Taking engine controls to the next tier - technology

Diesel Progress North American Edition, March, 2004 by Mike Brezonick

Continuing the expansion of its microprocessor control system for engine-powered equipment applications, Controls Inc. has developed a new engine controller designed specifically for use on Tier 2 engines using SAE J1939 communications protocols. The EngineMaster Plus T2 is designed to provide complete engine and throttle control and can b used to integrate other electronically controlled systems and component into a single control architecture, according to the Medina, Ohio, company.

"Controls Inc. has had a J1939 engine control product out in the market for over a year," said Bob Cowen Controls Inc. president. "The new" EM Plus T2 has been redesigned from the circuit board and software level up, taking into account customer feedback and the goal of providing more flexibility and expanded capabilities.

"The ability to control engine speed in a variety of ways and to integrate other systems and components into the engine control unit has resulted in a high value-added engine control solution that is very cost competitive."

The EM Plus T2 controllers are designed to provide extensive engine monitoring, control and protection capabilities. The following engine parameters are displayed continuously on a large 32-character LCD display: engine hours, engine rpm, oil pressure, water temperature, battery, voltage and fuel rate or level. Fault codes, service interval messages and other engine parameters can also be displayed.

In addition, the system offers a number of throttle control capabilities, remote and local start/stop and automatic shutdown protections under fault conditions such as low oil pressure, high coolant temperature, low fuel level, etc.

Having a variety of engine speed control options, external system integration capabilities and logic processing, the EM Plus T2 control is completely customizable to the specific needs of any application, the company said. Engine control parameters can be done at the factory and also through a flout panel touch pad, the company said.

The throttle control capabilities of the EM Plus T2 control offer a range of options. For example, it allows engine speed to be controlled in several ways: manually within a predetermined operating range; manually with preset engine speed levels (multistate); or automatically. In manual mode, engine speed is raised or lowered by the operator pressing up and down buttons on the keypad. In multistate mode, engine speed is controlled by a combination of preprogrammed setting and the operator. One to six predetermined engine speeds can be set.

In automatic mode, the engine responds on its own to external variables, then goes through a profile throttle routing that operates the engine at specified speeds. Using a dewatering application as an example, the engine can be started in response to a specific water level, run through an operating sequence and then automatically shut down when the programmed variable is achieved. The operating cycle can include warm up, ramp up, ramp down and cool down parameters.

In a machine such as a wood chipper, the unit can be programmed to monitor engine rpm levels and the material feed system. When engine speed falls below a programmed level because of a heavy load or possibly a jam in the feeder system, the controller can disengage, and/or reverse the feeder automatically re-engaging it when the engine rpm level is back to normal.

This approach to the industrial engine market is a concept that the company has labeled "mass customization." In other words, a standard universal engine control product that allows each customer to implement a specific engine control system/solution for the particular application. "The new EM Plus T2 is a cost-effective solution, whether the need is for a simple engine control or a sophisticated, comprehensive control system," Cowen said. "It gives each customer the ability, to implement a custom solution at the same cost of a standard product."

Controls Inc. builds its systems at its 4000 sq.ft, facility in north central Ohio. The company is scheduled to expand into a new 5600 sq.ft, facility sometime in the second quarter of this year.