R2VEC -
Digital Electronic Controller

R2VEC - Digital Electronic Controller

R2VEC was originally designed to control a 25 litre V12 engine.  It provides the system builder with the enhanced flexibility and diagnostic capability which results from the use of modern digital technology.  The concepts for enhanced user value have been proven in a working partnership with an engine manufacturer over a number of years. The unit is based on a 32-bit processor, giving substantial computation power and accuracy.  The software can be written in C or Ada to suit the application requirements.

R2VEC is a versatile and flexible controller suitable for many uses.  It offers:

• fast real-time control response,
• very short boot-up reaction time,
• highly safety-conscious software standard,
• comprehensive diagnostics for short down-times,
• easy-to-use monitor tool gives faster configuration and tuning,
• good range of available interfaces for sensors and actuators,
• extremely rugged for high vibration and aggressive environments.

Applications include:

• machine tool positioning,
• actuator control,
• wind generator turbine control,
• transmission and drivetrain control,
• engine speed and fuelling control,
• air handling equipment regulation,
• vehicle body system control.

Physical Details

The unit is housed in a rugged aluminium case, 300 x 210 x 120mm, with four fixing holes. It is connected to the engine systems by up to seven connectors. A flat top surface allows the unit to accommodate either cooling fins or a fluid-cooled plate.

It has the capabilities to interface with the following peripheral equipment:

• an in-line fuel pump, including associated sensors,
• analogue sensors - temperatures, including thermocouple, pressures etc. - up to 43 inputs can be accommodated,
• inductive sensors for position etc.,
• actuators - solenoids, valves, lamps etc. - up to 29 outputs are available,
• a transmission controller,
• a diagnostic monitoring tool - a standard PC running R2Scope.

Environmental Performance

The case is designed to withstand operation mounted on or near the engine, protected to IEC529 IP67 including total submersion and air transportation.  The operating temperature range is from -50 to +85°C, storage range is from -55 to +120°C.

Communications Facilities

• MIL-STD-1553
• EIA/TIA232
• Controller Area Network (J1939)
• RS485/RS422
• J1708

Software Functions

The software can provide a wide range of control and protection strategies for the engine which enhance performance.  Facilities which have been provided include:

• control of fuelling using a wide selection of standard or custom regimes, including two speed with long range idle, all speed or single speed governors.  Driveability is improved by the use of techniques to smooth the transitions between engine running modes and a sophisticated governors are available to provide features such as soft start and stall reduction.
• engine protection against damaging conditions such as overspeed by either cutbacks or an engine shutdown.  Protection is facilitated by use of dedicated diagnostic sensors and / or correlation between readings.  Sophisticated diagnostics and prognostics can also be implemented depending on requirements.
• continuous monitoring of sensors and actuators to detect system faults, and reversionary actions to continue running where possible.  This includes the substitution of alternative measurements, cutback of power and partial or full shutdown.  Multilevel fault logging and reporting is also implemented using a dedicated logbook memory.
• coupled with the wide range of interfaces, software modules are available to control subsystems and peripheral devices, for example air handlers, transmission, variable geometry turbochargers, generator synchronisation and load sharing.
• data exchange facilities to allow the unit to act as interface between serial databus ports of various formats.

Software Reliability

The performance of controller specifications has focussed more and more closely on reliability in recent years.  This is because users have begun to appreciate how serious a software failure can be, and how difficult it is to be confident a failure will be handled gracefully.  R2G2 has invested many man-years into the development of tools and methods to detect and handle all types of failure, from misunderstood specifications to data corrupted by particle radiation.

These techniques have proved valuable in ensuring that our control equipment gives the maximum levels of system availability.

Flexibility

The available processing power and wide range of interfaces allow the R2VEC to be adapted to almost any application, and the design architecture is structured to give the maintenance crew greater insight into the engine performance.  Using a laptop computer the unit may be configured to log operating data for later download.  Detailed measurements of peripheral characteristics may be taken without direct access to the engine, speeding diagnosis and reducing downtime.

The flexibility in data interfaces and signal connections permits co-operation with many types of drivetrain equipment.