CODESYS® in Mobile Automation

CODESYS is the number one Development System for ECUs in mobile machines.

CODESYS Inspiring Automation Solutions 2

CODESYS in Mobile Automation

CODESYS is the market-leading automation software for programmable control units (ECUs) used in off-highway vehicles or other mobile machines. CODESYS-compatible controllers can be found in many construction machines, cranes, industrial trucks, surface mining machines and transporters. And not without reason: CODESYS can be used in ECUs / mobile controllers of completely different designs and performance classes. It offers integrated support for the most important fieldbus systems and a comprehensive visualization functionality perfectly suited for mobile applications. Another outstanding plus is the certified suitability for programming IEC 61508 SIL2 safety applications.

Construction Mining Marine

Agriculture TransportationIn industrial use around the world

Thousands of off-highway vehicles, mobile machines, plants and applica-tions in the most different industries are automated with CODESYS.

Its comprehensive functionality and flexibility make CODESYS the ideal tool for mobile automation applications.

� Mobile construction cranes and wheeled excavators

� Container cranes � Grab dredgers � Excavators, rock crushers and other utility vehicles for underground and surface mining

� Driverless transport systems for logistics � Industrial trucks and fork lifts � Tractors, harvesters and mobile feed mills � Aircraft tractors � Yacht automation

� Truck mounted sweepers � Road pavers and other machinery for road construction

� Wheeled forestry harvesters � Transport and utility vehicles such as dumpers and trucks

� Marine diesel engines � Control and operating units in trains and trams

� Mobile industrial compressors � Snow groomers

A selection of CODESYS applications in different industrial sectors:

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Mobile Automation3

CODESYS in fork lift trucks

CODESYS in cranes

CODESYS in construction machines

Programming environ-ment for application software: CODESYS Development System

Operating panel / display: CODESYS TargetVisu

ECU / mobile controller: CODESYS Control Embeddedd

Fieldbus configura-tion and protocol stack: CODESYS CANopen / J1939

Programming environment for safe application software, SIL2: CODESYS Development System certified to SIL2

HMI Panel: CODESYS HMIFieldbus protocol stack: CODESYS CANopen Safety according to EN 50325-5

Typical application configurations with CODESYS

Mixed operation of CANopen and CANopen Safety slave modules

SIL2 ECU / mobile controller: CODESYS Control certified to IEC 61508 SIL2

CANopen Safety

IEC 61131-3 programming environment: CODESYS Development System with application libraries e.g. for direct CAN access

External diagnostics systems: CODESYS PLCHandler

ECU / mobile controller: CODESYS Control Embedded for 16-/32-bit CPUs

CANopen J1939

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CODESYS Inspiring Automation Solutions 4

Why use CODESYS for mobile industrial applications?

Power and usability for the effective realization of complex automation projects:

� Fast machine code for all ECUs: industrially proven compilers for compact mobile controllers through to high-performance central controllers exploit the device performance to the optimum

� Scalable functionality of the CODESYS Development System: - Use of simple editors / configurators - Powerful add-on tools for static code analysis,

integrated UML diagrams, source control with Apache Subversion or automated application tests, suitable for safety-critical applications

� Well-thought-out concept for the reusability of function blocks in libraries

2Everything integrated in one single user interface, the CODESYS Development System:

� Complete IEC 61131-3 development system (free of charge for users): for the linking of simple logic modules through to the complex object-oriented programming of industrial ECUs / mobile controllers

� Extensive debugging and commissioning functions: troubleshooting and optimization on-site without additional software directly in the application code

� Programming access via CAN interface � Development of user-friendly operating interfaces and driver displays with modern visualization elements: integrated visualization editor in the CODESYS Development System

� Display of the created operating interfaces for testing, commissioning and machine operation on different platforms: in the CODESYS Development System, directly on the device display of a mobile controller or on driver displays

� Fully integrated configurator for local inputs and outputs, for CANopen, J1939, EtherCAT and other fieldbus systems: declaration and use of sensors, actuators, signals and joysticks

� Layer 7 master protocol stacks for CANopen, J1939 and EtherCAT can be used as portable CODESYS libraries without implementation effort

� Raw CAN access with proprietary protocol, can be encapsulated in customized function libraries

� CODESYS Store: access to application libraries as well as tested add-on tools for the development of mobile machines

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Ideal conditions for mobile industrial applications:

� Proven system platform: in more than 500,000 mobile control applications

� Large selection of ECUs / mobile controllers, pro-grammable with CODESYS: listed in the CODESYS Device Directory at www.codesys.net

� Large community for mobile industrial machines: know-how support for the creation of applications by CODESYS System Partners or engineering offices

� Compatible additional equipment: suitable HMI devices, diagnostic tools etc.

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CODESYS in industrial applications

� Alstom Transport � E&K Automation � Goldhofer � Jungheinrich � Liebherr Mining Equipment � MAN Diesel & Turbo � Rolls Royce Marine � Sandvik Mining and Construction Oy � Trepel Airport Equipment

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CODESYS SAE J1939

� SAE J1939 configurator for ECUs fully integrated in the CODESYS Development System: definition / map-ping of the signals and parameter groups (PG)

� Complete PG database including SAE signal docu-mentation: direct access to the documentation of the signal specifications

� Portable SAE J1939 communication stack in form of a CODESYS library: dynamically compiled and linked with the application

� Functional scope of the stack: simulation of ECUs, dynamic address claiming, Arbitrary Adress Capable, support for the parameter groups > 8 bytes, optional signal conversion, etc.

� Intelligent signal processing: raw signal / implicit conversion with automatic data type determination, consistent I/O channel generation

Product components for mobile applications

CODESYS CANopen Master

� CANopen Master/Slave configurator fully integrated in the CODESYS Development System: integration of slaves on the basis of EDS or DCF files without exter-nal tools for the configuration of the bus system

� Mapping of I/O data in the integrated configurator � CiA 301 CANopen communication stack in form of a CODESYS library: dynamically compiled and linked with the application

� Application interface according to CiA 405 for the diagnosis and use of SDOs

� Configuration of PDOs without additional tool

Horizontal directional drilling system for the trenchless installation of underground pipes in mixed soil conditions and rock: The system is automated and visualized with CODESYS.

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� Due to the integration: easier, more user-friendly development and more functionality compared to conventional visualization systems

� Modern visualization elements included: fast and easy creation of industrially applicable operating and diagnostics screens

� Reusability: one source file for different visualization clients - Directly in the CODESYS Development System – ideal

for testing and commissioning - On remote terminals – for the operation of machines

with HMI panels - On panel controllers – operation and logic control with

one single device - In a web browser on a tablet or smart phone – ideal for

diagnostics or remote maintenance � Comprehensive and powerful functionality: practical controls, integrated alarm management, advanced user management, user-friendly style, language and image switch, compact data recording modules, flexible communication concept

CODESYS Visualization for mobile applications

� Visualization editor fully integrated in the CODESYS Development System: development of logic programs and visualizations in one single development environment

� Availability of a pre-certified runtime system, including test framework for most parts of the firmware reduces the development time for a safety controller

� Display of the control data of the safety application in a standard CODESYS Web Visualization or HMI

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CODESYS Safety SIL2

� Certification for the development of software applications on safety controllers in accordance with EN ISO 13849, up to PL d, category 2 or 3 / IEC 61508 SIL2 by TÜV Süd

� Validated CODESYS Development System for the editors Structured Text (ST), Function Block Diagram (FBD) and Ladder Diagram (LD)

� Certified CANopen safety master stack, based on the proven CODESYS CANopen stack

� Parallel operation of CANopen safety and standard CANopen devices

� Data monitoring of the safety application during safe operation

� Debugging of the safety application as well as forcing or writing of values by switching to a special debug mode

� Simplified certification of safety applications by using the language scope specified by the PLCopen Safety Working Group

Mobile Automation7

Why should a manufacturer of mobile controllers choose CODESYS?

� Support for the commonly used CPUs / operating systems in ECUs / mobile controllers: - CPUs for compact controllers such as Tricore and C167

family, ARMx / Cortex Mx with or without proprietary operating system

- high-performance CPUs for mobile applications, such as Intel Atom or Cortex A8 / A15 e. g. with WinCE, VxWorks or Linux

� Simple porting and scaling of the runtime system on the basis of a runtime toolkit: with defined interfaces for device-specific functions

� Embedding of specific technology functions / visualiza-tion elements in CODESYS libraries – with licensing if necessary

How to make a mobile controller programmable with the CODESYS Development System

� Selection of CPU and operating system � Implementation / adaptation of the CODESYS Runtime System using an SDK: - Adaptation of the system-specific functionality of

the runtime system with tool support as described in the integration manual

- Configuration / adaptation of the communication drivers to the CODESYS Development System

- Integration of special device libraries to be called from the IEC 61131-3 application

- Integration of customized add-on functionality based on defined interfaces

- Compilation of the adapted runtime system which is then embedded into the device

- Qualified adaptation support by experienced project engineers in all phases of the implemen-tation / adaptation process

� Validation and test of the system, optionally with integrated CODESYS Test Manager

� Marketing and sale of the mobile controller equipped with the CODESYS Development System and, if desi-red, with additional customized plug-in extensions

Manufacturers of mobile controllers with CODESYS technology:

� Bosch Rexroth AG Mobile Hydraulics � CrossControl

� EPEC Oy � Hirschmann Automation and Control � ifm electronic � InterControl � Janz Tec � MOBA Mobile Automation � STW Sensor Technik Wiedemann � TTControl

� Proven interface for the connection of additional opera-ting or diagnostic devices or software systems

� Software components that are pre-certified to IEC 61508 SIL2 (development system, runtime system and CANopen safety master stack) simplify the certification of a SIL2 mobile controller.

� Development costs for the programmable control unit can easily be precalculated: defined interfaces, integration manual for the runtime system, qualified adaptation support

� Expandability of the CODESYS Development System by adding device-specific or manufacturer-specific plug-in components

� High market acceptance due to widespread use in mobile applications

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CODESYS – the leading manufacturer-independent IEC 61131-3 automation software.

CODESYS for further industries:

3S-Smart Software Solutions GmbHMemminger Straße 15187439 Kempten, GermanyTel: +49-831-54031-0Fax: +49-831-54031-50info@codesys.com

China Branch OfficeCODESYS Software System (Beijing) Co.,Ltd.Phone: +86-10-858889-37Fax: +86-10-858889-38info@codesys.cn

CODESYS® a trademark of3S-Smart Software Solutions GmbHwww.codesys.com

CODESYS® is a registered trademark of 3S-Smart Software Solutions GmbH. Technical specifications are subject to change. Errors and omissions excepted. No reproduction or distribution, in whole or in part, without prior permission. Inspiring Automation Solutions

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