DC Control System -- Sensors Available

• Solid State Relays
• Opto-Isolators
• Hall-Affect Current Sensors
• Thermal Sensors
• Speed/RPM Sensors
• PIC Microcontrollers (8,12,20,28,40, 64, 80, 100 pin)
• Positional Sensors
• Distance Sensors
• Wireless Zigbee Communications
• GPS Sensors
• USB Data-Drives
• Secure-Digital / MMC Memory Cards
• Bi-Directional Remote Controls
• Pressure Sensors
• Meterological Sensors
• 1-Wire Body Badges
• Data Recording iButtons
• Security iButtons

SSRs

Fundamental to Controls Plus USA's designs is a Solid State Relay device (SSR) featuring Vertical Intelligent Power, (VIPower), a patented technology established over 17 years ago and widely used in automotive applications everywhere.

Solid State Relays (SSRs) are power switches that can drive a variety of different types of loads like: DC motors, solenoids, filament lamps or LED's, engine controls, horns & alarms, and gauges & indicators. They can handle high currents and work up to about 40V supply voltage. Control systems that control large numbers of actuators are perfect environments for these devices. A considerable improvement in reliability and reduction in down time is a benefit of having no moving parts or contacts to get pitted. They have internal protection for over-current, under-voltage, over-temperature open load and un-commanded turn-on that will shut down the SSR under abnormal conditions. The integrated diagnostic information signal helps the on-board microcontroller to quickly identify and isolate faults, saving repair time and often improving safety.

The overcurrent protection is a particularly valuable feature of SSRs. When a short circuit occurs the SSR instantly shuts down. It will get quite hot but no damage is done and it returns to normal operation with virtually no delay after the short is removed. In all practical situations there is no danger to Printed Circuit Board (PCB) tracks or vehicle wires from these high peak current for tracks and wires designed to handle the nominal load current. Of course this protects the loads but also in our designs we make sure that even circuits feeding switches are fed through a SSR to provide protection. We usually incorporate fuses and circuit breakers, but these devices are redundant as the SSR protection keeps them from blowing in almost all circumstances.

SSRs require only a simple logic input and it is easy to introduce differences in the control logic to produce controls with features that adapt to different working environments. SSRs can reduce the size and weight of switch modules and dramatically reduce the size of the wiring harness.

Almost every electronic switch used in a modern vehicle application is a SSR in a high side switch configuration, i.e. connected between the load and the positive power source. High side drivers offer numerous advantages over the popular automotive relays used today. This configuration is preferred for vehicle use because it protects the load from continuous operation and resulting failure if there is a short circuit to the ground. Also high side drivers cause fewer problems with electrochemical corrosion that occurs in adverse temperature and humidity environments, or the presence of salt. This is because the electrical component is not powered (the greatest part of the lifetime of the vehicle) and with no voltage applied electrochemical corrosion does not take place.

Opto-isolators

An opto-isolator is a small device in which an electrical signal is converted to a light beam that illuminates a photo-transistor switch that in turn converts back to an electrical signal. This means that there is no direct electrical connection between the source and destination circuits. This "isolation" keeps the vehicle voltage separate from the control signal voltage allowing a wide range in compatible vehicle voltages and provides high electrical "noise" immunity to the controls from vehicle generated interference emanating from motors or solenoids.

Current Sensors

We use Hall effect current sensors. A current sensor is snapped around the wire feeding a load as shown. When electric current flows through the wire it creates a magnetic field that surrounds the sensor and produces a small signal proportional to the amount of power used. This power usage signal can be fed into a computer chip for control purposes.

Thermal Sensors

Measure temperature by contact or from a distance.

Speed/RPM sensors

Measures speed or engine RPMs

Positional sensors

Measures the position of various booms and arms.

Distance sensors

Measures the distance between various objects truck booms and arms.

PIC microcontrollers

Microcontrollers are the "brains" of the control unit. Base memory available up to 128KB. Additional memory on ancillary ICs or using memory cards.

Wireless Zigbee communications

Allows the control unit to wirelessly communicate with other devices including our two-way remote controls.

GPS Sensors

Senses lattitude & longitude and provides this data to the PIC microcontroller. Used for tracking and location enabling.

USB data-keys

Long Term Storage. Easily readable with any modern PC.

Secure-Digital / MMC Cards

Long Term Storage. Easily readable with any modern PC.

Two-way remote controls

Sends back confirmation, status, etc.

Pressure sensors

Measures pressure and converts these values to an analog signal for input into the PIC microcontroller.

Meteorological sensors

Measures wind, temperature, solar radiance, humidity, etc.

One-wire body badges

Portable data recording "IButtons"

Records various data elements on a stainless steel memory button. Practically industructible.

Security Ibuttons

Mountable on key fobs. Allows the system to enforce user authorization to operate certain functions.