CODESYS in Mobile Automation

CODESYS is the number one Development System for ECUs in mobile machines.
CODESYS Inspiring Automation Solutions 2

CODESYS in Mobile Automation

CODESYS is the market-leading automation software for programmable control units (ECUs) used in off-highway vehicles
or other mobile machines. CODESYS-compatible controllers can be found in many construction machines, cranes,
industrial trucks, surface mining machines and transporters. And not without reason: CODESYS can be used in ECUs / 
mobile controllers of completely different designs and performance classes. It offers integrated support for the most
important fieldbus systems and a comprehensive visualization functionality perfectly suited for mobile applications.
Another outstanding plus is the certified suitability for programming IEC 61508 SIL2 safety applications.

Picture: © ALSTOM / E.Lamperti

Picture: © CrossControl AB

Picture: © Hydrautronics
A selection of CODESYS applications in different industrial sectors:
ƒƒ Mobile construction cranes and wheeled ƒƒ Truck mounted sweepers
excavators ƒƒ Road pavers and other machinery for
ƒƒ Container cranes road construction
ƒƒ Grab dredgers ƒƒ Wheeled forestry harvesters
ƒƒ Excavators, rock crushers and other utility ƒƒ Transport and utility vehicles such as
vehicles for underground and surface dumpers and trucks
mining ƒƒ Marine diesel engines
ƒƒ Driverless transport systems for logistics ƒƒ Control and operating units in trains and
ƒƒ Industrial trucks and fork lifts trams
ƒƒ Tractors, harvesters and mobile feed mills ƒƒ Mobile industrial compressors
ƒƒ Aircraft tractors ƒƒ Snow groomers
ƒƒ Yacht automation
Picture: © Evren Kalinbacak – iStockphoto.com

Construction Mining Marine

Picture: © Darryl Peroni – iStockphoto.com
Picture: © ewg3D – iStockphoto.com

In industrial use around the world

Agriculture Transportation
Picture: © small_frog – iStockphoto.com

Thousands of off-highway vehicles,

mobile machines, plants and applica-
Picture: © RATP/ J-F Mauboussin

tions in the most different industries are

automated with CODESYS.
Its comprehensive functionality and
flexibility make CODESYS the ideal tool
for mobile automation applications.
 3 Mobile Automation

Typical application configurations with CODESYS

CODESYS in construction machines

Programming environ- Operating panel / 

ment for application display: CODESYS
software: CODESYS TargetVisu
Development System
CANopen
J1939

ECU / mobile controller: Fieldbus configura-

CODESYS Control tion and protocol
Embeddedd stack: CODESYS
CANopen / J1939

CODESYS in cranes

Programming environment for HMI Panel:

safe application software, SIL2: CODESYS HMI
CODESYS Development System Fieldbus protocol stack:
certified to SIL2 CODESYS CANopen
Safety according to
CANopen
EN 50325-5
Safety

SIL2 ECU / mobile Mixed operation

controller: CODESYS of CANopen and
Control certified to CANopen Safety
IEC 61508 SIL2 slave modules

CODESYS in fork lift trucks

IEC 61131-3 programming External diagnostics

environment: CODESYS systems: CODESYS
Development System with PLCHandler
application libraries e.g. for
direct CAN access
CAN

ECU / mobile controller:
CODESYS Control
Embedded for 16-/32-bit
CPUs
CODESYS Inspiring Automation Solutions 4

Why use CODESYS for mobile industrial applications?

1 2
Everything integrated in one single user interface, the Power and usability for the effective realization of
CODESYS Development System: complex automation projects:
ƒƒ Complete IEC 61131-3 development system (free ƒƒ Fast machine code for all ECUs: industrially proven
of charge for users): for the linking of simple logic compilers for compact mobile controllers through
modules through to the complex object-oriented to high-performance central controllers exploit the
programming of industrial ECUs / mobile controllers device performance to the optimum
ƒƒ Extensive debugging and commissioning functions: ƒƒ Scalable functionality of the CODESYS Development
troubleshooting and optimization on-site without System:
additional software directly in the application code -- Use of simple editors / configurators
ƒƒ Programming access via CAN interface -- Powerful add-on tools for static code analysis,
integrated UML diagrams, source control with
ƒƒ Development of user-friendly operating interfaces Apache Subversion or automated application
and driver displays with modern visualization tests, suitable for safety-critical applications
elements: integrated visualization editor in the ƒƒ Well-thought-out concept for the reusability of
CODESYS Development System function blocks in libraries
ƒƒ Display of the created operating interfaces for
testing, commissioning and machine operation on
different platforms: in the CODESYS Development
System, directly on the device display of a mobile
controller or on driver displays
ƒƒ Fully integrated configurator for local inputs and 3
outputs, for CANopen, J1939, EtherCAT and other
Ideal conditions for mobile industrial applications:
fieldbus systems: declaration and use of sensors,
actuators, signals and joysticks ƒƒ Proven system platform: in more than 500,000
ƒƒ Layer 7 master protocol stacks for CANopen, J1939 mobile control applications
and EtherCAT can be used as portable CODESYS ƒƒ Large selection of ECUs / mobile controllers, pro-
libraries without implementation effort grammable with CODESYS: listed in the CODESYS
ƒƒ Raw CAN access with proprietary protocol, can be Device Directory at www.codesys.net
encapsulated in customized function libraries ƒƒ Large community for mobile industrial machines:
ƒƒ CODESYS Store: access to application libraries as know-how support for the creation of applications
well as tested add-on tools for the development of by CODESYS System Partners or engineering offices
mobile machines ƒƒ Compatible additional equipment: suitable HMI
devices, diagnostic tools etc.

CODESYS in industrial applications

ƒƒ Alstom Transport
ƒƒ E&K Automation
ƒƒ Goldhofer
Picture: © Liebherr Mining Equipment Co.

ƒƒ Jungheinrich
ƒƒ Liebherr Mining Equipment
ƒƒ MAN Diesel & Turbo
ƒƒ Rolls Royce Marine
ƒƒ Sandvik Mining and Construction Oy
ƒƒ Trepel Airport Equipment
 5 Mobile Automation

Product components for mobile applications

CODESYS CANopen Master

ƒƒ CANopen Master/Slave configurator fully integrated
in the CODESYS Development System: integration of
slaves on the basis of EDS or DCF files without exter-
nal tools for the configuration of the bus system
ƒƒ Mapping of I/O data in the integrated configurator
ƒƒ CiA 301 CANopen communication stack in form of
a CODESYS library: dynamically compiled and linked
with the application
ƒƒ Application interface according to CiA 405 for the
diagnosis and use of SDOs
ƒƒ Configuration of PDOs without additional tool

CODESYS SAE J1939

ƒƒ SAE J1939 configurator for ECUs fully integrated in
the CODESYS Development System: definition / map-
ping of the signals and parameter groups (PG)
ƒƒ Complete PG database including SAE signal docu-
mentation: direct access to the documentation of the
signal specifications
ƒƒ Portable SAE J1939 communication stack in form of
a CODESYS library: dynamically compiled and linked
with the application
ƒƒ Functional scope of the stack: simulation of ECUs,
dynamic address claiming, Arbitrary Adress Capable,
support for the parameter groups > 8 bytes, optional
signal conversion, etc.
ƒƒ Intelligent signal processing: raw signal / implicit
conversion with automatic data type determination,
consistent I/O channel generation

Horizontal directional drilling system for the trenchless

installation of underground pipes in mixed soil conditions and
rock: The system is automated and visualized with CODESYS.
Pictures: © TRACTO-TECHNIK GmbH & Co. KG
CODESYS Inspiring Automation Solutions
CODESYS Safety SIL2
ƒƒ Certification for the development of software
applications on safety controllers in accordance with
EN ISO 13849, up to PL d, category 2 or 3 / IEC 61508
SIL2 by TÜV Süd
ƒƒ Validated CODESYS Development System for the
editors Structured Text (ST), Function Block Diagram
(FBD) and Ladder Diagram (LD)
ƒƒ Certified CANopen safety master stack, based on the
proven CODESYS CANopen stack
ƒƒ Parallel operation of CANopen safety and standard
CANopen devices
ƒƒ Data monitoring of the safety application during safe
operation
ƒƒ Debugging of the safety application as well as forcing
or writing of values by switching to a special debug
mode
ƒƒ Simplified certification of safety applications by using
the language scope specified by the PLCopen Safety
Working Group
CODESYS Visualization for mobile applications
ƒƒ Visualization editor fully integrated in the
CODESYS Development System: development of logic
programs and visualizations in one single development
environment
6
ƒƒ Availability of a pre-certified runtime system, including
test framework for most parts of the firmware reduces
the development time for a safety controller
ƒƒ Display of the control data of the safety application in a
standard CODESYS Web Visualization or HMI
Picture: © Fliegl Agrartechnik GmbH
ƒƒ Due to the integration: easier, more user-friendly
development and more functionality compared to
conventional visualization systems
ƒƒ Modern visualization elements included: fast and
easy creation of industrially applicable operating and
diagnostics screens
ƒƒ Reusability: one source file for different visualization
clients
-- Directly in the CODESYS Development System – ideal
for testing and commissioning
-- On remote terminals – for the operation of machines
with HMI panels
-- On panel controllers – operation and logic control with
one single device
-- In a web browser on a tablet or smart phone – ideal for
diagnostics or remote maintenance
ƒƒ Comprehensive and powerful functionality: practical
controls, integrated alarm management, advanced
user management, user-friendly style, language and
image switch, compact data recording modules, flexible
communication concept
 7 Mobile Automation

Why should a manufacturer of mobile controllers choose CODESYS?

ƒƒ Support for the commonly used CPUs / operating systems
in ECUs / mobile controllers:
-- CPUs for compact controllers such as Tricore and C167
family, ARMx / Cortex Mx with or without proprietary
operating system
-- high-performance CPUs for mobile applications, such
as Intel Atom or Cortex A8 / A15 e. g. with WinCE,
VxWorks or Linux
ƒƒ Simple porting and scaling of the runtime system on the
basis of a runtime toolkit: with defined interfaces for
device-specific functions
ƒƒ Embedding of specific technology functions / visualiza-
tion elements in CODESYS libraries – with licensing if
necessary
ƒƒ Proven interface for the connection of additional opera-
ting or diagnostic devices or software systems
ƒƒ Software components that are pre-certified to IEC 61508
SIL2 (development system, runtime system and CANopen
safety master stack) simplify the certification of a SIL2
mobile controller.
ƒƒ Development costs for the programmable control
unit can easily be precalculated: defined interfaces,
integration manual for the runtime system, qualified
adaptation support
ƒƒ Expandability of the CODESYS Development System by
adding device-specific or manufacturer-specific plug-in
components
ƒƒ High market acceptance due to widespread use in mobile
applications

How to make a mobile controller programmable with

the CODESYS Development System
ƒƒ Selection of CPU and operating system
ƒƒ Implementation / adaptation of the CODESYS Runtime
System using an SDK:
-- Adaptation of the system-specific functionality of
the runtime system with tool support as described
in the integration manual
-- Configuration / adaptation of the communication
drivers to the CODESYS Development System
-- Integration of special device libraries to be called
from the IEC 61131-3 application
Picture: © Th. Buschhoff GmbH & Co. KG

-- Integration of customized add-on functionality

based on defined interfaces
-- Compilation of the adapted runtime system which
is then embedded into the device
-- Qualified adaptation support by experienced
project engineers in all phases of the implemen-
tation / adaptation process
ƒƒ Validation and test of the system, optionally with
integrated CODESYS Test Manager
ƒƒ Marketing and sale of the mobile controller equipped
with the CODESYS Development System and, if desi-
red, with additional customized plug-in extensions
Manufacturers of mobile controllers with
CODESYS technology:
ƒƒ Bosch Rexroth AG Mobile Hydraulics
ƒƒ CrossControl
ƒƒ EPEC Oy
Picture: © MOBA Mobile Automation AG

ƒƒ Hirschmann Automation and Control

ƒƒ ifm electronic
ƒƒ InterControl
ƒƒ Janz Tec
ƒƒ MOBA Mobile Automation
ƒƒ STW Sensor Technik Wiedemann
ƒƒ TTControl
 3S-Smart Software
Solutions GmbH
Memminger Straße 151
87439 Kempten, Germany
Tel: +49-831-54031-0
Fax: +49-831-54031-50
info@codesys.com

China Branch Office

CODESYS Software System (Beijing) Co.,Ltd.
Phone: +86-10-858889-37
Fax: +86-10-858889-38
info@codesys.cn

CODESYS® a trademark of
3S-Smart Software Solutions GmbH
www.codesys.com

CODESYS – the leading manufacturer-independent

IEC 61131-3 automation software.

CODESYS for further industries:

Factory Automation

Energy Automation

Embedded Automation

Process Automation

Building Automation

CODESYS is a registered trademark of 3S-Smart

®

Software Solutions GmbH. Technical specifications

are subject to change. Errors and omissions
excepted. No reproduction or distribution, in
whole or in part, without prior permission. Inspiring Automation Solutions