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MilCAN on FCLV HUMS
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Background
FCLV is one of the first UK Military Vehicles to include HUMS as a requirement from the onset. Alvis Vickers Limited has won the contract to supply FCLV, and Syen has been awarded the contract to provide HUMS for the vehicle. Vehicle trials begin in late summer of 2004 and vehicle production starts in 2006.
The system that Syen has applied to the project is based on a number of years of investigating the need for Military Vehicle HUMS, analysing the problems to be addressed, and evaluating the technologies to provide solutions. Syen has worked closely with Alvis Vickers to ensure the system satisfies the requirement of FCLV HUMS and provides expansion and enhancement capability.
However, the Syen HUMS is applicable across a wide range of Military Vehicles from low cost legacy vehicle upgrades to new high-technology developments. The backbone of the Syen HUMS is a MilCAN network.
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FCLV Data Acquisition, Processing and Storage
To meet the requirements of the FCLV programme, the HUMS must interface to a wide range of sensors and equipment and log the data at a level of detail that satisfies the need for off-board analysis without unnecessary volumes of information storage.
The Syen HUMS is extremely flexible and can be configured, without software modification, to log data at different rates and statistically reduce the data over a configurable time period. It can interface to data sources through a wide range of I/O ports including analogue, digital, and frequency/pulse sensors, J1939 (CAN), MilCAN, RS232, and RS485 communications. This is achieved through a specially developed Vehicle Monitoring Unit.
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Vehicle Monitoring Unit (VMU)
The Syen Vehicle Monitoring Unit (VMU) is the central component for Syen’s Military HUMS. It is designed to interface to vehicle ECUs, sensors, and installed components, to measure and record the vehicle usage and operational state. It provides real-time statistical reduction of data as well as event and failure recording.
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VMU is reliable and rugged, designed to meet the arduous conditions of both automotive and military environments. Its sealed enclosure and connectors allow it to be mounted without environmental protection and its operating temperature range enables it to be used anywhere but the ‘hot spots’ of the engine compartment.
As well as the normal data logging mode, VMU can run in data streaming mode which provides real time data output for testing, diagnosis, and trials data recording.
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VMU Summary Specification:
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Power supply
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Operational between 10v and 40v DC
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Designed to cope with vehicle power transients and load dump
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Sensors
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on-board 3-axis accelerometer (± 10g X and Z, ± 5g Y)
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on-board temperature sensor
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Analogue input
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total of 28 channels of analogue input configurable as a mixture of single ended and differential, voltage or resistive measurement (with on board current source),
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Programmable offset and gain.
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up to 14 bit conversion, software programmable.
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Digital input
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24 channels of switch monitoring
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Frequency input
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4 channels of pulse/frequency input designed to cope with a wide range of sensors
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Digital Output
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8 ch of programmable digital switches capable of sinking 500mA at 28v
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Communications
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1 channel of RS232
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1 channel of RS485
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3 channels of CAN Bus including MilCAN
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Packaging
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VMU is housed in a sealed aluminium enclosure (240 x 165 x 55mm) that, together with the MIL-C-38999 connectors, provides protection to IP67.
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Environmental
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operational temperature –40 to +85°C
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shock and vibration: designed to satisfy MIL-STD 810E
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EMC – designed to satisfy the EU Directive 95/54/ec
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VSI Compliant Architecture
To guarantee the compatibility of HUMS and vehicle equipment it is necessary to define the overall architecture in terms of the types of interface available. Ideally this will make maximum use of multi-drop network designs such as CAN Bus, and use the minimum of direct-wired point-to-point communications such as RS232. However, the current mix of new and legacy vehicles, and new and legacy mission equipment, means that not all (if any) architectures are VSI compliant.
Syen’s HUMS has been designed to sit in a VSI compliant architecture. It provides three separate CAN Buses and uses J1939 and MilCAN protocols. However, it can act as a gateway to non-VSI compliant equipments through its serial communications.
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Configurable Application
As well as the need for a flexible design that includes capacity for enhancement in the future, HUMS needs to be configurable. The application of the technology to a particular vehicle must not require great levels of software and hardware re-design and the consequent costs involved.
The solution is a networked expandable system where the functionality and interfaces can be re-configured as the needs change. Using Syen HUMS there is no need to write software to define the parameters that are to be logged from the J1939 interface from the engine ECU; it can be defined by plugging in a terminal and configuring the system interfaces. In the same way, no new code is needed when a new sensor is added; the channel can be defined, calibrated, scaled, and actioned by configuration.
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