General Technical manual AESS

LILAAS AS, KONGEVEIEN 75, P.B. 705, N-3196 HORTEN, NORWAY TEL +4733031850, FAX +4733031860, E-MAIL LILAAS@LILAAS.NO
General Technical manual
AESS
Lilaas AS
Instruction manual
Product/Project:
TH1014A
Document no:
TH1014
AESS
Rev.:
A
Document title:
INSTRUCTION MANUAL
Document description:
This manual includes all necessary information for an elshaft system with LF90, LF120 and
LF70
A
Rev:
Rev.
Date:
Change no:
First Issue
J.Waage
Ø. Lilaas
Comments:
Author:
Approved:
Revision history
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TABLE OF CONTENTS
TABLE OF CONTENTS ........................................................................................................................................
1.
GENERAL .......................................................................................................................................................
1.1.
1.2.
ABBREVIATIONS, ACRONYMES AND DEFINITIONS .....................................................................................
BRIEF DESCRIPTION ..................................................................................................................................
2.
SCOPE ..............................................................................................................................................................
3.
SYSTEM DESCRIPTION ..............................................................................................................................
3.1.
DETAILED DESCRIPTION ............................................................................................................................
3.1.1. Node Electronics..................................................................................................................................
3.1.2. Communication ....................................................................................................................................
3.1.3. CAN bus controller ..............................................................................................................................
3.1.4. Bus Transceiver ...................................................................................................................................
3.1.5. Bus Cable.............................................................................................................................................
3.2.
SOFTWARE ................................................................................................................................................
3.2.1. Real time kernel ...................................................................................................................................
3.2.2. Communication task ............................................................................................................................
3.2.3. Servo loop task.....................................................................................................................................
3.2.4. Watch-dog............................................................................................................................................
4.
SPECIFICATIONS .........................................................................................................................................
4.1.
4.2.
5.
ENVIRONMENT..........................................................................................................................................
ELECTRIC ..................................................................................................................................................
INSTALLATION ............................................................................................................................................
4.1.
INSTALLATION ..........................................................................................................................................
4.2.
CONFIGURATION .......................................................................................................................................
5.2.1.
6.
MAINTENANCE ............................................................................................................................................
8.
APPENDIXES .................................................................................................................................................
8.2.
WIRING DIAGRAMS ...................................................................................................................................
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1. General
1.1. Abbreviations, acronymes and definitions
ADC
Analog Digital Converter
AESS
Azimuth Electronic Shaft System
AES
Azimuth Electronic Shaft
ASC
Asynchronous/synchronous Serial Controller
CAN
Controller Area Network (License Bosch)
CMOS
Complementary Metal Oxide Silicon
CPU
Central Processing Unit
ES
Emergency steering
Flash
Non-volatile memory that may be electrically erased
IO
Input/Output
LED
Light Emitting Diode
OTP
One Time Programmable memory
PLL
Phase Locked Loop
PWM
Pulse Width Modulation
RAM
Random Access Memory
SSC
Synchronous Serial Controller
XRAM
On-chip extension RAM
1.2. Brief description
The Electronic Shaft System is a system for controlling follow up of control levers. This system
integrates up to 8 double lever positions for 4 propulsion systems into one redundant network.
Each control lever is a node in the network and consists of one control lever and an electronic unit.
This is a fully autonomous system regarding all servo functions and man machine interfaces. The
system administrates the master selection, slave positions and fault detection. The system will give
throttle information to the supervisory system from the potentiometers on the levers. An additional
gang on the potentiometers will give throttle and angle information to the AESS system.
2. Scope
This manual describes specifications, user manual, installation manual, functional description and
maintenance procedures. All information needed for the product lifecycle is described in this
manual.
3. System description
This system consists of 3 control levers and 3 electronic units configured as 1 system with 3
levers. The levers has double ganged potentiometer for signal input to supervisory system
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3.1. Detailed description
3.1.1. Node Electronics
Processor
The processor is a 16-bit single–chip micro controller, C167CS from Infineon. This processor has
many built-in resources well suited for this application.
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Clock Generation via on-chip PLL (factors 1:1/2/2.5/3/4/5)
4 Kbyte internal RAM
16 channel 10-bit A/D Converter
Two 16-Channel Capture/Compare Units
4 channel PWM Unit
Two Multi-functional General Purpose Timer Units with 5 Timers
Two Serial Channels
Two CAN interfaces
Up to 16Mbyte External Address Space
Five Programmable Chip-Select Signals
Idle and Power Down Modes
Programmable Watchdog Timer and Oscillator Watchdog
Up to 111 General Purpose I/O Lines
The A/D converter is used for sampling of the shaft angle and throttle. The PWM unit is used for
servo motor output. One serial channel is used for the debug interface. The CAN interface is used
for CAN bus control.
Memory
Internal
 4 Kbyte RAM
External
 256 Kbyte Flash (Program)
 2kbyte EEPROM (Calibration coefficients)
 128 kbyte RAM
Motor drivers
The motor driver is an integrated full bridge motor drive circuit LMD18200. This circuit offers a
set of built in protection features. In addition some external protection circuitry is designed in to
give the following protection.
 Over voltage detection.
 Junction over temperature warning and shut down
 Shorted load protection
 Shoot through protection
Clutch drivers
The clutch driver is a International rectifier IR9410 (or similar). This is a MosFET transistor with
a low threshold voltage. This allows direct logic control from the processor I/O line without
expensive level converter circuitry.
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Debug interface
The module does have a RS-232 interface for debugging and software download. This could be
connected to a PC, running different terminal programs. Depending on the terminal program used
different applications and tools will be loaded and executed. This enables simple debugging of
user code and downloading program to Flash memory.
Shaft angle measurements
There is a sin/cos potentiometer indicating the angle. The A/D converter on the processor will
sample this potentiometer. This is a 10-bit converter. The angle measurement resolution is 0.5
Shaft throttle measurements
There is a linear potentiometer indicating the throttle. The A/D converter on the processor will
sample this potentiometer. This is a 10-bit converter. The throttle measurement resolution is
0.25%
Master / slave control
The module will have a Master input. This allows more than one module in a panel to be set to
Master mode using a single button. The input is isolated from the rest of the module by an opto
coupler.
18 – 29 V
Vcc
Figure 1 Master input
Spare output
The module is equipped with two relay outputs. This could be used for application specific
purposes.
Maximum contact ratings:
Voltage:
Current:
3.1.2. Communication
Inter bus Communication
Non Return to Zero (NRZ) bit encoding (with bit-stuffing) for data communication on a
differential two wire bus. NRZ encoding ensures compact messages with a minimum number of
transitions and high resilience to external disturbance.
CAN will operate in extremely harsh environments and the extensive error checking mechanisms
ensure that any transmission errors are detected. CAN uses and enhanced Carrier Sense, Multiple
Access with Collision Detection Protocol (CSMA/CD). Unlike Ethernet, when frames are
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transmitted at the same time, non-destructive bitwise arbitration allows the highest priority
message to gain bus access.
3.1.3. CAN bus controller
The Inifineon C167-CS is chosen due to its built-in dual CAN controller. The processor will
continuously monitor the CAN controllers and change active CAN bus if any error is detected.
The CAN bus controller handles the completely autonomous transmission and reception of CAN
frames in accordance with the CAN specification V2.0 part B (active), i.e. the on-chip CAN
Module can receive and transmit standard frames with 11-bit identifiers as well as extended
frames with 29-bit identifiers. The bit timing is programmable up to 1 Mbit/S. For this system the
maximum transmission rate should not exceed 125 kbit/S, due to the cable length of the bus cable.
3.1.4. Bus Transceiver
Each of the two CAN controllers are connected to its own transceivers to enable a redundant CAN
bus. The CAN bus transceivers are isolated with optocouplers.
3.1.5. Bus Cable
Shielding:
The Cable must be a shielded cable
Nr. of pairs:
2 twisted pairs.
Impedance:
120 ohm nom 108 ohm min. 132 ohm max.
Delay:
<= 5 ns/m
Cable cross section >= 0.75 mm2
3.2. Software
3.2.1. Real time kernel
The software is based on a simple real time kernel to improve system reliability and handle
resource priorities.
3.2.2. Communication task
A fieldbus network performs the interconnection between system units. The CAN fieldbus
standard is selected due to its reliability, efficiency and widespread industrial use.
CAN is an advanced serial bus system that efficiently supports distributed, real-time control.
The control functions between system units are done by bus messages. The message types are:
 Process Data messages are used to exchange application data. Performs cyclic
distribution of process data (i.e., setpoints). These are high priority CAN messages.
 Service Data messages are used to read and write of all system parameters stored in the
system object dictionary. These data are transferred asynchronously (on demand). These
are low priority CAN messages.
 Start-up initialisation.
 Communication sync messages.
 Exception (Error) messages
3.2.3. Servo loop task
The servo loop task performs the actuator (motor drive) control signals based on configuration
parameters and setpoint data received in the Process Data messages.
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3.2.4. Watch-dog
The Microcontroller provides a Watchdog Timer to allow recovery from software or hardware
failure. If the software fails to service this timer before an overflow occurs, an internal reset
sequence will be initiated. The watchdog timer will supervise the program execution, as it only
will overflow if the program does not progress properly. The watchdog timer will also time out if
a software error was due to hardware related failures. This prevents the controller from
malfunctioning for longer than a user-specified time.
4. Specifications
4.1. Environment
Temperature
Shock
Vibration
-25 til +70 degrades celsius
3-13.2Hz/+/- 1mm
13.2-100Hz/0,7g
4.2. Electric
Input Voltage:
Power consuption, idle:
Power consuption, max
Bus System:
Bus speed:
Max bus length(@125kbps):
24Vdc
120mA (Clutch on)
0.75A
Redundant CAN
125kbps
500m
5. Installation
5.1. Installation
Necessary tools:
 PC with a terminal emulator
 RS232 cable
 8mm wrench
 Screw drivers
The cables between lever and electronic unit are 2m. Mount the electronic unit within this range
from the lever. The electronic unit is mounted with two M6 bolts (not included) on the ends of the
DIN rail.
Connect the cable between levers and electronic unit.
Connect external wiring according to wiring diagram LF12927 in appendix A
5.2. Configuration
5.2.1 Connectors on AESS boards
Connector J1 (Phoenix MC 1.5/12-GF-3,5)
General description:
Used for connection of lever motors, lever clutches and 24V supply. Mating cable connector:
Phoenix MC 1,5/12-STF-3,5.
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Figure 2 Picture of header Phoenix MC 1.5/12-GF-3,5
Figure 3 Connector J1 with pin numeration, seen from mating side.
CONNECTOR J1
Pin number
1
2
3
4
5
6
7
8
9
10
11
12
Signal to be connected
Motor 2, positive terminal (-)
Motor 2, negative terminal (+)
Clutch 2, positive terminal (+)
Clutch 2, negative terminal (-)
Motor 1, positive terminal (+)
Motor 1, negative terminal (-)
Clutch 1, positive terminal (+)
Clutch 1, negative terminal (+)
Electroluminescent display, positive terminal (+)
Ground for Electroluminescent display (-)
Ground for 24 Volt supply
24 V DC supply
Table 1 pin configuration for header J1
Connector J2 (Phoenix MC 1.5/12-GF-3,5)
General description:
Used for connection of linear potentiometers mounted on the levers. Mating cable connector:
Phoenix MC 1,5/12-STF-3,5.
Figure 4 Connector J2 with pin numeration, seen into connector on board.
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CONNECTOR J2
Pin number
1
2
3
4
5
6
7
8
9
10
11
12
Signal to be connected
Potentiometer 2 , positive terminal (+, )
Potentiometer 2, wiper, NC
Potentiometer 2, negative terminal (-)
No connection
Potentiometer 1, positive terminal (+, pin 1)
potentiometer , wiper
Potentiometer 1, negative terminal (-, pin 3)
No connection
No connection
No connection
No connection
No connection
Table 2 pin configuration for header J2
Connector J3 (DIN41651-14p) (not mounted on this system)
General description:
J3 is for connection of display board via flat cable. Mating cable connector: AMP 1-215882-4 or
similar.
Figure 5 Picture of connector J3
Figure 6 Connector J3 with pin numeration. Seen into connector on board.
CONNECTOR J3- display board connector
Pin
number
1
2
3
4
5
6
Signal to be connected
No connection
No connection
Ground
Serial clock input
Ground
Load data input 1
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Ground
Load data input 2
Ground
Serial Data Input
Ground
VCC (5V from AESS board)
Ground
VCC (5V from AESS board)
Table 3 pin configuration for connector J3 (display board)
Connector P1 (9 pins DSUB Female-RS232)
General description:
Used for connection of PC via the RS232 port. Mating cable connector: AMP 747904-2 or similar.
Figure 7 Connector P1 (female) with pin numeration. Seen into connector on board.
CONNECTOR P1- RS232
Pin
number
1
2
3
4
5
6
7
8
9
Signal to be connected
No connection
TX-RS232
RX-RS232
No connection
Ground
No connection
No connection
No connection
No connection
Table 4 pin configuration for P1 (RS-232)
Connector P2 (9 pins DSUB Male-CAN1)
General description:
Used for connection of CAN bus no. 1. Mating cable connector: AMP 747905-2 or similar.
Figure 8 Connector P2 (male) with pin numeration. Seen into connector on board.
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CONNECTOR P2- CAN 1
Pin
number
1
2
3
4
5
6
7
8
9
Signal to be connected
No connection
CAN1_L
Isolated ground (ISOGND)
No connection
No connection
CAN1_V- = ISOGND
CAN1_H
No connection
No connection
Table 5 pin configuration for connector P2 (CAN 1)
Connector P3 (9 pins DSUB Male-CAN2)
General description:
Used for connection of CAN bus no. 2. Mating cable connector: AMP 747905-2 or similar.
Figure 9 Connector P3 (male) with pin numeration. Seen into connector on board.
CONNECTOR P3- CAN 2
Pin
number
1
2
3
4
5
6
7
8
9
Signal to be connected
No connection
CAN2_L
Isolated ground (ISOGND)
No connection
No connection
CAN2_V- = ISOGND
CAN2_H
No connection
No connection
Table 6 pin configuration for connector P3 (CAN 2)
Connector P4 (15 pins DSUB Female-inputs/outputs)
General description:
P4 is used for connection of different control signals. Some pins are spare inputs and outputs. All
signals are galvanic isolated from AESS board and from each other by means of magnetic
coupling (relays) or optocouplers, except the dimming signal for electroluminescent film (pins 4
and 8), which is referenced to the same ground as the AESS board. Mating cable connector: AMP
747908-2 or similar.
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Figure 10 Connector P4 (female) with pin numeration. Seen into connector on board.
CONNECTOR P4- general inputs/outputs
Pin
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Signal to be connected
In Command, positive terminal (+10 to 24V DC)
SW1, positive terminal (+10 to 24V DC)
Alarm, terminal 1
Dimming signal to electroluminescent film (0-5V)
In Command, negative terminal (-)
SW1, negative terminal (-)
Alarm, terminal 2
AESS Ground, reference for dimming signal to electroluminescent film
Spare input 1, positive terminal (+10 to 24V DC)
Spare input 2, positive terminal (+10 to 24V DC)
In command indicator, terminal 1
No connection
Spare input 1, negative terminal (-)
Spare input 2, negative terminal (-)
In command indicator, terminal 2
Table 7 pin configuration
6. Maintenance
This system is designed to be maintenance free. However it is recommended to perform the
calibration routine and the functional test described in 5.7.3 and 5.7.4 once a year.
8.1. Wiring diagrams
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Instruction manual
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