Fjdynamics Fjd 3d Assembly instructions

Hardware Installation Manual for FJD 3D Excavator Guidance System

FJD 3D Excavator Guidance System

Hardware Installation Manual

FJ Dynamics Technology Co., Ltd.

Hardware Installation Manual for FJD 3D Excavator Guidance System

Disclaimer

◆ The products, services, or features you purchase are subject to commercial contracts and terms thereof. All or part of the products, services, or features

described herein may be excluded from the scope of your purchased or used products, services, or features. Unless otherwise agreed in the contract, FJD

makes no statement, expressed or implied, with respect to this document.

◆ Due to product upgrades or other reasons, the contents of this document will be updated from time to time. FJD reserves the right to modify the contents

of the document without any notice or prompt.

◆ This manual is only used as a guide. FJD has tried its best to ensure that the contents are accurate and reliable, but it doesn’t guarantee that this manual is

completely free of errors or omissions. Information in this manual does not constitute any express or implied guarantee.

Hardware Installation Manual for FJD 3D Excavator Guidance System

Foreword

Thank you for using the products of FJ Dynamics Technology Co., Ltd. This manual covers detailed hardware installation instructions. If you encounter any

problems in the process of using this manual, please contact the FJD customer service, and we will serve you wholeheartedly.

Scope of application

This manual mainly presents some physical characteristics of the product and specifies installation steps, technical specifications, as well as specifications and

usage guidelines for harnesses and connectors. This manual applies to users who understand the above contents and have some experience in hardware

installation and maintenance, assuming that users are familiar with related terms and concepts.

Technical support

FJD official website: https://www.fjdynamics.com/

Hardware Installation Manual for FJD 3D Excavator Guidance System

Contents

I. Introduction .................................................................................................................................... 1

1.1 Main Hardware and Specifications ........................................................................................ 1

1.2 Main Performance Parameters .............................................................................................. 3

2. Preparation before Installation .................................................................................................... 3

2.1 Safety Instruction................................................................................................................... 3

2.2 Requirements for Installation Site.......................................................................................... 4

2.3 Installation Tools .................................................................................................................... 5

2.4 Open-package Inspection ...................................................................................................... 6

3. Installation ..................................................................................................................................... 7

3.1 Check before Installation ....................................................................................................... 8

3.2 Installation Process ................................................................................................................ 9

3.3 Precautions for Installation .................................................................................................. 10

4.Installation Steps ......................................................................................................................... 10

4.1 Installation of Control Terminal ........................................................................................... 10

4.1.1 Required Materials ................................................................................................... 10

4.1.2 Installation Steps....................................................................................................... 11

4.2 Installation of Attitude Sensor ............................................................................................. 12

4.2.1 Required Materials ................................................................................................... 12

4.2.2 Installation Steps....................................................................................................... 12

4.3 Installation of Antenna ........................................................................................................ 15

4.3.1 Required Materials ................................................................................................... 15

4.3.2 Installation steps ....................................................................................................... 15

4.4 Installation of Harness ......................................................................................................... 17

4.4.1 Required Materials ................................................................................................... 17

4.4.2 Installation Steps....................................................................................................... 17

4.5 Installation of SIM Card ....................................................................................................... 19

4.5.1 Required Materials ................................................................................................... 19

4.5.2 Installation steps ....................................................................................................... 20

5. System Commissioning ............................................................................................................. 20

5.1 Check before Commissioning ............................................................................................... 20

5.2 Power-on and Startup .......................................................................................................... 21

5.2.1 Inspection before Power-on ...................................................................................... 21

5.2.2 Inspection after Power-on ........................................................................................ 21

5.3 Specification Commissioning ............................................................................................... 21

Hardware Installation Manual for FJD 3D Excavator Guidance System

I. Introduction

FJD 3D Excavator Guidance System is a rear-mounted excavator guidance system, which adopts Beidou

high-precision real-time dynamic positioning technology. It gets the real-time precise 3D position

information of the bucket by reading attitude sensors installed on the excavator and calculating the

calibrated main pivot sizes. The current cut-and-fill workload is displayed in real time in coordination

with the work tasks generated by the self-designed transformation software to complete the goal of

digitally guided excavation and construction. The bucket is able to complete the work accurately even

in blind areas with poor eyesight, completely changing people's understanding of the traditional

construction method of excavators. This system is composed of RTK high-precision positioning

equipment, data communication equipment, and on-board tablet computer (display equipment),

attitude transducers, communication antennas, and harnesses. The on-board tablet computer is

equipped with an excavator guidance software independently developed by FJD, namely FJD 3D

Excavator Guidance System, which makes real-time statistics of the excavation depth, slope, elevation,

and satellite positioning of the current operating equipment.

1.1 Main Hardware and Specifications

S/N Assembly Component Specification

1 Control

terminal

Control

terminal

Size: 300×190×43mm;

10.1 capacitive touch LED, backlight 1280*800 pixels,

700cd/m2 LCD screen; double loudspeakers; 2G of run

memory, 8G of storage memory;

Covering a variety of digital and analog output

interfaces, etc.;

Power supply: 10V~30V;

Covering radio, positioning satellites, 4G and other

signals;

Operating temperature: -30℃~+70℃;

Storage temperature: -40℃~+85℃;

IP rating: IP65;

Hardware Installation Manual for FJD 3D Excavator Guidance System

Relative humidity: 0%~95%, at 40 ℃ (non-

condensation );

Wi-Fi specification: 2.4GHz frequency band;

Frequency range: 2.4GHz~2.5GHz; output power:

14dB±1.5dB;

Antenna

assembly

GNSS

antenna

Frequency range: GPS L1/L2, GLONASS L1/L2, BDS

B1/B2/B3;

Operating voltage: 3.3V~12V;

Operating current: ≤45mA;

Size: 152*63mm;

3 4G antenna

Sucker antenna:

Frequency range: B1/B2/B3/B5/B8/B38/B39/B40/B41;

VSWR:≤2.0; Gain(dBi): 2±0.5;

Impedance(Ω): 50;

Polarization: Linear, Vertical;

Max. power: 100W;

Antenna size: Ф375*82mm;

Operating temperature: -20℃~ +65℃;

Radio

antenna

(optional)

Sucker antenna:

Frequency range: 433/470MHz;

VSWR:≤2.0; Gain(dBi): 2±0.5;

Impedance(Ω): 50;

Polarization: Linear, Vertical;

Max. power: 100W;

Antenna size: Ф495*82mm;

Operating temperature: -20℃~ +65℃;

5 Attitude sensor Attitude

sensor

Axes (Tilt): Pitch；Roll;

Range: Pitch ±70°, Roll±180°;

Resolution: <0.05°;

Hardware Installation Manual for FJD 3D Excavator Guidance System

Max Angular Rate: ≤400

⁰

/s;

Static Accuracy: 0.15°;

Dynamic Accuracy: 0.50°;

Temperature Stability：0.05°;

Axes (Acceleration): X,Y,Z;

Range: ±78m/s/s;

Resolution: 0.01m/s/s;

Accuracy: ±0.1m/s/s;

Output Data Rate (Hz): Selectable to 100 Hz;

Operating voltage: 4.9V~32V;

Power:<400mW;

Operating temperature: -40℃~ +85℃；

Protection class：IP 67;

1.2 Main Performance Parameters

The system can currently guide and assist the excavator, and the operation accuracy is as follows:

Static accuracy ＜±3cm (RMS)

Assisted Operation accuracy ＜±5cm (RMS)

2. Preparation before Installation

2.1 Safety Instruction

In order to avoid harm to people and equipment, please read the safety recommendations herein

carefully before installation.

Note: Not all risks are covered by the following safety recommendations.

Installation Safety

1. Don’t install this system in an environment susceptible to electromagnetic interference (large radar

stations, transmitting stations, substations) which features high temperature, much dust, harmful gas,

flammable and explosive articles, unstable voltage, much vibration or strong noise, as this

environment is not conducive to the operation of the equipment.

Hardware Installation Manual for FJD 3D Excavator Guidance System

2. Don’t install the equipment in places where water accumulation, water seepage, dripping, and

moisture condensation most likely happen.

3. Install or remove the equipment as described in the hardware installation manual.

Removal Safety

1. Once installed, don’t frequently remove the equipment to avoid damages.

2. Turn off all power supplies and disconnect all power lines and cables before removal.

Electrical Safety

1. The local laws and regulations must be observed during electrical operations. The relevant

personnel must be qualified.

2. Please carefully check for potential hazards in the work area, for example, wet ground.

3. Before installation, be familiar with the location of the emergency power switch and turn off the

power switch first in the event of an accident.

4. Check carefully when it is necessary to turn off the power.

5. Do not put the equipment in a humid place, and no liquid is allowed to enter the equipment.

6. Keep away from wireless transmitting stations, radar transmitting stations, high-frequency and

high-current equipment, microwave ovens, and other high-power wireless equipment.

7. Direct or indirect contact with high voltage or mains power through wet objects may cause fatal

danger.

8. Irregular and incorrect electrical operations may cause accidents such as fire or electric shock, and

even cause serious and fatal harm to the human body and equipment.

2.2 Requirements for Installation Site

To ensure the normal operation of the equipment and prolong its service life, the installation site is

required to meet the following standards.

Installation Location Requirements

1. Install the equipment in an open environment, and ensure that the closed environment where the

equipment is installed has a good ventilation and cooling system.

2.Ensure that the equipment is installed at a position firm enough to support the weight of control

terminal and accessories.

3. Ensure that the installation location is suitable for the size of control terminal, with some space left

Hardware Installation Manual for FJD 3D Excavator Guidance System

around to facilitate heat dissipation.

Temperature and Humidity Requirements

1. To ensure the normal operation and the service life of the equipment, temperature and humidity

in the operating environment should be up to standard.

2. Long-term operation in an environment that does not meet the temperature and humidity

requirements will cause damage to the equipment.

3. Operation in an environment with high relative humidity is most likely to cause poor insulation of

the insulating material and even leakage. Sometimes, changes in the mechanical properties of

materials and corrosion of metal parts are also prone to occur.

4. Operation in an environment with low relative humidity will cause the insulating sheet to dry and

shrink, and meanwhile, most likely generate static electricity, which will harm the circuits in the

equipment.

5. Operation in an environment with excessively high temperature will be more harmful and will

greatly reduce the reliability of the equipment. The long-term high temperature will also affect the

service life and accelerate aging.

Cleanliness Requirements

For the environment where the equipment is located, there are strict requirements on the salt, acid,

and sulfide contained in the air. Some harmful substances will accelerate the corrosion of metals and

the aging of certain parts. Intrusion of harmful gases (sulfur dioxide, hydrogen sulfide, nitrogen dioxide,

chlorine, etc.) should be avoided.

Power Requirements

Kit voltage input:

1.The input voltage should be within the range of 12±1V; a lower input voltage is allowed, but it will

affect the accuracy.

2.The input voltage should be within the range of 24±1.5V. The impact on accuracy will be reduced

after the excavator is started.

2.3 Installation Tools

Before the installation, please prepare the following tools.

Hardware Installation Manual for FJD 3D Excavator Guidance System

Assembly Tools for FJD 3D Excavator Guidance System

S/N Tool Model Qty Function

1 Cross

screwdriver Mid-size 1 Install control terminal and bracket base

plate

2 Hex key set T3~T6 1 Install attitude sensor, bracket screws, etc.

3 Open-end

wrench 1 Choose different wrenches depending on

the actual screws of the excavator

4 Utility knife 1 Unpacking

5 Scissors 1 Cutting the straps and 3M double-sided

tape

6 Multimeter 1 Measure voltage and circuit on/off

7 Total station 1 Calibrate measurement parameters

8 Strap 1 Fix harnesses

9 3M tape 1 Fix the sensor

10 Carburetor

cleaner 1 Clean body oil stain

2.4 Open-package Inspection

After preparing the tools mentioned above, please check the following packing list.

Packaging Box of Excavator Guidance System

S/N Item Spec./model Quantity Remark

1 Control terminal 1

2 Attitude sensor 4

3 RTK antenna 2

4 4G sucker antenna 1

5 Beidou 1 feeder 1

6 Beidou 2 feeder 1

7 Attitude sensor mount 2

Hardware Installation Manual for FJD 3D Excavator Guidance System

8 Protective cover for

sensors 2

9 Hexagon socket head cap

screw M5×12 9

10 Hexagon socket head cap

screw M10×25 9

11 Pan head bolt with elastic

flat washer M6×14 13

12 Hexagon Nut Class 1 M4 18

13 Standard Spring Washer φ10 9

14 Flat Washer φ12 9

15 Attitude sensor harness 1

16 Power harness 1

17 Smart main harness 1

18 Adapter bracket of control

terminal 1

RTK bracket 2

20 RTK bracket antenna

mount 2

21 Antenna convertor 2

22 3M VHB double-

sided

tape 4

23 Nylon Strap Several

The items listed above are delivered in general cases. The delivered items may slightly differ

depending on the order contract. Please check the cargoes carefully in accordance with the packing

list or the order contract. Please contact our dealers if any questions or mistakes.

3. Installation

Hardware Installation Manual for FJD 3D Excavator Guidance System

Please be sure that you have carefully read the content of Chapter 2 and that the requirements

described in Chapter 2 have been met.

3.1 Check before Installation

Before installation, make thorough plans and arrangements for the installation location, power supply,

and wiring of the equipment. Please verify the following points before installation:

1. Enough space should be provided at the installation location to meet the heat dissipation

requirements.

2. The installation location must meet the environmental requirements of the equipment for

temperature and humidity.

3. The installation location must meet the requirements of the equipment for power and current.

4. The selected power supply must meet the power requirements of the system.

5. The installation location must meet the requirements of the equipment for installation location

selection.

6. For user-specific equipment, please check whether the equipment meets the specific requirements

before installation.

Hardware Installation Manual for FJD 3D Excavator Guidance System

3.2 Installation Process

Start

Incoming materials are

complete

Determine where to

install the controller

Select the installation

location of the 4G sucker

antenna

Install the 4G sucker

antenna

End

Install the Control

Terminal adapter bracket

Install the Control

Terminal

Assemble the atti tude

sensor and mount

Install the attitude sensor

of the slewing platform

Install the attitude sensor

of the boom

Install the attitude sensor

of the arm

Install the attitude sensor

of the bucket link

Assemble the RTK

antenna and bracket

Select the installation

location of the RTK

antenna

Install the RTK antenna

Unpack and check the

list of incoming materials

Install the harnesses

Install the power

harness

connector

Install the Control

Terminal sensor

connector

Install the

attitude sensor

connector

Install the RTK

antenna

connector

Install the 4G

sucker antenna

connector

Contact our dealers for

repl enishment

Hardware Installation Manual for FJD 3D Excavator Guidance System

3.3 Precautions for Installation

1. Do not power on the equipment when installing it.

2. Place the equipment in a well-ventilated environment.

3. Avoid placing the equipment in a high temperature environment.

4. Keep the equipment away from high-voltage cables.

5. Keep the equipment away from strong thunderstorms and strong electric fields.

6. Remove the power plug before cleaning the equipment.

7. Do not clean the equipment with liquids.

8. Do not open the enclosure.

9. Fix the equipment firmly.

4.Installation Steps

4.1 Installation of Control Terminal

4.1.1 Required Materials

S/N Item Qty Spec./model Remark

1 Control terminal 1

2 Pan head bolt with elastic

plain washer 4 M5x12

3 Control terminal baseplate 1

Supplied with

control terminal

bracket assembly

4 Adapter bracket 1 M6x20

5 Hexagon nut 4 M6

6 Base 1

7 U-bolt 2

Hardware Installation Manual for FJD 3D Excavator Guidance System

4.1.2 Installation Steps

Step 1: Fix the base. Choose the round steel position on the door side of the cab for easy operation

(depending on model structures). After determining the installation position, fix the bracket base of

control terminal with U-bolts and nuts.

Step 2: Take control terminal, rotate the bracket handle counterclockwise, and then loosen the bracket

ball socket to install the back ball of control terminal into the ball socket of the bracket.

Step 3: Install control terminal assembled in Step 2 on the base ball, and turn the handle clockwise to

tighten it. The control terminal is required to be well fastened.

Hardware Installation Manual for FJD 3D Excavator Guidance System

4.2 Installation of Attitude Sensor

4.2.1 Required Materials

S/N Name Quantity Spec./model Remark

1 Attitude sensor 4

2 Attitude sensor mount 4

3 Protective cover for sensor 2

4 Hexagon socket head cap

screw

8 M5x12

5 Hexagon Nut Class 1 18 M4

6 3M VHB double-sided tape 4

4.2.2 Installation Steps

1. Install the attitude sensor of boom and arm on its mounting plate and fasten it with M5x12 hexagon

socket head cap screws. Install attitude sensors of bucket and car body on the base plate of protective

cover and fasten it by M4 nuts.

2. Stick 3M VHB double-sided tape on the back of the angle sensor.

3. Stick the attitude sensors after selecting the positions of the slewing platform, boom, arm, and

bucket link according to direction as shown in the figure（Note that all are mounted on the left side）.

(1) Attitude Sensor (Excavator body)

Hardware Installation Manual for FJD 3D Excavator Guidance System

This sensor is intended to realize terrain data compensation to ensure the accuracy of the excavator

in operating environments such as slopes, foundation pits, and water.

(2) Attitude Sensor (Boom)

This sensor is intended to monitor the boom extension angle and judge the boom angle in real time.

Hardware Installation Manual for FJD 3D Excavator Guidance System

(3) Attitude Sensor (Arm)

This sensor is intended to monitor the arm extension angle and judge the arm angle in real time.

(4) Attitude Sensor (Bucket)

This sensor is intended to monitor the bucket extension angle and judge the bucket angle in real time.

Hardware Installation Manual for FJD 3D Excavator Guidance System

4.3 Installation of Antenna

4.3.1 Required Materials

Item Qty Spec./model Remark

1 RTK antenna 2

2 4G sucker antenna 1

3 RTK bracket 2

4 RTK bracket base 2

5 Antenna convertor 2

6 Hexagon socket head cap

screw

8 M10×25

7 Pan head bolt with elastic

flat washer

8 M6x14

8 Standard spring washer 8 φ10

9 Flat washer 8 φ12

4.3.2 Installation steps

1. Place the RTK antenna convertor in the welded sleeve of the RTK bracket, align the screw holes, and

fasten it by M6x50 Pan head bolt with elastic flat washers.

Hardware Installation Manual for FJD 3D Excavator Guidance System

2. Install the RTK antenna on top of the mounted bracket, and ensure that the threads are tightened.

3.Weld RTK bracket base to two symmetrical positions respectively on both end of excavator backside.

The spray layer of the welded position needs to be polished before welding. The exposed surface

needs to be panted for protection when welding is completed, and then fix the bracket to it with M10

x 25 head cap screws. (If welding is not available, the bracket can be fixed directly to excavator with

3M tape.)

4. The antenna on the right side of excavator is Beidou 2 directional antenna, and that on the left side

is Beidou 1 positioning antenna, as shown in the figure below.

5. The 4G sucker antenna should be arranged according to the on-site location as required below: (1)

The magnet adsorption is available at the arrangement location; (2) The signal is unobstructed.

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