtering of CAN IDs

| file read and write via CAN by CAN capable ECUs (e. g. ESX®)

| file read and write via USB from the PC

| wake on CAN


the desired identifiers, or it can be used like

a memory stick to read and write files over

CAN or USB.

Electric motor

GND UB

– MotorDIR

Direction

PWM Speed+ Motor

Controller (e. g. ESX®)

Motor bridge ESX®-MB

16

Software

ESX®-KEFEXESX®-KEFEX is the service and integration

suite for the freely programmable control

units of the ESX® Family. Use ESX®-KEFEX

for enhanced system management, and a

transparent view in- to the state of mobile

machines.

System configuration, calibration and

failure diagnosis

Calibration and display of system

parameters

Display and capture of CAN messages

ECU program download

Large library of visualization components

for the creation of PC service tools

CoDeSysProgramming of the control units is possible

in the high level language C, or with the

IEC-61131-3 compliant CoDeSys develop-

ment environment using:

Instruction List (IL)

Structured Text (ST)

Sequential Function Chart (SFC)

Function Block Diagram (FBD)

Ladder Diagram (LD)

Continuous Function Chart (CFC).

The application software can be quickly

realized with the help of extensive libraries

and pre-prepared function blocks. First and

foremost the programming environment

CoDeSys enables application development

without extensive knowledge of a low level

programming language.

19

Further Business Segments

Hybrid Technic in mobile MachinesIn recent years, the hybrid drive concept has become synonymous with environmentally

friendly mobility. The powerMELA system offers electric drives, power inverters, batteries,

battery management systems, power management and safety and connection technology

designed specifically for mobile machinery.

Measuring and Sensor TechnologyWe design and manufacture both individual components and complete sensors for

measuring pressure, distance and force.

In-Cylinder Pressure Measurement for Combustion EnginesThe combination of a special strain gauge material and our expert know-how enables

continuous in-cylinder pressure monitoring and closed-loop feedback control in production

engines.

Sensors in Thin-Film TechnologyWe design pressure and force sensors for various areas of industrial and automotive

measuring technology, including novel and highly demanding applications.

Product Design and DevelopmentAs well as standard products, we develop customer specific electronics, guaranteed to

work in the most demanding environments, such as in the automotive and aviation

industries.

Manufacturing and ProductionOur production facilities and years of experience enable us to manufacture your products

in your required quantities. We also manage the entire logistic process from material

purchasing to delivery for you.

Head OfficeSensor-Technik Wiedemann GmbH Steuer- und RegelelektronikAm Bärenwald 6

87600 Kaufbeuren

GERMANY

Telephone +49 (0) 83 41-95 05-0

Telefax +49 (0) 83 41-95 05-55

E-Mail [email protected]

Internet www.sensor-technik.de

International SubsidiariesSTW-Technic, LPMobile Controllers and

Measurement Technologies

3000 Northwoods Pkwy. Suite 260

Norcross, GA 30071 USA

Telephone +1 (770) 2 42-10 02

Telefax +1 (770) 2 42-10 06


Internet www.stw-technic.com

Sensor-Technik UK Ltd.Unit 1, Stoke Mills

Mill Road, Sharnbrook

Bedfordshire MK44 1NN

ENGLAND

Telephone +44 (0) 12 34-78 20-49

Telefax +44 (0) 12 34-78 20-56


Internet www.sensor-technik.co.uk

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Stuttgart

Ulm Augsburg

Memmingen

Lindau

Kempten

Zurich Garmisch

Munich

Salzburg

Regensburg

Landsberg

Kaufbeuren

from Nuremberg from Frankfurt from Würzburg

2011

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