ErgoDrive. Driver s Aid. Operating Instructions. Professional. March 2018

Transcription

1 Driver s Aid ErgoDrive Professional Operating Instructions March mailbox@cbb.de Exhaust emission certification Gear box optimization Testing of vehicle cooling Brake force measurement

2 Content: 1 Safety instructions Observe instruction manual Liability for function respectively damages Introduction Description of the structure of ErgoDrive Professional Connection to the chassis dynamometer Software connection via LabMap Installation of the hardware (data acquisition clamps with fieldbus coupler) Connection of the fieldbus coupler Incremental encoder interface Digital output terminal e.g. for bag sampling control Analogue output terminal (optional) End clamp Operating of a climatic chamber suitable monitor Airbag in the test vehicle Connecting the cable set to the monitor Establishing the HDMI connection to the LCD monitor Connecting the power supply Connecting to VDC Switching On and Off Autosync-push button Operation in sub-zero ambient temperatures Drying cartridge Specification of safety classes Technical data Connector assignment Assignment of the voltage connection (see marking on the cable): Assignment RS232-connector (standard assignment): Installation instructions for the touch screen driver Calibration of the touch-screen Page 2 from 116

3 6 Usage of the suction cup fastening Airbag in the test vehicle Attaching the suction cup fastening Rules for using the suction cup fastenings The stand s fastening screws Installation of the tripod fastening (optional) Installation of the notebook fastening (optional) Programme start of the DA ErgoDrive Professional Operation of the DA ErgoDrive Professional Drive curves of the DA Speed cycles (Exhaust gas laws) v = f(t) Drive curve pass routes (gradient to test stand computer) gradient = f(s) Display of measurement values Drive curve height = f(s) (2D-height profile) Drive curve 3D-pass routes height= f(s) (3D-road simulation) Drive curve mountain with variable speed Drive curve temperature cycles, T = f(t) ,4 LCD-Display Airbag in the test vehicle Fastening of the suction stand of the LCD-display Connecting the cable set to the LCD-monitor Establishing the VGA-connection to the LCD-monitor Connecting the power supply Connection to VDC Page 3 from 116

4 13 Recorded measurement values Program call Open a log file Conversion Entry of test data Conversion of the customer drive cycles Conversion of the gradient Later conversion of further cycles Installation of the drive cycle conversion programme Starting the drive cycle conversion programme Conversion with the drive cycle conversion programme Editing the data record for the operating mode v over t Gear change table for the operating mode speed over time Tolerance field data for the operating mode v over t Driving cycle data for the operating mode v over t Gear change point entries in the data record Setting of digital outlets (optional) Bag sampling control (optional) Supplied data records for driving cycles in operating mode v over t Editing the data record for operating mode 2D altitude profile Construction of the data record in the operating mode 3D road simulation Description of the objects in the operating mode 3D road simulation Car Object Page 4 from 116

5 19 Data record for further values such as e.g. gradient Possible variables in the data record Declaration of the values Determine display of the course in the DA Time controlled data record Route controlled data record Use of variables in the data records Table of the variables used Display of information from data records Display of cycle number and position number Display of the profile name Display of the message profile end Use of the variables with control function Switching to display (v- and mountain cycle running automatically) Setting of digital outputs (switching 4 channels) Conversion of GPS-data records (optional) Installation of the GPS-converter Use of GPS-receive system in the vehicle Function of the GPS-converter Starting the application Main screen Add source file Delete source file Entry format Output format Output path Start conversion End programme Page 5 from 116

6 22.4 Step by step instructions Necessary data for the conversion Parameters for the conversion Error recovery Maximum acceleration Maximum delay Maximum change in gradient Error handling Maximum number of errors before cancellation General information for data recording with GPS devices: Coast-/Beacon radio EGNOS Omnistar Experience with GPS data Contact Page 6 from 116

7 1 Safety instructions For your safety please observe the following advice. The provided equipment with all appending components (monitors, mountings, notebooks etc.) may under no circumstances be applied within the working range of an airbag. cbb software GmbH does not accept any liability for damages of any kind that arise from failure to comply with this warning! Please strictly observe the safety instructions in the following chapters and operating instructions of additional equipment. cbb software GmbH does not accept any liability for damages of any kind that arise from failure to comply with this warning! 1.1 Observe instruction manual Any handling of the driver s aid ErgoDrive Professional requires an exact knowledge and observance of this instruction manual. This program is only meant for the described technical purposes. Furthermore, when operating the chassis dynamometer, the instruction manuals as well as the safety regulations of the chassis dynamometer producer must be observed. 1.2 Liability for function respectively damages The liability for the function is in every way transferred to the owner or user in case of operation and handling that is not in accordance with the intended use. cbb software GmbH is not liable for damages that occur due to disregard of the preceding directions. Warranty- and liability terms in the cbb software GmbH conditions of sale and terms of delivery are not extended by the preceding directions. The supplied display devices as well as their holding fixtures may under no circumstances be applied within the working range of an airbag. cbb software GmbH does not accept any liability for damages of any kind that arise from failure to comply with this warning! Page 7 from 116

8 2 Introduction The driver s aid (DA) ErgoDrive Professional is the indispensable interface to the driver in manned test drives on chassis dynamometers. Just like on the real road, the test driver is integrated in the driving process as controller via the driver s aid as visual feedback. The set and actual speed or the actual and the future gradient are presented to the driver as main values on the ErgoDrive in a clear and ergonomic way. This enables the driver to carry out his tasks also for longer periods of time in a concentrated and relaxed way while providing reproducible results. The process data produced on the chassis dynamometer during vehicle testing (e.g. speed, gradient, height, traction, power, temperature, humidity, insolation) are captured via the corresponding inputs and are displayed as digital values in a display field (optional). Additionally this data is stored by ErgoDrive Professional in a log file, which enables evaluation of the data with a conversion programme (log2xls) in Microsoft Excel.. In order to display the different test requirements, the DA offers the following surfaces for the different versions (software modules), which can also be purchased at a later point in time: Speed over time: - Vertically scrolling speed profile with display of a tolerance range and the gear shift points, - Depiction of the overall profile in a second window on the left side of the screen with marking of the actual position with a red line, - Recording of drive violations occurred when leaving the tolerance range on the right side of the screen, - Display of data from the DA as well as measurement values from the climatic wind tunnel such as cycle name, actual speed, overall actual traction, actual wind speed, wind temperature, humidity, drive cycle, drive fault time, remaining and driven time, remaining and driven route, actual speed in mph as well as time shown as digital values on the left side of the screen. - Firm background and mobile speed-actual-value-cursor for drive cycles up to 70 km/h and 110 km/h. - Moving background and mobile speed-actual-value cursor for drive cycles of more than 110 km/h. Surface files have the file ending.cfg and begin for speed over time display with the file name speed. An automatic loading when opening a time controlled speed cycle can be realized at the customer s request. Page 8 from 116

9 Universal graphic data display (display of values such as e.g. gradient over route or temperature over time): - Horizontally or vertically scrolling profile depending on route or time. - Display of the overall profile in a second window with marking of the actual position. - Display of data from the DA as well as measurement values from the climatic wind tunnel such as cycle name, actual speed, overall actual traction, actual wind speed, wind temperature, humidity, drive cycle, drive fault time, remaining and driven time, remaining and driven route, actual speed in mph as well as time shown as digital display on the left side of the screen possible. The surface files have the file ending.cfg and begin for the gradient over route display with the file name pass_drive_2d. Automatic loading when opening a route controlled mountain cycle can be realized at the customer s request. Display of measurement values - Display of measurement values from the climatic wind tunnel such as actual wind speed in km/h and mph, wind temperature, humidity, insolation, actual speed in km/h and mph, traction for front roller (only KW II), rear roller (only KW II) and overall traction, power of front roller (only KW II), rear roller (only KW II) and overall power as well as the time as digital display. The surface files have the file ending.cfg and begin with the file name measurement_diaplay. Automatic loading when opening a corresponding cycle can be realized at the customer s request. Up- and downhill drive with variable speed (display of speed over route): - Vertically scrolling speed profile with display of a tolerance range and the gear shift points. - Display of the overall profile in a second window on the left with marking of the actual position via a red line. - Recording of drive violations when leaving the tolerance range in the upper right window corner. - Display of the gradient profile in a third window at the bottom with marking of the actual position via a red line. - Display of data from the DA as well as from the climatic wind tunnel such as cycle name, actual speed, change of gradient, delta gradient, actual gradient, next set gradient, actual overall traction, position-no., maximum and actual height as well as remaining and driven route as digital display on the left side of the screen. - Additional display of the gradient in a round instrument. The surface files have the file ending.cfg and begin for the gradient over route display with the file name hill_drive_var_v. Automatic loading when opening a route controlled mountain cycle can be realized at the customer s request. Page 9 from 116

10 2D-altitude profile (display of the height over route): - Horizontally scrolling height profile. - Display of the overall profile in a second window at the bottom with marking of the actual position with a red line. - Display of data from the DA as well as from the climatic wind tunnel such as cycle name, actual speed, change of gradient, delta gradient, actual gradient, next set gradient, actual overall traction, position number, maximum and actual height as well as remaining and driven route as digital display on the left side of the window. The surface files have the file ending.cfg and begin with the file name 2D_altutude. Automatic loading when opening a route controlled mountain cycle can be realized at the customer s request. 3D-road display (display of the height over route and the real route): - Three-dimensional display of the route course, - Display of landscape objects, - Display of the overall profile in a second window at the bottom with marking of the actual position with a red line. - Display of data from the DA as well as from the climatic wind tunnel such as cycle name, change of gradient, delta gradient, actual gradient, next set gradient, actual overall traction, position number, maximum and actual height as well as remaining and driven route as digital display on the left window side. The surface files have the file ending.cfg and begin for the 3D-road display with the file name pass_drive_3d. Automatic loading when opening a route controlled 3D-mountain cycle can be realized at the customer s request. The following chapters describe the operation and functions of the ErgoDrive Professional. Page 10 from 116

11 3 Description of the structure of ErgoDrive Professional The connection of the driver s aid (DA) ErgoDrive Professional to the chassis dynamometer can be realized via fieldbus interface, digital interfaces or analogue interfaces. The set and actual values of the process data between DA and chassis dynamometer or climatic chamber are exchanged via this interface. The following Figure 1: shows the software structure of the DA. DA-computer DA Data computer 1 (optional) : Data computer n (optional) DA Client Application LabVIEW, Delphi,... LabMap LabMap LabNet Labxxx Interface to chassis dynamometer Connection of chassis dynamometer, climatic chamber etc. Figure 1: Software structure of the driver s aid DA: Driver s aid ErgoDrive Professional, visualisation of the test run. Selection in accordance with the DA-client s requirements. DA-client: Operation of the driver s aid (cycle, start, pause, end, open drive cycle, load display mode (surface) etc.). Page 11 from 116

12 Softwarebus LabMap: Middleware for data acquisition and data distribution, here for data exchange between hardware and DA-software or other assessment software on other data computers. LabNet: Global data exchange with other computers. This e.g. serves as remote control of the DA or for display of process data e.g. with LabVIEW. Labxxx: Interface (software connection) between the interface hardware and LabMap, e.g. Lab- Modbus for fieldbus coupler, LabAK or similar. Interface to chassis dynamometer: Hardware for interfacing to the chassis dynamometer and exchange of the necessary data and signals, e.g. via fieldbus coupler with input-/output modules, network card, digital I/O-card or similar. The display of the driver s aid device ErgoDrive Professional in the test vehicle can be carried out on a second monitor on the test vehicle, via a projector, via a display or on a mobile outdoor-pc with TFT monitor in the test vehicle. In the operator-room the same surface is displayed on a monitor. The monitor or the display in the vehicle are connected via cable with the driver s aid computer. Operation via a second keyboard from the vehicle with an automatic change-over switch is also possible. When using an outdoor-pc (optional, also climatic chamber applicable execution) the connection to the driver s aid computer is established via radio-ethernet. The outdoor PC is designed as an independent computer so that the drive profile in the vehicle and the one in the operator-room are running simultaneously. Page 12 from 116

13 4 Connection to the chassis dynamometer Depending on your order the connection of ErgoDrive Professional to the chassis dynamometer is carried out with software via LabMap (see Figure 1: Software structure of the driver s aid) or with hardware via data acquisition clamps with fieldbus coupler. 4.1 Software connection via LabMap If your driver s aid ErgoDrive Professional is connected to the chassis dynamometer through software via LabMap, all necessary measures have been carried out automatically during the installation (this also applies to a necessary new installation, where the settings are carried out automatically). 4.2 Installation of the hardware (data acquisition clamps with fieldbus coupler) If your driver's aid ErgoDrive Professional is connected with the chassis dynamometer with hardware via data acquisition clamps with fieldbus coupler, the clamps must be connected as follows Connection of the fieldbus coupler The fieldbus coupler of Wago Kontakttechnik GmbH ensures the data exchange between the data acquisition clamps and the driver's aid computer via Ethernet-protocol and the softwarebus LabMap. The fieldbus controller comprises of: Device supply with internal system supply module for the system supply as well as power jumper contacts for the field supply via assembled I/O modules Fieldbus interface with the bus connection Display elements (LED s) for status display of the operation, the bus communication, the operating voltages as well as for fault messages and diagnosis Configuration and programming interface Operating mode switch Electronics for communication with the I/O modules (internal bus) and the fieldbus interface The connection of the fieldbus to the network card in the driver s aid computer is carried out by an RJ45 connector also called western connector. A category 5, shielded/unshielded twisted pair cable (S-UTP) with an impedance of 100 Ohm ±15% is mandatory as a connecting line for the 10BaseT Interface. The connection point is physically lowered for the coupler/controller to fit in an 80 mm high switch box once connected. The electrical isolation between the fieldbus system and the electronics is achieved by means of DC/DC converters and optocouplers in the fieldbus interface. Page 13 from 116

14 Figure 2: fieldbus coupler Furthermore the power supply of the data acquisition clamps is carried out via the fieldbus coupler. The supply with 24 V DC voltage from a power supply unit (e.g. Wago-power supply unit ) is fed via clamps with CAGE CLAMP -connection: 24V (red) plus and 0 Volt (blue) minus. The power supply for the devices serves the system supply and the field supply. The power supply integrated in the fieldbus coupler generates the necessary voltages for the supply of the electronics and the stringed bus terminals. The fieldbus interface is supplied with a galvanically separated voltage from the power supply unit. If another power supply unit is used there should be a capacity of 1 A. The operating condition of the fieldbus coupler respectively the node is indicated with LEDs. LED Colour Meaning ON green Fieldbus initialization is correct. LINK green Link to a physical network exists. TxD/RxD green Data exchange taking place. ERROR red Error on the fieldbus. IO red /green/orange The I/O -LED indicates the operation of the node and signals faults encountered. A green Status of the operating voltage - system B or C green Status of the operating voltage - power jumper contacts (LED position is manufacturing dependent) Further information on the fieldbus coupler you can find in the enclosed documentation on the Wago-I/O-system Page 14 from 116

15 4.2.2 Incremental encoder interface The driver's aid computer receives the actual speed of the chassis dynamometer from the evaluation of the signal from the incremental encoder. The incremental encoder is connected to the incremental encoder interface in the following way: Figure 3: incremental encoder interface This module is an interface for any incremental encoder with a RS 422 connection. A counter with quadrature decoder as well as a latch for the zero impulse can be read or enabled by the control. The control can set the counter or transmit the counter value to the Latch. As an alternative this can also be done using input C or Latch. The frequency data is automatically acquired and can also be transmitted to the control. A counter lock-out is possible using input G. Input Ref can be used to activate the initial point C function. The outputs N1 and N2 indicate whether the counter value is within a defined range of values. The range can be adjusted. The module must be powered using an external 24 V DC power supply. It is then possible to supply the encoder with 24 V DC, or alternatively with 5 V DC derived internally from the terminations (Ue/U0). The shield (screen) is directly connected to the carrier rail. The monitor connection is lead directly to the bracket. Further information you can obtain from the enclosed documentation on the Wago-I/O-system. Page 15 from 116

16 4.2.3 Digital output terminal e.g. for bag sampling control The Digital Output Relay (2 changeover contacts isolated outputs, AC 250 V, 1 A) is intended e.g. for the connection of a bag sampling control for exhaust emission analysis. Figure 4: digital output terminal The power supply for the relay coils is not made via the power jumper contacts but directly from the electronics. The respective output contacts of the switching element are therefore always positioned at the field side. The power supply is made via a series-connected supply terminal block for the respective operating voltage. Power connections are made automatically from module to module when snapped onto the DIN rail. One termination point of these contacts must be directly connected to the power supply. These I/O modules are not provided with integrated power jumper contacts. Care should be taken to supply each isolated module with separate power supply connections. The connection to the change over contact 1 is carried out with feed to clamp 1, the outlet is connected to clamp 12 (normally closed contact) or clamp 14 (normally open contact). Please find further information in the enclosed documentation on the Wago-I/O-system Page 16 from 116

17 4.2.4 Analogue output terminal (optional) The analogue output terminals create an analogue output signal in the form ±10V. This can be used e.g. for the output of the set speed value or the gradient value, if this is required as analogue value. Sensors should be connected to "AO" and to the common ground. The shield is connected to "S". The connection is made automatically when snapped onto the DIN rail. These I/O modules are not provided with integrated power jumper contacts. The power supply is made by the data contacts with a DC-DC converter. There are 2 analogue outputs for each output terminal. Figure 5: analogue output terminal The bus terminals have no integrated power contacts. The input of the necessary power supply is carried out via the data contacts with DC-DC converter. This guarantees the operation of these bus terminals, independent of the supply voltage for the field side. Please obtain further information from the enclosed documentation on the Wago-I/O-system End clamp One end clamp (e.g ) must be set at the end of a fieldbus node. This closes the internal clamp bus and the proper data transmission is guaranteed. Page 17 from 116

18 5 Operating of a climatic chamber suitable monitor For operating of a climatic chamber suitable monitor with touch screen (model 12 and 15 ) please note the following information: Figure 6: Climatic chamber suitable 15 monitor with suction cup fastening Warning: This device may under no circumstances be applied within the working range of an airbag. cbb software GmbH does not accept any liability for damages of any kind that arise from failure to comply with this warning! 5.1 Airbag in the test vehicle An existing airbag must be deactivated when using the monitor in the test vehicle, if the monitor is secured in any way on the steering wheel, or is used within the working range of a steering wheel, passenger, side or other airbag. cbb software GmbH accepts no liability for damage of any kind that arises from failure to comply with this warning! Safety Instructions: The monitor may be not secured at a location where, in the event of an accident, it could be thrown against the driver/passenger, as this could cause severe injuries. The monitor must under no circumstances be mounted within the working range of an airbag. The glass substrate of the display is covered with a plastic layer, but pieces of glass or the metal housing could cause personal injury in the event of a serious accident. Discuss the installation location in the vehicle with a safety officer and follow the safety instructions. Exclusion of Liability: No responsibility is accepted for accidents or injuries that arise from failure to comply with the rules and safety instructions detailed above. 5.2 Connecting the cable set to the monitor Connection cables are included with the monitor to transmit the HDMI signal (HDMI connection cable), to transmit the touch screen signals (RS 232) and to supply the power ( VDC), either via a 230 V AC power unit or via the on-board socket in the vehicle. The permissible input voltage range amounts to 9 36 VDC. Page 18 from 116

19 5.3 Establishing the HDMI connection to the LCD monitor Switch off the computer and the supply to the monitor and plug in the connection cable to the HDMI output of the computer. The correct side of the cable is marked with Source. Plug in the other cable end to the display in the HDM. This side is marked with HDMI device. Please do not interchange the ends because the signal is amplified and then the signal transmission does not work. 5.4 Connecting the power supply Plug the connector of the connection cable into the associated socket of the display and turn the connector gently until tight. The connectors used are reverse polarity protected. Before pulling the connection out again, loosen the screw-type locking. Plug the main cable into the power unit located at the other end of the power supply cable. Only connect the power unit to a power supply in the range VAC, Hz. A green LED indicates whether there is a power supply to the power unit. Operating with direct current or with voltage or frequency ranges other than given, can damage the power unit and the monitor! 5.5 Connecting to VDC For use in a normal car, the monitor s input voltage range amounts to 9 36 volts of direct current. This monitor is also suitable for use in HGVs. Check that you have the correct vehicle voltage for the monitor before connection, as otherwise this could be damaged. A green LED in the connector for the on-board socket indicates whether there is a power supply when using the connection cable for the on-board socket. Operating with alternating current or at voltages larger than stated leads to damage of the monitor! Safety Instructions: Power supply to the monitor must only be effected via an electric circuit protected by a cut-out fuse. Pressure on the supply line when it is connected to an insecure circuit could cause a dangerous cable fire and this could lead to personal injury! The connection cables may only be installed in such a way that ensures they cannot accidentally touch the operational controls of the vehicle and do not block or reduce the effect of safety equipment. The driver must not be hindered by the cables in any way (steering wheel, pedals, gear change, operational controls, etc.) 5.6 Switching On and Off The monitor can be switched on and off using the On/Off button. The thermostatically controlled heating cannot be switched off and heats automatically from ca. +5 C. 5.7 Autosync-push button The Autosync -button optimises the display for the current image signal. Further adjustments are executed automatically by the monitor so that user intervention is not necessary. Page 19 from 116

20 5.8 Operation in sub-zero ambient temperatures In ambient temperatures between 0 C to -20 C the monitor must be connected to the power supply for ca. 30 minutes before operation so that the device can preheat. In extreme environmental conditions (ambient temperature below -35 C) the monitor may only be used with the provided 230V power unit. In these environmental conditions the power supply must be permanently ensured. 5.9 Drying cartridge When the drying cartridge has been used up (blue colour is no longer visible), this must be replaced by a new cartridge, to prevent condensation build-up on the inside of the device. The drying cartridge is located at the top left on the monitor Specification of safety classes Generally the device complies with the safety class IP 54, the following shows the exact specification for the ports: - Connected connector receptacle (HDMI, RS232): IP54 - Connected connector power supply: IP67 - shielded connector receptacle, covers bolted (HDMI, RS232): IP54 - shielded connector power supply: IP67 - unshielded connector receptacle (HDMI, RS232): IP50 (for the contacts of the connector receptacles) - unshielded connectors power supply: IP50 (for the contacts of the connector receptacles) For the device (except ports) with unshielded ports still IP54 applies Technical data Power supply: max VDC Power consumption: max. 100 watt (max. 30 W for the monitor and max. 70 W for the radiators). Display: 15,1 colour-tft, screen resolution: 1024 x 768 pixels, brightness: 350 cd/m² Measurements: 320 x 260 x 50 mm, weight approx 4,5 kg without holding device Operating temperature range: C, Storage temperature range: C Ports: Power supply, HDMI, RS232 for touch Scope of delivery: Connecting cable 2 m for cigarette lighter / on board socket, ext. power supply VAC incl. 30m cable, set of cables HDMI/RS232 30m Page 20 from 116

21 5.12 Connector assignment Assignment of the voltage connection (see marking on the cable): PIN 1 = GND PIN 2 = GND (radiator) PIN 3 = Plus (radiator VDC) PIN 4 = VDC Assignment RS232-connector (standard assignment): (on monitor) 9 PIN D-SUB FEMALE on monitor: Pin Name RS232 V.24 Dir Description 1 n.c. 2 RD BB 104 Receive Data 3 TD BA 103 Transmit Data 4 n.c. 5 GND AB 102 System Ground 6 n.c. 7 n.c. 8 n.c. 9 n.c. Page 21 from 116

22 5.13 Installation instructions for the touch screen driver 1. Insert the touch-screen-driver CD in the CD-ROM disc drive. 2. In explorer change to CD. 3. Open the directory on the CD. 4. Double click the file setup.exe. The installation routine for the driver will be started. 5. Click Next, in order to reach the next step. 6. Accept the licence agreement by ticking (click) the Check-Box and then click Next. 7. Select the type of controller 12 or 10 bit controller. Then select Serial (RS/232) as controller interface. Click Next. 8. Click Finish, in order to start the installation. 9. After finalising the installation click OK in order to restart the computer Calibration of the touch-screen 1. Click the Windows button Start and enter the menu Programme. 2. Click Hampshire TSHARC Control Panel, in order to open the touch screen calibration control panel. 3. Select the controller type in the register window Controller Selection. This step is not necessary if there is only one controller. 4. Open the register window Calibration. 5. Click the button configure, in order to stipulate the number of calibration points (3, 4, 16 or 21). The more points are stipulated, the more exact is the calibration. 6. After stipulation of the number of calibration points click on the large button in the middle (with the red pointers), in order to start the calibration. 7. Now touch the touch-screen exactly at the stipulated point and wait a short moment. Release the touch when the word RELEASE appears next to the touch point (note small writing). Follow the instructions on the touch-screen. 8. Continue these steps in accordance with the instructions on the touch-screen until all calibration points have been set. Then click Accept, in order to finalize the calibration. Then close the control panel. 9. The touch-screen is now ready for operation. NB: The calibration process can at any time be abandoned by clicking on the button Abort. Page 22 from 116

23 6 Usage of the suction cup fastening Using the suction cup fastening with hydraulic stand belonging to the climatic chamber suitable monitors with touch screen (model 12 and 15 ) please note the following information: 6.1 Airbag in the test vehicle Figure 7: suction cup fastening with hydraulic stand An existing airbag must be deactivated when using the suction cup fastening in the test vehicle, if the fastening is secured in any way on the steering wheel, or is used within the working range of a steering wheel, passenger, side or other airbag. cbb software GmbH accepts no liability for damage of any kind that arises from failure to comply with this warning! Please always observe the operating instructions included with the device mounted on the fastening! 6.2 Attaching the suction cup fastening First select a suitable place to install the monitor in the vehicle. The monitor should be supported on the dashboard if possible. To avoid scratches or other damage to the dashboard, lay something soft (e.g. a piece of foam) between the monitor and the dashboard. Loosen the hand wheel of the hydraulic stand delicately and carefully until you can feel no more resistance. Do not turn any further under any circumstances! Note: Never turn the hand wheel so far that it comes off completely, as hydraulic oil leaks out and air gets into the hydraulics. This would damage the stand irreparably! Set up the hydraulic stand so that the monitor is aligned perfectly and supported if possible on the dashboard. Tighten the hand wheel as far as it goes. Only tighten the hand wheel by hand! Press the cleaned suction plate of the suction cup against the surface to which the fastening is to be secured (e.g. windscreen) and create the necessary pressure by pulling on the fixing lever. Check that the stand has a secure hold! The suction cups can be removed again by pulling the lever back. Page 23 from 116

24 6.3 Rules for using the suction cup fastenings To achieve the greatest possible safety when using the suction cup, the following rules should always be observed: Only use the suction cups on even and sealed surfaces, which are clean, dry and free from oil and grease. The load bearing capacity is reduced on rough surfaces. Always keep the suction cups, and particularly the rubber discs, clean and free from oils and grease. The rubber discs must be stored in an unstressed condition. Examine the suction cups before each use for function and possible damage. Attach the suction cups again if the hold does not appear satisfactory to you. This applies especially to longer periods of use. The suction cups are to be checked regularly for strong hold. Try not to remove the rubber discs with sharp-edged objects or tools; you would damage them. Never use suction cups with damaged rubber discs. The suction fastening is intended for short periods of use. For longer periods of use, the suction pressure must be re-established under suitable conditions. If this is not possible another method of fastening must be selected. Please be careful that the device does not fall off due to inadequate pressure, as it could be damaged and could also cause personal injury! Loosen the hand wheel of the hydraulic stand carefully until you can feel no more resistance. Do not turn any further under any circumstances! Never turn the hand wheel so far that it comes off completely, as hydraulic oil leaks out and air gets into the hydraulics. This would damage the stand irreparably! Always tighten the hand wheel as far as it goes. Only tighten the hand wheel by hand! Do not use a tool! Set up the hydraulic stand in such a way that the monitor is aligned perfectly and supported if possible on the dashboard. Safety Instructions: The suction cup fastening with the device on it may be not secured at a location where, in the event of an accident, it could be thrown against the driver/passenger, as there would be a danger of severe or fatal injuries. The suction cup fastening with the device on it must not be mounted within the working range of an airbag under any circumstances. Set up the hydraulic stand in such a way that the monitor is supported if possible on the dashboard. Renew the suction pressure daily by remounting the stand. Discuss the installation location in the vehicle with a safety officer and follow the safety instructions. Exclusion of Liability: No responsibility is accepted for accidents or injuries that arise from failure to comply with the rules and safety instructions detailed above. 6.4 The stand s fastening screws The screws, with which the stand is fastened to the mount and the mount to the monitor, have been secured with Loctite High Performance. Loctite High Performance is a special material for permanent screw connections that can no longer be removed. These screw connections can only be removed with difficulty with normal tools (by heating to 300 C) Be careful not to damage the monitor during this process! Page 24 from 116

25 7 Installation of the tripod fastening (optional) Place the tripod fastening e.g. on the floor in front of the front passenger seat outside of the working range of an airbag. Otherwise the airbag must be deactivated. Adjust the fastening so that you have an optimal view of the display retaining plate. The length of the tripod legs can be adjusted telescopically. For this purpose release the latch on the tripod leg by pulling. Now adjust the desired length of the tripod leg. Then fasten the latch again, the tripod leg are now fastened. Display plate with projection platform Latch Telescope leg Figure 8: tripod fastening in the vehicle Please make sure that the tripod fastening has a safe foothold. Now place the projection platform on the display retainer plate, make sure that the Velcro strips on the back of the projection platform are connected with the Velcro strips on the retaining plate. Now establish all necessary connections (e.g. power supply) between the projection platform and the driver's aid. Warning The tripod fastening may under no circumstances be used within the working range of an airbag. cbb software GmbH is not liable for any damages that arise from violation of this warning! Page 25 from 116

26 8 Installation of the notebook fastening (optional) Place the notebook fastening e.g. on the floor before the front passenger seat outside of the working range on an airbag. Otherwise the airbag must be deactivated. Adjust the fastening so that you have an optimal view of the display of the notebook. The incline of the notebook retainer plate is adjustable. For this purpose release the upper twist grip and secure it again after adjustment of the optimal position. The length of the tripod leg can be adjusted telescopically. For this purpose release the lower twist grip. Now adjust the optimal length of the tripod leg and the secure the twist grip again. Notebook retaining plate Retaining springs Upper twist grip Lower twist grip Telescope leg Figure 9: notebook fastening It is absolutely necessary to ensure that the notebook fastening has a safe foothold. Now place the notebook on the display retaining plate, at the same time pull the retaining springs on the side apart. Make sure that the Velcro strips on the back of the notebook are connected with the Velcro strips on the retainer plate. Now make all the necessary connections between the projection platform and the driver's aid. Warning The notebook fastening may under no circumstances be used within the working range of an airbag. cbb software GmbH is not liable for any damages that arise from a violation of this warning! Page 26 from 116

27 9 Programme start of the DA ErgoDrive Professional After starting the computer, ErgoDrive Professional is started with a double click on the button ErgoDrive on the desktop. The standard directory of the driver s aid (DA) is on the DA -PC (drive C:\ErgoDrive). 10 Operation of the DA ErgoDrive Professional After the start of the programme the DA surface appears. Below the surface is the control panel (DA- Client), Figure 10, from which the operation of the DA ErgoDrive Professional and the selection of the drive cycles (drive profiles) are carried out. 1. load drive curve manually (selection of display surface) 2. open drive cycle (drive profile) 3. start the drive cycle with the DA 4. end DA ErgoDrive Professional Figure 10: Control panel of the DA after start of the programme The individual operating instruments have the following functionalities: 1. Load drive curves: For loading of the surface display of drive curves in the DA. The standard directory of drive curves is: C:\ErgoDrive\configurations. The available surfaces depend on the scope of delivery. Missing surfaces can at any time be purchased separately. speed_70.cfg: Speed cycles (exhaust gas laws) v = f(t) with firm background in the range of 0 to 70 km/h speed_110.cfg: Speed cycles (exhaust gas laws) v = f(t) with firm background in the range of 0 to 110 km/h speed_floating.cfg: Speed cycles (exhaust gas laws) v = f(t) with sliding background in the range of 0 to 220 km/h pass_drive_2d.cfg: Pass routes (gradient on chassis dynamometer computer) Gradient = f(s) display of the set gradient over route hill_drive_var_v.cfg: Pass routes with variable speed, display of the speed over route with handover of the gradient to the chassis dynamometer computer. 2D_altitude.cfg: 2D-height profile for display of the height over route with handover of the gradient to the chassis dynamometer pass_drive_3d.cfg: 3D-road display with display of the height over route with handover of the gradient to the chassis dynamometer measurement_display.cfg: Display of measurement values as digital display without display of drive curves, for KW I without and for KW II with front- and rear values for traction and performance. Page 27 from 116

28 2. Load drive cycle: Selection of the desired drive cycle, e.g. ECE or mountain pass. The included ASCII files as well as own data records can be selected as data record. The standard-directory for the drive cycles is: C:\ErgoDrive\profiles. 3. Start: This button activates the drive cycle (the test run) with the DA as well as recording (logging, optional) of the measurement values. For this also see Figure End: This button ends ErgoDrive Professional. A query window prevents the unintentional termination of the programme, e.g. through accidental clicking on the button with the mouse. Confirm with yes, when you want to end the programme or with no, if you want to continue the programme. An accidental termination of the programme during a test run is not possible, because the function of this button changes to the pause/continue function during the test (see Figure 11). After the start of the drive cycle with the DA by activating the button 3. the buttons in the menu bar change: Start the functions of 1. load drive curve manually (selection of display surface) 2. open drive cycle (drive profile) 5. end the drive cycle with the DA 6. Pause (interrupt the drive cycle with the DA) 4. end DA ErgoDrive Professional Figure 11: Menu bar of the DA after the start of a drive cycle 5. End drive cycle: The drive cycle and the recording (logging, optional) of the measurement values are ended. A query window prevents the unintentional termination of the test, e.g. through accidental clicking on the button with the mouse. Confirm with yes, if you want to end the cycle or with no, if you want to continue the cycle. The DA automatically goes back to the beginning of the loaded drive cycle. The function of the buttons changes again as shown in Figure 10. The logged measurement values you can find in the directory: C:\ErgoDrive\Data-Log. (see chapter 13 Recorded measurement values ). The DA is now automatically at the beginning of the loaded drive cycle in pause mode. Now a new drive cycle can be loaded or another test can be carried out with the loaded drive cycle. In order to start the test, again the button 5. Start must be activated. 6. Pause: The cycle is interrupted with this button. The symbol on the button changes into pushed Pause (Figure 12), the DA surface shows the message Pause. The recording of the measurement values (logging) continues in pause mode, however only the values with the corresponding support points changing during pause mode are recorded. Page 28 from 116

29 1. load drive curve manually (selection of display surface) 2. open drive cycle (drive profile) 5. end the drive cycle with the DA 6. Pause (continue the drive cycle) 4. end DA ErgoDrive Professional Figure 12: Menu bar of the DA after start of a drive cycle In order to continue the drive cycle at this point, press the button 6. Pause (Continue the drive cycle) again, the symbol of the button changes into not pushed Pause (interrupt drive cycle), see Figure 11. This function only interrupts and continues the drive cycle at this point. The cycle and the recording of the measurement values are not terminated. The button 7. End drive cycle must be used in order to terminate the drive cycle (also in case of premature termination of the test). Page 29 from 116

30 11 Drive curves of the DA The following shows the drive curves (configuration files) of the DA. Further configuration files can be supplied by cbb software GmbH at the customer s request Speed cycles (Exhaust gas laws) v = f(t) The drive curve speed cycles v = f(t) is based on the software module speed over time of the DA, which realizes speed over time. The creation of the corresponding data records of speed cycles is described from chapter 15 on. Loading of this drive curve is carried out from the directory C:\ErgoDrive\configurations. The following surfaces are available: speed_70.cfg: Firm background in the range of 0 to 70 km/h speed_110.cfg: Firm background in the range of 0 to 110 km/h speed_floating.cfg: Sliding background in the range of 0 to km/h The following Figure 13 shows the display speed_70.cfg with a loaded ECE-cycle as an example of a DA surface: Page 30 from 116

31 1. Status message/ display of loaded drive cycle 2. Display of the loaded drive cycle 3. Display field measurement values 4. Tolerance range 5. Set speed in km/h 6. Display of drive violations 7. Overall view of the speed profile 8. Time scale in s 9. Speed scale in km/h 10. Actual speed in km/h 11. Set gear Figure 13: Drive curve speed cycles The surface of the drive curve speed_70.cfg (module v over t) as shown in Figure 13 has the following functionalities: 1. Status message : The status- and fault messages of ErgoDrive Professional appear in the menu bar. If there are no messages, the presently loaded cycle file is displayed. 2. Display of the loaded drive cycle : The presently loaded drive cycle file is displayed (here ECE). Page 31 from 116

32 3. Display of measurement values : This data field shows data from the DA as well as measurement values from the chassis dynamometer or the climatic chamber (optional) as digital-display field. 4. Tolerance range : The actual speed must be within this tolerance range. The range can be changed (chapter 15.2). 5. Set speed in km/h : The set speed is shown as vertically scrolling speed profile, whereby the time scale is located on the left side and the speed scale at the bottom of the screen. The set speed is equipped with a tolerance range which can be adapted to the individual requirements. Furthermore the gear shift points are displayed. These can also be configured. 6. Display of drive violations : When the tolerance range is exceeded, these driving violations are recorded and displayed. The display shows the overall time in which the actual speed was outside the tolerance range as well as the number of cases, where the tolerance range (depending on time and speed) has been violated. The overall time is also shown as fault in the display field of the measurement values. 7. Overall view of the speed profile : The overall profile is displayed in a second window. The marking of the actual position is done with a red line. 8. Time scale in s : Designation of the time axis in the vertically scrolling speed profile in seconds. 9. Speed scale in km/h : Designation of the speed axis in the vertically scrolling speed profile in km/h. 10. Actual speed in km/h : The actual speed is shown as a cursor in which there is a little lamp. This shines green when the actual speed is within the tolerance range. If the tolerance range is violated, this lamps shines red. 11. Set gear : Display that shows which gear shall be chosen at a certain set speed (gear shift points). For better identification each gear has its own coloured section on the set speed line. The gear shift points can be set (chapters 15.1 and 15.4). Display of the message Pause during pause mode. Display of a Flag as a symbol that the end of the loaded drive cycle has been reached as well as blinking red letters that tell you that you have come to the end. The text can be set in the profile, e.g. End of test. Page 32 from 116

33 11.2 Drive curve pass routes (gradient to test stand computer) gradient = f(s) The drive curve pass routes gradient = f(s) is based on the software module universal graphic data display of the DA. In this data display the values are displayed over time or over route. In this case the gradient is displayed over the route. The creation of the corresponding data records of route controlled cycles is described from chapter 16 and the integration of the gradient from chapter 19. This drive curve is loaded from the directory C:\ErgoDrive\configurations. The name of the file is inclination_over_way.cfg. The following Figure 14 shows the DA-surface: 1. Status message / display of loaded drive cycle 2. Display of loaded drive cycle 3. Display of measurement values 4. Set gradient 5. Act. position 6. Overall profile 7. Route scale 8. Gradient scale 9. Act. position Figure 14: Drive curve pass routes gradient = f(s) Page 33 from 116

34 The surface shown in Figure 14 of the drive curve pass routes gradient = f(s) (gradient over route) has the following functionalities: 1. Status message : The status- and fault messages of ErgoDrive Professional are displayed in the title bar. If there are no messages, the presently loaded cycle file is displayed. 2. Display of the loaded drive cycle : The presently loaded drive cycle file is displayed. 3. Display of measurement values : This data field shows data from the DA as well as measurement values from the chassis dynamometer or the climatic chamber (optional). 4. Set gradient in % : The set gradient is displayed as vertically scrolling gradient profile. The route scale is on the left side of the screen and the gradient scale is at the bottom of the screen. 5. Actual position : The actual position in the overall view of the gradient profile is shown as a red line. 6. Overall profile : The overall profile is shown in a second window. The actual position is marked with a red line (5.). 7. Route scale in m : Designation of the route axis in a vertically scrolling speed profile in meters. 8. Gradient scale in % : Designation of the gradient axis in the gradient profile in percent. 9. Actual position : The actual position in the gradient profile is marked as a red line. Display of the message Pause during the pause mode Display of the message End of test after reaching the end of the loaded drive cycle in red letters. Page 34 from 116

35 11.3 Display of measurement values This surface displays measurement values from the chassis dynamometer or from the climatic chamber (optional), when tests are carried out there for which the DA is not needed but the measurement values are still to be displayed. This drive curve is loaded from the directory C:\ErgoDrive\configurations. The name of the file is measurement_value.cfg. Figure 15 shows the DA surface: Figure 15: Display of measurement values Page 35 from 116

36 11.4 Drive curve height = f(s) (2D-height profile) The drive curve height = f(s) is based on the software module 2D-height profile of the DA. In the software module height/route 2D (2D height profile) the height is displayed over the route. This is a horizontally scrolling height profile. The creation of cycles is described in chapter 16. In order to load this drive curve the file 2d_altitude.cfg must be invoked from the directory C:\ErgoDrive\configurations. Figure 16 shows the DA surface: 1. Status message / display of loaded drive cycle 2. Display of loaded drive cycle 3. Display of measurement values 4. 2D-height profile 5. Act. position 6. Act. position 7. Overall profile Figure 16: Drive curve pass routes height = f(s) Page 36 from 116

37 The following functionalities are integrated in the surface of the drive curve height = f(s) (2D height profile, Figure 16): 1. Status message : The status- and fault messages of ErgoDrive Professional are displayed in the title bar. If there are no messages, the presently loaded cycle file is displayed. 2. Display of the loaded drive cycle : The presently loaded drive cycle file is displayed. 3. Display of measurement values : This data field shows data from the DA or the climatic chamber (optional). 4. Height profile : Horizontally scrolling display of the height profile as display of the height over route. 5. Actual position : The actual position in the overall view of the gradient profile is shown as a red line. 6. Actual position : Display of the actual position in the horizontally scrolling height profile (4.) as cursor. 7. Overall profile : The overall profile is shown in a second window. The actual position is marked with a red line (5.). Display of the message Pause during pause mode in the middle of the height profile. Display of a Flag as a symbol when reaching the end of the loaded drive cycle as well as blinking red letters that tell you that you have reached the end. The text can be set in the profile, e.g. End of test. Page 37 from 116

38 11.5 Drive curve 3D-pass routes height= f(s) (3D-road simulation) The drive curve 3D-pass routes height = f(s) is based on the software module 3D-road simulation of the DA. A realistic depiction of the road simulation via a detailed 3D-landscape helps the driver with orientation along the route. The simulation of up- and downhill driving or starting the car on a hill can thus be realized on the chassis dynamometer. The test driver is able to drive with foresight just like in reality. This is necessary to reproduce driven routes on the chassis dynamometer with a view to consumption and exhaust values. The 3D-road simulation offers the ideal prerequisites for the area of driveability-testing of vehicles where the testing of driving behaviour can be realized easily on the chassis dynamometer. In order to load this drive curve the file pass_drive_3d.cfg must be invoked from the directory C:\ErgoDrive\configurations. Figure 17 shows the DA surface: 1. Status message / display of loaded drive cycle 2. Display of loaded drive cycle 3. Display of measurement values 4. 3D-road simulation with height profile 5. Act. position 6. 2D display of the height as overall profile Figure 17: Drive curve 3D-pass routes height = f(s) Page 38 from 116

39 The following functionalities are integrated in the surface of the drive curve 3D-pass routes height = f(s) (3D road simulation, Figure 17): 1. Status message : The status- and fault messages of ErgoDrive Professional are displayed in the title bar. If there are no messages, the presently loaded cycle file is displayed. 2. Display of the loaded drive cycle : The presently loaded drive cycle file is displayed. 3. Display of measurement values : This data field shows data from the DA as well as the climatic wind tunnel: cycle name, actual speed, change in gradient, delta gradient, current gradient, next set gradient, overall actual traction, position number, maximum height, actual height, remaining route and driven route. 4. 3D-road simulation with height profile : This shows a 3-dimensional test route as course with height profile. It is also possible to show bends in the road. The 3-dimensional display can also be equipped with landscape features. A description of the design of profile files can be found in the chapters 17 and Actual position : The actual position in the overall view of the height profile is shown as a red line. 6. 2D display of the height as overall profile : The overall profile is shown in a second window. The actual position is marked with a red line (5.). Display of the message Pause during pause mode in the middle of the height profile. Display of a Flag as a symbol when reaching the end of the loaded drive cycle as well as blinking red letters that tell you that you have reached the end. The text can be set in the profile, e.g. End of test. Page 39 from 116

40 11.6 Drive curve mountain with variable speed The drive curve mountain with variable speed is based on the software module display of speed of the DA where the speed is realized over the route. The creation of the corresponding data records of speed cycles is described from chapter 15. In order to load this drive curve invoke the file hill_drive_var_v.cfg from the directory C:\ErgoDrive\configurations: Pass routes with variable speed, display of speed over route with handover of the gradient to the chassis dynamometer computer. The following Figure 18 shows the DA surface e.g. as a sliding surface with a loaded FTP-cycle: 1. Status message / display of loaded drive cycle 2. Display of loaded drive cycle 3. Display of measurement values 4. Tolerance range 5. Set speed in km/h 6. Display of drive violations 7. Overall view of the speed profile 9. Route scale in km/h 10. Actual speed in km/h 12. Speed scale in km/h 13.Set gear 8. Display of gradient in a round instrument 11. Overall view of the course of gradient Figure 18: Drive curve mountain with variable speed Page 40 from 116

41 The surface of the drive curve speed over route as shown in Figure 18 has the following functionalities: 1. Status message : The status- and fault messages of ErgoDrive Professional are displayed in the title bar. If there are no messages, the presently loaded cycle file is displayed. 2. Display of the loaded drive cycle : The presently loaded drive cycle file is displayed. 3. Display of measurement values : This data field shows data from the DA as well as the climatic wind tunnel: cycle name, actual speed, change in gradient, delta gradient, current gradient, next set gradient, overall actual traction, position number, maximum height, actual height, remaining route and driven route as digital display. 4. Tolerance range : The actual speed must be within this tolerance range. The tolerance range can be adjusted (chapter 15.2). 5. Set speed in km/h : The set speed is depicted as vertically scrolling speed profile, where the time scale is found on the left side of the screen and the speed scale at the bottom. The set speed is equipped with a tolerance range which can be adapted to the respective requirements. Furthermore gear shift points are displayed which can also be configured. 6. Display of speed violations : When the tolerance range is violated, this is recorded and displayed. The display shows the overall time in which the actual speed has been outside the tolerance range as well as the number of violations. 7. Overall view of the speed profile : The overall profile speed over route is shown in a second window. Marking of the actual position is done with a red line. 8. Gradient display : Display of the gradient in a round instrument. 9. Route scale in km : Depiction of the distance axis in a vertically scrolling speed profile in kilometres. 10. Actual speed in km/h : The actual speed is shown as a cursor, in which there is a small lamp. This lamp shines green as long as the actual speed is within the tolerance range. If the tolerance range is violated, the lamp blinks red. 11. Overall view of the gradient course : Depiction of the total gradient course over the route as overall view in a third window with marking of the actual position with a red line. 12. Speed scale in km/h : Name of the speed axis in the vertically scrolling speed profile in km/h. 13. Set gear : Display into which gear the driver must shift when reaching a certain set speed (gear shift points). For better identification each gear has is own coloured section on the set speed line. The gear shift points can be configured (chapters 15.1 and 15.4). Display of the message Pause during pause mode. Display of a Flag as a symbol when reaching the end of the loaded drive cycle as well as blinking red letters that tell you that you have reached the end. The text can be set in the profile, e.g. End of test. Page 41 from 116

42 11.7 Drive curve temperature cycles, T = f(t) The drive curve temperature cycles, T = f (t) (set value temperature control) is based on the software module universal graphic data display of the DA. This data display depicts the values over time or over route. In this case the temperature is depicted over time. The design of the corresponding data records of time controlled cycles is described from chapter 15 and the integration of the temperature from chapter 19. Loading of this drive curve is carried out from the directory C:\ErgoDrive\configurations. The name of the file is temperature.cfg. The following Figure 19 shows the DA surface: 1. Status message / display of loaded drive cycle 2. Display of loaded drive cycle 3. Display of measurement values 4. Set temperature 5. Act. position 6. Overall profile 7. Time scale 8. Temp.-scale 9. Act. position Figure 19: Display of the temperature course over time Page 42 from 116

43 The surface shown in Figure 19 of the drive curve pass routes gradient = f(s) (gradient over route) has the following functionalities: 1. Status message : The status- and fault messages of ErgoDrive Professional are displayed in the title bar. If there are no messages, the presently loaded cycle file is displayed. 2. Display of the loaded drive cycle : The presently loaded drive cycle file is displayed. 3. Display of measurement values : This data field shows data from the DA as well as the climatic wind tunnel: cycle name, set temperature value, actual wind temperature, next set temperature, time till next change in temperature, present position no., remaining time and driven time, humidity, actual and maximum height, actual wind speed in km/h and mph as well as the time as digital display. 4. Set temperature in C : The set temperature is shown as vertically scrolling temperature profile, where the time scale is on the left side of the screen and the temperature scale at the bottom of the screen. 5. Actual position : The actual position in the overall view of the temperature profile is shown as a red line. 6. Overall view of the temperature profile : The overall profile is shown in a second window. The marking of the actual position is carried out with a red line. 7. Time scale in s : Designation of the time axis in a vertically scrolling temperature profile in seconds. 8. Temperature scale in C : Designation of the temperature axis in the temperature profile in degree Celsius. 9. Actual position : The actual position in the temperature profile is shown as a red line. Display of the message Pause during pause mode. Display of the message End of test in red letters when the end of the loaded drive cycle has been reached. Page 43 from 116

44 12 10,4 LCD-Display 12.1 Airbag in the test vehicle An existing airbag must be deactivated when using the LCD-display in the test vehicle, if the LCDdisplay is secured in any way on the steering wheel, or is used within the working range of a steering wheel or passenger-, side- or other airbag. cbb software GmbH accepts no liability for damages of any kind that arise from failure to comply with this warning! The supplied manual of the LCD-display must be observed! 12.2 Fastening of the suction stand of the LCD-display First select a suitable place for the LCD-Monitor in the vehicle and install the suction pad stand supplied with the monitor. For this purpose loosen the lock lever of the suction mechanism. Press the cleaned suction pad against the surface on which the stand is to be fastened and achieve the necessary vacuum by turning the lock lever. Check that the stand is securely fastened! In order to guarantee the highest possible safety when using the suction pad fastening the following instructions should be observed at all times: Only use the suction pads on even and sealed surfaces which are clean, dry and free of oil and grease. The carrying capacity is reduced on rough surfaces. Always keep the suction pads and particularly the rubber discs clean and free of oils and grease. The rubber discs must be stored in an unstressed condition. Examine the suction pads before each new use with respect to function and possible damage. Remove the suction pads and repeat the fastening procedure if the hold does not appear to be secure. This especially applies for longer periods of use. The hold of the suction pads must be checked regularly. Do not try to remove the rubber discs with sharp-edged objects or tools. They would damage the discs. Never use suction pads with damaged rubber discs. In order to adjust the ball joint, the screw must be loosened with at least ½ a turn, because otherwise the ball is damaged and the grip is reduced. The fastening with suction is intended for short-time use. If this is used over longer periods of time, the suction vacuum must be renewed regularly. If this is not possible, a different type of fastening must be applied. Be aware of the fact that the device may drop due to lack of vacuum and this may damage the monitor. Page 44 from 116

45 The suction fastening can be removed by loosening the lock lever. Safety Instructions: The LCD monitor may not be fastened in a place where, in the event of an accident, it could be thrown against the driver/passenger, as this could cause severe or fatal injuries. The LCD monitor must under no circumstances be mounted within the working range of an airbag. The glass substrate of the display is covered with a plastic screen. In case of a severe accident however, splinters of glass as well as the metal casing can cause personal injuries. It is important to secure the suction stand additionally with a strong, industrial adhesive tape or another fastening system and to renew the suction vacuum every day by remounting the stand. Discuss the installation location in the vehicle with a safety officer and follow the safety instructions. Exclusion of Liability: No responsibility is accepted for accidents or injuries that arise from failure to comply with the rules and safety instructions detailed above Connecting the cable set to the LCD-monitor A special connection cable is included in the scope of delivery of the LCD-monitor, which transmits the VGA-signals of the graphics card and supplies the power. The LCD-monitor is equipped with an integrated DC/DC-converter for an input voltage of VDC and is supplied via a 3-pole Lemosa connector. The permissible input voltage is VDC Establishing the VGA-connection to the LCD-monitor First switch off the computer and the supply of the DC/DC-converter and connect the connection cable with the 15-pole VGA-output of the computer. Secure the SubD-connector by carefully tightening the two knurled screws. Plug the other cable end into the SubD-connector on the display and secure this connection too Connecting the power supply Plug the 2- respectively 3-pole Lemosa-connector of the connection cable into the corresponding socket of the display in such a way that the red marking on the connector casing points in the direction of the red marking of the socket. The high-quality Lemosa-connectors that we use are selflocking and are reverse polarity protected. The Lemosa-connectors can be pulled out by pulling at the knurled sleeve. Page 45 from 116

46 12.6 Connection to VDC For use in a normal vehicle the input voltage of the monitor is Volt DC voltage, the power consumption is approximately 1 Ampere. For the application in trucks etc. a monitor with a DC/DCconverter with Volt input voltage must be used. Check that you have the correct vehicle voltage for the converter as this otherwise can be destroyed. Operation with alternating voltage or voltages larger than the ones stated will destroy the DC/DC converter in the monitor! Safety instructions: Power supply to the monitor is only allowed via a protected circuit in the vehicle. The display has its own backup but in case the feed is interrupted through squeezing, a dangerous cable fire can occur and people can be injured if a connection has been made with a circuit that is not protected! The connection cables must be placed in a way that they cannot accidentally activate the operating instruments in the car or block safety devices or reduce the functions of these safety devices. The driver must under no circumstances be hindered by the cables (steering wheel, pedals, gear shift, operating controls etc.) Page 46 from 116

47 13 Recorded measurement values The recording of the measurement values begins with the start of the drive cycle in the DA (activating button 3. Start ) and ends with the termination of the drive cycle (activating button 7. End drive cycle ). If the pause mode is used between these two steps, the recording of the measurement values continues also during this pause. The recorded measurement values are found in the directory: C:\ErgoDrive\Data-Log. The file name is constructed as follows: Cycle name, year (named y), month (named m), day (named d), hour (named h), minute (named m), second (named s). This data refers to the starting point of the drive cycle and not its end. If a cycle was started at 14:40 and ended at 15:41, the time in the file name would be 14h40m. The file name FTP2005y06m08d_14h40m18.372s.log thus means: Cycle: FTP Test start: 8. June 2005, 14:40, 18,372 seconds Program call Figure 20: Log files in directory C:\ErgoDrive\Data-Log The conversion programme for measurement values is started by double clicking the symbol Log2xls (2 gearwheels, Figure 21) on the desktop: Figure 21: Symbol of the conversion programme on the desktop Please note, that a version of Microsoft Exel must be installed on your PC. The surface of the conversion programme appears (see Figure 22): Page 47 from 116

48 ErgoDrive\Log Figure 22: Programme surface of the conversion programme 13.2 Open a log file First of all it is necessary to open a log file created by the DA. For this click the button Open file at the top left in the programme window. The dialog Open file appears: Figure 23: Dialog open file Select the desired log file. The file name consists of the date and the time (see chapter 13 Recorded measurement values ). After selecting the desired log file click open. The file will be taken over from the conversion programme, the file name appears in the window on the right next to the button Open file. Page 48 from 116

49 The measurement values contained in the selected log file are now displayed in the lower area of the window of the conversion programme (see Figure 24). The standard layout is from top to bottom in ascending order according to the number assignment (handle-no. in LabMap) of the individual measurement values. In order to sort the measurement values in alphabetical order click the grey field Name at the top. Likewise the measurement values can be sorted according to units, for this purpose click on the field Unit Conversion ErgoDrive\Log Figure 24:Conversion programme after loading of a log file First enter the amount of time between the entries of values in the Excel-table in the upper area of the window to the right of the button Convert. For this purpose select the unit for the time next to the entry field ( ms for milliseconds, s for seconds, min for minutes or h for hours). By ticking Interpolation you determine a linear interpolation of the values when they are stored. If only one value is found in a column, this is extrapolated, i.e. this value is taken over as constant (e.g. a height of 10 m). Tick Show Excel, in order to start Excel automatically with the converted profile file. The field Log file created on states the time when the recording of the measurement values began. The field Log file closed states the time when the recording of the measurement values was ended. In order to start conversion click the button Convert. An entry mask for the entry of test data appears (see chapter 13.4, Figure 25). The button Cancel terminates the conversion. The conversion programme is ended with the button Close. Page 49 from 116

50 13.4 Entry of test data Figure 25 Entry of test data Write the test data into the fields. If a field is left empty, this will also remain empty in the Exceltable. Afterwards click the button OK. The conversion is executed and the Excel-table is filled in: In order to print from Excel please use the Excel-print function and the printer that is connected to your PC. Figure 26: Excel with an opened log file Page 50 from 116

51 14 Conversion of the customer drive cycles The drive cycles used by the customer have been converted by cbb software GmbH for the new DA. A special drive cycle conversion programme was used for this purpose Conversion of the gradient The 2D-height display of the DA used in the beginning cannot process the gradient directly from the drive cycles but calculates the gradient from the height (meanwhile the gradient is directly displayed with the surface pass drive_2d). Some customer cycles contained gradient as well as also height information. Therefore the cycles are converted in two ways: 1. The gradient was calculated with the height stated in the customer cycle. These files you will find in the directory C:\flg\profiles\cbb_txt_calculate. 2. The gradient was taken over directly from the customer cycles. These files are found in the directory C:\flg\profiles\cbb_txt_take Later conversion of further cycles Further cycles that have not been converted by cbb software GmbH, can also be converted into the new format at a later point in time with the drive cycle conversion programme which is supplied to the customer Installation of the drive cycle conversion programme The drive cycle conversion programme can be installed on every PC that is equipped with the operating system Windows P Professional. The two files flgconvertdll.dll and flgconvert.exe must be copied into a directory created for this purpose (file). It is very important that both files are in the same directory, that this directory contains no other files and that the file names are not changed. The directory name and the position (e.g. subdirectory) are not important Starting the drive cycle conversion programme The drive cycle conversion programme is started by executing the file flgconvert.exe from the directory in which the drive cycle conversion programme has been installed. The main screen of the conversion programme is depicted in the following Figure 27: Page 51 from 116

52 End programme Add drive cycle Remove drive cycle Calculate gradient from the height contained in the cycle Take over gradient from cycle Listbox Selection/entry of path in which the converted cycles are to be stored Start conversion End programme Progress of conversion Programme status Figure 27: drive cycle conversion programme 14.5 Conversion with the drive cycle conversion programme In a first step the drive cycles that are to be converted are selected with the button Add Profile. It is possible to select more than one profile. If drive cycles are selected from different directories, the button Add Profile must be activated for each new directory. The selected drive cycles are displayed with their complete paths in the large white listbox. If by mistake the wrong files have been selected, these can be deleted individually from the listbox. For this activate the button Delete Profile. The entry marked in blue will be deleted from the list. The Destination Path shows the path in which the converted cycles are to be stored after conversion. The selection can be done with the mouse by clicking the button or via the keyboard by writing the path (e.g., when a new directory is to be created). Conversion is started by activating the button Start. Status shows the progress. As soon as the conversion is finalised, the programme can be terminated. Page 52 from 116

53 15 Editing the data record for the operating mode v over t The data record for the operating mode v over t (speed profile over time) consists of the gear change table (optional, chapter 15.1), the tolerance field data (optional, chapter 15.2), the driving cycle data (chapter 15.3) and the gear change points (optional, chapter 15.4) described in the following. The creation of the data record is carried out as ASCII-files. The ASCII-files can be created and edited with any ASCII-editor (e.g. Word, Notepad). The files however can also be created with Microsoft Excel and be saved as text format (text (tabulators separated).txt) Gear change table for the operating mode speed over time The following shows an example data record for a gear change table which is optional in the data record. The gear change table can be used if no gear change points are stated in the driving profile. Caution: if gear change points are used in the driving profile, these are valid, the gear change table is not used then. # *** Gear change table *** (optional) # let gear.change.01->02 20 [km/h] # From 1 st to 2 nd gear at 20 km/h let gear.change.02->03 40 [km/h] # From 2 nd to 3 rd gear at 40 km/h let gear.change.03->04 60 [km/h] # From 3 rd to 4 th gear at 60 km/h let gear.change.04->05 80 [km/h] # From 4 th to 5 th gear at 80 km/h let gear.change.05-> [km/h] # 5 th gear is the last gear The left part of the gear shift table contains the command. The command in the 1 st line let gear.change.01->02 20 [km/h] means that the shift from the 1 st into the 2 nd gear is carried out at 20 km/h. The right part of the table contains comments. A comment is introduced with # and is thus ignored by ErgoDrive Professional. The last gear is shown in the last line of the gear change table: let gear.change.05-> [km/h] here means that gear 5 is the last gear. If for this command a lower speed value is entered (e.g. let gear.change.05->06 75 [km/h] ) as entered for the previous command, the driver's aid already shows the previous gear (in this case gear 4) as the last gear. The gear change table is valid for as long as the respective file is loaded. If a file is loaded with another gear change table, this data likewise remains valid for as long as the respective file is loaded. If a file is loaded that contains no gear change table, the loaded gear change table remains valid. The gear change table is always valid until a new gear change table is loaded or a driving profile with gear change points is used. The gear change points from a driving profile also remain valid until a profile with new gear change points or a gear change table in a profile without gear change points is loaded. Figure 28 shows the illustration of the gear change in the driver's aid. For this purpose the following gear change table was loaded into the driver's aid: Page 53 from 116

54 # Example data record driving profile # # *** Gear change table *** (optional) # let gear.change.01->02 "15 [km/h]" # From 1 st to 2 nd gear at 15 km/h let gear.change.02->03 "25 [km/h]" # From 2 nd to 3 rd gear at 25 km/h let gear.change.03->04 "40 [km/h]" # From 3 rd to 4 th gear at 40 km/h let gear.change.04->05 "55 [km/h]" # From 4 th to 5 th gear at 55 km/h let gear.change.05->06 "60 [km/h]" # 5 th gear is the last gear # # *** Tolerance field data (optional) *** # let error.t 1 [s] # tolerance field range: 1s let error.v 3.2 [km/h] # tolerance field range: 3,2 km/h # # # *** driving cycle data *** # # Time Speed # [s] 0.0 [km/h] Figure 28: illustration of the gear change table Page 54 from 116

55 15.2 Tolerance field data for the operating mode v over t The following shows an example of a data record for tolerance field data that is optional in the data record. Comments in the data record are introduced with a #: # *** Tolerance field data (optional) *** # Example data record # let error.t 1 [s] # tolerance field range: 1 s let error.v 3.2 [km/h] # tolerance field range: 3,2 km/h The left part of the tolerance field data contains the command, the right part of the table contains comments. A comment is introduced with # and is thus ignored by ErgoDrive Professional. The command in the 1 st line let error.t 1 [s] means that the tolerance field range is 1 second. The command in the 2 nd line let error.v 3.2 [km/h] means that the tolerance field range is 3,2 km/h. The tolerance field data remains valid until a file with other tolerance field data is loaded. This data again remains valid as long as the respective file remains loaded. If a file is loaded that contains no tolerance field data, the tolerance field data which was loaded last remains valid. The tolerance field range must be chosen according to the requirements of the test run and the legal requirements for exhaust emission testing. Leaving the tolerance range is a driving violation, the number of driving violations and the overall duration in which the test driver was outside of the tolerance range are shown in the driver's aid. The data record shown above for the tolerance field data represents the tolerance field range shown in Figure 29: Page 55 from 116

56 Figure 29: tolerance field range t = 1,0 s, v = 3,2 s The following tolerance field data represents the tolerance field range shown in Figure 30: let error.t 0.5 [s] # tolerance field range: 0,5 s let error.v 1.2 [km/h] # tolerance field range: 1,2 km/h Figure 30: tolerance field range t = 0,5 s, v = 1,2 s The driving cycle data (see chapter 15.3) is arranged underneath the tolerance field data. Page 56 from 116

57 15.3 Driving cycle data for the operating mode v over t The following shows an example of a data record for the operating mode v over t (speed profile over time). # *** Driving cycle data *** # Example data record driving profile # # Time Speed Gear # [s] 0.0 [km/h] 0 :Gear :Gear :Gear :Gear :Gear :Gear :Gear The first five lines are comments (comments are introduced with #) and are thus ignored by ErgoDrive Professional. In the first column there is the reference value (time), through which the curve is shown. Through the unit [s] (seconds) it is stipulated clearly in this data record that all data is shown over time and that the entries in this column represent the time. The second column has the unit of speed in [km/h], which stipulates that this column contains data on the set speed. The third column contains the change points described in detail in chapter In the above example data record the set speed at 3 s = 0 km/h, at 7 s = 10 km/h and at 12 s = 40 km/h. The driver's aid begins to let the set speed rise at 3 s from 0 km/h during the execution of the profile until it reaches 10 km/h at 7 s and at 12 s the value of 40 km/h. The set acceleration is higher in the range between 7 and 12 seconds, in this example the test driver must accelerate a little bit more in order to keep the set speed. Afterwards the set value is reduced to 10 km/h within 20 s and then falls to 0 km/h in the range between 40 s and 50 s. The entry at 30 s solely serves the illustration of the change point (see chapter 15.4) and can be ignored in an illustration without change points. The entry 60 s is the last entry in the data record, at the end of the 60 s the chequered flag appears on the driver's aid surface which shows the test driver the end of the driving profile and thus also the end of the test drive. The example data record shown above represents the illustration shown in Figure 31 in the driver's aid: Page 57 from 116

58 Figure 31: Illustration of the example data record The following page shows another example data record: Page 58 from 116

59 Illustration of another example data record for the operating mode v over t (speed profile over time). Compared with the previous example different set speeds have been chosen for the same times. # *** Driving cycle data *** # Example data record driving profile # # time speed gear # [s] 0.0 [km/h] 0 :Gear :Gear :Gear :Gear :Gear :Gear :Gear The example data record shown above represents the illustration in Figure 32 in the driver's aid: Figure 32: illustration of a second example data record Page 59 from 116

60 15.4 Gear change point entries in the data record Gear change points in the data record are entered in a third column. Every gear change point starts with the gear number, then comes a blank and then the description :Gear. In neutral gear there is the entry 0 :Gear, in order to switch into reverse gear (not allowed on every chassis dynamometer!) R :Gear shall be entered. The following example data record represents the gear change points: # *** Driving cycle data *** # Example data record driving profile # # time speed gear # [s] 0.0 [km/h] 0 :Gear :Gear :Gear :Gear :Gear :Gear :Gear After 3 s the test driver is asked to shift into 1 st gear, after 7 s he should switch into 2 nd gear and after 12 s he should switch into 3 rd gear. After 20 s the test driver should declutch and operate the vehicle in neutral gear, he should engage the clutch in 2 nd gear after 30 s in order to brake for 10 s with the motor while he declutches again at 40 s. The following Figure 33 shows the illustration of the above data record in the driver's aid: Figure 33: gear change in the data record Page 60 from 116

61 Another example data record for the illustration of the gear change points # *** Driving cycle data *** # Example data record driving profile # # time speed gear # [s] 0.0 [km/h] 0 :Gear :Gear :Gear :Gear :Gear :Gear :Gear :Gear :Gear After 1 s the test driver is asked to shift into 1 st gear, after 3 s he shall shift into 2 nd gear and after 7 s into the 3 rd gear. After 12 s the test driver shall shift into 2 nd gear in order to brake for 5 s with the motor, and afterwards he shall declutch. After 20 s the test driver shall shift into the 1 st gear in order to accelerate the vehicle to 20 km/h within 5 s and afterwards the driver shall drive consistently for 10 s in 2 nd gear. The following Figure 34 shows the illustration of the above data record in the driver's aid: Figure 34: another example with gear change points Page 61 from 116

62 Further example data record for the illustration of the gear change points with reverse gear: CAUTION! Use this function only when reverse driving is allowed on your chassis dynamometer! # *** Driving cycle data *** # Example data record driving profile # # time speed gear # [s] 0.0 [km/h] 0 :Gear :Gear :Gear :Gear :Gear :Gear :Gear R :Gear :Gear :Gear After 1 s the test driver is asked to shift into 1 st gear, after 3 s he shall shift into 2 nd gear and after 7 s into 3 rd gear. After 12 s he shall shift into 2 nd gear in order to brake for 5 s with the motor, afterwards he shall declutch. After 23 s the test driver shall shift into reverse gear (CAUTION! Use this function only when reverse driving is allowed on your chassis dynamometer!) in order to reverse for 2 s, afterwards the test driver will accelerate with 1 st gear until the set speed 0 km/h has been reached. The following Figure 35 shows the illustration of the above data record in the driver's aid: Figure 35: illustration of the gear change points with reverse gear Page 62 from 116

63 15.5 Setting of digital outlets (optional) As an option the driver's aid can be equipped with up to 8 digital outlets which can be used for different applications e.g. start and stop of some processes in your test environment. The setting respectively resetting of these outlets is carried out in another column of the data record with the help of an 8-Bit-ASCII-value. This column must be separated from the previous data with a ;. The digital outlets are arranged as follows: , i.e. if the outlet 1 shall be set the whole right bit shall be set. The respective set outlet is set with "x, it is reset with "o. # *** Driving cycle data *** # Example data record driving profile # # time speed gear LED information # [s] 0.0 [km/h] 0 :Gear ; ooooooox # outlet 1 set :Gear ; ooooooxo # outlet 2 set :Gear ; oooxoooo # outlet 5 set :Gear ; oxoooooo # outlet 7 set :Gear ; ooooxoox # outlet 1+4 set 15.6 Bag sampling control (optional) As an option the driver's aid can be used for a control bag sampling for exhaust emission analysis with up to 8 bags. The setting respectively resetting of these outlets is carried out in another column of the data record with the help of an 8-Bit-ASCII-value. This column must be separated from the previous data with a ;. The bags are arranged as follows: , i.e. if the bag 1 shall be start the whole right bit shall be set. The respective set bag is set with "x, it is reset with "o. # *** Driving cycle data *** # Example data record driving profile # # time speed gear LED information # [s] 0.0 [km/h] 0 :Gear ; ooooooox # bag 1 set :Gear ; ooooooxo # bag 2 set (1 reset) :Gear ; oooxoooo # bag 5 set (2 reset) :Gear ; oxoooooo # bag 7 set (5 reset) :Gear ; ooooxoox # bag 1+4 set (7 reset) :Gear ; ooooxoxx # bag set :Gear ; ooooxoox # bag 1+4 set (2 reset) :Gear ; ooooxooo # bag 1 set (1 reset) :Gear ; oooooooo # all bags reset So if you will use a bag for a longer time, you have to set the bit with a x in all lines you will use the bag sampling command. Page 63 from 116

64 15.7 Supplied data records for driving cycles in operating mode v over t The driver s aid (DA) for illustration of speed over time contains the following data records for driving cycles: EPA IM240 Inspection & Maintenance Driving Schedule EPA FTP Federal Test Procedure EPA UDDS Urban Dynamometer Driving Schedule EPA HDUDDS Urban Dynamometer Driving Schedule for Heavy Duty Vehicles EPA HWFET Highway Fuel Economy Test EPA NYCC New York City Cycle EPA SC03 Supplemental FTP Driving Schedule EPA US06 Supplemental FTP Driving Schedule UN/ECE Elementary Urban and UN/ECE Extra Urban Cycle (Part One and Two of the Type 1 Test) UN/ECE Elementary Urban Cycle UN/ECE Reg 83 Extra-Urban Driving Cycle for Low-Powered Vehicles UN/ECE Reg 83 Extra-Urban Driving Cycle ECE15.05 COLD UN-ECE-WLTP Worldwide harmonized Light vehicles Test Procedure Class 1 vehicles UN-ECE-WLTP Worldwide harmonized Light vehicles Test Procedure Class 2 vehicles UN-ECE-WLTP Worldwide harmonized Light vehicles Test Procedure Class 3 vehicles JC08 Japanese Dynamometer Driving Schedule (Jpn. CD 34 (8 mode) Driving Schedule) Japanese Exhaust Emission & Fuel Economy Driving Schedule Japanese 10 Dynamometer Driving Schedule Japanese 15 Dynamometer Driving Schedule Worldwide Motorcycle transient Cycle Indian Motor cycle Chinese Performance Test Standard Road Cycle The data records are stored on the computer DA (operator-room) in the directory Profiles. Further profiles can be purchased and integrated in the driver s aid without any difficulties. For this purpose please contact your supplier. Page 64 from 116

65 16 Editing the data record for operating mode 2D altitude profile The following shows an extract from a data record for a altitude profile (2D) with speed instructions: # Example data record 2D altitude profile # # Route Altitude Speed # [m] 0.0 [m] 0.0 [km/h] # the speed column is necessary to # fade in the chequered flag at the # the end of the profile The first four lines are comments (comments are introduced with #) and are thus ignored by the ErgoDrive Professional. The first column always contains the reference value (route), over which the display is carried out. The meaning of the individual columns can be seen from the unit that is placed in square brackets. The unit [m] stipulates clearly that in this data record all data is displayed over the route in meters. The second column also has a unit of length in [m], which clearly stipulates that this is the altitude. The above data record can be interpreted as follows: Line 1 At position 0 m the altitude is 0 m Line 2 After 30 m the absolute altitude is 2 m. In order to achieve an even altitude profile the calculation of the altitude profile is carried out with a spline of 3 rd order. Line 3 After 50 m the absolute altitude is still 2 m. Line 4 After 120 m the absolute altitude is 10 m. Line 5 After 170 m the altitude is 8 m. Page 65 from 116

66 Line 6 After 220 m the absolute altitude is still 8 m. Line 7 After 270 m the absolute altitude is 4 m. Line 8 After 300 m the altitude is 3 m. Line 9 After 350 m the absolute altitude is again 0 m. In addition to the route and the altitude there is also a speed column. A positive speed value must appear here for the last but one value (here in line 9), so that the driver's aid shows the chequered flag at the end of the profile (here after 380 m in line 10). If there is no speed column or if only speeds of 0 km/h are entered the chequered flag already appears when starting. The following Figure 36 shows the illustration of the above altitude profile in the driver's aid: Figure 36: illustration of the altitude profile Page 66 from 116

67 The following shows another data record for a altitude profile (2D) with speed instructions: # Example data record 2D altitude profile # # route altitude speed # [m] 0.0 [m] 0.0 [km/h] # the speed column is necessary for # the fading in of the chequered flag # at the end of the profile The altitude begins to rise from 0 to 2 m between 0 and 30 m of the route, it then remains constant at 2 m for 20 m and falls to 0 m on a route of 70 m. The it begins to rise to 3 m on the next 50 m of the route, in order to fall again to 0 m on a route of further 50 m. The it rises again by 1 m on a route of 50 m and then remains constant for another 30 m route, before it once more falls to 0 m. The following Figure 37 shows this data record in the driver's aid: Figure 37: illustration of another altitude profile Page 67 from 116

68 17 Construction of the data record in the operating mode 3D road simulation The following constraints apply for the operating mode 3D road simulation with respect to the maximum angle of gradient, the maximum angle for driving through a bend as well as the maximum number of 3D-objects for the illustration of the landscape: The maximum angle of gradient in the road gradient profile may not exceed 20 The maximum angle for driving through a bend may not exceed 50 The following limits apply for the number of objects that can be fit into the three-dimensional landscape illustration: Object maximum number traffic lights images bridges bridges to be crossed bus stops intersections highway/country road crossing points poles (beginning and end) signs special objects speed signs city beginning and end tunnels beginning and end street points clouds forest beginning and end A disregard of these limitations causes an incorrect display of the three-dimensional landscape. Page 68 from 116

69 The following is an excerpt from the data record for a altitude profile (3D) with speed instructions, a forest and crash barrier: # Route Altitude Speed Course Object Data # [m] 0 [m] 0.0 [km/h] 0 [degree] 3,4,10,15 : forest ,50 : milestones : forest The first two lines are comments (comments are introduced with #) and are thus ignored by the ErgoDrive Professional. The first column always defines the reference value (route), over which the display is carried out. The meaning of the individual columns can be recognised from the unit that is put in square brackets. The unit [m] in this data record clearly stipulates that all data is displayed over the route in meters. The second column also has a unit of length in [m], which clearly stipulates that this is the altitude. The third column has the unit of a speed in [km/h], which stipulates that this column contains data on the set speed. The fourth column contains the course for the illustration of curves in the driving profile. Reference value is here 0 (straight on) for the route position 0 m. A value which in sum is negative between two route points means a left curve, a value which in sum is positive means a right curve. If the value is constant between two route points (e.g. both times 30 ) a straight route is illustrated between these two points. The data on the 3D objects comes after the profile data. The object data described in Table 1 in chapter 18 shall be used here. First the parameters 1 to 4 are listed separated by comma. The object identification (see Table 1) is after the last parameter and is separated from this by :. Page 69 from 116

70 The above data record can be interpreted as follows: Line 1 At position 0 m the altitude is 0 m and a forest begins with the following parameters: parameter 1 = 3: the forest is on both sides of the road. parameter 2 = 4: the trees have a minimum distance to the road side of at least 4 m. parameter 3 = 10: the average tree distance is 10 meters. parameter 4 = 15: the forest has a width of 15 meters. Line 2 After 50 meters the altitude is likewise 0 m, the course is 30, i.e. between these two points a right curve of altogether 30 is illustrated. Line 3 After 100 m the absolute altitude is 5 m. In order to overcome the altitude difference from 0 m to 5 m the calculation of the altitude profile is carried out with support values over a spline of 3 rd order. For an interpolation with a spline the altitude varies in the whole area. Here only the average value of the altitude is 5,74 degrees. The course here is 20, i.e. a left curve of altogether 10 is illustrated at route point 50 m. With the object data milestones are added on both sides with a distance of 50 m between poles from this position. Line 4 After 120 m the absolute altitude is still 5 m. The course is 30, i.e. a right curve is illustrated between the route points 100 m and 120 of altogether 10. Line 5 After 300 m the absolute altitude and the course are unchanged. As object data a forest is here added with the parameter 0. This means that the forest ends at this point. The route between the route points 120 m and 300 m is illustrated as straight line. The following Figure 38 shows the above described example profile at the route point 0 m, Figure 39 shows the profile at the route point 80 m. Page 70 from 116

71 Figure 38: example data record at route point 0 m Figure 39: example data record at route point 80 m Page 71 from 116

72 18 Description of the objects in the operating mode 3D road simulation Besides the altitude profile the data record contains information on the objects of the 3D landscape. In Table 1 there is a list of all objects presently available in the 3D landscape. An in Table 1 means that the respective parameter is not necessary and can thus be left out. The objects are listed in the data record in the last column (object data) see the following example line: # Route Altitude Speed Course Object Data # [m] 3 [m] 50.0 [km/h] 30 [degree] 3,4,10,15 : forest At 50 m route a forest would begin starting on both sides 4 m from the roadside, the trees are 10 m apart and the width is 15 m. Object Par 1 Par 2 Par 3 Par 4 description STOP sign speed limit sign 10 km/h " 20 km/h " 30 km/h " 40 km/h " 50 km/h " 60 km/h " 70 km/h " 80 km/h " 90 km/h " 100 km/h " 110 km/h " 120 km/h : limit : limit : limit : limit : limit : limit : limit : limit : limit : limit : limit : limit : limit Bus stop Block bridge Stone arch bridge Concrete bridge Telephone box Hydrant Petrol station Distance from road middle [m] Waiting time [s] Distance from road side [m] Distance to bus stop. (begin waiting time) [m] 1: Light signal 0 or : without light signal : bus station : block : brick : concrete : special : special : special Country road Motorway Bridge (to drive over) beginning Bridge (to drive over) end : highway : highway : bridge over : bridge over Page 72 from 116

73 Object Par 1 Par 2 Par 3 Par 4 Identifier Tunnel beginning Tunnel end 1 0 : tunnel : tunnel Pole end Pole right 0 1 Distance between : milestones : milestones Pole left 2 poles : milestones Poles on both sides 3 [m] : milestones Forest end 0 : forest Forest right 1 Distance from Distance between Width of the : forest Forest left 2 road side trees forest : forest Forest on both sides 3 [m] [m] [m] : forest Town end 0 : town Town right 1 Distance from Distance between Width of the : town Town left 2 road side [m] houses town : town Town on both sides 3 [m] [m] : town Car see description car object below (chapter 18.1) : car Table 1: objects with the corresponding parameters The following example shows the illustration of some speed limit signs in the driver's aid: # Route Speed Altitude Course Object # # 0 [m] 0.0 [km/h] 0 [m] 0 [degree] 3,25 : milestones ,5,7,35 : forest : limit : limit : limit : limit : limit ,1 : special ,1,10,11 : forest : limit The speed limit signs are shown in 10 km/h-intervals, the highest sign is 120 km/h. If a speed value is entered in the profile for the illustration of a speed limit sign which is between two decimal places, e.g. 74 km/h, always the next lower sign is shown, in this case 70 km/h. If numbers are entered which are larger than 120 km/h (e.g. 140 km/h), the speed limit sign 120 km/h appears. The following Figure 40 shows the illustration of the above profile in the driver's aid. Page 73 from 116

74 Figure 40: illustration of speed limit signs Page 74 from 116

75 18.1 Car Object The 3D road simulation allows to show traffic in the driving profile. There are three different types of traffic display possible: Meeting Simulation Profile The display type 'Meeting' and 'Simulation' has three parameters the display type 'Profile' has two parameters. The parameters are separated by commas and then follows the object description i.e. ': car'. For example, par1 par2 par3 description "vwbeatle, Meeting, 5.0" :Car The first parameter (par1) specifies the brand and the model of the car. There are six models of three different brands, shown in Table 2. The second and third parameter specifies the type of the traffic for that the car will be used: Meeting: It stipulates that the car travels in the opposite direction of driver's car. The third parameter in this type of car specifies the velocity of this car. Profile: It specifies that the care travels in the same direction of driver's car. This type does not require the third parameter. It travels exactly according to the velocities specified in the profile. Simulation: It specifies that this is the driver's car. The third parameter is the starting velocity of the car at the point in profile where it has been defined. Some example data record is given below to define different types of cars. # [m] 0[km/h] 0[m] "vwbeatle,meeting, 5.0" : Car "vwphaeton, Meeting, 4.0" : Car "mklasse, simulation, 2.1" : Car "mklasse, Profile" : Car "fiatpanda, Meeting 1.0" : Car The following Table 2 shows the models of the cars: Page 75 from 116

76 Parameter 1 vwbeatle Car image vwphaeton vwtouareg aklasse mklasse fiatpanda Table 2: Car models of ErgoDrive Professional Page 76 from 116

77 19 Data record for further values such as e.g. gradient The following shows the handling of other values in the data record such as e.g. gradient, temperature, humidity etc. The basis for the application of this data is always a time controlled (creation see chapter 15) or route controlled (creation see chapter 16) data record. The construction of the data record consists of ASCII-files. The ASCII-files can be created and edited with every ASCII-editor (e.g. Word, Notepad). The files can also be created with Microsoft Excel and stored in text format (Text (Tabs separated).txt) Possible variables in the data record The driver s aid ErgoDrive Professional offers the possibility to show additional variables (set values) from the data records or to hand these over to the existing hardware. It is however only possible to use set values that have also been defined in the software structure of the driver s aid (Software bus LabMap). The following variables (all set values) can be depicted: Roller traction: Frolle Wind temperature: Twind Humidity: Fwind Height (to PAS): Hoehe Insolation intensity: Bestr.Staerke Insolation: Bestr.Front Position of the sun: Bestr.Winkel Gradient: Steigung Wind speed: Vwind Furthermore there are additional variables that are necessary for the control of the DA or for the display of information: Cycle number time controlled: CircleNoTime Cycle number route controlled: CircleNoWay Name of loaded data record time controlled: ProfileNameTime Name of loaded data record route controlled: ProfileNameWay End of data record (blinking message in DA): ProfileEnd Type of display time controlled: ConfigNameTime Type of display route controlled: ConfigNameWay Digital outputs 1 to 4: DigOut Page 77 from 116

78 19.2 Declaration of the values At the beginning of each data record it is necessary to declare the variables used in the data record. For the sake of easy handling we recommend generally to declare all variables, i.e. to copy the declaration block from an existing data record into a new data record. Depending on whether it is a time- or route controlled data record, the variables must be declared accordingly. Declaration is carried out as follows: # *** Drive cycle data *** # Example data record drive profile time controlled # delete; declare Twind: stepped (t) [ C]; The first three lines are comments (comments are introduced with an #) and are thus ignored by ErgoDrive Professional. In the fourth line there is the command delete;, this deletes previously stored variables from other data records which have previously been loaded in ErgoDrive Professional. This delete command should always be used at the beginning of a data record. The following line declares the variable Twind (wind temperature). This is done through the command declare, as well as the name of the variable Twind, separated by a blank. The type of display of the variable in the DA (see chapter 19.3) as well as the assignment to time controlled (t), see chapter 19.4 or route controlled data records (s), see chapter 19.5 is determined after the colon, each separated by blanks. Furthermore the unit of the variables must be determined. This is done with square brackets. The declaration command is ended with a semicolon. Page 78 from 116

79 19.3 Determine display of the course in the DA There are two options for the display of the course of the variables in the DA that are explained with the following example of a set temperature course over time: At time 0 seconds the set temperature is 25 C, at time 3 seconds the set temperature is still 25 C, at switch point 7 seconds the set temperature is 38 C. For the first option the course of the set temperature is shown continuously rising or falling between two definition points. For the example this means that there is a linear increase of the set temperature from time 3 seconds and 25 C to time 7 seconds and 38 C. For this purpose select the type of display continuous when declaring the set temperature. The corresponding data record would look like this : # *** Drive cycle data *** # Example data record drive profile time controlled # delete; declare Twind: continuous (t) [ C]; # # time speed temperature # [s] 0.0 [km/h] 25:Twind The basis is the time controlled data record (see chapter 15). The set temperature is defined as the third column of the data record by putting a colon after the uppermost value and by stating the name of the variable (without blanks respectively). Thus all values contained in this column will be assigned to the stated variable name. The unit has already been assigned at the beginning of the data record by declaring the variable in the square brackets. In the data record the beginning and the end of the course have to be defined for this type of display. When displaying a straight line (e.g. continuous course over a certain time) thus the starting time and the ending time must be stated in the data record. The set value must be the same. In the example data record the starting time of the constant 25 C-course is 0 seconds and the ending time 3 seconds, the starting time of the constant 38 C-course is 7 seconds and the ending time 10 seconds. The set temperature is depicted as a linear increase in the section between 3 seconds (starting point) and 7 seconds (ending point). The following Figure 41 shows the above mentioned example of a data record: Page 79 from 116

80 Figure 41: Continuous set temperature course In the second option the course of the set temperature is shown as jump. For the example this means that the set temperature from time 0 seconds on is constantly 25 C and jumps from 25 C to 38 C at time 7 seconds. When declaring the set temperature select the type of display stepped for this purpose. The corresponding data record would be as follows: # *** Drive cycle data *** # Example data record drive profile time controlled # delete; declare Twind: stepped (t) [ C]; # # time speed temperature # [s] 0.0 [km/h] 25:Twind It is necessary to determine the definition points in this data record where a jump of value is to occur. The value will then remain constant at the set value until a new definition point is reached. In the above data record the definition points 3 seconds and 10 seconds are obsolete because their display does not cause a change of the values. The following Figure 42 shows the example: Page 80 from 116

81 Figure 42: Stepped set temperature course Page 81 from 116

82 19.4 Time controlled data record The time controlled data record is always the basis for time controlled variables. The creation of the time controlled data record is found in chapter 15. The time controlled data record always states the time in the first column. Please be aware that time controlled data records must always contain a speed column with at least one positive value (e.g. 0.1 km/h). At the beginning of every data record it is necessary to declare the variables used. For the sake of easy handling we recommend generally to declare all variables, i.e. to copy the declaration block from an existing data record into a new data record. The following shows the example of a data record with the declaration of all existing time controlled variables: #Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC # Header information # delete; declare Frolle: continuous (t) [N]; declare Twind: stepped (t) [ C]; declare Fwind: continuous (t) [%]; declare Hoehe: continuous (t) [m]; declare Bestr.Staerke: stepped (t) [W/m²]; declare Bestr.Front: stepped (t) [W/m²]; declare Bestr.Winkel: stepped (t) [ ]; declare DigOut: integer (t); declare CirclenoTime: String (t); declare CirclenoWay: String (s); declare ProfileNameTime: String (t); declare ProfileNameWay: String (s); declare Steigung: stepped (s) [%]; declare ProfileEnd: String (t); declare ConfigNameTime: String (t); declare ConfigNameWay: String (s); declare Vwind: stepped (t) [km/h]; let error.t 2.0[s] #Time Speed Gear Comment # # Section a # [s] 00.0[km/h] 0:gear " ":ProfileEnd "1":CircleNoTime "Zeitgest.":ProfileNameTime # Sektion b # [s] 00.0[km/h] 0 "1a": CircleNoTime "End!!!":ProfileEnd Page 82 from 116

83 The following Figure 43 shows the aforementioned data record example at the actual position of 35 seconds Figure 43: Time controlled data record example Page 83 from 116

84 19.5 Route controlled data record The route controlled data record is always the basis for route controlled variables. The creation of this data record is described in chapter 16. The route controlled data record always has a route in the first column. Please be aware of the fact that also route controlled data records must contain a speed column with at least one positive value (e.g. 0.1 km/h), in order to avoid the appearance of the flag at programme start. At the beginning of each data record it is necessary to declare the variables used. For the sake of easy handling we recommend generally to declare all variables, i.e. to copy the declaration block from an existing data record into a new data record. The following shows the example of a data record with the declaration of all existing route controlled variables: #Converted Profile: L:\flgconvert\Originale_CYC\GG_64.CYC # Header information # # height taken from file delete; declare Frolle: continuous (s) [N]; declare Twind: stepped (s) [ C]; declare Fwind: continuous (s) [%]; declare Hoehe: continuous (s) [m]; declare Bestr.Staerke: stepped (s) [W/m²]; declare Bestr.Front: stepped (s) [W/m²]; declare Bestr.Winkel: stepped (s) [ ]; declare DigOut: integer (s); declare CircleNoTime: String (t); declare CircleNoWay: String (s); declare ProfileNameTime: String (t); declare ProfileNameWay: String (s); declare Steigung: stepped (s) [%]; declare ProfileEnd: String (s); declare ConfigNameTime: String (t); declare ConfigNameWay: String (s); declare Vwind: stepped (s) [km/h]; #Way Height Comment # # Section a # [m] 0[km/h] 0[m] 0:Steigung " ":ProfileEnd "Großglockner GG_64":ProfileNameWay "End!!!":ProfileEnd Page 84 from 116

85 Figure 44 shows the route controlled data record example: Figure 44: Route controlled data record example Page 85 from 116

86 19.6 Use of variables in the data records The first column of a data record is always for the time in time controlled data records and for the route in route controlled data records. There must always be a speed column with at least one positive value (e.g. 0.1 km/h). The following columns can then be used for the variables. The assignment of a column to a variable is achieved by writing a colon in the first line of the data record after the first value and by stating the name of the variable (each without blanks). Thus all values contained in this column are assigned to the stated variable name. A unit has already been assigned at the beginning of the data record by declaring the variable with a square bracket. The following is an example of a data record: # *** Drive cycle data *** # Example data record climate values, drive profile time controlled # delete; declare Frolle: continuous (t) [N]; declare Twind: stepped (t) [ C]; declare Fwind: continuous (t) [%]; declare Hoehe: continuous (t) [m]; declare Bestr.Staerke: stepped (t) [W/m²]; declare Bestr.Front: stepped (t) [W/m²]; declare Bestr.Winkel: stepped (t) [ ]; declare DigOut: integer (t); declare CirclenoTime: String (t); declare CirclenoWay: String (s); declare ProfileNameTime: String (t); declare ProfileNameWay: String (s); declare Steigung: stepped (s) [%]; declare ProfileEnd: String (t); declare ConfigNameTime: String (t); declare ConfigNameWay: String (s); declare Vwind: stepped (t) [km/h]; # 0[s] 0[mph] 0:Hoehe 23:TWind 40:FWind 0:VWind "1":CircleNoTime "Temp/Zeit":ProfileNameTime "1":CircleNoTime "2":CircleNoTime "End":CircleNoTime Page 86 from 116

87 In this example the time is stated in the first column, the speed is in the second column and the height is in the third column, the set temperature value is in the fourth column, the humidity set value is in the fifth column and the set wind speed is in the sixth column. The set temperature would from the beginning be a constant 23 C, at time 20 seconds it would jump to 30 C and at time 40 seconds it would jump to 60 C, as stepped was chosen during declaration (see chapter 19.3). The set humidity value starts at 40 % and rises continuously between the times 10 and 20 seconds to 50 %. Between the times 20 and 30 seconds there is continuous increase from 50 % to 70 %. Between 30 and 40 seconds the humidity is reduced continuously from 70 % to 40 %, as continuous was selected during declaration (see chapter 19.3). For the set wind speed again stepped was selected and this means that the set wind speed jumps to the stated value at the stated time, at 40 seconds this would be from 30 km/h to 100 km/h. The following Figure 45 shows the course of the set temperature over time based on the above mentioned data record at the actual position 20 seconds: Figure 45: Course of set temperature of the example data record Page 87 from 116

88 19.7 Table of the variables used The following Table 3 states the variables in which values can be assigned in the DA ErgoDrive Professional: Variable (set value) Name in data record Unit Time controlled Route controlled Roller traction Frolle N yes yes Wind temperature Twind C yes yes Humidity Fwind % yes yes Height (to PAS) Hoehe m yes yes Sunlight intensity Bestr.Staerke W/m² yes yes Insolation Bestr.Front W/m² yes yes Position of sun Bestr.Winkel yes yes Gradient Steigung % yes yes Wind speed Vwind km/h yes yes Table 3: Value variables of the DA ErgoDrive Professional The following Table 4 states the variables that either serve the control or display of information in the DA ErgoDrive Professional: Variable Cycle number time controlled Cycle number route controlled Name of loaded data record time controlled Name of loaded data record route controlled End of data record (blinking message in DA) Type of display time controlled Type of display route controlled Name in data record Task Time controlled Route controlled CircleNoTime Info yes no CircleNoWay Info no yes ProfileNameTime Info yes no ProfileNameWay Info no yes ProfileEnd Info yes yes ConfigNameTime Control yes no ConfigNameWay Control no yes Digital outputs 1-4 DigOut Control yes yes Table 4: Control variables of the DA ErgoDrive Professional The specification and the use of these variables are described in the following chapters 20 and Page 88 from 116

89 20 Display of information from data records The display of information from the data records is carried out via the information variables as shown in Table 4 Cycle number time controlled: CircleNoTime Cycle number route controlled: CircleNoWay Name of the loaded data record time controlled: ProfileNameTime Name of the loaded data record route controlled: ProfileNameWay End of data record (blinking message in DA): ProfileEnd 20.1 Display of cycle number and position number The current cycle number for time controlled data records and the current position number for route controlled data records are shown from the profile in the display field for measurement values of the DA ErgoDrive Professional with the variables CircleNoTime and CircleNoWay. For this purpose the corresponding value in the data record is written between inverted commas at the end of the respective definition point and is separated from the last column by at least one blank or through a tabulator. A colon and the term CircleNoTime or CircleNoWay are added without a further blank. The value is displayed until it is overwritten with a new value. The value can only be of a certain length, as only a certain amount of characters can fit into the display field. If the value is too long it is cut off at the beginning and the end. The following shows as an example an extract from the time controlled ECE-cycle: #Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC # Header information # delete; declare Frolle: continuous (t) [N]; declare Twind: stepped (t) [ C]; declare Fwind: continuous (t) [%]; declare Hoehe: continuous (t) [m]; declare Bestr.Staerke: stepped (t) [W/m²]; declare Bestr.Front: stepped (t) [W/m²]; declare Bestr.Winkel: stepped (t) [ ]; declare DigOut: integer (t); declare CirclenoTime: String (t); declare CirclenoWay: String (s); declare ProfileNameTime: String (t); declare ProfileNameWay: String (s); declare Steigung: stepped (s) [%]; declare ProfileEnd: String (t); declare ConfigNameTime: String (t); declare ConfigNameWay: String (s); declare Vwind: stepped (t) [km/h]; let error.t 2.0[s] #Time Speed Gear Comment # Page 89 from 116

90 # Sektion a # [s] 00.0[km/h] 0:gear " ":ProfileEnd "1":CircleNoTime # Sektion b # [s] 00.0[km/h] 0 "1a":CircleNoTime # Sektion c # [s] 00.0[km/h] 0 "1b":CircleNoTime # Sektion d1 # [s] 00.0[km/h] 1 "1c":CircleNoTime "Ende 1. Zyklus":CircleNoTime # Sektion b # # [s] 00.0[km/h] 0 "2a":CircleNoTime From the time 0 seconds the cycle number 1 is displayed. At time 46 seconds the display changes to 1a, at time 84 seconds to 1b, at time 152 seconds to 1c and at time 235 seconds to End 1. cycle. At time 241 seconds 2a is displayed. The following Figure 46 shows the DA-surface at time 165 seconds, the cycle display is at 1c: Figure 46: ECE-cycle at time 165 seconds Page 90 from 116

91 In the mountain profile the value of the variable CircleNoWay appears in the display field below the value current position number as shown in the following example: #Converted Profile: L:\flgconvert\Originale_CYC\PP1.CYC # Header information # # height taken from file delete; declare Frolle: continuous (s) [N]; declare Twind: stepped (s) [ C]; declare Fwind: continuous (s) [%]; declare Hoehe: continuous (s) [m]; declare Bestr.Staerke: stepped (s) [W/m²]; declare Bestr.Front: stepped (s) [W/m²]; declare Bestr.Winkel: stepped (s) [ ]; declare DigOut: integer (s); declare CirclenoTime: String (t); declare CirclenoWay: String (s); declare ProfileNameTime: String (t); declare ProfileNameWay: String (s); declare Steigung: stepped (s) [%]; declare ProfileEnd: String (s); declare ConfigNameTime: String (t); declare ConfigNameWay: String (s); declare Vwind: stepped (s) [km/h]; # #Way Height Comment # [m] 30[km/h] 0[m] 0:Gradient "1":CircleNoWay "1":CircleNoWay "2":CircleNoWay "3":CircleNoWay "4":CircleNoWay The following Figure 47 shows the display of the position number in the 2D-height display: Page 91 from 116

92 Figure 47: Display of the position number in the 2D-height display Page 92 from 116

93 20.2 Display of the profile name The profile name is shown as the first value in the display field of the measurement values of the DA ErgoDrive Professional from the profile with the help of the variables ProfileNameTime or ProfileNameTime. For this purpose the value in the data record is written between inverted commas in the first line separated by at least one blank or a tabulator from the last column or from an already existing variable. A colon and the term ProfileNameTime or ProfileNameTime are added without further blank. The value is displayed until it is overwritten with a new value. The value can only be of a certain length, as only a certain amount of characters can fit into the display field. If the value is too long it is cut off at the beginning and the end. The following shows as an example an extract from the ECE-cycle: #Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC # Header information # delete; declare Frolle: continuous (t) [N]; declare Twind: stepped (t) [ C]; declare Fwind: continuous (t) [%]; declare Hoehe: continuous (t) [m]; declare Bestr.Staerke: stepped (t) [W/m²]; declare Bestr.Front: stepped (t) [W/m²]; declare Bestr.Winkel: stepped (t) [ ]; declare DigOut: integer (t); declare CirclenoTime: String (t); declare CirclenoWay: String (s); declare ProfileNameTime: String (t); declare ProfileNameWay: String (s); declare Steigung: stepped (s) [%]; declare ProfileEnd: String (t); declare ConfigNameTime: String (t); declare ConfigNameWay: String (s); declare Vwind: stepped (t) [km/h]; let error.t 2.0[s] #Time Speed Gear Comment # # Sektion a # [s] 00.0[km/h] 0:gear " ":ProfileEnd "ECE":ProfileNameTime # Sektion b # [s] 00.0[km/h] 0 "1a":CircleNoTime Page 93 from 116

94 From the time 0 seconds the profile name ECE is displayed. As this variable only appears once in the data record, the display remains. If at a later time there is a new entry with the variable Profile- Name, ECE would at this point be overwritten with the new value. The following Figure 48 shows the DA surface with the display of the profile name at time 45 seconds: Figure 48: ECE-cycle at time 45 seconds Page 94 from 116

95 In the mountain profile the value of the variable ProfileNameWay appears as the first value in the display window just like in the speed profile. The following example shows the data record: #Converted Profile: L:\flgconvert\Originale_CYC\PP1.CYC # Header information # # height taken from file delete; declare Frolle: continuous (s) [N]; declare Twind: stepped (s) [ C]; declare Fwind: continuous (s) [%]; declare Hoehe: continuous (s) [m]; declare Bestr.Staerke: stepped (s) [W/m²]; declare Bestr.Front: stepped (s) [W/m²]; declare Bestr.Winkel: stepped (s) [ ]; declare DigOut: integer (s); declare CirclenoTime: String (t); declare CirclenoWay: String (s); declare ProfileNameTime: String (t); declare ProfileNameWay: String (s); declare Steigung: stepped (s) [%]; declare ProfileEnd: String (s); declare ConfigNameTime: String (t); declare ConfigNameWay: String (s); declare Vwind: stepped (s) [km/h]; # #Way Height Comment # [m] 30[km/h] 0[m] 0:Steigung "Gradient":ProfileNameWay "1":CircleNoWay The following Figure 49 shows the display of the profile name in the 2D-height display: Page 95 from 116

96 Figure 49: Display of the profile name in the 2D-height display Page 96 from 116

97 20.3 Display of the message profile end Next to the flag which appears at the end of the profile there is also a text message in blinking red letters on the screen. The displayed text is stored in the data record with the variable ProfileEnd and is displayed from the profile. For this purpose the corresponding value is also written in inverted commas in the data record and is separated by at least one blank or a tabulator from the last column or from an already existing variable. Without further blank a colon and the term ProfileEnd are added. For this it is necessary to state the variable ProfilEnd as blank value in the first line of the data record as otherwise the message appears immediately. Instead of a text write a blank between the two inverted commas. Do not use the command without blanks between the inverted commas as otherwise this will result in errors or a systems crash when loading the data record. In the last line of the data record the desired text is then stored. The following shows as an example an extract from the ECE-cycle: #Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC # Header information # delete; declare Frolle: continuous (t) [N]; declare Twind: stepped (t) [ C]; declare Fwind: continuous (t) [%]; declare Hoehe: continuous (t) [m]; declare Bestr.Staerke: stepped (t) [W/m²]; declare Bestr.Front: stepped (t) [W/m²]; declare Bestr.Winkel: stepped (t) [ ]; declare DigOut: integer (t); declare CirclenoTime: String (t); declare CirclenoWay: String (s); declare ProfileNameTime: String (t); declare ProfileNameWay: String (s); declare Steigung: stepped (s) [%]; declare ProfileEnd: String (t); declare ConfigNameTime: String (t); declare ConfigNameWay: String (s); declare Vwind: stepped (t) [km/h]; let error.t 2.0[s] #Time Speed Gear Comment # # Section a # [s] 00.0[km/h] 0:gear " ":ProfileEnd "ECE":ProfileNameTime # Section b # [s] 00.0[km/h] 0 "1a":CircleNoTime "End of test!!!":profileend Page 97 from 116

98 From the time 0 seconds the variable ProfileEnd is set back with the blank between the inverted commas so that the message test end reached does not already appear at the beginning of the test. In the last line the variable is then supplied with the corresponding message, e.g. test end which then appears in the DA programme. This is the same for the mountain profile. Page 98 from 116

99 21 Use of the variables with control function The DA ErgoDrive Professional offers the option to load the operation modes (surfaces of the drive curves) directly from the data record. Therefore it is possible first to drive a time controlled cycle (e.g. speed over time) and to switch to another mode e.g. mountain cycle with depiction of the gradient over route after a certain amount of time. The following variables serve this purpose: Display time controlled: ConfigNameTime Display route controlled: ConfigNameWay Another variable helps to control four digital outputs. Digital output 1 to 4: DigOut 21.1 Switching to display (v- and mountain cycle running automatically) In this application there is an automatic switch from the data record between the time and route controlled cycle. Switching is carried out at the corresponding time- or route point with the DA command xtime, where the value 1 presents time controlled and the value 0 route controlled. It is absolutely necessary to continue the cycle with the already driven time respectively with the already driven route after switching (set value). Otherwise the display can have errors and there is the risk of a systems crash. 0:xTime: 1:xTime: Switching from the time controlled into the route controlled mode. The route controlled profile must be continued with the driven route calculated from the set speed value of the previous time controlled mode. Switching from the route controlled into the time controlled mode. The time controlled profile must be continued with the time already driven in the route controlled mode. Furthermore loading of the surface is also done automatically from the data record. This is done with the commands ConfigNameTime for time controlled cycles and ConfigNameWay for route controlled cycles. Besides the file name of the surface to be loaded the complete path name of the store address of the surface file is necessary. The variable ProfileEnd should only be used in the last part of the data record (in the following example this would be the route controlled part). The following data record shows an example of the switch: Page 99 from 116

100 #Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC # Header information # delete; declare Frolle: continuous (s) [N]; declare Twind: stepped (s) [ C]; declare Fwind: continuous (s) [%]; declare Hoehe: continuous (s) [m]; declare Bestr.Staerke: stepped (s) [W/m²]; declare Bestr.Front: stepped (s) [W/m²]; declare Bestr.Winkel: stepped (s) [ ]; declare DigOut: integer (s); declare CirclenoTime: String (t); declare CirclenoWay: String (s); declare ProfileNameTime: String (t); declare ProfileNameWay: String (s); declare ConfigNameTime: String (t); declare ConfigNameWay: String (s); declare Steigung: stepped (s) [%]; declare ProfileEnd: String (s); declare Vwind: stepped (s) [km/h]; let error.t 2.0[s] #Time Speed Gear Comment # [s] 00.0[km/h] 0:gear "C:\Programme\ErgoDrive\configurations\ speed_70.cfg":confignametime "1a":CircleNoTime "v und Berg":ProfileNameTime # [s] 00.0[km/h] 0 "A":CircleNoTime "C:\Programme\ErgoDrive\configurations\ speed_floating.cfg":confignametime "C:\Programme\ErgoDrive\configurations\ speed_110.cfg":confignametime # [s] 00.0[km/h] 0 "1c": CircleNoTime :xTime "C:\Programme\ErgoDrive\ configurations\2d_altitude.cfg":confignameway # Sektion a # [m] 0[m] 0:Steigung "a": CircleNoWay "Townes-Pass PP1":ProfileNameWay " ":ProfileEnd "Test end":profileend Page 100 from 116

101 In the first line of the data record the time controlled surface speed_70.cfg is displayed with the command ConfigNameTime. By loading the above described cycle file the surface vt_value is automatically displayed in the DA (see Figure 50). In the following example the DA was fed a constant actual speed of 20 km/h. Figure 50: Surface vt_neu after loading the example data record At time 8 seconds there is a switch to the time controlled surface speed_floating.cfg with the help of the command ConfigNameTime (see Figure 51): Figure 51: Surface v_t_value at time 13 seconds Page 101 from 116

102 At time 18 seconds there is another switch to the time controlled surface speed_110.cfg (see Figure 52): Figure 52: Surface vt_neu at time 29 seconds At time 42 seconds there is a change to the route controlled mode as well as loading of the route controlled surface 2d_altiude.cfg (see Figure 53). The route controlled profile begins with the already driven route of 138,75 m from the time profile calculated from the set speed value: Figure 53: Surface 2D_altitude at time 26 seconds Page 102 from 116

103 21.2 Setting of digital outputs (switching 4 channels) 4 digital outputs have been planned for the control of additional devices (switching four channels). Each of the 4 digital outputs has in set mode an output voltage of 24V DC and in turned off mode an output voltage of 0V DC. The output current is 0,5 A. The digital outputs are operated via fieldbus coupler in binary format. Switching the digital outputs on and off is executed with the variable DigOut in the data record. The variable has the Integerformat, i.e. operation of the output is carried out as decimal number. The output one is always assigned the value 1, the output two the value 2, the output three the value 4 and the output four the value 8. In order to set several outputs simultaneously, these values must be added accordingly (see Table 5). Setting back all outputs simultaneously is done with the value 0. The corresponding value is written without inverted commas in the data record separated with at least one blank or a tabulator from the last column or from an already existing variable respectively. A colon and the term DigOut are added without another blank. The variable must be used for each selected change in status of one or several outputs. The following Table 5 presents the values for the operation of the digital outputs: Value: DigOut Output to be set 0 No output / set back all outputs 1 only 1 2 only 2 4 only 3 8 only and and and and and and 4 7 1, 2 and , 2 and , 3 and , 3 and , 2, 3 and 4 Table 5: Value assignment for setting of digital outputs The following example is an extract from the ECE-cycle: Page 103 from 116

104 #Converted Profile: L:\flgconvert\Originale_CYC\ECE.CYC # Header information # delete; declare Frolle: continuous (t) [N]; declare Twind: stepped (t) [ C]; declare Fwind: continuous (t) [%]; declare Hoehe: continuous (t) [m]; declare Bestr.Staerke: stepped (t) [W/m²]; declare Bestr.Front: stepped (t) [W/m²]; declare Bestr.Winkel: stepped (t) [ ]; declare DigOut: integer (t); declare CirclenoTime: String (t); declare CirclenoWay: String (s); declare ProfileNameTime: String (t); declare ProfileNameWay: String (s); declare Steigung: stepped (s) [%]; declare ProfileEnd: String (t); declare ConfigNameTime: String (t); declare ConfigNameWay: String (s); declare Vwind: stepped (t) [km/h]; let error.t 2.0[s] #Time Speed Gear Comment # # Sektion a # [s] 00.0[km/h] 0:gear " ":ProfileEnd"ECE":ProfileNameTime :DigOut # Output 3 on # Sektion b # [s] 00.0[km/h] 0 "1a":CircleNoTime :DigOut # Output 3 off # Sektion c # # [s] 00.0[km/h] 0 "1b":CircleNoTime :DigOut # Output 3 off :DigOut # Output 1 and 3 on :DigOut # Output 1 on, 3 off :DigOut # Output 1 and 2 on # Sektion d1 # # [s] 00.0[km/h] 1 "1c":CircleNoTime :DigOut # All outputs on :DigOut # All outputs off "End!!!":ProfileEnd At time 40 seconds the output three is switched on. This is to be switched off at time 51 seconds. As no other output is to be switched on at this point in time, the value 0 is used for switching off. At time 89 seconds output three is switched on again. At time 94 seconds additionally to output 3 output one is switched on. At time 101 seconds output one remains switched on, output three is switched off. At time 133 seconds additionally to output one output two is switched on, at time 162 seconds the outputs three and four follow. At time 173 all outputs are switched off. Page 104 from 116

105 22 Conversion of GPS-data records (optional) The following chapter describes the conversion of recorded route profiles via GPS-receive data system into the ErgoDrive-format Installation of the GPS-converter Only the two files gpsconvert.exe and the corresponding file gps_filter.dll are necessary for the installation of the GPS-converter. Both files must be copied together onto the hard disc in a directory which must be created for this purpose (e.g. C:\GPSconvert) Use of GPS-receive system in the vehicle If you use GPS-receive systems in the vehicle in order to record GPS-log data files during the drive please observe the following instructions: An existing airbag must be deactivated when using the GPS-receive system in the vehicle, if parts of this GPS-receive system are used in any way within in the working range of the steering wheel, or is used within the working range of a passenger-, side- or other airbag. cbb software GmbH accepts no liability for damage of any kind that arises from failure to comply with this warning! Safety Instructions: The components of a used GPS-receive system (e.g. receiver, accumulator, cables, USB-adapter, laptop for data recording etc.) must not be fastened in a place where, in the event of an accident, they could be thrown against the driver/passenger, as this could cause severe or fatal injuries. The components of a used GPS-receive system (e.g. receiver, accumulator, cables, USB-adapter, laptop for data recording etc.) must under no circumstances be mounted within the working range of an airbag. Discuss the installation location in the vehicle with a safety officer and follow the safety instructions. Safety instructions for the use of a GPS-antenna with a magnetic base: Only install the magnetic base on even and clean magnetic surfaces (e.g. the roof of the vehicle) which are free of oil and grease. When choosing the location take the expected wind pressure, the longitudinal and lateral dynamics as well as possible effects of driving through potholes into consideration. At all times keep the magnetic base free of oils and greases. When driving generally secure the antenna of the magnetic base additionally e.g. by using a steel cord that is tightly connected to the vehicle and has a tensile strength that is suitable for the speed and the forces occurring when driving. Make sure that the permissible measurements in accordance with the traffic regulations are observed. All rules in accordance with the traffic regulations must be observed!!! Additionally discuss the use of the magnetic base antenna with a safety office and follow the safety instructions. Exclusion of Liability: No responsibility is accepted for accidents or injuries that arise from failure to comply with the rules and safety instructions detailed above. Page 105 from 116

106 22.3 Function of the GPS-converter The only function of the GPS-converter is the creation of profile files for the DA ErgoDrive Professional from GPS-based NMEA-log files. The data required for this procedure is described in chapter Starting the application In order to start the application please call up the file gpsconvert.exe from the corresponding directory on your hard disc (e.g. C:\GPSconvert) Main screen The following Figure 54 shows the main screen of the GPS-converter: Add source file Delete source file Parameter field Entry format Output format Error recovery Output path Start conversion End programme Figure 54: Main screen of the GPS-converter Page 106 from 116

107 Add source file After activating the button Add, the dialogue window below appears and a new entry file can be added. This then appears in the listbox. Figure 55: Dialogue Add source file Delete source file After selecting a file from the listbox, this can be deleted from the listbox again by clicking on the button Delete. This will not physically delete the file from the hard disc. Figure 56: Dialogue Delete source file Page 107 from 116

108 Entry format The format of the source files is defined via the dropdown-box Entry format. The conversion programme presently supports the NMEA-format as well as some customer specific formats which however, are only available to the specific customer. If you should have no other special formats, the dropdown-box only offers the NMEA-format. Figure 57: Dropdown-box source file format Output format The output format is selected via the dropdown-box output format. The entry DA time profile creates a time controlled profile file for the DA ErgoDrive Professional (e.g. for the speed over time display). The entry DA route profile creates a corresponding route profile for the ErgoDrive Professional (e.g. for 2D-height display, 3D-road simulation or gradient over route display). Figure 58: Dropdown-box output format Output path The entry field output path stipulates where the output files are to be stored. If the small button with the three small dots... to the right of the entry field is activated, the dialogue below appears. In this dialogue an existing path can be chosen or a new directory can be created if necessary. Figure 59: Selection window output path Page 108 from 116

109 Start conversion The source files in the listbox are opened and converted one by one. Afterwards the ready profile files can be found in the output path described in chapter The created file has the same name as the source file. This is a profile file for the driver s aid ErgoDrive Professional and has the known format of these profiles: Figure 60: Construction of a profile file The data in the created profile file is stored in columns, the content of these columns can be seen from the assignment at the beginning of the profile file. Further information regarding the creation and editing of ErgoDrive profile files you can find in the instruction manual of the driver s aid Ergo- Drive Professional. If errors should occur during the conversion, this is signalled via a popup-window. The cause of the error is then displayed in the status field End programme With the button End you can end the conversion programme. Page 109 from 116

110 22.4 Step by step instructions This section shows you the separate operating steps in the order that is necessary for the execution of the conversion of a NMEA-log-file into a driver s aid profile file. In a first step, as described in chapter , the corresponding entry file has to be selected. This then appears in the selection list. In this example a NMEA-log-file with the name gps_test.txt was selected. Figure 61: Source file in the selection list The NMEA-format must now be selected as input format if you can use further optional formats. Otherwise the only option offered is the NMEA-format. As output format you have the choice between a time- or route profile. In this example a time profile is being generated and therefore the choice is DA time profile : Figure 62: Select input and output format Page 110 from 116

111 The other parameters are described in chapter 22.6 and must normally not be changed. Therefore they are not adapted for this example. The next step is to define the output path for the target file. This is done in the entry field output path and is possible via the button..., to the right of this entry field. The desired target path can now be selected in the following dialogue: Figure 63: Select target path In this example the target path C:\Programme was selected. Then conversion is executed by activating the button Start. When the conversion has been finalised without errors the message Conversion finalised without error appears in the status field. If errors occur during conversion this is signalled via a popup-window. The reason for the error is then displayed in the status field. Figure 64: Conversion finalised without error The created profile file can then be found in the path defined as output path. It has the same name as the source file, that is gps_test.txt. This file can now, as described in the instruction manual of the driver s aid ErgoDrive Professional, be edited, loaded and used. Page 111 from 116

112 22.5 Necessary data for the conversion NMEA-log files that comply with the NMEA standard 0183 are necessary for the creation of the profile files of the driver s aid ErgoDrive Professional. The existing source file must at least contain the data record GPGGA. This contains among other things the following data: Time stamp Longitude Longitude direction Latitude Latitude direction Height Number of satellites (at least 4 satellites required) If these values are missing in the NMEA-log-file, conversion is interrupted with a fault message. The following figure shows an example of an NMEA-log file: Figure 65: NMEA-source file 22.6 Parameters for the conversion Figure 66: Entry of parameters The field Minimum number of satellites defines the minimum number of satellites required the whole time so that the conversion is not interrupted. A minimum of 4 satellites are necessary for the GPS device to determine the height. A number of at least 6 satellites makes sense. This value is the standard setting. The field Maximum course for 3D defines the maximum course correction before the conversion is interrupted. This entry is necessary when the source file is to be converted into a driver s aid profile and then used for a 3D-road simulation. Presently the maximum course correction that can be displayed by the 3D-road simulation without errors, is 30 degrees. If this parameter is set to zero, the course in the output file is always zero too. This offers the possibility of driving straight on the whole time even though the recorded route contains bends. Page 112 from 116

113 If the check box Calculated speed is activated, the actual speed is calculated from the existing timeand GPS-data in the source file. Otherwise the source file is searched for the NMEA-data record GPRMC. This contains speed information edited by the GPS-device. This method is more precise than speed calculated from the existing time- and GPS data and should therefore, if possible, be preferred. By activating the checkbox Calculate gradient a column gradient is generated in the driver s aid profile file in addition to the column height. The gradient is here calculated from the GPS-coordinates in the NMEA-log file and the height values. At the last point of this file the gradient is automatically set at Error recovery The conversion programme offers the possibility of automatic filtering of speed peaks caused by faulty GPS-peaks (through change of satellite etc.). The following Figure 67 shows the window for error recovery: Figure 67: Error recovery The following section describes the criteria as well as the possible procedures in detail Maximum acceleration A criterion for the automatic error recovery is the acceleration calculated from the GPS-data. If this is higher than the value set in this field, a correction is made according to the procedures selected in the field error recovery (see chapter ). This means that data is corrected in a way that acceleration is limited to the value set in this field Maximum delay Another criterion for the correction is the maximum delay. If this exceeds the set value a correction is made according to the set procedure Maximum change in gradient If the calculated gradient exceeds this value the gradient and the corresponding height are corrected. If a jump in height is detected, the previous height will be maintained and an offset is accepted for the following height values. Page 113 from 116