OTIS Load Weighing Board (LWB)

Part:
No.: GAA24270AB_BD1

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LWB Load Weighing Board

Running on PCB: GAA 24270 AB

Authorization Date: 26-May-2000

Software Version: GAA 30339 AAB

Document Revision:
Date Author Comment
01-Feb-2000 M. Hoinkis GAA 30339 AAA
01-Mar-2000 M. Hoinkis E2PROM storing time
05-Apr-2000 M. Hoinkis GAA 30339 AAB

Copyright 2000, OTIS GmbH & Co. OHG Berlin

No part of this document may be copied or reproduced in any form or by any means without the prior written consent of OTIS GmbH & Co.
OHG
 OTIS Load Weighing Board (LWB)
Part:
No.: GAA24270AB_BD1

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Berlin Date: 05-Apr-2000

Table of Contents

1 INTRODUCTION ............................................................................................................. 3
1.1 Overview .................................................................................................................................... 3
1.2 Hardware Requirements .......................................................................................................... 3
1.3 Software Requirements............................................................................................................ 3
1.4 Referenced Documents............................................................................................................ 4
2 INTERFACE .................................................................................................................... 4
2.1 LED’s .......................................................................................................................................... 4
2.1.1 CAN_OK (LED 1) ............................................................................................................... 4
2.1.2 RSL_OK (LED 2)................................................................................................................ 4
2.1.3 LWB_OK (LED 3) ............................................................................................................... 5
2.2 RSL ............................................................................................................................................. 5
2.3 CAN ............................................................................................................................................ 5
2.4 Internal CAN (OPB) Interface................................................................................................... 6
2.5 Error Codes ............................................................................................................................... 7
3 FUNCTIONS .................................................................................................................... 8
3.1 Initialization And Selftest ......................................................................................................... 8
3.2 Sending New Parameters For Load Calculation To The LWB ............................................. 9
3.3 Offset Calibration...................................................................................................................... 9
3.4 Gain Calibration ........................................................................................................................ 9
3.5 Normal Mode ........................................................................................................................... 10
3.6 Load Calculation ..................................................................................................................... 10
3.7 A/D Converter .......................................................................................................................... 11
4 CAPABILITY SPECIFICATIONS .................................................................................. 11
4.1 Range ....................................................................................................................................... 11
4.2 Resolution................................................................................................................................ 12
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Part:
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1 INTRODUCTION

1.1 Overview
This document describes the software of the Load Weighing Board. This Software will be
used for GeN2 elevator system and will provide the car load information to the Vector Con-
trol Board (VCB) via CAN and to the Traction Control Board (TCB) via RSL communication.
The parameters of the LWB can be set by the Motion Control Board (MCB) with a Service
Tool. The MCB is connected with the VCB. The car load information is published in % of the
duty load to the VCB. Only the discret load informations (ANS, LNS, OLD) are transmitted to
the TCB. The LWB uses a maximum of four sensors. For using the CAN bus, the LWB uses
the software package ‘Otis Peripheral Bus’ (OPB)

1.2 Hardware Requirements

• VCB: GBA 26800 AS2 or higher
• MCB: GCA 26800 H1 or higher
• TCB: GAA 26800 BA or higher
• LWB: GAA 24270 AB or higher
• LWB: The OTP C505CA (1kB XRAM, 32kB ROM) with 8Mhz system clock is necessary.
The complete XRAM is nearly used and 26kB of the 32kB ROM are used. 57 bytes of
the EEPROM are used (0x0A - 0x43).

1.3 Software Requirements

• VCB: GAA 30583 AAA or higher
• MCB: GAA 30582 AAA or higher
• TCB: GAA 30084 AAA or higher
• OPB (CAN): G15 30335 AAA or higher
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1.4 Referenced Documents

• Design Requirement Specification LWB from 30-Jun-1999
• ATOR OG1
• OPB Network Requirement Specification
• Load Weighing Network Bus Messages

2 INTERFACE

2.1 LED’s

2.1.1 CAN_OK (LED 1)

signal description

on OK
flashing sometimes the LWB can not send messages; could be a periodically interrupt
of the CAN wire or an overloaded CAN bus (transmit que is full)
off no CAN connection is available or the LWB can not send messages; could be
an interrupt of the CAN wire or CanH and CanL are exchanged; first: check
CAN wiring; second: change LWB

2.1.2 RSL_OK (LED 2)

signal description

on hardware error; first: check RSL wiring; second: check RSL master (TCB);
third: change LWB
flashing OK
off no RSL connection is available; could be an interrupt of the RSL wire
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2.1.3 LWB_OK (LED 3)

If the watchdog would not triggered during 1,6s (min. 1s; max. 2,25s), the hardware will re-
sets. The software trys to trigger the watchdog every 500ms.
signal description

on hardware error; could be on for max. 2,25s; change LWB

flashing = OK
500ms

flashing ≠ initializations phase (<1s, after start up) or a software fail; change LWB
500ms
off no power or software do not trigger the watchdog; first: check RSL voltage
(power supply for LWB); second: change LWB

2.2 RSL
If the load for ANS, LNS and OLD is reach, the LWB will inform the TCB via RSL every
500ms. The percent values are fixed. The ‘9’ is a typically RSL address for the LWB:

on

1 2 3 4 5 6

event RSL input pin

ANS 100 kg 1
LNS 80% of duty load 2
OLD 110% of duty load 3

2.3 CAN
You can request the software configuration number of the LWB, current mode, last error,
current voltage of the sensors, current number of sensors, gain values… via CAN. The LWB
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publishes their current mode and error on state change. The LWB reacts on messages,
which transmit new values for the parameters for the load calculation, starts offset and gain
calibration. 15 seconds after losing CAN communication the LWB will reset itself.

2.4 Internal CAN (OPB) Interface

The LWB has the fixed node address of ‘1’.

message IDs sent by LWB:

• opb_MsgIdLwssLoadValue
• opb_MsgIdLwssMode
• opb_MsgIdLwssError
• opb_MsgIdLwssDiagnostics

message IDs received by LWB:

• opb_MsgIdLwssRequest
• opb_MsgIdLwssCalibration
• opb_MsgIdLwssSetConfigData
• opb_MsgIdLwssScn

functions of OPB used by LWB:

• opb_Publish()

functions for OPB prepared by LWB:

• opb_GetMsg()
• opb_ReceivedLwssSetConfigData()
• opb_ReceivedLwssCalibration()
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2.5 Error Codes
Error codes will be transmitted to the VCB / MCB.
code possible reason
10 • reading of EEPROM failed
11 • writing on EEPROM failed
20 • offset calibration failed; The LWB
recognized a different number of
sensors as specified in the setup
menu.
• One or more sensor voltages were
not between 2V and 10V during
the offset calibration.
21 • gain calibration failed
• One or more sensor voltages were
not between 2V and 16V during
the offset calibration.
• One or more calculated gains
were not between 8 and 40mV/kg
• error 22 happens
22 • sensor can reach its saturation
value; After the gain calibration the
LWB predicts the sensor voltage
with overload. Error # 21 happens
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action
• change LWB
• change LWB
• check that the anti jumping screws
are not tied
• Check the number of sensors and
transfer the parameters to the LWB
one more time.
• One or more sensors are defect.
Replace these sensors.
• ??? The car is to heavy for the cur-
rent number of pads / sensors. In-
crease the number of pads, change
parameters and repeat offset / gain
calibration. Or replace the sensors
by new sensors with lower gains.
???
• check that calibration load is even
distributed inside the car
• check the load for the gain calibra-
tion (load in car has to be equal to
the input on the SVTool for the gain
calibration)
• One or more sensors are defect.
Replace these sensors.
• Replace the sensors by new sen-
sors with lower gains.
• ??? The car is to heavy for the cur-
rent number of pads / sensors. In-
crease the number of pads, change
parameters and repeat offset / gain
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too. calibration. Or replace the sensors

30 • sensor lost during normal mode;
One or more sensor voltage was
lower than 2V.
31 • one or more sensors reached their
saturation; the sensor voltage was
>= 16V during normal mode; In
that case a load value of 125% will
be published (OLD).
• the car was tripped (no action is
necessary)
40 • wrong parameters were sent to the
LWB (out of range)
by new sensors with lower gains.
???
• One or more sensors are defect.
Replace these sensors.
• One or more sensors are defekt.
Replace these sensors.
• The car is to heavy for the current
number of pads / sensors. Increase
the number of pads, change pa-
rameters and repeat offset / gain
calibration.
• Replace the sensors by new sen-
sors with lower gains.
• check all parameters and transfer
the parameters to the LWB again

3 FUNCTIONS

3.1 Initialization And Selftest

The initializations phase needs less than one second. During this time the following func-
tions are done: RAM test, ROM test, reading parameters from EEPROM. After initialization
the LWB switches to normal mode.
The checksum is stored at the end of the internal OTP-ROM (last two bytes). The stored
checksum is equal to the calculated checksum of the programer.
If the RAM or ROM test fails, the LWB will stay in an endless loop. So the watchdog will not
be triggered. That will provoke a hardware reset and a new selftest will be performed (see
LED LWB_OK). You will not see the message ‘LwssModeLoadingParameterFromEeprom’
at the CAN bus. In this case you must change the OTP.
Until all available sensors are sampled by the AD converter one time, the LWB will publish a
load of 48%. This load prevents the ANS mode after power on or a reset.
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3.2 Sending New Parameters For Load Calculation To The LWB

The parameters full load, total number of pads, number of sensors can be set via CAN. Af-
ter this, a new calibration of the LWB has to follow. Of course the E2PROM needs 10ms to
store one byte, a new parameter message (or similar) should not be transmitted before a
delay of 40ms.

3.3 Offset Calibration

The offset calibration routine decides which sensor will be used for the load measurement
and stores the sensor values for an empty car (until the next offset calibration). After an off-
set calibration the gain calibration has to follow (otherwise the load information is wrong)

!!!The calibration load has to put into the middle of the car. Otherwise the measured
gain values are not even and the load measurement will be incorrect!!!

If you set (via CAN) more or less sensors than the offset routine recognize, then you will get
an error (error code 20).
A sensor will be recognized during the offset calibration, if his measured voltage is higher
than 2 Volt and lower than 10 Volt.

3.4 Gain Calibration

The gain calibration routine stores the gain for each sensor (until the next gain calibration),
which is recognized during offset (the other gains are not changed). To calibrate the gain,
you have to put some load into the car and then you have to start the calibration routine with
a message via CAN. The messages have to include the value of the current load in kg,
which you put into the car.
A sensor will be recognized during the gain calibration, if his current voltage is higher than 2
Volt and lower than 16 Volt. If a sensor has mot a valid range during gain calibration an er-
ror message (error code 21) will be published.
If the calculate gain is lower than 8 mV/kg and higher than 40 mV/kg an error message (er-
ror code 21) will be published.
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After calculating the gain values the LWB checks, if a sensor can reach its saturation (16V)
during normal mode with a load between 0% and 125%:
16V >= Offset (mV) + (((full load x 125%) / total # pads) + 30kg) x Gain(mV/kg)?
The 30kg are added for the worst case that the car is uneven loaded. That means that the
car pushes one sensor / pad with 30kg more than the others sensors / pads.
After a successfull calibration or every correction the error logging should be cleared at the
MCB.

3.5 Normal Mode

• The load information is published periodically every 500ms. If one or more sensors
(which were valid during offset calibration) are lost during normal mode (lower than 2
Volt and higher than 16 Volt), the LWB will send an error message via CAN and will cal-
culate the load information with the remaining sensors. This failure management allows
operation with degrade performance. In other words the result of this calculation has a
lower accuracy.
If the lost sensor comes back, it will be used for the load measurement again (if it was rec-
ognized during offset calibration)

3.6 Load Calculation

The load measurement is done by up to 4 analog input values. The sensor input signals are
summarized, and weighted according the actual ratio of sensors versus rubber pads used.
The below formula is used for the basic load calculation
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V 1T ,V 2T ,V 3T ,...V 8T Actual Voltage Value (at Time=T)

V 1E ,V 2 E ,V 3 E ,...V 8 E Empty Car Value (from calibration routine)

S 1, S 2, S 3,...S 8 Gain of the Sensors (sensitivity factor, typically 24mV/kg)

VnT − VnE
NS

∑
Sn Total # ofPads
FL% value = n =1 • Coef • 100 Coef =
FL # ofSensors

VnTc − VnE Tc = Value during calibration with load in car

Sn =
∆f LoadinCarDuringTc
∆f =
Total # ofPads
Figure 1: Equations for load calculation

3.7 A/D Converter

The A/D converter uses an offset of 1.3Volt. That means every input voltage between 0 and
1.3 Volt is recognized (and displayed at SVTool (MCB)) as 0 Volt.

4 CAPABILITY SPECIFICATIONS

4.1 Range
These ranges do not correspond with the GeN2 operation range.
name min. max. typically

full load 240kg 2000kg -

load during gain calibration 1kg 2000kg 1000kg
number of sensors 1 4 2
total number of pads 4 12 4
gain 8mV/kg 40mV/kg 24mV/kg
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sensor voltages 2V 16V -

sensor offset calibration voltage 2V 10V 6V
transmitted percent of full load 0% 255% -

4.2 Resolution
The typical sensor sensitivity is 24mV/kg. ⇒ ~ 1kg resolution per sensor
The effective output voltage of the sensors is between 2 V and 16 V. Clipping the input volt-
age at 17.2 V and shifting the Signal Ground by 1.3V will adapt the input voltage range to
15.9 V.
The resolution for a 10bit A/D converter is 15.5mV ⇒ ~ 0.6kg resolution per sensor (not
possible, sensor delivers 1kg resolution)
Assuming a 1000kg unit with 4 sensors and 2 rubber pads following resolution error may
occur:
Fr = 4 x 1kg x 6/4 = 6kg
The resolution is about 0.6%. This is within the range of the sensor accuracy of ±5 %. The
load measurement accuracy is related to full load in car.
The resolution of the load in car value in % is 1% (by the software)