SOLUTIONS FOR Mobile Machines

SOLUTIONS FOR

Mobile Machines

Automation Connectivity Electrification Measurement Systems and Sensors

Product and Solutions Catalog 2016

PRODUCT AND SOLUTIONS CATALOG

Table of Contents

INTRODUCTION System and Solution Overview...........................................................................4 Sensor-Technik Wiedemann ................................................................................5 Novelties...............................................................................................................6

SOLUTIONS FOR AUTOMATION ESX Solution Overview........................................................................................9 Central Controllers ESX-3...................................................................................10 Central Controllers ESX-2...................................................................................16 Compact Controllers...........................................................................................20 Controller Modules............................................................................................22 I/O Modules........................................................................................................23 Display and Control Panels................................................................................25

DATA MANAGEMENT AND CONNECTIVITY SOLUTIONS System Overview...............................................................................................29 On-Board Modules.............................................................................................30 On-Board Software............................................................................................32 Machine Monitoring..........................................................................................33 Data and Process Management.........................................................................35

ELECTRIFICATION SOLUTIONS Drive Train...........................................................................................................39 Power Generation and Distribution..................................................................42 Battery Management.........................................................................................44 Power Management Solutions..........................................................................50

MEASUREMENT SYSTEMS AND SENSORS digiSENS Solution Overview.............................................................................55 Sensors................................................................................................................56 Measurement Systems.......................................................................................58

3

INTRODUCTION

System and Solution Overview

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INTRODUCTION

Sensor-Technik Wiedemann Sensor-Technik Wiedemann GmbH (STW) is a manufacturer of sophisticated electronics solutions in the fields of automation, data management and connectivity as well as power electrification. Founded in 1985, STW has developed into an internationally active company and today employs a staff of 440, which serve small and medium-sized companies as well as leading OEMs. During the development and production of the OEM solutions, STW utilises its existing know-how, its technology and its infrastructure, to deliver both small batch quantities and to full serial production. The standard product range comprises control unit solutions, displays and operator units, data management and telematics modules, solutions for power distribution, power electrification and e-Mobility and sensors and measuring technology which are all introduced in this catalogue. The portfolio is complemented by according software support comprising BIOS, hardware abstraction layer, telematics applications framework and protocols and cloud based IoT solutions. Beyond this we support our customers with training, during deployment and while monitoring and maintaining their products. Our proposition is focused on the mobile machine market. For specific requirements we offer engineering and development services for variants and introduce compatible or supplementing products of selected partners. We also develop and manufacture solutions for other markets such as industry or medical technology - tailored to the individual requirements of our customers. In collaboration with our partners, we also realize projects in the fields of sensors, micro and power electronics, and embedded as well as application software programming. Naturally, we also deliver safety certified solutions. Our headquarter is based in Kaufbeuren, Germany. To ensure close customer relations we rely on two independent STW companies in the USA and the United Kingdom as work with system integrators and sales partners in more than 15 countries. Being an independent company we support our employees and acknowledge our responsibility for the society and the environment.

5

INTRODUCTION

Novelties

ESX-3CM – A new member for the established ESX Central Control Units Developed and manufactured for use in harshest environment the ESX-3CM combines the advantages of the 32 bit ESX family of central control units with the typical configuration requirements of mobile working machines. With a total of 56 analog and digital inputs and outputs in its standard configuration the freely programmable central control unit is designed for sensor and actor management. Of course, the tried and tested development environments for the programming language “C” as well as for CODESYS are also available for the ESX-3CM. Further support comes with STW’s analysis, configuration and update tool KEFEX. The ESX-3CM complies to the CE and E1 standards and the standards of the automotive, agriculture and construction machinery. For 2016 another variant for safety oriented applications according to PL d (DIN EN ISO13489-1 2008-12) or SIL 2 (IEC 61508 Edition 2.0 2010-04) is planned.

Smart and Safe Operator Terminal for mobile working machines New to STW’s product portfolio are intelligent operator terminals, the interACT VSX display family. With support of safety related application according to SIL2, available in different sizes and with a sophisticated toolchain for graphical programming the new VSX display family not only offers an innovative HMI generation but also scalable functionality for the application without compare. The new family was created in close cooperation with a technology leader in displays which has worked as a pioneer for safety related displays in railway applications. Adding their wide expertise and experience both companies benefit mutually in this technology and production partnership. 6

INTRODUCTION

Novelties

Vehicle Electric Centers – Useful and intelligent Vehicle electric centers or power boards are responsible for the protection and safeguarding, the distribution, the switching and controlling of electrical energy in a vehicle. Beyond protecting single circuits higher loads can be switched and controlled directly. By combining proven connector and press fit technology and the deep knowledge in control electronics regarding design and series production STW can today offer intelligent vehicle electric centers that meet customer requirements towards performance and quality in the market of mobile working machines and automotive applications. Standard products but also customer specific designs lead to solutions with field-proven technology that are functionality and cost optimized.

Data Management and Connectivity newly defined Based on on-board platforms such as the TC3G, the TC1 or the EB07 STW offers its customers solution oriented possibilities to efficiently manage machine and process data. The solutions make use of the freely programmable Linux environment and on STW’s Telematics Application Framework (TAF) which are available on all on-board modules. STW’s Vehicle Data Management System VDS allows the configuration, collection and visualization of machine data. By using predefined and certified “connectors” the platforms extend to offthe-shelf solutions which can be effortlessly adapted to partner or customer solutions. This works also with STW’s solution “machines.cloud” which allows the easy horizontal and vertical integration in process landscapes and lays ground for a fast and cost-efficient deployment of new business models. 7

SOLUTIONS FOR AUTOMATION

ESX Solution Overview

8


ESX Solution Overview

For the automation of functions in working machines it is necessary to implement the safe and reliable detection of different states, the interaction with the operator and the management of the resulting control and regulation tasks of these machine functions. With the product groups out of STW’s portfolio all automation jobs can be realized:

Central and Compact Control Systems For this STW offers a wide range of central and compact control systems with 16 and 32 bit processors.

Central control systems are used for the central control of complex machines and the decentralized control of complex machine parts. In addition they work as the central node for the connection of operator and display terminals, of decentral control units and of additional I/O units via BUS systems. It goes without saying that a direct or BUS-based connection of sensors and actors via the interfaces of the central unit is possible, too.

STW’s 32-bit control units are complemented by proven and established 16-bit platforms. The control units of the two families are capable of supporting safety-relevant applications and reach SIL 2 according to IEC 61508 and PL d according to DIN EN ISO13489.

I/O Modules

I/O modules extend the input and output functionality of central and compact controllers. They are connected to the control units by bus protocols and reduce the efforts for cabling between sensors, actors and the control units.

Display and Control Panels

Displays show the operation status of mobile machines and offer possibilities for the operator to interact with the machine via touchscreen or keys.

Compact control units can be found in more simple machines or for the decentralized control of complex machines.

9


Central Controllers ESX-3

The ESX-3XL and the ESX-3XM can be individually adapted regarding number and type of I/Os or communication interfaces to a multitude of requirements using expansion boards. The pre-configured ESX-3CM is the cost-efficient entry into the world of 32 bit control units.

Central Controllers for free configuration ESX-3XL Safety basic version

ESX-3XM Safety basic version

Expansion Boards (EB)

6 Slots for expansion boards


Processor

32 bit TriCore @ 150 MHz Separate system supervisor with programmable watchdog

Memory

SRAM (Processor internal): 80 kB SRAM (external): 4 MB Flash (Processor internal): 2 MB Flash (external): 4 MB EEPROM: 32 kB

Interfaces

4 x CAN

In-/Outputs

28 x multifunction inputs *3 8 x digital / PWM Out (4 A) with current measurement 16 x digital / PWM Out (2.5 A) with current measurement

15 x multifunction inputs *3 8 x digital / PWM Out (2.5 A) with current measurement

In-/Outputs Non-Interfering

Expandable up to 136 I/Os with various expansion boards *1

Expandable up to 56 I/Os with various expansion boards *1

Safety

SIL 2 according to IEC 61508 PL d according to EN 13849


Programming

„C“, CODESYS V3.x


10


Central Controllers ESX-3 Expansion boards for ESX-3Xx family

Communication Expansion

I/O + Communication Expansion

I/O Expansion

I/O Safety Expansion

Expansion Board

STW Article ID

Interfaces

In-/Outputs

Data memory

Number of required slots

EB06

37176

10 x digital Out (2 A) 6 x PWM Out (2 A) 1 x analog Out (0 ... 20 mA or 5 ... 10 V) 16 x digital or voltage inputs (0 ... 40 V) 2 x digital or current inputs (0 ... 20 mA) 2 x digital inputs or resistance measurement (500 ... 2500 Ω)

EB02

33022

12 x digital or voltage inputs (0 ... 40 V), max. 3 pairs as incremental input 1 x digital Out (4 A) *1

1

EB04

35770

12 x digital Out (2.5 A) *1

1

EB04

35950

12 x PVG Out *1

1

EB05

35771

8 x PWM Out (4 A) 4 x digital or voltage inputs (0 ... 40 V) *1

1

EB05

5439

8 x PWM Out (0 ... 150 mA) 4 x digital or voltage inputs (0 ... 40 V) *1

1

EB08

50777

8 x digital Out Low-Side (2.5 A) 4 x digital or voltage inputs (0 ... 40 V) *1

1

EB08

50778

8 x PWM Out Low-Side (2.5 A) 4 x voltage inputs *1

1

EB09

55168

12 x multifunction inputs *1, *2

1

EB11

60619

6 x analog In (0 ... 5/10/40 V / 4 ... 20 mA / 6.5 kOhm) 6 x analog Out ( 0 ... 10 V / 4 ... 20 mA) 1 x Stabilized sensor supply (2.0 ... 10.5 V) *1

1

EB03

33021

2 x RS232 RTC *1

4 x digital or voltage inputs (0 ... 40 V) *1

1 MB Flash

1

EB03

54512

2 x RS485 RTC *1

4 x digital or voltage inputs (0 ... 40 V) *1

1 MB Flash

1

EB10

62458

4 x CAN 1 x RS232 *1

47349

1 x CAN 1 x RS232 1 x Ethernet 1 x USB RTC *1

EB07

3

Particularities

No combination with other EBs except EB06 possible

1

1 GB Flash

1

Programmable via mainboard BIOS functions or Linux on MPC5200B controller. See also EB07 under Data Management and Connectivity Solutions.

Customer specific expansion boards on request. *1) Non-Interfering I/Os / Interfaces can be used for non-secure application parts and do not affect the safe application part. *2) To expand the Safety I/Os. Redundant input pairs per motherboard + Expansion Board EB06. *3) Measurement of voltage or frequency / speed. Use as a digital input or in pairs as incremental input.

11



Preconfigured Central Controllers ESX-3XL ESX-3XL Safety & Communication

ESX-3XL Safety Max

With expansion boards configured to optimize communication capabilities through various interfaces and to increase the number of important inputs and outputs.

With expansion boards configured to maximize the inputs and outputs.


EB07, EB03, EB10, 2 x EB04, EB09

2 x EB06

Processor


Memory

SRAM (Processor internal): 80 kB SRAM (external): 4 MB Flash (Processor internal): 2 MB Flash (external): 4 MB EEPROM: 32 kB Data Flash: 1 GB (EB07) Data Flash: 1 MB (EB03) 4 x CAN, 1x RS232

Interfaces

Additionally due to non-interfering EBs *1 1 x CAN (EB07) 4 x CAN (EB10) 1 x Ethernet (EB07) 1 x USB (EB07) 1 x RTC (EB07) 2 x RS232 or RS485 (EB03) 1 x RS232 (EB10) 28 x multifunction inputs *3 8 x digital/PWM Out (4 A) with current measurement 16 x digital/PWM Out (2.5 A) with current measurement

In-/Outputs

additionally due to non-interfering EBs * 4 x Uin (EB03) 24 x digital Out (2.5 A) (2 x EB04) 12 x multifunction inputs (EB09)

1

Safety


Programming


12

additionally due to 2 x EB06 *2 20 x digital Out (2 A) 12 x PWM Out (2 A) 2 x analog Out (0 ... 20 mA or 5 ... 10 V) 32 x digital or voltage input (0 ... 40 V) 4 x current input (4 ... 20 mA) 4 x resistance measuring (500 ... 2500 Ω)



Preconfigured Central Controllers ESX-3XM ESX-3XM Safety & Communication

ESX-3XM Safety Max

With expansion boards configured to optimize communication capabilities through various interfaces and to increase the number of important inputs and outputs.

With an expansion board configured to maximize the inputs and outputs.


EB07, EB03, EB10

EB06

Processor


Memory

SRAM (Processor internal): 80 kB SRAM (external): 4 MB Flash (Processor internal): 2 MB Flash (external): 4 MB EEPROM: 32 kB Data Flash: 1 GB (EB07) Data Flash: 1 MB (EB03) 4x CAN

Interfaces

Additionally due to non-interfering EBs *1 1 x CAN (EB07) 4 x CAN (EB10) 1 x Ethernet (EB07) 1 x USB (EB07) 1 x RTC (EB07) 2 x RS232 or RS485 (EB03) 1 x RS232 (EB10) 15 x multifunction inputs *3 8 x digital/PWM Out (2.5 A) with current measurement

In-/Outputs

additionally due to non-interfering EBs *1 4 x Uin (EB03)

Safety


Programming


additionally due to EB06 *2 10 x digital Out (2 A) 6 x PWM Out (2 A) 1 x analog Out (0 ... 20 mA or 5 ... 10 V) 16 x digital or voltage input (0 ... 40 V) 2 x current input (4 ... 20 mA) 2 x resistance measuring (500 ... 2500 Ω)

*1) Non-Interfering I/Os / Interfaces can be used for non-secure application parts and do not affect the safe application part. *2) To expand the Safety I/Os. Redundant input pairs per motherboard + Expansion Board EB06. *3) Measurement of voltage or frequency / speed. Use as a digital input or in pairs as incremental input.

13



Integrated Central Controller ESX-3CM ESX-3CM Processor


Memory

SRAM (Processor internal): 288 kB SDRAM (external): 8 MB Flash (Processor internal): 4 MB EEPROM: 32 kB

Interfaces

4 x CAN or 3 x CAN and 1 x RS485 1 x RS232 1 x Ethernet (optionally)

In-/Outputs

8 x analog input 8 x multifunction inputs 5 V *4 12 x multifunction inputs 35 V *5 4 x digital / PWM output 4 A with current measurement 16 x digital / PWM output 4 A with current feedback 8 x digital outputs

Safety

Safety variant SIL 2 / PL d in preparation

Programming


*4) Measurement of voltage or frequency / speed. Use for edge detection, as digital input or as SENT interface. *5) Measurement of voltage or frequency / speed. Use for edge detection, as digital input or as NAMUR interface. Use in pairs as incremental input.

14



15



The ESX-2-4 can be extended with additional I/Os using expansion boards. Other members of the 16 bit control unit family are available in plenty of hardware variations that have been optimized to different use cases. The variants have been created either with additional (optional) or other (alternative) hardware components. In a given hardware configuration it is possible to configure the hardware by software in different ways.

Freely configurable Central Controller ESX-2-4 ESX-2-4 Expandable


Processor

16 bit C167 @ 20 / 40 MHz Separate system supervisor with programmable watchdog

Memory

RAM: 256 kB/1 MB Flash: 512 kB/1 MB EEPROM/FRAM: 8 kB

Interfaces

1 x / 2 x CAN 1 x RS232

In-/Outputs

16 x digital or speed input 8 x analog inputs (4 … 20 mA / 0 … 8.5 V) 5 x digital / PWM outputs (4 A) with current measurement 3 x digital / PWM outputs (4 A) with current measurement 5 x digital / PWM outputs (2.5 A) with current measurement alternatively up to 12 x PVG outputs Expandable up to 48 I/Os with various expansion boards

Safety

PL d according to EN ISO 13849-1:2008 SIL 2 according to EN 61508-1/2/3:2002 Cat.3 according to EN 954-1:1997

Programming

„C“ and CODESYS V2.x

16


Central Controllers ESX-2 Expansion boards for ESX-2-4

Type A

STW Article ID

Type B Type C

In-/Outputs

3911

6 x digital outputs (HS 4 A)

8769

6 x voltage inputs (0 … 8.5 V)

10017

6 x voltage inputs (0 … 10 V)

10158

6 x digital inputs

11770

6 x voltage inputs (0 … 32 V)

17806

Type I

Interfaces

RTC

6 x digital outputs (HS 4 A)

21036

6 x digital outputs (LS 4 A)

21138

CAN non-interfering

2 x digital outputs (HS 4 A) 2 x digital outputs (LS 4 A)

6333 7232

6 x PWM outputs (HS 4 A) with current measurement / PVG / Voltage input 8.5 V / 32 V CAN non-interfering

4 x PWM outputs (HS 4 A) with current measurement / PVG / Voltage input 8.5 V / 32 V

9064

4 x current input (0...20 mA) 1 x incremental input / counter

9085

3 x incremental input / counter

11365

6 x voltage inputs (0 … 5 V) 12 bit-ADC

11366

6 x voltage inputs (0 … 10 V) 12 bit-ADC

11687

6 x analog output (0 … 10 V) 12 bit-DAC / 6 x voltage inputs (0 … 10 V)

14423

6 x analog output (0 … 130 mA) 12 bit-DAC / 6 x analog input (0 … 10 V / 0 … 130 mA)

17777

6 x analog output (0 … 10 V / 0 … 20 mA) 12 bit-DAC / 6 x analog input (0 … 10 V / 0 … 32 V)

22998

6 x analog output (0 … 10 V / 0 … 20 mA) 12 bit-DAC / 6 x analog input (0 … 10 V / 0 … 20 mA)

26546

6 x analog output (0 … 10 V / 0 … 20 mA) 12 bit-DAC / 6 x analog input (0 … 32 V / 0 … 20 mA) 15 bit-ADC

All expansion boards are non-interfering.

17


Central Controllers ESX-2 Integrated Central Controller ESX-LT ESX-LT Processor

16 bit C167 @ 20 / 40 MHz Separate system supervisor with watchdog

Memory

RAM: 256 kB / 1 MB Flash: 512 kB / 1MB EEPROM / FRAM: 8 kB

Interfaces

1 x CAN, alternatively 2 x CAN 1 x RS232

In-/Outputs

Maximum 28: 8 x digital or speed inputs 8 x multifunction inputs *6 4 x digital / PWM outputs (4 A) with current measurement, alternatively 4 x PVG outputs 4 x digital / PWM outputs (2.5 A) with current detection 4 x Low Side Digital / PWM outputs (1.5 A) Sensor supply 10 V

Programming


*6) Measurement of voltage, current, frequency / speed or use as a digital input.

Integrated Central Controller ESX-LTplus ESX-LTplus

Option 1

Option 2

Option 3

Processor

16 bit C167 @ 40 MHz Separate system supervisor with watchdog

Memory

RAM: 512 kB Flash: 1 MB EEPROM/FRAM: 8 kB 1 x CAN, alternatively 2 x CAN 1 x RS232

Interfaces

In-/Outputs

4 x voltage inputs 0 … 32 V 8 x current inputs 4 … 20 mA 4 x frequency input up to 8.9 kHz 4 x digital / PWM output 3.6 A with current measurement 12 x digital / PWM output 3.6 A with current detection

8 x current inputs 4 … 20 mA 4 x frequency input up to 8.9 kHz 20 x digital / PWM output 3.6 A with current detection

8 x current inputs 4 … 20 mA 4 x d igital / PWM output 3.6 A with current measurement 20 x d igital / PWM output 3.6 A high side, with current detection or 12 x d igital / PWM output 3.6 A high side, with current detection 8 x d igital / PWM output 3.6 A low side, with current detection

Configurability

Maximum 24 voltage inputs 0 … 32 V, if digital / PWM outputs are configured as inputs

Programming


18


Central Controllers ESX-2 Integrated Central Controller ESX-C ESX-C

Option 1

Option 2

Option 3

Processor

16 bit ST10 @ 40 MHz Separate system supervisor with watchdog

Memory

RAM: 512 kB Flash: 832 kB EEPROM/FRAM: 8 kB 2 x CAN 1 x RS232

Interfaces

In- / Outputs

Programming

8 x digital / speed inputs max. 7.2 kHz 8 x digital / voltage inputs 0 … 32 V 8 x analog inputs 0 … 10 V, 0 … 25 mA 1 x digital / PWM outputs 3 A 4 x digital / PWM outputs 2.5 A with current feedback 5 x digital / PWM outputs 3 A with current measurement 1 x sensor supply 8.5 V / 10 V

8 x digital / speed inputs max. 7.2 kHz 10 x digital / voltage inputs 0 … 32 V 8 x analog inputs 0 … 10 V, 0 … 25 mA 1 x digital / PWM outputs 3 A 8 x d igital / PWM outputs 2.5 A with current feedback 2 x d igital / PWM outputs 5 A with current feedback 11 x d igital / PWM outputs 3 A with current feedback 1 x sensor supply 8.5 V / 10 V

8 x digital / speed inputs max. 7.2 kHz 10 x digital / voltage inputs 0 … 32 V 8 x analog inputs 0 … 10 V, 0 … 25 mA 1 x digital / PWM outputs 3 A 8 x d igital / PWM outputs 2.5 A with current feedback 2 x d igital / PWM outputs 5 A with current feedback 3 x d igital / PWM outputs 3 A with current measurement 8 x PVG outputs 1 x sensor supply 8.5 V / 10 V


19


Compact Controllers


Compact Controllers

Compact Controller ESX-IOXp ESX-IOXp

Option 1

Option 2

Option 3

Processor

16 bit XC2287 @ 80 MHz Separate system supervisor with watchdog

Memory

SRAM: 1 MB Flash: 768 kB EEPROM/FRAM: 8 kB 2 x CAN 1 x RS232

Interfaces 2 x digital inputs 6 x RPM / digital inputs max. 7 kHz

In-/Outputs

Configurable as incremental inputs in pairs (max. 4)

6 x voltage / digital inputs 0 … 10 V, low active 8 x current inputs 4 … 20 mA 4 x PWM outputs 3 A high side with current measurement 1 x sensor supply 5 V / 10 V

1 x digital input 3 x RPM / digital inputs max 7 kHz

Configurable as incremental inputs in pairs (max. 2)

6 x voltage / digital inputs 0 … 10 V, low active 8 x current inputs 4 … 20 mA 4 x P WM outputs 3 A high side with current measurement

6 x voltage / digital inputs 0 … 10 V, low active 8 x current inputs 4 … 20 mA 4 x P WM outputs 3 A high side with current measurement

4 x digital / PWM outputs 0.5 … 4 A high side with current feedback 1 x sensor supply 5/10 V

8 x digital / PWM outputs 0.5 … 4 A high side with current feedback 4 x digital outputs 4 A low side 1 x sensor supply 5 / 10 V

Alternatively: 4 x PVG outputs 1 x sensor supply 10 V

4 x PVG outputs 4 x digital / PWM outputs 0.5 … 4 A high side with current feedback 1 x sensor supply 10 V

Configurability

All outputs can be configured as inputs for voltage measurement

Programming

"C" and CODESYS V2.x

20


Compact Controllers

Compact Controller ESX-micro ESX-micro Processor

16 bit ST10F269 @ 40 MHz Separate system supervisor with watchdog

Memory

SRAM: 512 kB Flash: 256 kB, alternatively 1 MB EEPROM/FRAM: 8 kB

Interfaces


In-/Outputs

Maximum 10: up to 4 x analog inputs 4 … 20 mA or 0...10 V up to 4 x voltage inputs 0 … 10 V up to 2 x RPM inputs max. 6.5 kHz up to 8 x digital inputs active high / low, threshold configurable up to 2 x digital inputs active high / low up to 4 x digital / PWM outputs 2 A high side or 2 x digital / PWM outputs 4 A high side with current feedback up to 2 x digital / PWM outputs 2 A high side up to 6 x PVG outputs up to 2 x voltage outputs 0 ... 10 V up to 2 x current outputs 4 ... 20 mA 1 x motor bridge (3.5 A) two half bridges or full bridge with current measurement

21


Controller Modules


Controller Modules

For extending third party products with control functionality e. g. power boards in versions Expert and Expert Plus

Controller Module ESX-CM2 ESX-CM2 CAN Interface

Yes

Programming

"C", CODESYS

Protocol

SAE J1939

Processor

16 bit ST10F269 @ 40 MHz Separate system supervisor with watchdog

Memory

SRAM: 512 kB Flash: 256 kB, alternatively 1 MB EEPROM/FRAM: 8 kB

Interfaces


In-/Outputs

up to 17 x Low Side outputs 250 mA up to 4 x analog inputs 4 ... 20 mA up to 26 x voltage inputs 0 ... 40 V up to 4 x RPM inputs max. 6.5 kHz up to 4 x digital / PWM Out 3 A high side with current feedback up to 10 x digital / PWM Out 2 A high side

Connection

Pin-and-socket / press-fit connectors

Another option is the use of the processor board of the ESX-3CM with according specifications.

22


I/O Modules


I/O Modules

STW offers I/O modules in different housings and protection classes. Products with digital and analog inputs and outputs with different switching capacity and a motor bridge form this product family.

ESX I/O Modules ESX-IOX

ESX-MBC

ESX-DIOS

ESX-DIOM

Interface

CAN

CAN

CAN

CAN

Protocol

CANOpen

J1939

CANOpen

CANOpen

In-/Outputs

Maximum 28: 2 x digital / RPM inputs up to 12 x digital / analog inputs (0 … 32 V) up to 6 x digital / analog inputs (0 … 10 V) 8 x analog inputs (4 … 20 mA) up to 4 x digital / PWM outputs (3 A) with current measurement optionally 4 x additionally equipped LS-Switch (4 A) alternatively 4 x PVG outputs up to 8 x digital / PWM outputs (4 A) with current measurement

4 x multifunction inputs (digital high / low active, RPM 0.6 Hz ... 1 kHz, 0 ... 10 V / 0 ... 35 V, 0 ... 20 mA) 4 x PWM half bridges 10 A with current measurement 2 x digital outputs 4 A with current measurement 1 x digital output 200 mA 1 x sensor supply 5 ... 12 V

Maximum 8: up to 8 x digital inputs up to 4 x d igital / PWM outputs (4 A) with current measurement up to 8 x digital outputs (4 A)

Maximal 24: up to 24 x digital inputs up to 12 x d igital / PWM outputs (4 A) with current measurement up to 24 x digital outputs (4 A)

Maximum Current

11 A

30 A

30 A

70 A

23


interACT Overview

24


Display and Control Panels

For interaction between humans and machines STW offers a multitude of different units. One can find customer-specific developments as well as STW standard products and products by STW partners. The units allow input for operation either via keys or touchscreens and outputs for visualization. The communication to the control units works through BUS systems.

interACT VSX Product Family

STW’s new VSX display family is a Linux based platform for IP65 operator terminals with display sizes from 7” to 15”. The models

VSX 7W, 8W (W for widescreen), 10 and 12 will become available as standards. More variants can be realized quickly due to the underlying platform concept. The operation works via touch and / or soft keys. The units can be integrated into a dashboard or mounted separately using a VESA mount. Intuitive programming is done with the graphical development kit. All units reach SIL2 for visualization, touchscreen and soft key operation, video and communication.

25


Display and Control Panels VSX-7W

VSX-8W

Samples in Q4 / 2016 Series planned for Q2 / 2017

VSX-10

Processing Core Display

VSX-12W

VSX-15

Available on request

Main Memory

512 MB DDR3 RAM 16 bits optionally 1 GB DDR3 RAM 32 bits, ECC available

NAND Memory

512 MB Flash with ECC optionally 2 GB Flash with ECC

FRAM Memory

256 kbit FRAM optionally 1 Mbit FRAM optionally available (Expansion Board)

Size

7.0“ 15:9

8.0“ 15:9

10.4“ 4:3

12.1“ 4:3

8.4“ 4:3

10.6“ 15:9

12.1“ 16:10

15.0“ 4:3

Resolution

800 x 480

800 x 480

1024 x 768

1024 x 768

1024 x 768

1280 x 768

1280 x 800

1024 x 768

Viewing Angles

H +/- 80° V +80° / -60° IPS version on request

H +/- 80° V +/- 80°

H +/- 85° V +/- 85°

H +/- 80° V +/- 80°

H +/- 80° V +80° / -60°

H +/- 85° V +/- 85°

H +/- 80° V +80° / -60°

H +/- 80° V +80° / -60°

Brightness

1500 cd/m²

1200 cd/m²

1000 cd/m²

1300 cd/m²

1000 cd/m²

1000 cd/m²

1500 cd/m²

1500 cd/m²

Contrast

600:1

700:1

700:1

800:1

600:1

1000:1

700:1

800:1

MTTH

100,000h

100,000h

100,000h

100,000h

100,000h

100,000h

100,000h

60,000h

Keys User Interface

VSX-10W

Cortex A9 DualCore 800 MHz

uSD

optionally available

Encoder

on request Without Touchscreen optionally Standard 3H touch optionally GFG 7H rugged with glass surface

Touch Sound In/Out

Interfaces

VSX-8

Samples available Series planned for Q4 / 2016

Processor

optionally available (Expansion Board)

Ethernet 1

1 x 10 / 100 Mbit / s

Ethernet 2

optionally available (Gigabit Ethernet)

CAN 1

CAN1 without galvanic isolation optionally CAN1 with galvanic isolation

CAN 2

CAN 2 without galvanic isolation optionally CAN2 with CAN WakeUp

CAN 3

Without CAN3 optionally CAN3 without galvanic isolation

CAN 4

Without CAN4 optionally CAN4 without galvanic isolation

USB Host CCTV1 CCTV2

1 x USB 2.0 1 out of 2 displayable

CCTV1 (PAL / NTSC) CCTV2 (PAL / NTSC)

CCTV3

optionally CCTV3 (PAL / NTSC)

CCTV4

optionally CCTV4 (PAL / NTSC)

Digital I / O

26

VSX-12

4 x IN (NPN / PNP) ; 2 x IN (NPN) 2 x OUT (1 A)

2 out of 4 displayable


Display and Control Panels VSX-7W

VSX-8W

Samples in Q4 / 2016 Series planned for Q2 / 2017 Real Time Clock

Others

Buzzer

Connectivity Safety Toolchain Mechanics

VSX-12

VSX-8

VSX-10W

Samples available Series planned for Q4 / 2016

Buzzer

OpenGL Graphical Effects and 3D Graphics

Optionally OpenGL ES 1.1 GPU Hardware acceleration IEEE 802.11 a,b,g,n,d,e,l compliant, 2.4 and 5 GHz, optionally available (Expansion Board) GSM / GPRS / EDGE Quad Band, UMTS / HSPA+ Five Band, optionally available (Expansion Board)

GSM Telephony

on request

GPS/GLONASS

GLONASS and GPS simultaneously, optionally available (with "Cellular nets" Expansion Board)

Bluetooth

optionally available (Expansion Board)

Safe HW Version

SIL 2 HW Version, optionally available

Safe SW Platform

SIL 2 Platform, optionally available

Safe Visualisation

yes, SIL 2 (with safe hardware and software)

Safe Touchscreen


Safe Keys


Safe Video


Safe Communication


Programming CODESYS Support Safe Toolchain

Graphical Programming Interface and toolchain planned for Q2 / 2017 available, fully SIL2 qualified for all safety functions

Housing Material Front

Plastic / Aluminum-composite

Housing Material Rear

Aluminum

Mounting Options Supply Voltage Range

RAM / VESA or Panel mount 9VDC - 32VDC continuous, e1 voltage variations

Operating Temperature

-30° C to +70° C full device -40° C to +80° C electronics Self-Heating below -30° C

Storage Temperature

-40° C to +80° C

Ingress Protection

VSX-15

With Goldcap (24h), optionally battery backed (10 years, externally)

H.264 Hardware accelerated 4x4CIF

Cellular nets

VSX-12W

Available on request

Streaming Ethernet Video

WLAN

Environment

VSX-10

IP65 and IP67

27

DATA MANAGEMENT AND CONNECTIVITY SOLUTIONS

System Overview

STW offers a multitude of solutions for data management and connectivity based on offthe-shelf on-board modules. These modules are made for the vehicle, adapted to the environmental conditions and use for data management and connectivity in mobile working machines, and equipped with a Linux computer. They provide data connectivity within the vehicle (CAN), between vehicles (M2M), with a network (WiFi, cellular), and with local user and service devices (WiFi, Ethernet, USB). The modules add integrated sensor information such as position and movement information and allow a direct connection with sensors (CAN, LIN). On top their computing power can be used for data conversion (gateway) and processing for assistance and infotainment applications.

28


System Overview

Customer solution

STW

Partner database solution

STW machines.cloud IoT platform • Reliable, state-of-the-art core by Cumulocity • Certified carrier grade security • Standard REST API for data access (ERP/CRM) • Highly scalable and extendable • Unique STW features (live view, track evaluation) • Visualization, location based services, alarming

Internet

Cloud Solutions

For machine monitoring machine data are collected on the modules and either locally or remotely presented for diagnose, service and development purposes.

Customer data connector Partner data connector

Cloud data connector

VDS application

STW data logger, visualization and configuration tool Easy to use HTML interface

Customer On-board applications

To complete its proposition STW cooperates with providers of proprietary or standardized data base and cloud service software solutions. The available data (machine and operation data, other sensor data) are collected, presented or connected with higher level systems such as ERP or FMIM thus supporting the work process in which the machines are used.

On-board Modules

Teleservice Application Framework (TAF)

Local Data

Board Support Package (BSP)

Utility tool-set for data management and connectivity

Linux-based OS Extended and optimized for usability and performance

On-Board Hardware

STW on-board modules providing machine, customer device and infrastructure interfaces fitting the needs of mobile machine requirements

29


On-Board Modules


On-Board Modules

The product family comprises the on-board modules DMM, TC3G and TC1 with integrated wireless communication technology for data transmission and GPS/GLONASS sensors for positioning. The Telematics Application Framework is an integral part for programming data collection, storage, connectivity and alarming.

The expansion board EB07 covers the functionality of these modules for the control units ESX-3XL and ESX-3XM, just without wireless communication or GPS/GLONASS sensors.

On-Board Hardware DMM (Concept)

TC3Ge / TC3Gi

TC1

EB07

Required Controller

None

None

None

ESX-3XL / 3XM

Performance

1 GHZ - QuadCore Processor (single /dual - option) – Freescale i.MX6 ARM Cortex A9 platform

400 MHz Processor Freescale MPC5200B platform



Memory

512 kB … 2 GB DDR3 RAM 8 … 64 GB eMMC Flash Memory 128 MB NOR Flash (optionally) 2 x 64 KB EEPROM

128 MB SRAM 1 GB NAND Flash 64 MB NOR Flash 2 x 8 KB EEPROM

128 MB SRAM 1 GB NAND Flash 64 MB NOR Flash 8 KB EEPROM

128 MB SRAM 1 GB NAND Flash 64 MB NOR Flash 2 x 8 KB EEPROM

30


On-Board Modules

DMM (Concept)

TC3Ge / TC3Gi

TC1

2G / 3G / 4G (global coverage) optionally: CDMA WLAN 2.4 / 5 GHz (Access point, WiFi-Direct and infrastructure mode) Bluetooth (V2.1 + EDR) & BLE M2M (regional variations) 169 MHz - (max 500 mW) - up to 10 km 868 MHz - (max 500 mW) - up to 10 km 915 MHz - (max 500 mW) - up to 10 km Satellit - Iridium

2G / 3G (worldwide coverage) WLAN 2.4 / 5 GHz (Access point, WiFi-Direct and infrastructure mode) Bluetooth (V2.1 + EDR) & BLE

TC1-Mobile: 2G / 3G (worldwide coverage) TC1-WiFi / TC1-WiFi+: WLAN 2.4 / 5 GHz (Access point, WiFi-Direct and infrastructure mode) Bluetooth (V2.1 + EDR) & BLE (Bluetooth Low Energy)

Interfaces

3x Ethernet / BroadR Reach 1 … 3 x Industrial Ethernet 10/100 MBit 1 … 2 x Automotive Ethernet (BroadR Reach = single twisted pair ethernet) 1 x USB2.0 (OTG - on the go) host and device mode 4 x Serial Interfaces 1 … 4 x RS232 Interfaces 1 … 2 x RS485 Interfaces

1 x Ethernet 1 x USB1.1 host interface (for service) 1 x RS232 interface

1 x Ethernet 1 x RS232 interface

1 x Ethernet 1 x U SB1.1 host interface (for service) 1 x RS232 interface

Machine BUS

4 x CAN Bus (2 x galvanically isolated) 1 x LIN Bus

2 x CAN Bus

2 x CAN Bus

2 x CAN Bus

Sensors

GPS + GLONASS (10 Hz) NFC Communication 3D accelerometer 3D inclinometer Internal temperature sensor UBAT/IBAT Measurements (for Power Management)

GPS + GLONASS 3D accelerometer Internal temperature sensor

TC1-Mobile / TC1-WiFi+: GPS + GLONASS TC1-Mobile / TC1-WiFi / TC1-WiFi+: Internal temperature sensor

I/O

8 x analog inputs (voltage: 0 … UB, 0 … 24 mA or digital) 4 x digital inputs 1 x digital High-Side output

1x digital input 1x digital High-Side output

1x digital input 1x digital High-Side output

Wakeups

Ignition Movement (accelerometer) RTC (time and interval triggered) CAN-Bus (CAN Message triggered) UB spike (starter events) USB (plugin of additional load) BroadR reach (network traffic)

Ignition Movement (accelerometer) RTC (time and interval triggered)

Ignition RTC (time and interval triggered)

via ESX-3XL / 3XM

MMI

Keyboard Buzzer 2 x bicolor LEDs 1 x LVDS interface (display)

Buzzer 1x tricolor LED

Future-Proof

ESIM card Expansion board 8 x digital High-Side output SD card slot Battery Pack option PCIe - SSD memory expansion

Optionally ESIM Card

Annotations

Internal or external antennas (mix possible)

Internal or external antennas SIM card slot integrated in the connector

External antennas TC1-Mobile: SIM card slot integrated in the connector

Available for ESX-3XL / 3XM

Radio Technologies

EB07

Customer specific variants on request.

31


On-Board Software


On-Board Software

The STW on-board modules are delivered with the Telematics Application Framework for ease of programming.

Teleservice Application Framework (TAF) Teleservice Application Framework (TAF)

Libraries

Daemons

Develop your own telematics solution based on the powerful, robust and scalable telematics framework by STW.

Collect data

Define and manage your consistent database for all your applications.

Data storage

Data are written on certain trigger events by the daemon into a file.

Connectivity

Stay online, the daemon connects your vehicle to the Internet through the appropriate interface.

Localization

Quick access to the current position.

Alarming

Pre- and user-defined events will trigger alarms.

Programming language

The daemons can be configured by configuration files.

libtaf

Adding the Library to your own application, the functions of deamons are made available.

CANopen J1939

The Library provides access to CAN protocols.

HTTP

Simple communication with the server.

Programming language

C Script based

32


Machine Monitoring


Machine Monitoring

For machine monitoring one can use either the on-board software VDS locally or for remote access the STW VPN solution. With a VPN tunnel the advantages of the local VDS can be used via a central server remotely. An administration concept (see “machines. cloud” page 36ff) with different roles and rights for users allows the separation of the data by companies and users.

Alternatively proprietary solutions for different industry sectors and data usage concepts with a defined scope of functions are available. STW’s on-board modules are an integral part of these solutions.

33


Machine Monitoring VDS/VDS-R

VDS Local solution for data management and connectivity

Worldwide unique solution that allows local access to the devices in the field that are running a Web server on the STW control unit.

Hosting

Device configuration

Security

Fees

√

Data backup

√

Real-time display

√

Update

√

Reports

√

Localization

√*6

Customer specific

not necessary

STW Hosting

not necessary

Provider Hosting

not necessary

Local access

√

Remote access

√ via VPN managed by "machines.cloud"

Device communication User management

Functions

Data storage

Individual permissions assignment

√ via "machines.cloud"

http

√

https

√

Security certificates

√

VPN support

√

Operating costs

Infrastructure

Supported Platforms

*6) Local access via log data.

34

– Client based solution

DMM (concept)

√

TC3G

√

TC1

√

EB07

√


Data and Process Management



Solutions for data and process management offer functions for further processing of collected data in different ways along with interfaces to higher-level systems. STW’s on-board modules are certified for these solutions.

IoT Platform machines.cloud

Data are collected by compatible STW modules and transmitted to machines.cloud. There they are stored, presented, processed or forwarded to higher-level systems with ERP, billing or other functionality.

By defining certain events activities in the final system can be triggered. Data and process management are supported with predefined function blocks (mapping, alarming, reporting, etc.) and can be extended in a customer-specific way using plug-ins. The characteristics of the platform are defined by STW, by the user or by using an already existing solution powered by Cumulocity (such as the “Cloud der Dinge” by Deutsche Telekom).

35



machines.cloud The Device and Application Management Portal for Your Machines Until today the use of telematics systems is mostly limited to visualizing machine data remotely. We go a step further and offer you our IoT platform “machines.cloud”. With “machines.cloud” you gain access to the right infrastructure for the integration and automation of your business processes. Very often you have to implement conformity requirements and legal directives in a timely manner. With the well-described interfaces of “machines.cloud” you create a connection to your ERP or CRM system thus obtaining insight and control of your KPI’s (Key Performance Indicators). Your time-to-

36

market for new services and business models will decrease drastically. This allows an early ROI (Return on Investment). A multitude of standard tools as well as a flexible and open ecosystem with connectors to 3rd-parties and services build the basis to deploy even short-lived business models with minor effort at reduced risk. The open, “no-vendor-lock-in” approach guarantees the necessary security of investment. Together with our established network of partners we are ready to advise and consult you along your projects, services and business models. Increase your efficiency, profitability and flexibility of your enterprise now!



machines.cloud Basic Features • Widgets • Dashboards • Data Analysis • Track Evaluation • Data To Area

Visualisation

• Positioning • Routing • Geo Fencing

• Alarm Management • Notification • Escalation Management

• Device Configuration • Software Update • Service Monitoring • Shell • Command History • Device Control

Location Based

Notification

Servicing

• Plug & Use Registration • Grouping

• User & User Group Administration • Tenant Dashboard • Repository Management

• Smart Rules • Smart Apps • Customer Apps

Device Admin

System Admin

Extension Functionality

machines.cloud Extended Features • Set single / multiple device(s) live • Up to 1 second update period • Transient storage of incoming data

• Use DBC files to import CAN bus data • Change CAN data rate

• Create multiple logger jobs with individual settings • Assign any CAN variable to any logger job • Log non-CAN data

Live View

CAN Configuration

CAN Logging

• Standardized debian based package management system • Single / bulk update • Add pre- and postscripts

• Configurable whitelist of allowed shell commands • Manage user shell access rights

Firmware Update

Extended Shell

37

POWER MANAGEMENT

Hybrid Technology

DC

AC

AC

DC

AC AC

DC DC

AC

DC

AC

DC

HV 300-750 VDC

DC DC AC

DC

DC

AC

DC

DC AC

DC

AC

DC

DC

AC

AC

DC

AC

DC

°C

AC

DC COOLING CONCEPT

AC

BRAKE DC AC

CHOPPER

DC

SAFETY CONCEPT

AC

DC

powerMELA-SCHEMA_GB.indd 1

12.03.2013 13:20:50

ELECTRIFICATION SOLUTIONS

powerMELA Solution Overview

The solutions for power electrification include all components to generate, switch, distribute, store, supervise and convert electrical energy for the high voltage power electrification and for the low-voltage board electrical system (12 V / 24 V).

38


Drive Train


Drive Train

The drive train is realized with motors of the product family of integrated powerMELA E-drives. These motors distinguish themselves with an integrated inverter which allows four-quadrant-operation. They have been developed with focus on use in mobile working and special machines with a high voltage DC traction net of up to 800 V. Two power classes with 80 kW and 140 kW continuous power are available. E-drives and inverters are available as separate components, too.

E-Drives powerMELA-C powerMELA-C 140 kW

powerMELA-C 80 kW Integrated E-Drives

Power [kW]

140

80

Rated torque [Nm]

450

250

Rated voltage [VDC]

650

650

Number of phases

2x3

1x3

Rated Speed [RPM]

3000

3000

IP6K9K

IP6K9K

Protection class

39


Drive Train

Inverter powerMELA-WR C powerMELA-WR C Inverter

Setup

80 kW

2 x 80 kW

160 kW

80

160

160

300 … 800

300 … 800

300 … 800

0 … 650 (UDC = 800 V)

0 … 650 (UDC = 800 V)

0 … 650 (UDC = 800 V)

Nominal (maximum) output current per phase [Aeff]

120 (160)

120 (160)

120 (160)

Switching frequency [kHz]

2 … 10

2 … 10

2 … 10

Output frequency [Hz]

0 … 500

0 … 500

0 … 500

Resolver, SinCos, Absolute Encoder



2 x CAN

2 x CAN

2 x CAN

Transformer oil up to +65° C / 50 l/min



Temperature range [° C]

–40... +85

–40... +85

–40... +85

Protection class

IP65 / IP67

IP65 / IP67

IP65 / IP67

ca. 22

31

31

TBD

521 x 296 x 192

521 x 296 x 192

Rated power [kW] DC input voltage range [V] AC output voltage [Veff]

Locator Control Interface Cooling

Weight [kg] Dimensions L x W x H [mm]

40


Drive Train

The electrical energy generated while breaking can be turned into thermal energy using the brake chopper powerMELA-BC in case it can’t be stored in other components such as the battery management system along with according batteries.

Brake Chopper powerMELA-BC powerMELA-BC Brake chopper 50 kW

Size (resistance) Rated power [kW]

3x2R2 50 @ 600 Vdc continuous

Rated voltage DC [V]

Up to 800 VDC

Safety class

Safety Class II

Number of phases Resistance characteristic

1x3 0.7 Ohm @ 100% PWM

PWM properties [%]

1 - 99

Power overload [%]

1000 for 2 seconds

Efficiency [%]

100

Construction

Frame mount

Dimensions L x W x H [mm] Weight [kg] Protection class Temperature range [° C]

494 x 295 x 324 35 IP6k9k –40 … +85

41


Power Generation and Distribution


Power Generation and Distribution

All STW drives are designed as four-quadrant-drives and therefore usable as motor or generator. The classical, compact structural shape is connected to the drive train via a gearbox. The fly wheel generators powerMELA-FW are designed for direct mount to the crank shaft housing.

Generator powerMELA-FW powerMELA-FW

Rated capacity [kW]

130

Rated torque [Nm]

615

Rated voltage [V]

600

Number of phases

2x3

Rated RPM [min-1]

2100

Safety class Protection class

42

2 IP65


Power Generation and Distribution With the devices of the converter product family the voltages 12 V, 24 V and 48 V are provided from the high voltage net for the respective board nets.

Converter powerMELA-DC/DC powerMELA-DC/DC converter 3kW

MDA 12

MDA 24

MDA 36

Maximum Power [kW]

3

3

3

Voltage supply [V]

400-800

400-800

400-800

Maximum output current [A]

8

8

8

Output voltage [V]

9-14

18-28

36-56

Maximum output current [A]

217

110

55

Programming/Diagnosis

CAN

CAN

CAN

Protection class

IP67 / IP69k

IP67 / IP69k

IP67 / IP69k

Dimensions L x W x H [mm]

292 x 203 x 69

292 x 203 x 69

292 x 203 x 69

43


Battery Management

Scalable

nagement a M

stem Sy

Modular

Quick & Easy Integration

Batte ry

Complete Solution

Safe & Robust

Flexible & Open


Battery Management

Customer specific and standardized Lithium-Ion batteries are the energy storage of choice for modern drive systems. The battery management system powerMELA-mBMS fits ideally to the drives of the powerMELA product family. The mBMS supports all kinds of popular cell chemistries within the Lithium-Ion family: LFP, NMC and LTO. The powerMELA-mBMS is a mature and complete solution for your battery. It covers all electrical functions of a Lithium-Ion battery: • from the sensors to status supervision of the storage. • from balancing the cells to self-diagnosis of the electronics to an insulation guard.

44


Battery Management

STW will support you when deploying your battery system. If you plan a customer specific adaptation STW offers cost-efficient development and series production based on the mBMS reference design – the fastest and easiest way to a sophisticated, tailored solution.

Optional data management solutions

Battery system (parallel, series) • To increase capacity, performance and availability of your battery system • Plug and play

• Battery state surveillance anytime and anywhere • Data acquisition down to cell level

Energy Storage System (ESS)

• Savings of service costs by remote access and maintenance

ESS CAN-Interface

Battery Main Supervisor (BMS) • Interlock signal generation and surveillance

• Battery state determination (SoC, SoH, SoF … )

• Insulation surveillance

• Standardized interface description (DBC format)

• Adaptive pre-charging

• Support of CANopen and SAE J1939

• Intelligent contactor control • Management of battery cooling

Cell Sensor Circuit (CSC) • Cell voltage measurement

Power Measurement Board (PMB)

• Cell temperature measurement

• Current measurement up to 600 A

• Cell balancing

• Voltage measurement up to 800 V

Safety • Self diagnosis of electronics, connectors and relays • Multi-level safety architecture

Agricultural

Railway

Transportation

Maritime

Automotive

Stationary 45


Battery Management


powerMELA-mBMS Components

powerMELA-mBMS components for realization of your complete solution The Battery Main Supervisor (BMS) is the central control unit of the battery system. It includes three processors for highest levels of reliability and safety. It collects all information from the sensor modules, from the Cell Sensor Circuits and from the Power Measurement Board, calculates the status of the battery system and controls the HV contactors.

Lithium-Ion High Voltage Battery

HV-Contactor

EMC Filter

+

CDR

CSC

Cell Sensor Circuit

PMB Power Measurement Board

HV-Contactor

CAN

Pre-Charge Module

BMS

Battery-Main- Supervisor

EMC Filter

46

−


Battery Management

powerMELA-mBMS Components Component

BMS – Battery Main Supervisor

PMB – Power Measurement Board CSC – Cell Sensor Circuit

Dimensions (approx.)

212 x 100 x 33 mm (8.3“ x 3.9“ x 1.3“)

95 x 61 x 15 mm (3.7“ x 2.4“ x 0.6“)

300 x 75 x 13 mm (11.8“ x 3.0“ x 0.5“)

Weight (approx.)

230 g (0.51 lbs.)

100 g (0.22 lbs.)

260 g (0.57 lbs.)

Temperature range

−40° C ... +80° C (−40° F ... 176° F) environment temperature

Connector

23-pole AMPSEAL (TE connectivity)

Micro-Fit (Molex)

Micro-Fit (Molex)

Power supply

8 ... 32 V DC

powered by the BMS

powered by the BMS and battery cells

Power consumption (in operation)

350 mA @ UB = 12 V

included in the BMS consumption

10 mA @ Ucell = 4.2 V

Power consumption (sleep mode)

< 0.1 mA @ UB = 12 V

–

< 0.01 mA @ Ucell = 4.2 V

Communication Interfaces

4 x CAN 2.0 B CAN Wakeup

1 x CAN 2.0 B

1 x CAN 2.0 B

I/O’s

3 x 2 A digital outputs 1 x analog input Interlock detector & driver

Shunt for current measurement 3 inputs for high voltage measurement

48 x cell voltage measurement inputs 16 x Temperature sensor inputs (10k NTC)

Current measurement Range: ± 1000 A (1 s), ± 600 A (10 s) @ 100 μΩ ± 2000 A (1 s), ± 900 A (10 s) @ 50 μΩ Accuracy: Offset ±0.1 A, gain 1 %

Cell voltage measurement Range: 1 … 5 V Accuracy: 2.5 mV @ 2.5 … 4.3 V

Coolant temperature measurement Range: −55 … +125 ° C (−67 ... 257 °F) Accuracy: ±2 K plus sensor tolerance Operation

Insulation measurement Range: 1 ... 4500 kΩ Accuracy: 0 … −5 kΩ @ 1 … 20 kΩ 0 … −25 % @ 20 … 1000 kΩ

High voltage measurement Range: 0 … 800 V Accuracy: Offset ±0.1 V, Gain 1 %

Cell temperature measurement Range: −55 … +125° C (−67 ... 257 °F) Accuracy: ±2 K plus sensor tolerance Cell balancing (passive) Current: 120 mA @ Ucell = 3.6 V

47


Battery Management


powerMELA-mBMS Software

Configuration

Diagnosis

Update

The powerMELA-mBMS toolchain provides the straightforward solution to configure, update and diagnose your battery system.

powerMELA-mBMS Toolchain

Configuration

powerMELA-mBMS Toolchain Configuring the mBMS to suit your application. Safety parameters

Define and manage system security limits

Application parameters

Illustration of cell characteristics Define the battery application strategy

Update

Software update of the complete energy storage system (ESS)

48

One-Click-Update

Simple and convenient system update

Version Management

Software packages for easiest version management


Battery Management

Diagnosis

powerMELA-mBMS Toolchain Allows easy and quick commissioning of the energy storage system (ESS) Battery data

Running mBMS functions and displaying battery data

Failure diagnosis

Supports fault diagnosis by visualization of all sensor data

powerMELA-mBMS Diagnostic Tool

Open Architecture With the help of an open code basis (Standard ANSI-C99 API) the battery application can be adapted to individual requirements. Specific functions and algorithms (SoC, SoH, …) can be integrated in a flexible way.

Custom Algorithms

STW Battery Application

Open Application Interface (API) Hardware Abstraction Layer (HAL) Hardware (powerMELA-mBMS Modules)

49


Power Management Solutions




Customer specific and standardized power boards or vehicle electric centers are electronic units for intelligent control and supervision of the distribution and switching of electrical energy. Power boards or vehicle electric centers reduce the cabling effort and allow flexibility in machine variants and accessory options, combined with diagnostic capabilities. To solve the power management tasks STW offers three approaches:

Intelligent Vehicle Electric Centers

STW offers modular power management systems together with our partner ERNI. Standardized building blocks for switching and distributing electrical energy are complemented with intelligent, standardized control modules.

Modular Power Management

A modular approach adds a degree of freedom for the design. The structural shape of the unit as well as the dimensioning of the circuit components for switching the elec50

trical energy, such as the plug-in relays, can be defined together with the customer. To complete the solution STW offers intelligent modules with a defined performance.

Integrated Power Management

In this open approach STW works closely with the customer to jointly specify and develop the perfect solution. The final product will be a vehicle electric center combined with intelligent modules for control and connectivity within a single unit. The performance characteristics of the intelligent modules, type, number and characteristics of the inputs and outputs are adapted to the requirements. Even special components such as motor bridges or stepper motor drivers can be implemented. The structural shape of the unit and the circuitry components for switching relays, such as plug-in relays, are defined according to the desired type, number and required characteristics.


Intellignet Power Baords / Vehicle Electric Centers

Modular Power Management

Integrated Power Management


Customer specific requirements for power boards / vehicle electric center and controller

Integrated customer specific intelligent power board / vehicle electric center

STW Development

Customer specific passive power board / vehicle electric center

+

ESX Controller Module

Standard passive power board / vehicle electric center

+

ESX Controller Module

=

Customer specific intelligent power board / vehicle electric center

=

Intelligent power board / vehicle electric center

51


Power Management Solutions VEC Expert Plus*1

VEC Expert*1

VEC Basic*1

Inputs 150 A (M8)

2

Relay outputs 70 A

2

Relay outputs group 1 25 A

12

Relay outputs group 2 25 A

7 4

4

–

Lowside outputs 250 mA

3

3

–

Yes (Slave)

Yes (Slave)

–

Yes

Yes

–

C

C

–

SAE J1939

SAE J1939

–

CAN Interface Fuse / relay status Programming Protocol

Automation module

Highside outputs 3 A

TE Automotive MCP-Series Connector 21-way

3

Power elements Output terminal M6

2

Capacity

Maximum 300 A

Operating temperature Protection class

*1) Possible versions.

52

-40° C … +85° C (-40° C … +125° C on request) IP69

IP20

IP20



53

MEASUREMENT SYSTEMS AND SENSORS

digiSENS Solution Overview

54


digiSENS Solution Overview

To measure different physical variables such as pressure, temperature, strain, angle of inclination, angular velocity and position STW offers single sensors and measurement systems. All components are designed to survive in the harsh environment of mobile working machines.

With our vast experience on the field of sensors and measurement systems STW is able to solve many customer-specific measurement problems. Also outside the standard product portfolio specially adapted solutions can be developed, realized and manufactured.

Different output signals and protocols on the CANbus interface make the measured values available for further processing.

55


Sensors

digiSENS Sensors digiSENS-M01

digiSENS-M02

digiSENS-P01

Function

Pressure

Pressure

Pressure

Transducer / Switch

Transducer

Transducer

Switch

Measurement range

0 … 0.25 bar 0 … 2000 bar

0 … 10 bar 0 … 3500 bar

0 … 10 bar 0 … 2000 bar

Media connection

G 1/4 1/4 NPT G 1/4 with manometer pin 9/16 … 20 UNF (SAE 4) 9/16 … 18 UNF (SAE 6)

G 1/4

G 1/4 1/4 NPT G 1/4 with manometer pin 9/16 - 20 UNF (SAE 4) 9/16 - 18 UNF (SAE 6)

Electrical connection

M12 DIN-Bayonet (per DIN 72585) DT04 3-pole DT04 4-pole AMP-SuperSeal 1.5 Cable output

M12 (5 Pin) stainless steel

M12 DIN-Bayonet (per DIN 72585) DT04-3P Cable output

Linearity [%FS]

< 0.5

< 0.5

< 0.5

Overall accuracy at operating temperature [%FS]

≤ 1.0 (0 … +80° C) ≤ 1.5 (−25 … +100° C) ≤ 2.5 (−40 … +125° C)

≤ 1.0 (0 … +80° C) ≤ 1.5 (−25 … +100° C) ≤ 2.5 (−40 … +125° C)

≤ 1.0 (0 … +80° C) ≤ 1.5 (−25 … +100° C) ≤ 2.5 (−40 … +125° C)

Long-run stability [%FS p.a.]

< 0.2

< 0.2

< 0.2

Analog output signal

4 … 20 mA (2-wire) 0 / 4 … 20 mA (3-wire) 0 … 10 V 0 … 5 V 1 … 6 V 10 … 90 % VCC (ratiometric)

0 … 10 V 0.5 … 4.5 V 4 … 20 mA

1 x PNP 2 x PNP 1 x NPN 2 x NPN (Output current up to 500 mA)

CAN output protocol

CANopen SAE J1939

Voltage supply

9 … 36 VDC 14 … 36 VDC (0−10 V voltage output) 5 V ± 10 % VDC (ratiometric output)

9 … 36 VDC 14 … 36 VDC (0−10 V voltage output) 5 V ± 10 % VDC (ratiometric output)

9 … 36 VDC

Protection class

IP67 / IP69K

IP67

IP67 / IP69K

Safety

Certifications Special features

56

E1 Millions of combinations CAN support

E1 M12 Stainless steel electrical connector

Pressure switch


Sensors

digiSENS-F01

digiSENS-F02

digiSENS-T01

Function

Pressure

Pressure

Temperature

Transducer / Switch

Switch

Transducer

Transducer

Safety

PL d (Cat. 2)

PL d (Cat. 2)

Measurement range

0 … 50 bar 0 … 1000 bar

0 … 10 bar 0 … 1200 bar

−40 … +150° C

Media connection

G 1/4

G 1/4

G 1/4


M12

M12 M12 stainless steel

M12 M12 stainless steel

Linearity [%FS]

< 0.5

< 0.5

Overall accuracy at operating temperature [%FS]

≤ 2.5 (−40 … +85° C)

≤ 1.0 (0 … +80° C) ≤ 1.5 (−25 … +0° C) ≤ 2.5 (−40 … −25° C)

Long-run stability [%FS p.a.]

< 0.2

< 0.2


1 x PNP (max. 200 mA) + 0/4 … 20mA (3-wire) 2 x PNP (max. 200 mA)

2 x 4 … 20 mA (3-wire)

CAN output protocol

0.6 (−40° C … +150° C) 0.4 (−40° C … +85° C)

CANopen

Voltage supply

8 … 35 VDC

9 … 32 VDC

9 … 36 VDC

Protection class

IP67

IP67

IP76

E1

E1

E1

Certifications Special features

Safety pressure switch

Safety pressure transducer

Temperature transmitter with CAN support

57


Measurement Systems digiSENS Measurement Systems digiSENS-IVDMS

digiSENS-NGS2

digiSENS-FELIX

Function

Strain

Angular velocity Inclination angle

Position

Transducer / Switch

Transducer

Transducer

Transducer

Measurement range

± 2200 µm/m

± 50°/s ± 180° (CAN) / ± 90° (analog)

0 … 20 mm


1m cable

M12 (5 pin) (CAN) 8 pin (CAN and analog)

3 pin plug, AMP-Superseal 1,5

Linearity [%FS]

< 0.5

< 0.5

± 0.8 mm

Operating temperature

−25° C … +85° C

−40° C … +85° C

−30° C … +120° C


4 … 20 mA

0 … 20 mA 0 … 10 V

4 … 20 mA (3-wire)

CAN output protocol

CANopen

CANopen

Voltage supply

8 … 32 VDC

9 … 36 VDC 14 … 36 VDC (at 0−10 V output)

8 … 30 VDC

Protection class

IP65

IP67

IP67

58


Measurement Systems

STW-Technic, LP Mobile Controllers and Measurement Technologies 3000 Northwoods Parkway, Suite 240 Peachtree Corners, GA 30071, USA Telephone +1 770 242-1002 Telefax +1 770 242-1006 E-mail [email protected] Internet www.stw-technic.com

Sensor-Technik UK Ltd. Unit 21M Bedford Heights Business Centre Manton Lane, Bedford MK41 7PH, UK Telephone +44 1234 270770 Telefax +44 1234 348803 E-mail [email protected] Internet www.sensor-technik.co.uk

20161110 EN - Preliminary - Subject to change without notice

Sensor-Technik Wiedemann GmbH Steuer- und Regelelektronik Am Bärenwald 6 87600 Kaufbeuren Deutschland Telephone +49 8341 9505-0 Telefax +49 8341 9505-55 E-mail [email protected] Internet www.sensor-technik.de

SOLUTIONS FOR Mobile Machines

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