IR DD-158HFA Compactor, Electronic Control Module Replacement

[WILLS]

Hey all, I am working on a Ingersoll Rand Dual Drum Vibratory Compactor. Model DD-158HFA. This unit was purchased right around 2006 or 2007, the owner has had a problem with it for years where for no reason the parking brake comes on randomly. Obviously they cant operate like that. The mechanics have troubleshot down through all of the switches and hydraulics and are stumped. The dealer, Volvo, is also at a loss and cant figure it out. Basically it looks like there is a random fault in the VANSCO Control Module that runs the whole machine. The dealer cant help and isnt able to get a new one due to the changeover from IR to Volvo.

What I am doing is taking out the Vansco unit and replacing it with a mobile hardened PLC, I have the manuals from IR and have figured most of the Inputs and Outputs. I have programmed the safety interlocks required. The only thing I am not sure of is the Vibrations per min signal, and what type of a signal is coming from the drum speed sensors.

I am assuming that the VPM signal is an analog signal from the controller to the gauge on the console, probably 0-5Vdc. The drum speed sensors probably output either a pulse output like an encoder or mag pickup, or an analog output, but more than likely a pulse output.

Any thoughts on these two signals?

Thanks,

Will

 

[WILLS]

Okay, I have another question, there is an Vibration Auto/Manual switch, does this switch select the auto or manual vibration where manual sets a fixed vibration rate and auto changes the vibration rate based on speed of the machine? That would be my thought without looking into it any further.

 

[Ben Witter]

The controller is still available through Volvo. But I doubt the problem lies there. I suspect that the issue is more likely in the park brake circuit, either the switch or the harness. Connectors and the crimps on the wires were an issue. Also the resistors in the circuit were in the harness and there were issues with the connections to them.

What has the dealer replaced so far? This not to say the problem is not with the controller but it is more likely the main or pedestal harness.

 

[WILLS]

Ben, thanks for the reply, yes the mechanics said they can get the controller, and they have replaced the switches, and a bunch of the harnesses. Even had the boys from Volvo out and they were stumped. When I was called out to begin with, they asked me if I could connect to the controller and diagnose the issue, no way to do that other than with the breakout box which they cant get. I told them that they could go through it with a fine tooth comb and trace out all the wiring, but they didnt want to do that either. So basically what I proposed is that I design and program a new ECM with onboard diagnostics to read all of the fault codes.

This I can do because I have error detection on all of the inputs, and I can monitor all of the current on the outputs, if something goes out of whack, I just have to plug in one of my mobile screens and the errors show up there in plain language. Engine faults as well as I can read J1939 off the engine. They decided to go for it even though I said it would be fairly pricey, but its much less than buying a new roller, as this one is useless as it sits.

 

[Ben Witter]

In auto mode the controller controls the speed of the roller and the frequency of vibration. It is supposed to maintain roller speed in relationship to frequency to produce 12 impacts per foot, this can be adjusted by using different resisters.
Frequency is changed by the controller by detecting different amplitudes through the frequency sensors at the drum. It is very important to not over speed the vibratory shafts when in high amplitudes as the bearings will not last.

If you are designing a new controller I would be careful. The liability of this could be the end of you. Also the dealer and Volvo will most likely not support the machine after such a modification.

 

[WILLS]

I dont think Volvo is supporting this piece of equipment very well up here anyway, but thats besides the point. Ben whats the max speed of this type of roller when operating? I can match speed to VPM easily enough using a frequency counting input and a PID closed loop function in my controller to drive the Sauer 90S pump. As for liability, I will have a release signed. As well, if I can figure out what is cause the fault, I will fix it and replace the original ECU. But I cant do that until I can actually read the faults.

 

[Ben Witter]

It is all in my reply above.

If someone gets killed by by that machine a release will be worthless. You will more than likely be overriding all the safety features that are built into the machine.

 

[WILLS]

Ben, its not like this is the first time I have done this. I have built other machines from the ground up with electronic controlled drives, including full steering as well as propulsion and engine control. The manufacturer designed the machine with electronic controlled propulsion, I am doing the same thing. As for safety, I have copied all of the safety interlocks that the original machine has, operator not present, seat switch, E-stop you name it, its in there. I am no rookie at this and have been working on equipment for years. I am also an electronic technologist and a hydraulic specialist, so I know what I am talking about when it comes to Hydraulic EDC drives. You want to see some of my handywork, go here https://www.youtube.com/watch?v=vYkKhmMcuds

 

[csx7006]

any luck yet?

 

[WILLS]

Still working on the system, will keep you posted.

Thanks,

Will