driver´s aid ergodrive - cbb · 2019. 4. 16. · manual ergodrive professional short april 2019...

Driver´s Aid

Operating Instructions

(Short version)

April 2019

Exhaust emission certification

Gear box optimization

Testing of vehicle cooling

Brake force measurement

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ErgoDrive 1.1.1.1.1.1.1.1

Professional

®

Manual ErgoDrive Professional short April 2019 – v006 – Public

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Content:

1 Safety instructions ............................................................................................................................ 5

1.1 Observe instruction manual .............................................................................................. 5

1.2 Liability for function respectively damages ...................................................................... 5

2 Introduction ...................................................................................................................................... 6

3 Operating of a climatic chamber suitable monitor ........................................................................... 7

3.1 Airbag in the test vehicle ................................................................................................... 7

3.2 Connecting the cable set to the monitor .......................................................................... 7

3.3 Establishing the HDMI connection to the LCD monitor .................................................... 8

3.4 Connecting the power supply ........................................................................................... 8

3.5 Connecting to 9 ... 36 VDC ................................................................................................. 8

3.6 Switching On and Off ......................................................................................................... 8

3.7 Autosync-push button ....................................................................................................... 8

3.8 Operation in sub-zero ambient temperatures .................................................................. 9

3.9 Drying cartridge ................................................................................................................. 9

3.10 Specification of safety classes ........................................................................................... 9

3.11 Technical data .................................................................................................................... 9

3.12 Connector assignment ..................................................................................................... 10

3.12.1 Assignment of the voltage connection (see marking on the cable): .............................. 10

3.12.2 Assignment RS232-connector (standard assignment): ................................................... 10

3.13 Installation instructions for the touch screen driver ...................................................... 11

3.14 Calibration of the touch-screen ...................................................................................... 15

4 Usage of the suction cup fastening ................................................................................................. 18

4.1 Airbag in the test vehicle ................................................................................................. 18

4.2 Attaching the suction cup fastening ................................................................................ 18

4.3 Rules for using the suction cup fastenings ...................................................................... 19

4.4 The stand’s fastening screws ........................................................................................... 20


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5 Programme start of the DA ErgoDrive Professional ....................................................................... 20

6 Operation of the DA ErgoDrive Professional .................................................................................. 20

6.1 Special function for scrolling back and forward in driving cycle (optional) .................... 22

7 Drive curves of the DA .................................................................................................................... 23

7.1 Speed cycles (Exhaust gas laws) v = f(t) .......................................................................... 23

7.2 Drive curve pass routes (gradient to test stand computer) gradient = f(s) .................... 26

8 Recorded measurement values ...................................................................................................... 28

8.1 Program call ..................................................................................................................... 28

8.2 Open a log file .................................................................................................................. 29

8.3 Conversion ....................................................................................................................... 30

8.4 Entry of test data ............................................................................................................. 31

9 Editing the data record for the operating mode v over t ............................................................... 32

9.1 Gear change table for the operating mode speed over time ......................................... 32

9.2 Tolerance field data for the operating mode v over t ..................................................... 34

9.3 Driving cycle data for the operating mode v over t ........................................................ 36

9.4 Gear change point entries in the data record ................................................................. 39

9.5 Setting of digital outlets (optional) ................................................................................. 42

9.6 Bag sampling control (optional) ...................................................................................... 42

9.7 Supplied data records for driving cycles in operating mode v over t ............................. 43

10 Data record for further values such as e.g. gradient ...................................................................... 44

10.1 Possible variables in the data record .............................................................................. 44

10.2 Declaration of the values ................................................................................................ 45

10.3 Determine display of the course in the DA ..................................................................... 46

10.4 Time controlled data record ............................................................................................ 49

10.5 Route controlled data record .......................................................................................... 51

10.6 Use of variables in the data records ................................................................................ 53

10.7 Table of the variables used ............................................................................................. 55


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11 Display of information from data records ...................................................................................... 56

11.1 Display of cycle number and position number ............................................................... 56

11.2 Display of the profile name ............................................................................................. 58

11.3 Display of the message profile end ................................................................................. 60

12 Use of the variables with control function ..................................................................................... 62

12.1 Switching to display (v- and mountain cycle running automatically) ............................. 62

12.2 Setting of digital outputs (switching 4 channels) ............................................................ 66

Contact .................................................................................................................................................... 68


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1 Safety instructions

For your safety please observe the following advice.

1.1 Observe instruction manual

Any handling of the driver’s aid ErgoDrive Professional requires an exact knowledge and observance of this instruction manual. This program is only meant for the described technical purposes. Furthermore, when operating the chassis dynamometer, the instruction manuals as well as the safety regulations of the chassis dynamometer producer must be observed.

1.2 Liability for function respectively damages

The liability for the function is in every way transferred to the owner or user in case of operation and handling that is not in accordance with the intended use. cbb software GmbH is not liable for damages that occur due to disregard of the preceding directions. Warranty- and liability terms in the cbb software GmbH conditions of sale and terms of delivery are not extended by the preceding directions. The supplied display devices as well as their holding fixtures may under no circumstances be applied within the working range of an airbag. cbb software GmbH does not accept any liability for damages of any kind that arise from failure to comply with this warning!

The provided equipment with all appending components (monitors, mountings, note-books etc.) may under no circumstances be applied within the working range of an airbag. cbb software GmbH does not accept any liability for damages of any kind that arise from failure to comply with this warning!

Please strictly observe the safety instructions in the following chapters and operating instructions of additional equipment. cbb software GmbH does not accept any liability for damages of any kind that arise from failure to comply with this warning!


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2 Introduction

The driver´s aid (DA) ErgoDrive Professional is the indispensable interface to the driver in manned test drives on chassis dynamometers. Just like on the real road, the test driver is integrated in the driving process as controller via the driver´s aid as visual feedback. The set and actual speed or the actual and the future gradient are presented to the driver as main values on the ErgoDrive in a clear and ergonomic way. This enables the driver to carry out his tasks also for longer periods of time in a concentrated and relaxed way while providing reproducible results. The process data produced on the chassis dynamometer during vehicle testing (e.g. speed, gradient, height, traction, power, temperature, humidity, insolation) are captured via the corresponding inputs and are displayed as digital values in a display field (optional). Additionally this data is stored by Er-goDrive Professional in a log file, which enables evaluation of the data with a conversion programme (log2xls) in Microsoft Excel..


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3 Operating of a climatic chamber suitable monitor

For operating of a climatic chamber suitable monitor with touch screen (model 12“ and 15“) please note the following information:

Figure 1: Climatic chamber suitable 15” monitor with suction cup fastening

3.1 Airbag in the test vehicle

An existing airbag must be deactivated when using the monitor in the test vehicle, if the monitor is secured in any way on the steering wheel, or is used within the working range of a steering wheel, passenger, side or other airbag. cbb software GmbH accepts no liability for damage of any kind that arises from failure to comply with this warning! Safety Instructions: The monitor may be not secured at a location where, in the event of an acci-dent, it could be thrown against the driver/passenger, as this could cause severe injuries. The mon-itor must under no circumstances be mounted within the working range of an airbag. The glass substrate of the display is covered with a plastic layer, but pieces of glass or

the metal housing could cause personal injury in the event of a serious accident. Discuss the installation location in the vehicle with a safety officer and follow the safety

instructions. Exclusion of Liability: No responsibility is accepted for accidents or injuries that arise from failure to

comply with the rules and safety instructions detailed above.

3.2 Connecting the cable set to the monitor

Connection cables are included with the monitor to transmit the HDMI signal (HDMI connection ca-ble), to transmit the touch screen signals (RS 232) and to supply the power (+9 .... +36 VDC), either via a 230 V AC power unit or via the on-board socket in the vehicle. The permissible input voltage range amounts to 9 … 36 VDC.

Warning: This device may under no circumstances be applied within the working range of an airbag. cbb software GmbH does not accept any liability for damages of any kind that arise from failure to comply with this warning!


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3.3 Establishing the HDMI connection to the LCD monitor

Switch off the computer and the supply to the monitor and plug in the connection cable to the HDMI output of the computer. The correct side of the cable is marked with “Source”. Plug in the other cable end to the display in the HDM. This side is marked with HDMI device. Please do not interchange the ends because the signal is amplified and then the signal transmission does not work.

3.4 Connecting the power supply

Plug the connector of the connection cable into the associated socket of the display and turn the connector gently until tight. The connectors used are reverse polarity protected. Before pulling the connection out again, loosen the screw-type locking. Plug the main cable into the power unit located at the other end of the power supply cable. Only connect the power unit to a power supply in the range 100 … 240 VAC, 47 … 63 Hz. A green LED indicates whether there is a power supply to the pow-er unit. Operating with direct current or with voltage or frequency ranges other than given, can damage the power unit and the monitor!

3.5 Connecting to 9 ... 36 VDC

For use in a normal car, the monitor’s input voltage range amounts to 9 … 36 volts of direct current. This monitor is also suitable for use in HGVs. Check that you have the correct vehicle voltage for the monitor before connection, as otherwise this could be damaged. A green LED in the connector for the on-board socket indicates whether there is a power supply when using the connection cable for the on-board socket. Operating with alternating current or at voltages larger than stated leads to damage of the monitor! Safety Instructions: Power supply to the monitor must only be effected via an electric circuit pro-

tected by a cut-out fuse. Pressure on the supply line when it is connected to an inse-cure circuit could cause a dangerous cable fire and this could lead to personal injury!

The connection cables may only be installed in such a way that ensures they cannot accidentally touch the operational controls of the vehicle and do not block or reduce the effect of safety equipment. The driver must not be hindered by the cables in any way (steering wheel, pedals, gear change, operational controls, etc.)

3.6 Switching On and Off

The monitor can be switched on and off using the “On/Off” button. The thermostatically controlled heating cannot be switched off and heats automatically from ca. +5°C.

3.7 Autosync-push button

The „Autosync“-button optimises the display for the current image signal. Further adjustments are executed automatically by the monitor so that user intervention is not necessary.


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3.8 Operation in sub-zero ambient temperatures

In ambient temperatures between 0°C to -20°C the monitor must be connected to the power sup-ply for ca. 30 minutes before operation so that the device can preheat. In extreme environmental conditions (ambient temperature below -35°C) the monitor may only be used with the provided 230V power unit. In these environmental conditions the power supply must be permanently ensured.

3.9 Drying cartridge

When the drying cartridge has been used up (blue colour is no longer visible), this must be replaced by a new cartridge, to prevent condensation build-up on the inside of the device. The drying cartridge is located at the top left on the monitor.

3.10 Specification of safety classes

Generally the device complies with the safety class IP 54, the following shows the exact specifica-tion for the ports: - Connected connector receptacle (HDMI, RS232): IP54 - Connected connector power supply: IP67 - shielded connector receptacle, covers bolted (HDMI, RS232): IP54 - shielded connector power supply: IP67 - unshielded connector receptacle (HDMI, RS232): IP50 (for the contacts of the connector re-

ceptacles) - unshielded connectors power supply: IP50 (for the contacts of the connector receptacles)

For the device (except ports) with unshielded ports still IP54 applies.

3.11 Technical data

Power supply: max. 9-36 VDC

Power consumption: max. 100 watt (max. 30 W for the monitor and max. 70 W for the radi-ators).

Display: 15,1” colour-TFT, screen resolution: 1024 x 768 pixels, brightness: 350 cd/m²

Measurements: 320 x 260 x 50 mm, weight approx 4,5 kg without holding device

Operating temperature range: -40 … +55 °C,

Storage temperature range: -20 ... +70 °C

Ports: Power supply, HDMI, RS232 for touch

Scope of delivery: Connecting cable 2 m for cigarette lighter / on board socket, ext. power supply 100-240VAC incl. 30m cable, set of cables HDMI/RS232 30m


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3.12 Connector assignment

3.12.1 Assignment of the voltage connection (see marking on the cable):

PIN 1 = GND PIN 2 = GND (radiator) PIN 3 = Plus (radiator 12-24 VDC) PIN 4 = 12-24 VDC

3.12.2 Assignment RS232-connector (standard assignment):

(on monitor)

9 PIN D-SUB FEMALE on monitor:

Pin Name RS232 V.24 Dir Description

1 n.c.

2 RXD BB 104 Receive Data

3 TXD BA 103 Transmit Data

4 n.c.

5 GND AB 102 System Ground

6 n.c.

7 n.c.

8 n.c.

9 n.c.


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3.13 Installation instructions for the touch screen driver

To use the touch function of the climatic suitable touch screen you have install the driver for the

touch by using the following steps:

Insert the touch-screen-driver CD in the CD-ROM disc drive.

Then go to the folder PenMount Windows Universal Driver V2.4.5.350 WHQL (see Figure 2).

Figure 2: Touch driver folder

Click with the right mouse button on the “setup” file and choose “Run as administrator” in the drop

box (see Figure 3).

Figure 3: Run the setup file


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The setup starts. Click on the “Next” button (see Figure 4).

Figure 4: Installation of the touch driver

Accept the license agreement. Click on the “I Agree” button (see Figure 5).

Figure 5: License Agreement


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The Destination folder is shown. Click on the “Install-Button (see Figure 6). Be sure that the touch

screen is connected before you do this step.

Figure 6: Installation window

Click on the “Yes” button to use the touch as mouse device (see Figure 7).

Figure 7: Using as mouse device


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Now, the installation is started, the installation process is shown in the following window (see Figure

8).

Figure 8: Installation process window

The Installation is now complete. It is necessary to reboot the PC now. Click on the finish button (see

Figure 9) to reboot the PC.

Figure 9: Installation finished

The touch driver is installed. You can use the screen after the rebooting of the PC is finished. Some-

times it is necessary to calibrate the screen.


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3.14 Calibration of the touch-screen

Open the control panel in the start menu. Click on “Windows System” (see Figure 10) and choose

“PenMount Control Panel”.

Figure 10: Windows Start menu

Choose “Configure” in the PenMount Control Panel” (see Figure 11).

Figure 11: PenMount Control Panel


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Click the button “Standard Calibration” (see Figure 12).

Figure 12: PenMount Calibration Window

Now touch the touch-screen exactly at the stipulated point and wait a short moment. Release the

touch when the word ’release’ appears next to the touch point (note small writing). Follow the in-

structions on the touch-screen (see Figure 13).

Continue these steps in accordance with the instructions on the touch-screen until all calibration

points have been set.

Figure 13: Calibration Instructions


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After the calibration is finished the configuration Window is shown again. Click now on the button

“OK” (see Figure 14).

Figure 14: PenMount Calibration Window

The touch-screen is now ready for operation.


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4 Usage of the suction cup fastening

Using the suction cup fastening with hydraulic stand belonging to the climatic chamber suitable mon-itors with touch screen (model 12“ and 15“) please note the following information:

Figure 15: suction cup fastening with hydraulic stand

4.1 Airbag in the test vehicle

An existing airbag must be deactivated when using the suction cup fastening in the test vehicle, if the fastening is secured in any way on the steering wheel, or is used within the working range of a steering wheel, passenger, side or other airbag. cbb software GmbH accepts no liability for damage of any kind that arises from failure to comply with this warning! Please always observe the operating instructions included with the device mounted on the fas-tening!

4.2 Attaching the suction cup fastening

First select a suitable place to install the monitor in the vehicle. The monitor should be supported on the dashboard if possible. To avoid scratches or other damage to the dashboard, lay something soft (e.g. a piece of foam) between the monitor and the dashboard. Loosen the hand wheel of the hydraulic stand delicately and carefully until you can feel no more resistance. Do not turn any further under any circumstances! Note: Never turn the hand wheel so far that it comes off completely, as hydraulic oil leaks out and air gets into the hydraulics. This would damage the stand irreparably! Set up the hydraulic stand so that the monitor is aligned perfectly and supported if possible on the dashboard. Tighten the hand wheel as far as it goes. Only tighten the hand wheel by hand! Press the cleaned suction plate of the suction cup against the surface to which the fastening is to be secured (e.g. windscreen) and create the necessary pressure by pulling on the fixing lever. Check that the stand has a secure hold! The suction cups can be removed again by pulling the lever back.


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4.3 Rules for using the suction cup fastenings To achieve the greatest possible safety when using the suction cup, the following rules should always be observed:

Only use the suction cups on even and sealed surfaces, which are clean, dry and free from oil and grease. The load bearing capacity is reduced on rough surfaces.

Always keep the suction cups, and particularly the rubber discs, clean and free from oils and grease.

The rubber discs must be stored in an unstressed condition.

Examine the suction cups before each use for function and possible damage.

Attach the suction cups again if the hold does not appear satisfactory to you. This applies es-pecially to longer periods of use. The suction cups are to be checked regularly for strong hold.

Try not to remove the rubber discs with sharp-edged objects or tools; you would damage them.

Never use suction cups with damaged rubber discs.

The suction fastening is intended for short periods of use. For longer periods of use, the suc-tion pressure must be re-established under suitable conditions. If this is not possible another method of fastening must be selected.

Please be careful that the device does not fall off due to inadequate pressure, as it could be damaged and could also cause personal injury!

Loosen the hand wheel of the hydraulic stand carefully until you can feel no more re-sistance. Do not turn any further under any circumstances! Never turn the hand wheel so far that it comes off completely, as hydraulic oil leaks out and air gets into the hydraulics. This would damage the stand irreparably!

Always tighten the hand wheel as far as it goes. Only tighten the hand wheel by hand! Do not use a tool!

Set up the hydraulic stand in such a way that the monitor is aligned perfectly and supported if possi-ble on the dashboard.

Safety Instructions: The suction cup fastening with the device on it may be not secured at a location

where, in the event of an accident, it could be thrown against the driver/passenger, as there would be a danger of severe or fatal injuries. The suction cup fastening with the device on it must not be mounted within the working range of an airbag under any cir-cumstances.

Set up the hydraulic stand in such a way that the monitor is supported if possible on the dashboard.

Renew the suction pressure daily by remounting the stand. Discuss the installation location in the vehicle with a safety officer and follow the safety

instructions.

Exclusion of Liability: No responsibility is accepted for accidents or injuries that arise from failure to comply with the rules and safety instructions detailed above.


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4.4 The stand’s fastening screws The screws, with which the stand is fastened to the mount and the mount to the monitor, have been secured with “Loctite High Performance”. “Loctite High Performance“ is a special material for perma-nent screw connections that can no longer be removed. These screw connections can only be re-moved with difficulty with normal tools (by heating to 300°C) Be careful not to damage the monitor during this process!

5 Programme start of the DA ErgoDrive Professional

After starting the computer, ErgoDrive Professional is started with a double click on the button „Er-goDrive“ on the desktop. The standard directory of the driver´s aid (DA) is on the DA -PC (drive C:\ErgoDrive).

6 Operation of the DA ErgoDrive Professional

After the start of the programme the DA surface appears. Below the surface is the control panel (DA-Client), Figure 16, from which the operation of the DA ErgoDrive Professional and the selection of the drive cycles (drive profiles) are carried out.

Figure 16: Control panel of the DA after start of the programme

The individual operating instruments have the following functionalities:

1. Load drive curves: For loading of the surface display of drive curves in the DA. The standard directory of drive curves is: C:\ErgoDrive\configurations. The available surfaces depend on the scope of delivery. Missing surfaces can at any time be purchased separately.

speed_70.cfg: Speed cycles (exhaust gas laws) v = f(t) with firm background in the range of 0 to 70 km/h

speed_110.cfg: Speed cycles (exhaust gas laws) v = f(t) with firm background in the range of 0 to 110 km/h

speed_floating.cfg: Speed cycles (exhaust gas laws) v = f(t) with sliding background in the range of 0 to 220 km/h

pass_drive_2d.cfg: Pass routes (gradient on chassis dynamometer computer) Gradient = f(s) display of the set gradient over route

1. load drive curve manually (selection of display surface)

2. open drive cycle (drive profile)

3. start the drive cycle with the DA

4. end DA ErgoDrive Professional


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hill_drive_var_v.cfg: Pass routes with variable speed, display of the speed over route with handover of the gradient to the chassis dynamometer computer.

2D_altitude.cfg: 2D-height profile for display of the height over route with handover of the gra-dient to the chassis dynamometer

pass_drive_3d.cfg: 3D-road display with display of the height over route with handover of the gradient to the chassis dynamometer

measurement_display.cfg: Display of measurement values as digital display without display of drive curves, for KW I without and for KW II with front- and rear values for traction and per-formance.

2. Load drive cycle: Selection of the desired drive cycle, e.g. ECE or mountain pass. The includ-ed ASCII files as well as own data records can be selected as data record. The standard-directory for the drive cycles is: C:\ErgoDrive\profiles.

3. Start: This button activates the drive cycle (the test run) with the DA as well as recording (log-

ging, optional) of the measurement values. For this also see Figure 17.

4. End: This button ends ErgoDrive Professional. A query window prevents the unintentional termination of the programme, e.g. through accidental clicking on the button with the mouse. Confirm with „yes“, when you want to end the programme or with „no“, if you want to continue the programme. An accidental termination of the programme during a test run is not possible, because the func-tion of this button changes to the pause/continue function during the test (see Figure 17).

After the start of the drive cycle with the DA by activating the button „3. Start“ the functions of the buttons in the menu bar change:

Figure 17: Menu bar of the DA after the start of a drive cycle

5. End drive cycle: The drive cycle and the recording (logging, optional) of the measurement val-

ues are ended. A query window prevents the unintentional termination of the test, e.g. through accidental clicking on the button with the mouse. Confirm with „yes“, if you want to end the cycle or with „no“, if you want to continue the cycle. The DA automatically goes back to the beginning of the loaded drive cycle. The function of the buttons changes again as shown in Figure 16. The logged measurement values you can find in the directory: C:\ErgoDrive\Data-Log. (see chap-ter 8 „Recorded measurement values“). The DA is now automatically at the beginning of the loaded drive cycle in pause mode. Now a new drive cycle can be loaded or another test can be carried out with the loaded drive cycle. In order to start the test, again the button „5. Start“ must be activated.



5. end the drive cycle with the DA


6. Pause (interrupt the drive cycle with the DA)


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6. Pause: The cycle is interrupted with this button. The symbol on the button changes into pushed Pause (Figure 18), the DA surface shows the message „Pause“. The recording of the measurement values (logging) continues in pause mode, however only the values with the corre-sponding support points changing during pause mode are recorded.

Figure 18: Menu bar of the DA after start of a drive cycle

In order to continue the drive cycle at this point, press the button „6. Pause (Continue the drive cycle)“ again, the symbol of the button changes into not pushed „ Pause“ (interrupt drive cycle), see Figure 17. This function only interrupts and continues the drive cycle at this point. The cycle and the record-ing of the measurement values are not terminated. The button „7. End drive cycle“ must be used in order to terminate the drive cycle (also in case of premature termination of the test).

6.1 Special function for scrolling back and forward in driving cycle (optional)

The ErgoDrive Professional offers a special function with which you can scroll forwards or back-wards in the previously loaded drive cycle. Press the "F6" key on the keyboard to scroll forward in the cycle or the "F5" key to scroll back.



5. end the drive cycle with the DA


6. Pause (continue the drive cycle)


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7 Drive curves of the DA

The following shows the drive curves (configuration files) of the DA. Further configuration files can be supplied by cbb software GmbH at the customer´s request.

7.1 Speed cycles (Exhaust gas laws) v = f(t)

The drive curve speed cycles v = f(t) is based on the software module „speed over time“ of the DA, which realizes speed over time. The creation of the corresponding data records of speed cycles is described from chapter 15 on. Loading of this drive curve is carried out from the directory C:\ErgoDrive\configurations. The follow-ing surfaces are available:

speed_70.cfg: Firm background in the range of 0 to 70 km/h

speed_110.cfg: Firm background in the range of 0 to 110 km/h

speed_floating.cfg: Sliding background in the range of 0 to km/h The following Figure 19 shows the display speed_70.cfg with a loaded ECE-cycle as an example of a DA surface:


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Figure 19: Drive curve speed cycles

The surface of the drive curve speed_70.cfg (module v over t) as shown in Figure 19 has the following functionalities:

1. „Status message“: The status- and fault messages of ErgoDrive Professional appear in the menu bar. If there are no messages, the presently loaded cycle file is displayed.

2. „Display of the loaded drive cycle“: The presently loaded drive cycle file is displayed (here ECE).

6. Display of drive viola-tions

2. Display of the loaded drive cycle

in km/h

1. Status message/ display of loaded drive cycle

11. Set gear

4. Tolerance range

10. Actual speed in km/h

9. Speed scale in km/h 7. Overall view of the speed profile

8. Time scale in s

5. Set speed in km/h 3. Display field measurement values


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3. „Display of measurement values“: This data field shows data from the DA as well as measure-ment values from the chassis dynamometer or the climatic chamber (optional) as digital-display field.

4. „Tolerance range“: The actual speed must be within this tolerance range. The range can be changed (chapter 9.2).

5. „Set speed in km/h“: The set speed is shown as vertically scrolling speed profile, whereby the time scale is located on the left side and the speed scale at the bottom of the screen. The set speed is equipped with a tolerance range which can be adapted to the individual requirements. Furthermore the gear shift points are displayed. These can also be configured.

6. „Display of drive violations“: When the tolerance range is exceeded, these driving violations are recorded and displayed. The display shows the overall time in which the actual speed was out-side the tolerance range as well as the number of cases, where the tolerance range (depending on time and speed) has been violated. The overall time is also shown as fault in the display field of the measurement values.

7. „Overall view of the speed profile“: The overall profile is displayed in a second window. The marking of the actual position is done with a red line.

8. „Time scale in s“: Designation of the time axis in the vertically scrolling speed profile in seconds. 9. „Speed scale in km/h“: Designation of the speed axis in the vertically scrolling speed profile in

km/h. 10. „Actual speed in km/h“: The actual speed is shown as a cursor in which there is a little lamp. This

shines green when the actual speed is within the tolerance range. If the tolerance range is violat-ed, this lamps shines red.

11. „Set gear“: Display that shows which gear shall be chosen at a certain set speed (gear shift points). For better identification each gear has its own coloured section on the set speed line. The gear shift points can be set (chapters 9.1 and 9.4).

Display of the message „Pause“ during pause mode.

Display of a „Flag“ as a symbol that the end of the loaded drive cycle has been reached as well as blinking red letters that tell you that you have come to the end. The text can be set in the profile, e.g. „End of test“.


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7.2 Drive curve pass routes (gradient to test stand computer) gradient = f(s)

The drive curve pass routes gradient = f(s) is based on the software module “universal graphic data display“ of the DA. In this data display the values are displayed over time or over route. In this case the gradient is displayed over the route. The creation of the corresponding data records of route con-trolled cycles is described from chapter Fehler! Verweisquelle konnte nicht gefunden werden. and he integration of the gradient from chapter 10. This drive curve is loaded from the directory C:\ErgoDrive\configurations. The name of the file is incli-nation_over_way.cfg. The following Figure 20 shows the DA-surface:

Figure 20: Drive curve pass routes gradient = f(s)

2. Display of loaded drive cycle

4. Set gradient

6. Overall profile

3. Display of measure-ment values

5. Act. position

1. Status message / display of loaded drive cycle

7. Route scale 8. Gradient scale 9. Act. position


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The surface shown in Figure 20 of the drive curve pass routes gradient = f(s) (gradient over route) has the following functionalities: 1. „Status message“: The status- and fault messages of ErgoDrive Professional are displayed in the

title bar. If there are no messages, the presently loaded cycle file is displayed. 2. „Display of the loaded drive cycle“: The presently loaded drive cycle file is displayed. 3. „Display of measurement values“: This data field shows data from the DA as well as measure-

ment values from the chassis dynamometer or the climatic chamber (optional). 4. „Set gradient in %“: The set gradient is displayed as vertically scrolling gradient profile. The route

scale is on the left side of the screen and the gradient scale is at the bottom of the screen. 5. „Actual position“: The actual position in the overall view of the gradient profile is shown as a red

line. 6. „Overall profile“: The overall profile is shown in a second window. The actual position is marked

with a red line (5.). 7. „Route scale in m“: Designation of the route axis in a vertically scrolling speed profile in meters. 8. „Gradient scale in %“: Designation of the gradient axis in the gradient profile in percent. 9. „Actual position“: The actual position in the gradient profile is marked as a red line.

Display of the message „Pause“ during the pause mode

Display of the message „End of test“ after reaching the end of the loaded drive cycle in red let-ters.


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8 Recorded measurement values

The recording of the measurement values begins with the start of the drive cycle in the DA (activating button „3. Start“) and ends with the termination of the drive cycle (activating button „7. End drive cycle“). If the pause mode is used between these two steps, the recording of the measurement values continues also during this pause. The recorded measurement values are found in the directo-ry: C:\ErgoDrive\Data-Log. The file name is constructed as follows: Cycle name, year (named y), month (named m), day (named d), hour (named h), minute (named m), second (named s). This data refers to the starting point of the drive cycle and not its end. If a cycle was started at 14:40 and ended at 15:41, the time in the file name would be 14h40m. The file name FTP2005y06m08d_14h40m18.372s.log thus means: Cycle: FTP Test start: 8. June 2005, 14:40, 18,372 seconds.

8.1 Program call

The conversion programme for measurement values is started by double clicking the symbol Log2xls“ (2 gearwheels, Figure 22) on the desktop:

Please note, that a version of Microsoft Exel must be installed on your PC. The surface of the conver-sion programme appears (see Figure 23):

Figure 21: Log files in directory C:\ErgoDrive\Data-Log

Figure 22: Symbol of the conversion programme on the desktop


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Figure 23: Programme surface of the conversion programme

8.2 Open a log file

First of all it is necessary to open a log file created by the DA. For this click the button „Open file“ at the top left in the programme window. The dialog „Open file“ appears:

Figure 24: Dialog open file

Select the desired log file. The file name consists of the date and the time (see chapter 8 „Recorded measurement values“). After selecting the desired log file click „open“. The file will be taken over from the conversion pro-gramme, the file name appears in the window on the right next to the button „Open file“.

ErgoDrive\Log


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The measurement values contained in the selected log file are now displayed in the lower area of the window of the conversion programme (see Figure 25). The standard layout is from top to bottom in ascending order according to the number assignment (handle-No. in LabMap) of the individual meas-urement values. In order to sort the measurement values in alphabetical order click the grey field „Name“ at the top. Likewise the measurement values can be sorted according to units, for this purpose click on the field „Unit“.

8.3 Conversion

Figure 25:Conversion programme after loading of a log file

First enter the amount of time between the entries of values in the Excel-table in the upper area of the window to the right of the button „Convert“. For this purpose select the unit for the time next to the entry field („ms“ for milliseconds, „s“ for seconds, „min“ for minutes or „h“ for hours). By ticking „Interpolation“ you determine a linear interpolation of the values when they are stored. If only one value is found in a column, this is extrapolated, i.e. this value is taken over as constant (e.g. a height of 10 m). Tick „Show Excel“, in order to start Excel automatically with the converted profile file. The field „Log file created on“ states the time when the recording of the measurement values began. The field „Log file closed“ states the time when the recording of the measurement values was ended. In order to start conversion click the button „Convert“. An entry mask for the entry of test data ap-pears (see chapter 8.4, Figure 26). The button „Cancel“ terminates the conversion. The conversion programme is ended with the button „Close“.

ErgoDrive\Log


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8.4 Entry of test data

Figure 26 Entry of test data

Write the test data into the fields. If a field is left empty, this will also remain empty in the Excel-table. Afterwards click the button „OK“. The conversion is executed and the Excel-table is filled in: In order to print from Excel please use the Excel-print function and the printer that is connected to your PC.

Figure 27: Excel with an opened log file


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9 Editing the data record for the operating mode v over t

The data record for the operating mode v over t (speed profile over time) consists of the gear change table (optional, chapter 9.1), the tolerance field data (optional, chapter 9.2), the driving cycle data (chapter 9.3) and the gear change points (optional, chapter 9.4) described in the following. The creation of the data record is carried out as ASCII-files. The ASCII-files can be created and edited with any ASCII-editor (e.g. Word, Notepad). The files however can also be created with Microsoft Excel and be saved as text format (text (tabula-tors separated).txt).

9.1 Gear change table for the operating mode speed over time

The following shows an example data record for a gear change table which is optional in the data record. The gear change table can be used if no gear change points are stated in the driving profile. Caution: if gear change points are used in the driving profile, these are valid, the gear change table is not used then. # *** Gear change table *** (optional)

#

let gear.change.01->02 ”20 [km/h]” # From 1st to 2

nd gear at 20 km/h

let gear.change.02->03 ”40 [km/h]” # From 2nd to 3

rd gear at 40 km/h

let gear.change.03->04 ”60 [km/h]” # From 3rd to 4

th gear at 60 km/h

let gear.change.04->05 ”80 [km/h]” # From 4th to 5

th gear at 80 km/h

let gear.change.05->06 ”100 [km/h]” # 5th gear is the last gear

The left part of the gear shift table contains the command. The command in the 1st line „let gear.change.01->02 „20 [km/h]”“ means that the shift from the 1st into the 2nd gear is carried out at 20 km/h.

The right part of the table contains comments. A comment is introduced with # and is thus ig-nored by ErgoDrive Professional.

The last gear is shown in the last line of the gear change table: „let gear.change.05->06 ”100 [km/h]” “ here means that gear 5 is the last gear. If for this command a lower speed value is en-tered (e.g. „let gear.change.05->06 ”75 [km/h]”) as entered for the previous command, the driv-er's aid already shows the previous gear (in this case gear 4) as the last gear.

The gear change table is valid for as long as the respective file is loaded.

If a file is loaded with another gear change table, this data likewise remains valid for as long as the respective file is loaded.

If a file is loaded that contains no gear change table, the loaded gear change table remains valid. The gear change table is always valid until a new gear change table is loaded or a driving profile with gear change points is used. The gear change points from a driving profile also remain valid until a profile with new gear change points or a gear change table in a profile without gear change points is loaded. Figure 28 shows the illustration of the gear change in the driver's aid. For this purpose the following gear change table was loaded into the driver's aid:


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# Example data record driving profile

#

# *** Gear change table *** (optional)

#

let gear.change.01->02 "15 [km/h]" # From 1st to 2

nd gear at 15 km/h

let gear.change.02->03 "25 [km/h]" # From 2nd to 3

rd gear at 25 km/h

let gear.change.03->04 "40 [km/h]" # From 3rd to 4

th gear at 40 km/h

let gear.change.04->05 "55 [km/h]" # From 4th to 5

th gear at 55 km/h

let gear.change.05->06 "60 [km/h]" # 5th gear is the last gear

#

# *** Tolerance field data (optional) ***

#

let error.t ”1 [s]” # tolerance field range: 1s

let error.v ”3.2 [km/h]” # tolerance field range: 3,2 km/h

#

#

# *** driving cycle data ***

#

# Time Speed

# -------------------------

0 [s] 0.0 [km/h]

3 0.0

18 65.0

32 0.0

40 0.0

Figure 28: illustration of the gear change table


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9.2 Tolerance field data for the operating mode v over t

The following shows an example of a data record for tolerance field data that is optional in the data record. Comments in the data record are introduced with a #: # *** Tolerance field data (optional) ***

# Example data record

#

let error.t ”1 [s]” # tolerance field range: 1 s

let error.v ”3.2 [km/h]” # tolerance field range: 3,2 km/h

The left part of the tolerance field data contains the command, the right part of the table contains comments. A comment is introduced with # and is thus ignored by ErgoDrive Professional.

The command in the 1st line “let error.t “1 [s]”“ means that the tolerance field range is 1 second.

The command in the 2nd line “let error.v “3.2 [km/h]”“ means that the tolerance field range is 3,2 km/h.

The tolerance field data remains valid until a file with other tolerance field data is loaded. This data again remains valid as long as the respective file remains loaded.

If a file is loaded that contains no tolerance field data, the tolerance field data which was loaded last remains valid.

The tolerance field range must be chosen according to the requirements of the test run and the legal requirements for exhaust emission testing. Leaving the tolerance range is a driving violation, the number of driving violations and the overall duration in which the test driver was outside of the tol-erance range are shown in the driver's aid. The data record shown above for the tolerance field data represents the tolerance field range shown in Figure 29:


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Figure 29: tolerance field range t = 1,0 s, v = 3,2 s

The following tolerance field data represents the tolerance field range shown in Figure 30: let error.t ”0.5 [s]” # tolerance field range: 0,5 s let error.v ”1.2 [km/h]” # tolerance field range: 1,2 km/h

Figure 30: tolerance field range t = 0,5 s, v = 1,2 s

The driving cycle data (see chapter 9.3) is arranged underneath the tolerance field data.


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9.3 Driving cycle data for the operating mode v over t

The following shows an example of a data record for the operating mode v over t (speed profile over time). # *** Driving cycle data ***


#

# Time Speed Gear

# ------------------------------------------------------

0 [s] 0.0 [km/h] 0 :Gear

3 0.0 1 :Gear

7 10.0 2 :Gear

12 40.0 3 :Gear

20 70.0 0 :Gear

30 40.0 2 :Gear

40 10.0 0 :Gear

50 0.0

60 0.0

The first five lines are comments (comments are introduced with #) and are thus ignored by ErgoDrive Professional.

In the first column there is the reference value (time), through which the curve is shown. Through the unit [s] (seconds) it is stipulated clearly in this data record that all data is shown over time and that the entries in this column represent the time.

The second column has the unit of speed in [km/h], which stipulates that this column contains data on the set speed.

The third column contains the change points described in detail in chapter 9.4. In the above example data record the set speed at 3 s = 0 km/h, at 7 s = 10 km/h and at 12 s = 40 km/h. The driver's aid begins to let the set speed rise at 3 s from 0 km/h during the execution of the profile until it reaches 10 km/h at 7 s and at 12 s the value of 40 km/h. The set acceleration is higher in the range between 7 and 12 seconds, in this example the test driver must accelerate a little bit more in order to keep the set speed. Afterwards the set value is reduced to 10 km/h within 20 s and then falls to 0 km/h in the range between 40 s and 50 s. The entry at 30 s solely serves the illustration of the change point (see chapter 9.4) and can be ignored in an illustration without change points. The entry 60 s is the last entry in the data record, at the end of the 60 s the chequered flag appears on the driver's aid surface which shows the test driver the end of the driving profile and thus also the end of the test drive. The example data record shown above represents the illustration shown in Figure 31 in the driver's aid:


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Figure 31: Illustration of the example data record

The following page shows another example data record:


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Illustration of another example data record for the operating mode v over t (speed profile over time). Compared with the previous example different set speeds have been chosen for the same times.

# *** Driving cycle data ***


#

# time speed gear

# ------------------------------------------------------

0 [s] 0.0 [km/h] 0 :Gear

3 0.0 0 :Gear

7 0.0 1 :Gear

12 10.0 2 :Gear

20 40.0 0 :Gear

30 30.0 2 :Gear

40 10.0 0 :Gear

50 0.0

60 0.0

The example data record shown above represents the illustration in Figure 32 in the driver's aid:

Figure 32: illustration of a second example data record


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9.4 Gear change point entries in the data record

Gear change points in the data record are entered in a third column. Every gear change point starts with the gear number, then comes a blank and then the description :Gear. In neutral gear there is the entry 0 :Gear, in order to switch into reverse gear (not allowed on every chassis dynamometer!) R :Gear shall be entered. The following example data record represents the gear change points:



#

# time speed gear

# ------------------------------------------------------

0 [s] 0.0 [km/h] 0 :Gear

3 0.0 1 :Gear

7 10.0 2 :Gear

12 40.0 3 :Gear

20 70.0 0 :Gear

30 40.0 2 :Gear

40 10.0 0 :Gear

50 0.0

60 0.0

After 3 s the test driver is asked to shift into 1st gear, after 7 s he should switch into 2nd gear and after 12 s he should switch into 3rd gear. After 20 s the test driver should declutch and operate the vehicle in neutral gear, he should engage the clutch in 2nd gear after 30 s in order to brake for 10 s with the motor while he declutches again at 40 s. The following Figure 33 shows the illustration of the above data record in the driver's aid:

Figure 33: gear change in the data record


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Another example data record for the illustration of the gear change points



#

# time speed gear

# ------------------------------------------------------

0 [s] 0.0 [km/h] 0 :Gear

1 0.0 1 :Gear

3 10.0 2 :Gear

7 30.0 3 :Gear

12 40.0 2 :Gear

17 10.0 0 :Gear

20 0.0 1 :Gear

25 20.0 2 :Gear

35 20.0 0 :Gear

40 0.0

45 0.0

After 1 s the test driver is asked to shift into 1st gear, after 3 s he shall shift into 2nd gear and after 7 s into the 3rd gear. After 12 s the test driver shall shift into 2nd gear in order to brake for 5 s with the motor, and afterwards he shall declutch. After 20 s the test driver shall shift into the 1st gear in order to accelerate the vehicle to 20 km/h within 5 s and afterwards the driver shall drive consistently for 10 s in 2nd gear. The following Figure 34 shows the illustration of the above data record in the driver's aid:

Figure 34: another example with gear change points


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Further example data record for the illustration of the gear change points with reverse gear: CAUTION! Use this function only when reverse driving is allowed on your chassis dynamometer!



#

# time speed gear

# ------------------------------------------------------

0 [s] 0.0 [km/h] 0 :Gear

1 0.0 1 :Gear

3 10.0 2 :Gear

7 30.0 3 :Gear

12 40.0 2 :Gear

17 10.0 0 :Gear

20 0.0 0 :Gear

23 0.0 R :Gear

25 -5.0 1 :Gear

28 0.0 0 :Gear

30 0.0

After 1 s the test driver is asked to shift into 1st gear, after 3 s he shall shift into 2nd gear and after 7 s into 3rd gear. After 12 s he shall shift into 2nd gear in order to brake for 5 s with the motor, afterwards he shall declutch. After 23 s the test driver shall shift into reverse gear (CAUTION! Use this function only when reverse driving is allowed on your chassis dynamometer!) in order to reverse for 2 s, af-terwards the test driver will accelerate with 1st gear until the set speed 0 km/h has been reached. The following Figure 35 shows the illustration of the above data record in the driver's aid:

Figure 35: illustration of the gear change points with reverse gear


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9.5 Setting of digital outlets (optional)

As an option the driver's aid can be equipped with up to 8 digital outlets which can be used for differ-ent applications e.g. start and stop of some processes in your test environment. The setting respec-tively resetting of these outlets is carried out in another column of the data record with the help of an 8-Bit-ASCII-value. This column must be separated from the previous data with a „;“. The digital outlets are arranged as follows: 8 7 6 5 4 3 2 1, i.e. if the outlet 1 shall be set the whole right bit shall be set. The respective set outlet is set with "x“, it is reset with "o“.



#

# time speed gear LED information

# ------------------------------------------------------------------

0 [s] 0.0 [km/h] 0 :Gear ; ooooooox # outlet 1 set

3 0.0 0 :Gear ; ooooooxo # outlet 2 set

7 0.0 1 :Gear ; oooxoooo # outlet 5 set

12 10.0 2 :Gear ; oxoooooo # outlet 7 set

20 40.0 0 :Gear ; ooooxoox # outlet 1+4 set

9.6 Bag sampling control (optional)

As an option the driver's aid can be used for a control bag sampling for exhaust emission analysis with up to 8 bags. The setting respectively resetting of these outlets is carried out in another column of the data record with the help of an 8-Bit-ASCII-value. This column must be separated from the previ-ous data with a „;“. The bags are arranged as follows: 8 7 6 5 4 3 2 1, i.e. if the bag 1 shall be start the whole right bit shall be set. The respective set bag is set with "x“, it is reset with "o“.



#

# time speed gear LED information

# ------------------------------------------------------------------

0 [s] 0.0 [km/h] 0 :Gear ; ooooooox # bag 1 set

3 0.0 0 :Gear ; ooooooxo # bag 2 set (1 reset)

7 0.0 1 :Gear ; oooxoooo # bag 5 set (2 reset)

12 10.0 2 :Gear ; oxoooooo # bag 7 set (5 reset)

20 40.0 2 :Gear ; ooooxoox # bag 1+4 set (7 reset)

25 40.0 2 :Gear ; ooooxoxx # bag 1+2+4 set

35 40.0 2 :Gear ; ooooxoox # bag 1+4 set (2 reset)

45 40.0 2 :Gear ; ooooxooo # bag 1 set (1 reset)

65 0.0 0 :Gear ; oooooooo # all bags reset

So if you will use a bag for a longer time, you have to set the bit with a “x” in all lines you will use the bag sampling command.


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9.7 Supplied data records for driving cycles in operating mode v over t

The driver’s aid (DA) for illustration of speed over time contains the following data records for driving cycles:

EPA IM240 Inspection & Maintenance Driving Schedule

EPA FTP Federal Test Procedure

EPA UDDS Urban Dynamometer Driving Schedule

EPA HDUDDS Urban Dynamometer Driving Schedule for Heavy Duty Vehicles

EPA HWFET Highway Fuel Economy Test

EPA NYCC New York City Cycle

EPA SC03 Supplemental FTP Driving Schedule

EPA US06 Supplemental FTP Driving Schedule

UN/ECE Elementary Urban and UN/ECE Extra Urban Cycle (Part One and Two of the Type 1 Test)

UN/ECE Elementary Urban Cycle

UN/ECE Reg 83 Extra-Urban Driving Cycle for Low-Powered Vehicles

UN/ECE Reg 83 Extra-Urban Driving Cycle

ECE15.05 COLD

UN-ECE-WLTP Worldwide harmonized Light vehicles Test Procedure Class 1 vehicles



JC08 Japanese Dynamometer Driving Schedule (Jpn. CD 34 (8 mode) Driving Schedule)

Japanese 10-15 Exhaust Emission & Fuel Economy Driving Schedule

Japanese 10 Dynamometer Driving Schedule

Japanese 15 Dynamometer Driving Schedule

Worldwide Motorcycle transient Cycle

Indian Motor cycle

Chinese Performance Test

Standard Road Cycle The data records are stored on the computer DA (operator-room) in the directory “Profiles“. Further profiles can be purchased and integrated in the driver’s aid without any difficulties. For this purpose please contact your supplier.


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10 Data record for further values such as e.g. gradient

The following shows the handling of other values in the data record such as e.g. gradient, tempera-ture, humidity etc. The basis for the application of this data is always a time controlled (creation see chapter 9) or route controlled (creation see chapter Fehler! Verweisquelle konnte nicht gefunden erden.) data record. The construction of the data record consists of ASCII-files. The ASCII-files can be created and edited with every ASCII-editor (e.g. Word, Notepad). The files can also be created with Microsoft Excel and stored in text format (Text (Tabs separated) .txt).

10.1 Possible variables in the data record

The driver´s aid ErgoDrive Professional offers the possibility to show additional variables (set values) from the data records or to hand these over to the existing hardware. It is however only possible to use set values that have also been defined in the software structure of the driver´s aid (Software bus LabMap). The following variables (all set values) can be depicted:

Roller traction: Frolle

Wind temperature: Twind

Humidity: Fwind

Height (to PAS): Hoehe

Insolation intensity: Bestr.Staerke

Insolation: Bestr.Front

Position of the sun: Bestr.Winkel

Gradient: Steigung

Wind speed: Vwind Furthermore there are additional variables that are necessary for the control of the DA or for the dis-play of information:

Cycle number time controlled: CircleNoTime

Cycle number route controlled: CircleNoWay

Name of loaded data record time controlled: ProfileNameTime

Name of loaded data record route controlled: ProfileNameWay

End of data record (blinking message in DA): ProfileEnd

Type of display time controlled: ConfigNameTime

Type of display route controlled: ConfigNameWay

Digital outputs 1 to 4: DigOut


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10.2 Declaration of the values

At the beginning of each data record it is necessary to declare the variables used in the data record. For the sake of easy handling we recommend generally to declare all variables, i.e. to copy the decla-ration block from an existing data record into a new data record. Depending on whether it is a time- or route controlled data record, the variables must be declared accordingly. Declaration is carried out as follows: # *** Drive cycle data ***

# Example data record drive profile time controlled

# ------------------------------------------------------

delete;

declare Twind: stepped (t) [°C];

The first three lines are comments (comments are introduced with an #) and are thus ignored by ErgoDrive Professional.

In the fourth line there is the command „delete;“, this deletes previously stored variables from other data records which have previously been loaded in ErgoDrive Professional. This delete command should always be used at the beginning of a data record.

The following line declares the variable Twind (wind temperature). This is done through the command „declare“, as well as the name of the variable „Twind“, separated by a blank. The type of display of the variable in the DA (see chapter 10.3) as well as the assignment to time con-trolled „(t)“, see chapter 10.4 or route controlled data records „(s)“, see chapter 10.5 is deter-mined after the colon, each separated by blanks. Furthermore the unit of the variables must be determined. This is done with square brackets. The declaration command is ended with a semi-colon.


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10.3 Determine display of the course in the DA

There are two options for the display of the course of the variables in the DA that are explained with the following example of a set temperature course over time: At time 0 seconds the set temperature is 25 °C, at time 3 seconds the set temperature is still 25 °C, at switch point 7 seconds the set temperature is 38 °C. For the first option the course of the set temperature is shown continuously rising or falling between two definition points. For the example this means that there is a linear increase of the set tempera-ture from time 3 seconds and 25 °C to time 7 seconds and 38 °C. For this purpose select the type of display „continuous“ when declaring the set temperature. The corresponding data record would look like this : # *** Drive cycle data ***


# ------------------------------------------------------

delete;

declare Twind: continuous (t) [°C];

#

# time speed temperature

# ------------------------------------------------------

0 [s] 0.0 [km/h] 25:Twind

3 0.0 25

7 10.0 38

10 10.0 38

The basis is the time controlled data record (see chapter 9). The set temperature is defined as the third column of the data record by putting a colon after the uppermost value and by stating the name of the variable (without blanks respectively). Thus all values contained in this column will be assigned to the stated variable name. The unit has already been assigned at the beginning of the data record by declaring the variable in the square brackets. In the data record the beginning and the end of the course have to be defined for this type of display. When displaying a straight line (e.g. continuous course over a certain time) thus the starting time and the ending time must be stated in the data record. The set value must be the same. In the example data record the starting time of the constant 25 °C-course is 0 seconds and the ending time 3 sec-onds, the starting time of the constant 38 °C-course is 7 seconds and the ending time 10 seconds. The set temperature is depicted as a linear increase in the section between 3 seconds (starting point) and 7 seconds (ending point). The following Figure 36 shows the above mentioned example of a data record:


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Figure 36: Continuous set temperature course

In the second option the course of the set temperature is shown as jump. For the example this means that the set temperature from time 0 seconds on is constantly 25 °C and jumps from 25 °C to 38 °C at time 7 seconds. When declaring the set temperature select the type of display „stepped“ for this purpose. The corresponding data record would be as follows: # *** Drive cycle data ***


# ------------------------------------------------------

delete;


#

# time speed temperature

# ------------------------------------------------------

0 [s] 0.0 [km/h] 25:Twind

3 0.0 25

7 10.0 38

10 10.0 38

It is necessary to determine the definition points in this data record where a jump of value is to occur. The value will then remain constant at the set value until a new definition point is reached. In the above data record the definition points 3 seconds and 10 seconds are obsolete because their display does not cause a change of the values. The following Figure 37 shows the example:


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Figure 37: Stepped set temperature course


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10.4 Time controlled data record

The time controlled data record is always the basis for time controlled variables. The creation of the time controlled data record is found in chapter 9. The time controlled data record always states the time in the first column. Please be aware that time controlled data records must always contain a speed column with at least one positive value (e.g. 0.1 km/h). At the beginning of every data record it is necessary to declare the variables used. For the sake of easy handling we recommend generally to declare all variables, i.e. to copy the declaration block from an existing data record into a new data record. The following shows the example of a data record with the declaration of all existing time controlled variables: #Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC

# Header information

#---------------------------------------------------------------

delete;

declare Frolle: continuous (t) [N];


declare Fwind: continuous (t) [%];

declare Hoehe: continuous (t) [m];

declare Bestr.Staerke: stepped (t) [W/m²];

declare Bestr.Front: stepped (t) [W/m²];

declare Bestr.Winkel: stepped (t) [°];

declare DigOut: integer (t);

declare CirclenoTime: String (t);

declare CirclenoWay: String (s);

declare ProfileNameTime: String (t);

declare ProfileNameWay: String (s);

declare Steigung: stepped (s) [%];

declare ProfileEnd: String (t);

declare ConfigNameTime: String (t);

declare ConfigNameWay: String (s);

declare Vwind: stepped (t) [km/h];

let error.t 2.0[s]

#Time Speed Gear Comment

#---------------------------------------------------------------

# Section a

#-----------------------------------------------------------

0[s] 00.0[km/h] 0:gear " ":ProfileEnd "1":CircleNoTime

"Zeitgest.":ProfileNameTime

40 00.0 0

# Sektion b

#-----------------------------------------------------------

46[s] 00.0[km/h] 0 "1a": CircleNoTime

51 00.0 1

55 15.0 1

60 0.0 0 "End!!!":ProfileEnd


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The following Figure 38 shows the aforementioned data record example at the actual position of 35 seconds

Figure 38: Time controlled data record example


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10.5 Route controlled data record

The route controlled data record is always the basis for route controlled variables. The creation of this data record is described in chapter Fehler! Verweisquelle konnte nicht gefunden werden.. The oute controlled data record always has a route in the first column. Please be aware of the fact that also route controlled data records must contain a speed column with at least one positive value (e.g. 0.1 km/h), in order to avoid the appearance of the flag at programme start. At the beginning of each data record it is necessary to declare the variables used. For the sake of easy handling we recommend generally to declare all variables, i.e. to copy the declaration block from an existing data record into a new data record. The following shows the example of a data record with the declaration of all existing route controlled variables: #Converted Profile: L:\flgconvert\Originale_CYC\GG_64.CYC


#---------------------------------------------------------------

# height taken from file

delete;

declare Frolle: continuous (s) [N];

declare Twind: stepped (s) [°C];

declare Fwind: continuous (s) [%];

declare Hoehe: continuous (s) [m];

declare Bestr.Staerke: stepped (s) [W/m²];

declare Bestr.Front: stepped (s) [W/m²];

declare Bestr.Winkel: stepped (s) [°];

declare DigOut: integer (s);

declare CircleNoTime: String (t);

declare CircleNoWay: String (s);




declare ProfileEnd: String (s);



declare Vwind: stepped (s) [km/h];

#Way Height Comment

#---------------------------------------------------------------

# Section a

#-----------------------------------------------------------

0[m] 0[km/h] 0[m] 0:Steigung " ":ProfileEnd

"Großglockner GG_64":ProfileNameWay

60 0 0.2 7.1

130 0 0.7 7.2

200 0 1.2 7.2

280 0 1 7.2

360 0 1.6 7.2

525 0.1 2.8 7.1

530 0 2.8 7.1 "End!!!":ProfileEnd


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Figure 39 shows the route controlled data record example:

Figure 39: Route controlled data record example


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10.6 Use of variables in the data records

The first column of a data record is always for the time in time controlled data records and for the route in route controlled data records. There must always be a speed column with at least one posi-tive value (e.g. 0.1 km/h). The following columns can then be used for the variables. The assignment of a column to a variable is achieved by writing a colon in the first line of the data record after the first value and by stating the name of the variable (each without blanks). Thus all values contained in this column are assigned to the stated variable name. A unit has already been assigned at the beginning of the data record by declaring the variable with a square bracket. The fol-lowing is an example of a data record: # *** Drive cycle data ***

# Example data record climate values, drive profile time controlled

# ------------------------------------------------------

delete;


















#

0[s] 0[mph] 0:Hoehe 23:TWind 40:FWind 0:VWind "1":CircleNoTime

"Temp/Zeit":ProfileNameTime

10 0 1 23 40 0

20 0.1 2 30 50 30 "1":CircleNoTime

30 0 18 30 70 30

40 0 25 60 40 100 "2":CircleNoTime

50 0 39 60 60 100

60 0 50 35 100 220

70 0 59 35 80 220

85 0 75 10 80 220

95 0 105 10 50 110

105 0 115 -25 10 110

115 0 150 -25 0 110

145 0 179 -40 10 50

165 0 198 0 30 50

275 0 200 23 30 0

285 0 205 23 30 0 "End":CircleNoTime


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In this example the time is stated in the first column, the speed is in the second column and the height is in the third column, the set temperature value is in the fourth column, the humidity set val-ue is in the fifth column and the set wind speed is in the sixth column. The set temperature would from the beginning be a constant 23 °C, at time 20 seconds it would jump to 30 °C and at time 40 seconds it would jump to 60 °C, as „stepped“ was chosen during declaration (see chapter 10.3). The set humidity value starts at 40 % and rises continuously between the times 10 and 20 seconds to 50 %. Between the times 20 and 30 seconds there is continuous increase from 50 % to 70 %. Between 30 and 40 seconds the humidity is reduced continuously from 70 % to 40 %, as „continuous“ was se-lected during declaration (see chapter 10.3). For the set wind speed again „stepped“ was selected and this means that the set wind speed jumps to the stated value at the stated time, at 40 seconds this would be from 30 km/h to 100 km/h. The following Figure 40 shows the course of the set temperature over time based on the above men-tioned data record at the actual position 20 seconds:

Figure 40: Course of set temperature of the example data record


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10.7 Table of the variables used

The following Table 1 states the variables in which values can be assigned in the DA ErgoDrive Profes-sional:

Variable (set value) Name in data

record

Unit Time controlled

Route controlled

Roller traction Frolle N yes yes

Wind temperature Twind °C yes yes

Humidity Fwind % yes yes

Height (to PAS) Hoehe m yes yes

Sunlight intensity Bestr.Staerke W/m² yes yes

Insolation Bestr.Front W/m² yes yes

Position of sun Bestr.Winkel ° yes yes

Gradient Steigung % yes yes

Wind speed Vwind km/h yes yes

Table 1: Value variables of the DA ErgoDrive Professional

The following Table 2 states the variables that either serve the control or display of information in the DA ErgoDrive Professional:

Variable Name in data

record

Task Time controlled

Route controlled

Cycle number time con-trolled

CircleNoTime Info yes no

Cycle number route con-trolled

CircleNoWay Info no yes

Name of loaded data rec-ord time controlled

ProfileNameTime Info yes no

Name of loaded data rec-ord route controlled

ProfileNameWay Info no yes

End of data record (blink-ing message in DA)

ProfileEnd Info yes yes

Type of display time con-trolled

ConfigNameTime Control yes no

Type of display route con-trolled

ConfigNameWay Control no yes

Digital outputs 1 - 4 DigOut Control yes yes

Table 2: Control variables of the DA ErgoDrive Professional

The specification and the use of these variables are described in the following chapters 11 and 12.


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11 Display of information from data records

The display of information from the data records is carried out via the information variables as shown in Table 2

Cycle number time controlled: CircleNoTime

Cycle number route controlled: CircleNoWay

Name of the loaded data record time controlled: ProfileNameTime

Name of the loaded data record route controlled: ProfileNameWay

End of data record (blinking message in DA): ProfileEnd

11.1 Display of cycle number and position number

The current cycle number for time controlled data records and the current position number for route controlled data records are shown from the profile in the display field for measurement values of the DA ErgoDrive Professional with the variables „CircleNoTime“ and „CircleNoWay“. For this purpose the corresponding value in the data record is written between inverted commas at the end of the respec-tive definition point and is separated from the last column by at least one blank or through a tabula-tor. A colon and the term „CircleNoTime“ or „CircleNoWay“ are added without a further blank. The value is displayed until it is overwritten with a new value. The value can only be of a certain length, as only a certain amount of characters can fit into the display field. If the value is too long it is cut off at the beginning and the end. The following shows as an example an extract from the time controlled ECE-cycle: #Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC


#---------------------------------------------------------------

delete;


















let error.t 2.0[s]


#---------------------------------------------------------------


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# Sektion a

#-----------------------------------------------------------

0[s] 00.0[km/h] 0:gear " ":ProfileEnd "1":CircleNoTime

40 00.0 0

# Sektion b

#-----------------------------------------------------------

46[s] 00.0[km/h] 0 "1a":CircleNoTime

51 00.0 1

68 00.0 0

# Sektion c

#-----------------------------------------------------------

84[s] 00.0[km/h] 0 "1b":CircleNoTime

89 00.0 1

136 00.0 0

# Sektion d1

#-----------------------------------------------------------

152[s] 00.0[km/h] 1 "1c":CircleNoTime

157 00.0 1

228 00.0 0

235 00.0 0 "Ende 1. Zyklus":CircleNoTime

# Sektion b

#-----------------------------------------------------------

#235 00.0 0


246 00.0 1

From the time 0 seconds the cycle number 1 is displayed. At time 46 seconds the display changes to 1a, at time 84 seconds to 1b, at time 152 seconds to 1c and at time 235 seconds to „End 1. cycle“. At time 241 seconds 2a is displayed. The following Figure 41 shows the DA-surface at time 165 seconds, the cycle display is at 1c:

Figure 41: ECE-cycle at time 165 seconds


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11.2 Display of the profile name

The profile name is shown as the first value in the display field of the measurement values of the DA ErgoDrive Professional from the profile with the help of the variables „ProfileNameTime“ or „Pro-fileNameTime“. For this purpose the value in the data record is written between inverted commas in the first line separated by at least one blank or a tabulator from the last column or from an already existing variable. A colon and the term „ProfileNameTime“ or „ProfileNameTime“ are added without further blank. The value is displayed until it is overwritten with a new value. The value can only be of a certain length, as only a certain amount of characters can fit into the display field. If the value is too long it is cut off at the beginning and the end. The following shows as an example an extract from the ECE-cycle: #Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC


#---------------------------------------------------------------

delete;


















let error.t 2.0[s]


#---------------------------------------------------------------

# Sektion a

#-----------------------------------------------------------

0[s] 00.0[km/h] 0:gear " ":ProfileEnd "ECE":ProfileNameTime

40 00.0 0

# Sektion b

#-----------------------------------------------------------


51 00.0 1

68 00.0 0


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From the time 0 seconds the profile name „ECE“ is displayed. As this variable only appears once in the data record, the display remains. If at a later time there is a new entry with the variable „Profile-Name“,„ECE“ would at this point be overwritten with the new value. The following Figure 42 shows the DA surface with the display of the profile name at time 45 seconds:

Figure 42: ECE-cycle at time 45 seconds


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11.3 Display of the message profile end

Next to the flag which appears at the end of the profile there is also a text message in blinking red letters on the screen. The displayed text is stored in the data record with the variable „ProfileEnd“ and is displayed from the profile. For this purpose the corresponding value is also written in inverted commas in the data record and is separated by at least one blank or a tabulator from the last column or from an already existing variable. Without further blank a colon and the term „ProfileEnd“ are added. For this it is necessary to state the variable „ProfilEnd“ as blank value in the first line of the data record as otherwise the message appears immediately. Instead of a text write a blank between the two inverted commas. Do not use the command without blanks between the inverted commas as otherwise this will result in errors or a systems crash when loading the data record. In the last line of the data record the desired text is then stored. The following shows as an example an extract from the ECE-cycle: #Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC


#---------------------------------------------------------------

delete;


















let error.t 2.0[s]


#---------------------------------------------------------------

# Section a

#-----------------------------------------------------------


40 00.0 0

# Section b

#-----------------------------------------------------------


51 00.0 1

68 00.0 0 "End of test!!!":ProfileEnd


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From the time 0 seconds the variable „ProfileEnd“ is set back with the blank between the inverted commas so that the message „test end reached“ does not already appear at the beginning of the test. In the last line the variable is then supplied with the corresponding message, e.g. test end which then appears in the DA programme. This is the same for the mountain profile.


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12 Use of the variables with control function

The DA ErgoDrive Professional offers the option to load the operation modes (surfaces of the drive curves) directly from the data record. Therefore it is possible first to drive a time controlled cycle (e.g. speed over time) and to switch to another mode e.g. mountain cycle with depiction of the gradient over route after a certain amount of time. The following variables serve this purpose:

Display time controlled: ConfigNameTime

Display route controlled: ConfigNameWay Another variable helps to control four digital outputs.

Digital output 1 to 4: DigOut

12.1 Switching to display (v- and mountain cycle running automatically)

In this application there is an automatic switch from the data record between the time and route controlled cycle. Switching is carried out at the corresponding time- or route point with the DA com-mand xTime, where the value 1 presents time controlled and the value 0 route controlled. It is abso-lutely necessary to continue the cycle with the already driven time respectively with the already driv-en route after switching (set value). Otherwise the display can have errors and there is the risk of a systems crash. 0:xTime: Switching from the time controlled into the route controlled mode. The route controlled

profile must be continued with the driven route calculated from the set speed value of the previous time controlled mode.

1:xTime: Switching from the route controlled into the time controlled mode. The time controlled

profile must be continued with the time already driven in the route controlled mode. Furthermore loading of the surface is also done automatically from the data record. This is done with the commands „ConfigNameTime“ for time controlled cycles and „ConfigNameWay“ for route con-trolled cycles. Besides the file name of the surface to be loaded the complete path name of the store address of the surface file is necessary. The variable „ProfileEnd“ should only be used in the last part of the data record (in the following ex-ample this would be the route controlled part). The following data record shows an example of the switch:


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#Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC


#---------------------------------------------------------------

delete;

declare Frolle: continuous (s) [N];

declare Twind: stepped (s) [°C];

declare Fwind: continuous (s) [%];

declare Hoehe: continuous (s) [m];

declare Bestr.Staerke: stepped (s) [W/m²];

declare Bestr.Front: stepped (s) [W/m²];

declare Bestr.Winkel: stepped (s) [°];

declare DigOut: integer (s);








declare ProfileEnd: String (s);

declare Vwind: stepped (s) [km/h];

let error.t 2.0[s]


#---------------------------------------------------------------

0[s] 00.0[km/h] 0:gear "C:\Programme\ErgoDrive\configurations\

speed_70.cfg":ConfigNameTime "1a":CircleNoTime

"v und Berg":ProfileNameTime

#-----------------------------------------------------------

6[s] 00.0[km/h] 0 "A":CircleNoTime

8 00.0 1 "C:\Programme\ErgoDrive\configurations\

speed_floating.cfg":ConfigNameTime

10 15.0 1

13 15.0 1

15 10.0 0

18 00.0 0 "C:\Programme\ErgoDrive\configurations\

speed_110.cfg":ConfigNameTime

#-----------------------------------------------------------

19[s] 00.0[km/h] 0 "1c": CircleNoTime

20 00.0 1

22 15.0 2

31 32.0 2

39 10.0 0

40 0.0 0

42 00.0 0 0:xTime "C:\Programme\ErgoDrive\

configurations\2d_altitude.cfg":ConfigNameWay

# Sektion a

#-----------------------------------------------------------

138.75[m] 0[m] 0:Steigung "a": CircleNoWay

"Townes-Pass PP1":ProfileNameWay " ":ProfileEnd

179 0 0

180 1 2.3

200 3 2.3

240 5 0.6

360 0 0 "Test end":ProfileEnd


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In the first line of the data record the time controlled surface speed_70.cfg is displayed with the command „ConfigNameTime“. By loading the above described cycle file the surface vt_value is auto-matically displayed in the DA (see Figure 43). In the following example the DA was fed a constant ac-tual speed of 20 km/h.

Figure 43: Surface vt_neu after loading the example data record

At time 8 seconds there is a switch to the time controlled surface speed_floating.cfg with the help of the command „ConfigNameTime“ (see Figure 44):

Figure 44: Surface v_t_value at time 13 seconds


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At time 18 seconds there is another switch to the time controlled surface speed_110.cfg (see Figure 45):

At time 42 seconds there is a change to the route controlled mode as well as loading of the route controlled surface 2d_altiude.cfg (see Figure 46). The route controlled profile begins with the already driven route of 138,75 m from the time profile calculated from the set speed value:

Figure 45: Surface vt_neu at time 29 seconds

Figure 46: Surface 2D_altitude at time 26 seconds


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12.2 Setting of digital outputs (switching 4 channels)

4 digital outputs have been planned for the control of additional devices (switching four channels). Each of the 4 digital outputs has in set mode an output voltage of 24V DC and in turned off mode an output voltage of 0V DC. The output current is 0,5 A. The digital outputs are operated via fieldbus coupler in binary format. Switching the digital outputs on and off is executed with the variable „DigOut“ in the data record. The variable has the Integer-format, i.e. operation of the output is carried out as decimal number. The output one is always assigned the value „1“, the output two the value „2“, the output three the value „4“ and the output four the value „8“. In order to set several outputs simultaneously, these values must be added accordingly (see Table 3). Setting back all outputs simultaneously is done with the value „0“. The corresponding value is written without inverted commas in the data record separated with at least one blank or a tabulator from the last column or from an already existing variable respectively. A colon and the term „DigOut“ are added without another blank. The variable must be used for each selected change in status of one or several outputs. The following Table 3 presents the values for the operation of the digital outputs:

Value:

DigOut

Output to be set

0 No output / set back all outputs

1 only 1

2 only 2

4 only 3

8 only 4

3 1 and 2

5 1 and 3

9 1 and 4

6 2 and 3

10 2 and 4

12 3 and 4

7 1, 2 and 3

11 1, 2 and 4

13 1, 3 and 4

14 2, 3 and 4

15 1, 2, 3 and 4

Table 3: Value assignment for setting of digital outputs

The following example is an extract from the ECE-cycle:


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#Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC


#---------------------------------------------------------------

delete;


















let error.t 2.0[s]


#---------------------------------------------------------------

# Sektion a

#-----------------------------------------------------------


40 00.0 0 4:DigOut # Output 3 on

# Sektion b

#-----------------------------------------------------------


51 00.0 1 0:DigOut # Output 3 off

68 00.0 0

# Sektion c

#-----------------------------------------------------------

#68 00.0 0

84[s] 00.0[km/h] 0 "1b":CircleNoTime

89 00.0 1 4:DigOut # Output 3 off

94 15.0 2 5:DigOut # Output 1 and 3 on

96 15.0 2

101 32.0 2 1:DigOut # Output 1 on, 3 off

125 32.0 2

133 10.0 0 3:DigOut # Output 1 and 2 on

136 00.0 0

# Sektion d1

#-----------------------------------------------------------

#136 00.0 0

152[s] 00.0[km/h] 1 "1c":CircleNoTime

157 00.0 1

162 15.0 2 15:DigOut # All outputs on

164 15.0 2

173 35.0 3 0:DigOut # All outputs off

175 35.0 3

177 35.0 0 "End!!!":ProfileEnd

At time 40 seconds the output three is switched on. This is to be switched off at time 51 seconds. As no other output is to be switched on at this point in time, the value „0“ is used for switching off. At time 89 seconds output three is switched on again. At time 94 seconds additionally to output 3 output one is switched on. At time 101 seconds output one remains switched on, output three is switched off. At time 133 seconds additionally to output one output two is switched on, at time 162 seconds the outputs three and four follow. At time 173 all outputs are switched off.


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Contact

cbb software GmbH Isaac-Newton-Straße 8 · 23562 Lübeck · Germany Phone: +49 451 / 39 771-0 · Fax: +49 451 / 39 771-29 [email protected] www.cbb.de

driver´s aid ergodrive - cbb · 2019. 4. 16. · manual ergodrive professional short april 2019...

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