PLC-ECM Integration for Heavy Equipment Remote Control

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Solution Overview

Problem

Existing remote control systems for mobile heavy equipment are expensive, complex, and inefficient, particularly when they need to work with pulse width modulation (PWM) compatible electronic control modules (ECMs) that are incompatible with standard CAN communications, and require separate control units and complex switching systems, disabling diagnostic functions during remote operation.

Innovation Solution

Integration of a programmable logic controller (PLC) with the existing ECM to convert both manual and remote control signals into PWM protocol, allowing the ECM to process and respond to signals from either source without needing independent controllers or complex switching systems, enabling seamless manual or remote operation and maintaining diagnostic functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a separate remote control unit with dedicated control components is used, then remote control capability is achieved, but device complexity and cost increase significantly

Engineering Contradiction:

Improveremote control capabilityVSAvoidcontrol system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the remote control receiver with the existing ECM, allowing the ECM to directly process both manual PWM signals and remote CAN signals through a unified control architecture. This eliminates the need for separate control units and reduces system complexity while maintaining remote control capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The ECM is designed to perform multiple functions: it processes both manual PWM control signals and remote CAN control signals, and provides diagnostic capabilities for both operating modes. This multi-functionality eliminates the need for mode-specific control units and simplifies the overall system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If gang relays and switching systems are used to transfer control between manual and remote units, then control mode switching is enabled, but device complexity and cost increase

Engineering Contradiction:

Improvecontrol mode switchingVSAvoidswitching system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The PLC serves as an intermediary that receives both manual PWM signals and remote CAN signals, converts them to a unified format, and transmits them to the ECM. This mediator approach eliminates the need for complex gang relays and switching systems, as all control signals are processed through a single interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces mechanical switching systems (gang relays) with electronic signal processing. The PLC uses electronic conversion and signal routing to switch between manual and remote control modes, eliminating mechanical wear and reducing system complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If PWM compatible ECM is used for manual control, then precise control is achieved, but compatibility with standard CAN remote control systems is lost

Engineering Contradiction:

Improvecontrol precisionVSAvoidprotocol compatibility

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The PLC changes the signal protocol parameter by converting CAN protocol signals from remote control systems into PWM protocol signals that the ECM can process. This parameter transformation maintains control precision while achieving protocol compatibility between remote systems and the PWM-based ECM.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If independent remote control system is implemented, then remote operation is enabled, but diagnostic function availability is reduced or lost

Engineering Contradiction:

Improveremote operation capabilityVSAvoiddiagnostic function availability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

By merging the remote control receiver with the ECM and using a unified control architecture, the system maintains continuous access to diagnostic functions regardless of whether manual or remote control mode is active. The ECM's diagnostic capabilities remain fully available during remote operation.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9116787B1Electronic control system for mobile heavy equipment machinery

Publication Date: 2015.08.25 MARDEN IND INC D B A SUPERTRAK

AI summary

A control system for mobile heavy equipment machinery includes an electronic control module for receiving and processing pulse width modulated control signals. There is a programmable logic controller (PLC) that receives position sensor generated input signals selectively from manual and remote sources. The PLC processes the input signals and transmits such signals in pulse width modulated format to the electronic control module, which processes the signals and directs corresponding output signals to control operation of the equipment.