Elektronischer Motor-Regler (EMR)

Electronic Engine Controller

VM-O, 01.2003
 Elektronischer Motor-Regler (EMR)
Electronic governor

EMR is...
a family of electronic diesel engine speed and torque controllers
designed for several engine famlilies
(1012, 2012, 1013, 2013, 1015, 616, 620)
basically tailored to construction, agriculture and
material handling machinery
usable also for gensets, compressors, railroad, . . .
highly cost effective
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F01.01 VV-MV 07/98

easy to configure concerning engine rating and combination of functions

reconfigurable after engine delivery
 EMR - System Design Concept
The Targets
Only one system design for all engine families and all
applications (except automotive)
One type of programming and functional configuration
One type of diagnostic functions
One tool for programming, configuration, diagnostics for service, OEM, enduser
One type of connector for the customer

Integrated solution
Integration of the system in the existing engines without major changes
Using the existing injection system by only replacing the mechanical governor

Competitive price
Price lower than the presently used „add-on“-solutions
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 EMR
The Family

Control unit

Actuators

1012, 1013, 2013 1015 616, 620

Sensors
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engine speed redund. engine speed coolant temp. charge air pressure oil pressure
(optional) (optional)
 EMR
System Overview
Temperature

Shutdown
solenoid
(optional) warning lamp

Charge air engine speed (optional)

pressure
torque (optional)
Actuator with
position
sensor key switch

function switch (optional)

Speed
accelerator pedal
Second speed
(optional) hand accelerator (optional)
Oil pressure
(optional) CAN SAE J1939

diagnosis ISO 9141

central connector battery

(engine mounted)
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Engine wiring harness Vehicle wiring harness

 EMR
Basic Functions
Speed control
Governor with all speed, min-max or constant speed characteristic
Characteristic switchable by customer and/or reprogrammable
Droop programmable from 0 to 50%, switchable by customer

Torque control
Torque limitation according to max. torque, smoke, engine temperature
Two programmable max. torque curves, switchable by customer

Engine protection
Warning or power reduction or engine shut down due to overheating
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Warning or engine shut down due to low oil pressure (speed dependent)
 EMR
Speed Governor Characteristic
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 EMR
Torque Curves, Speed Droop
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 EMR
Speed Droop

Torque (Nm)
800

700

500

300
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500 1000 1500 2000 Speed (rpm)

 EMR
Engine Protection

Engine Temperature
whenever coolant temperature exceeds
prefixed limits for warning, reduction or shut down:
warning by continuous lamp
warning by continuous lamp and power reduction
after warning time, or
warning by flashing lamp and engine shut down
after warning time

Engine Oil Pressure

Whenever oil pressure sinks under prefixed speed
dependent limits:
warning by continuous lamp or
warning by continuous lamp and power reduction
after warning time
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warning by flashing lamp and engine shut down

after warning time
 EMR
Oilpressure Monitoring System
5

4,5

3,5
Oilpressure (bar)

3 typical oilpressure (95 deg.C)

2,5 oilpressure warning limit

2
oilpressure shutdown limit
1,5

0,5

0
0 500 1000 1500 2000 2500 3000
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Engine speed (rpm)

 EMR
Additional Functions

Cold start control

Excess start fuelling and speed ramping according to engine temperature

Smoke limitation
Smoke limitation during engine start
Smoke limitation according to charge air pressure

Data exchange
Outputs for speed and/or torque and/or fuel consumption
CAN/SAE J 1939 interface for communication with other ECUs
ISO 9141 interface for programming and diagnostics

Special customer specified functions

Depending on application
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 EMR
Cold Start Improvement
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 EMR
Data Exchange (Example)
to/from operators displays

diagnosis K ISO 9141, Keyword

programming L 500

data
exchange CAN, SAE J 1939, 250
kBd

EMR EMS
SAE J 1708 / SAE J 1587

to sensors

actors

to sensors
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 EMR
Customer Benefit: Improved Equipment-Performance
torque torque

adapted
speed characteristics
e.g. tractor

Droop = 0% Droop = 15%

e.g. genset e.g. drive
Droop = 4%
60 Hz = const.
e.g. excavator

Droop = 4%
higher starting moment e.g. work
e.g. tractor/forklift

„blue angel“

speed speed
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Optimal shaping of torque- and speed-characteristics.

 EMR
Service
DEUTZ Customer Service

Manual

ECU

Software
SERDIA
Interface
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Engine with actuator, sensors

and wiring harness
 Electronic Systems on Passenger Cars
Number of Failures
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 EMR
Wiring Harness „Construction Machinery“
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 EMR
Functions of EMR 1
Speed governing / regulation > via foot pedal and hand throttle (Drive-by-wire)
Switchable fixed speed > via digital-Input (1500 / 1800 etc)
Switchable governor behaviour > all speed governor (RQ)
> automotive governor (RS)
Torque restriction > adapted to machinery requirements
Speed droop flexibility > adapted to machinery requirements
LDA-volume limitation > avoidance of smoke puff at engine ramping
and / or load takeover
> higher torque at low speed
Cold start control > avoidance of start smoke puff
Temperature dependent engine ramping > decrease of cold start wear
> increase of engine lifetime
PWM-frequency (Puls width modulation) > interface for e.g.: torque monitoring, etc
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 EMR
Funktionen EMR 1

Emergency operation features (Limp-Home) > at failed boost pressure sensor the boost
pressure increase will be simulated
> at failed foot pedal sensor it will be switched
to pre programmed fixed speed
Communication interface > ISO 9141, diagnostic / adjustment
CAN interface > Data exchange in the drive management
Engine protection > avoidance of engine failures by:
* overspeed protection
* coolant temperature monitoring
* oil pressure monitoring
Diagnostic functions > monitoring of the electronic components
* Data logging
* engine service hour meter
* number of engine starts
* help to find system failures
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 EMR
Benefit: Low overall costs
Costs

Engines with
mechanical governor
Engines with EMR


 

No mechanical parts No mechanical or electrical Cost reduction Reduced cost for stock and
for linking a foot pedal parts and no installation and by low wear spare parts because of
or a hand accelerator maintenance cost for and tear programmability
to the engine - change of constant speed setting reduced engine
- vehicle speed limitation (Only one type of control
down time
- change of droop engine protection unit on stock for all ratings
- load sensing
fuel consumption and functions)
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F01.13 VV-MV 07/98

Minimal Minimal Minimal

installation costs operating costs logistical costs
Time
 EMR
Customer with EMR
ACE ABG Still
Same DEUTZ Fahr Alternativas Strüver
Airman (Japan) ISBIR Sun-Electric
Atlas-Copco Kali und Salz Svedala Wardenburg
Atlas Weyhausen Kershow (USA) Tyler (USA)
Bomag Kirsch Voegele
BPI Kohler Windhoff
Falch Kolben-Seeger WMS (DDP)
GHH Lindenberg Würgler
Breda Menarini Matrot AKSA
DAP Mecalac FARS Diesel
Dronningborg Merlo Lech-Motoren
Euro-Power Plasser&Theurer VOLVO
Fan to Flywheel (USA) Plustech (Grönblom) Wirtgen
Fendt Polyma XCMG (China)
Hamm Renault Agri.
HBM Schopf
HEPCO Schöma
Hitzinger (Austria) S&S
Henkelhausen Sennebogen
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IBH Svendsen
IML: Cometto, Cometi, Pramac
 Further Development of the Electronic
Engine Drive Management (EMR 2)
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 EMR 2
Development Motives

Production of microchip stopped end of 1999

Market requirements for new and additional functions

Extension of existing functions

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 EMR 2
Development Targets

Substitution of the microchip

Integration of additional functions

Extension of existing functions

Full compability to EMR 1

(function, plug, handling)
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 EMR 2
New Functions: Engine and Monitoring Functions

Function Status

Adjustment of the injection volume depending of the fuel temperature optional

Monitoring of charge air temperature optional

Altitude adjustment optional

Monitoring of the coolant level optional

Control of flame start device optional

Control of heater flange optional

Engine brake optional

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 EMR2
Fuel Density Compensation

+
100
%
Correction of fuel %
TK-EE, kraftstofftemp.ppt, 12.07.2001

Warning limit
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33 °C 75°C 90°C Temperature

 EMR 2
Correction of max fuel (engine power) depending on atmospheric pressure

Configuration

Engine speed
Correction map
Atmospheric pressure

Correction factor Corrected fuel

Fuel limiting
limiting
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 EMR 2
Control Unit Heater Flange
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 EMR 2
Control Unit Heater Flange
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 EMR 2
Engine Brake
Speed

Speed limit 2

Speed limit 1

Time

Engine brake switch

Exhaust flap control

Injection volume
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Time
 EMR 2
Engine Brake

Speed

Setted speed

Speed limit 2

Speed limit 1
Time

Engine brake switch

Exhaust flap control

Injection volume
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Time
 EMR 2
New Functions: Diagnostic and Comfort Functions

Functions Status

Simple diagnostic by blinkcode and diagnostic button standard

Determination of the engine load characteristic standard

Extended failure memory standard

Complete programming of operation software and parameter standard

Extension of the CAN functionality standard

Extension of the genset functions (synchronisation with SPS*) optional

Load dependent switch to low idle speed optional

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Three limiting curves optional

*): Speicher Programmierbare Steuerung (Programmable Logic Control)
 Electronic Engine Control
Service

DEUTZ Customer Service

Software
Manual SERDIA

EMR
ECU Interface

+ 12 / 24 V -
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engine with actuator, sensors, wiring harness

 Service at EMR 2
Failure Diagnostic with Blinkcode

DEUTZ Customer Service

Diagnostic button

EMR
ECU

Failure list

Failure diagnostic
+ 12 / 24 V -
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Engine with actuator, sensors, wiring harness

 EMR 2
Engine Load Map
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 EMR 2
Switch over from high to low idle at no load

load

time

signal 1
from
hydraulic
0 time

2200
speed
(rpm)
1000 time
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 EMR 2
Status

09/2001: 01/2002: 03/2002: End of 2002

Technical Engines with EMR 2 Series SOP
release in production release

Documentation for EMR 2:

Scopes are available within ELTAB in the next issue

Serdia 3.5 and Serdia 2000 (EMR2 compatible) available

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 EMR 2
Change from EMR 1 to EMR 2
What has to be noted?

Control of heater flange / flame start heater device, for step II

engines is activated by the EMR 2:
* adjustment of wiring harness and installation of the
heater flange ECU necessary
Adjustment of wiring harness for new functions
New connection and signal for function
„ speed limitation“ noteworthy
New functions of the EMR 2 with customers to communicate
Change to EMR 2 to co-ordinate with the customer
Stop solenoid not longer necessary, customer has to be informed
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 EMR 2
Change from EMR 1 to EMR 2

Inform the customer about CAN functions and if he is interested

coordinate with dept. VV-TS

Start of aquisition with EMR 2 immediately – inform headquarter

about customers requests to incorporate this into the
new scopes.
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 EMR 2
Comparison EMR 2 / GAC: Genset Functions
No. Function EMR GAC
.
1 One frequency genset  
2 Double frequency genset (1500/1800) switchable  (-)
3 One or double frequency genset (1500/1800) with switchable droop  -
4 Switchable power  -
5 Synchronic and parallel (load sharing) operating mode  
6 Presetting of governor parameters in the factory (no extra tuning  -
needed)
7 Combination of genset functions with engine monitoring functions  -
8 Constant engine power with fuel temperature compensation  -
9 Synchronization and load sharing by PLC-systems  -
10 CAN-interface for data exchange with other electronic systems  -
11 Adaptation and service tools
Applic Laptop with following Screw driver for the
functions : . tuning of governor
-tuning of speed governor
-display of measured values
-diagnosis
-programming of ECU
(adaptation of functionality)
VV-TS, 19.11.2001
VM-O, 01.2003
 EMR 2
Comparison EMR 1 / GAC: Genset Functions
No.. Function EMR GAC
1 One frequency genset  
2 Double frequency Genset (1500/1800) switch able  (-)
3 One or double frequency genset (1500/1800) with switch able droop  -
4 Switch able power  -
5 Synchronic and parallel (load sharing) operating mode  
6 Pre setting of governor parameters in the factory (no extra tuning  -
needed)
7 Combination of genset function with engine monitoring functions  -
8 CAN-interface for data exchange with other electronic systems  -
9 Service tool Laptop with following Screw driver for the
functions : . tuning of governor
-tuning of speed governor
-Display of measured values
-Diagnosis
-Programming of ECU
(adaptation of functionality)
VV-TS, 19.11.2001
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 EMR 2
Additional Customer Benefits against EMR1

Optimizing the total costs by integration of the

new functions and reduction of the omponents
at the engine

Optimal control of the engine performance and

avoidance of engine damages by the functions:
* altitude adjustment
* fuel temperature
* charge air temperature monitoring

Easier handling of failure diagnostics and dealing

with the new diagnostic and comfort functions

Increase of the operation reliability by higher

quality and new engine monitoring functions
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Increase of the EMR functionality

 EMR 2
Further measures......

What has to be done additionally to support you at your

sales activities

?
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 EMR 2
Characteristic Map BF4M 2012 C
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VM-O, 01.2003
 EMR 2
TPI 0130-00-0253
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 EMR 2
TPI 0130-00-0253
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 EMR 2
TPI 0130-00-0253
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 EMR 2
Further measures......
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