Mechatronics eurosens DSS User manual
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CONTENTS
1 General information 5
2 Specification of eurosens DSS 6
3 Installation of eurosens DSS 7
3.1 Choosing installation place 7
3.2 Installation recommendations 10
4 Connection of eurosens DSS 12
5 Settings and calibration of eurosens DSS 14
5.1 Connection procedure 14
5.2 Calibration of sensor 16
5.2.1 Sensor reset 16
5.2.2 Sensor calibration on server side 18
5.2.3 Calibration on sensor side 18
5.2.4 Support of several calibration tables 20
5.3 Sensor readings 20
5.4 Sensor settings 21
6 Additional information 23
6.1 Storage 23
6.2 Transportation 23
6.3 Disposal 23
6.4 Technical support 24
6.5 Contacts 24
Appendix 1. Dimensions of eurosens DSS 25
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TERMS AND DEFINITIONS:
Load controller/axle load sensor/sensor –eurosens DSS.
Calibration –changing of sensor settings.
PC –personal computer.
Vehicle –a truck, tractor, bus, locomotive, river boat, diesel genset, stationary tank,
boiler/burner.
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1GENERAL INFORMATION
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Load controller (axle load sensor) eurosens DSS (fig. 1.1) is used to determine the
axle load of a vehicle by measuring the microdeformations of the load-bearing
elements, such as an axle or suspension arms.
fig. 1.1. eurosens DSS
The load controller consists of a non-separable sensor case, fixed to the base, and
supports. During installation the sensor case is precisely positioned in the supports
with two pins and fixed with screws.
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2SPECIFICATION OF eurosens DSS
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Table 1
Parameter
Value
Power supply, V
10 - 50
Max current consumption, mA
50 (at 12 V)
Reverse polarity protection
Yes
Ambient operating temperature, °C
-40 - +85
Output interface
CAN
Data interface
CAN 2.0, J1939
Ingress protection rating
IP 67
Dimensions, mm
65x45x26
Measurement error of eurosens DSS depends on the microstrain of the
element the sensor is fixed on. The more the load-bearing element is
deformed under load, the more sensitive the sensor is to axle load
changes.
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3INSTALLATION OF eurosens DSS
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3.1 CHOOSING INSTALLATION PLACE
When choosing an installation place, consider the required dimensions of the
mounting pads and the axle deformation zones shown in fig. 3.1 and fig. 3.2.
fig. 3.1. Typical deformation zones of the front axle
fig. 3.2. Typical deformation zones of the rear (driving) axle
compression
decompression
leaf spring
leaf spring
compression
decompression
leaf spring
leaf spring
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•It is possible to install one sensor eurosens DSS in the center of the non-
driving (front) axle (fig. 3.3), or two sensors –each on the left and right
side of the axle (fig. 3.4).
If the sensor is installed in the center of the axle (fig. 3.3), the predicted
deformation (and resolution) is smaller.
When installing on the side of the axle, it is highly recommended to
install two sensors eurosens DSS –each on the left and right side of the
axle (fig. 3.4), since the uneven loading of a vehicle as well as the roll of
a vehicle can distort the values.
fig. 3.3. Installing the sensor in the center of the front axle
fig. 3.4. Installing two sensors on the front axle
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•When installing on the rear axle, the preferred installation location is the
section between the leaf spring mount and the wheel. In this case two
sensors eurosens DSS must be installed –each on the left and right side
of a vehicle (fig. 3.5).
The axle deformation is maximum in this section, as well as sensor
sensitivity. If installation is not possible in this section, the sensor can be
installed as shown in fig. 3.6.
eurosens DSS can be installed in both compression and tension zones,
above or below the axle.
fig. 3.5. Sensor installation between leaf spring mount and wheel
fig. 3.6. Sensor installation between gear housing and leaf spring mount
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3.2 INSTALLATION RECOMMENDATIONS
1) Clean the sensor installation site: degrease, remove excess moisture and all
kinds of non-metallic objects, remove rust and other contaminants.
2) Cleaning can be done manually by using metal brushes, files, emery paper,
or by using a grinder.
Surface cleaning is a very important step, since any contaminations can
lead to the pores and cracks, metal stress and decrease in mount quality.
3) Install the mounting pads with the help of a conductor and fix them using
spot welding.
4) Remove conductor and weld the mounting pads (fig. 3.7).
fig. 3.7. Installation of sensor pads
sensor mounting pads,
spot welding
conductor
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4CONNECTION OF eurosens DSS
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eurosens DSS sensor can be connected using CAN bus interface. Sensor pinout is
given in fig. 4.1.
1 –VBAT
2 –GND
3 –CANH
4 –CANL
red
brown
yellow
green
fig. 4.1. eurosens DSS pinout
•Use special T-Cables to create sensor network (fig. 4.2).
fig. 4.2. Connecting sensors via T-Cables
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5SETTINGS AND CALIBRATION OF eurosens DSS
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Configuration of eurosens DSS is performed with the service software
eurosens DSS CAN Configurator and the service adapter (programming device)
eurosens Destination CAN.
5.1 CONNECTION PROCEDURE
1) Download the service software eurosens DSS CAN Configurator from the
eurosens DSS CAN product page and install it on your PC.
2) Connect the service adapter eurosens Destination to your PC via a USB
port.
3) Run the service software and select the COM-port if necessary. The LED
“Send” on the service adapter will start blinking.
4) Connect the sensor to the service adapter (fig. 5.1).
The configurator automatically searches for the connected devices. The
“Information” tab shows the information about the connected sensor
eurosens DSS (fig. 5.2).
fig. 5.1. Connecting sensor to service adapter and PC
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fig. 5.2. Information about connected sensor
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5.2 CALIBRATION OF SENSOR
5.2.1 SENSOR RESET
Sensor calibration allows you to set the calculation table for conversion of the
primary sensor values (detector values) into the output values of the sensor.
•The detector values can vary from -32000 to 32000 and are directly related
to the deformation of the sensor under load: the values increase with sensor
compression and decrease with sensor decompression.
•After installation, the sensor has some initial deformation which depends on
the tightening of fastening bolts and position of the sensor.
After sensor installation it is necessary to open the tab “Firmware
update” and click the button “Reset settings” (fig. 5.3). This operation
resets initial deformation of the sensor and normalizes the sensor
output.
fig. 5.3. Settings reset
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•After reset procedure the initial detector value is set to 10000 and default
sensor calibration table looks as shown in fig. 5.4.
•Default calibration is linear (scaled 1:1). The output value of the sensor is
equal to the internal detector value.
fig. 5.4. Default sensor calibration table
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5.2.2 SENSOR CALIBRATION ON SERVER SIDE
With the "default" calibration stored in the sensor, the conversion of the detector
value into kilograms must be carried out on the server side.
•To create calibration table at server side there is no need to visit a vehicle
and measure real axle loads with direct connection to sensors.
•The vehicle with installed sensors must be weighed on truck scales for
several times and with different cargo weight. It is necessary to measure
individual axle loads (not the total weight of the vehicle!).
•Two measurements allow you to create the table "Sensor value - axle load"
in kg and program it using the server software.
Since axle deformations are elastic, the dependence "sensor output
value" - "axle load" is close to the linear one. Therefore, two points are
sufficient for the table.
5.2.3 CALIBRATION ON SENSOR SIDE
Calibration on sensor side is used when it is necessary to display information
onboard, for example using eurosens Display CAN.
The calibration procedure:
•carry out several measurements of axle loads using scales;
•make sure that the sensor is connected to the configuration software during
the measurement procedure;
•enter the current axle load value (from truck scales) in the field "Load, kg"
(fig. 5.5);
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•add a new line to the calibration table by pressing the button "Calibrate";
•make at least 2 records for an empty and fully loaded vehicle.
It is possible to fill in the calibration table in several steps by saving intermediate
calibration values to the sensor.
There are two points in the calibration table (fig. 5.5), corresponding
to a minimum axle load of 3000 kg (empty vehicle). Such calibration
will not allow the extrapolation of the axle load values to go below
3000 kg if the detector value is below 9900.
fig. 5.5. Sensor calibration table
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5.2.4 SUPPORT OF SEVERAL CALIBRATION TABLES
One sensor can store up to 3 independent calibration tables (fig. 5.5). It allows you
to use one sensor as a source of 3 independent axle loads. This feature is helpful
when a vehicle has several closely spaced axles. In this case we can install only one
sensor and calibrate it for measurement of two axle loads.
Three identical calibration tables result in three identical axle loads
calculated from one detector value. If axle load values of closely spaced
axles are different, these values can be entered into the independent
calibration tables.
5.3 SENSOR READINGS
The tab “Sensor values”shows instant values of detector and axle load values
calculated according to calibration tables (fig. 5.6).
fig. 5.6. Sensor values tab
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