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||||1|m||||| 1 nm 1111015111115!11111011 |||||||||||||| 11 United States Patent [19] Hoffman et al. [54] [11] Patent Number: [451 Date of Patent: COMPUTERIZED DIAGNOSTIC AND WO89/12279 12/1989 WtPO . MONITORING SYSTEM WO92/04693 WIPO . [75] Inventors: John P. Holfman, Peoria; Ricky D. Vance, Washington; Dennis A- Bam‘eyi Morton; J?seph G- Kozlevcar, P9999, an of I11_ _ 3/1992 5,453,939 Sep. 26, 1995 OTHER PUBLICATIONS Caterpillar Service Manual — “Computerized Monitoring System With LCD Bargraph Gauges”, published in 1991. Journal Article — “Microelectronics takes to the road in a big way: a special report”, pp. 113-122 in the Nov. 20, 1980 _ [73] Assignee: Caterpillar Inc., Peona, Ill. edition of Electronics Journal Article — “Expert-systems applied to earth-moving [21] Appl. No.: 945,451 _ vehicle transmission troubleshooting”, pp. 3840, published _ [22] med‘ in the Dec., 1990 edition of Automotive Engineer. Sep' 16,1992 Publication entitled “Introducing the Vital Signs Monitor [51] Int. Cl.“ ............................. .. G06F 11/00; B60Q 1/00 p111S Load Weighing System”, by Marathon LeTrouneau, [52] US. Cl. .............................. .. 364/551.01; 364/424.03; Pubhshed 9“ or ab0ut1988- [58] 73/1172; 340/433; 340/439; 340/461 Field of Search ....................... .. 364/55101, 424.01, Journal Article — “all on board with O & K” behved to have been Published on 0‘ abm“ Jan-t 199°, and Sales literature 364/424.03, 424.04; 73/116, 117.2, 117.3; attaFhed there“)- 340/438, 439, 461, 945, 959 [56] .. .... . _ ' _ _ Al’tlCl6 from Ropec II‘ldUS'tl'l?S, 1116., re “MlCtOlOgllC, trn Model SW100, which is a Vehicle Management System”. References Clted U‘S_ PATENT DOCUMENTS Utter _ Primary Examiner—Emanuel T. Voeltz Assistant Examiner—M. Kemper Attorney, Agent, or Finn-Thomas J. Bluth; Steven R. Janda 3,509,529 4/1970 3,516,063 6/1970 Arkin et a1. ....... .. . . . . .. 340/52 3,866,166 2/1975 Kerscher, HI et a1. .. 340/52 3,393,103 7/1975 McBride, In et a1 __ 3,906,437 9/1975 Brandwein et a1. . 4,053,868 10/1977 COX 9t 31- ---------- “ 4,072,925 2/1978 Yashlma 6‘ a1‘ 340/420 340/27 340/52 340/52 Systems for monitoring sensed parameters and diagnosing fault conditions are useful in many applications. Advanta geously, such systems are capable of operating in a plurality of operating modes and in connection with each of a 340/163 [57] ABSTRACT ' 4’128’005 12/1978 Amston et a1- ' 73/111743 plurality of machines. In the subject invention, a plurality of 4’197’650 4,223,302 4 271 402 4/1980 Bade?’ et a1‘ 9/1980 Hocking ........ .. 6,1981 Kasmm et al 33/ 3 340/525 340/52 gauges are included for indicating the levels of the sensed . . . . parameters. A plurality of symbols are included for identi 4,376,298 4,442,424 Simon et 3/1933 Sokol et al 4/1984 Shimsaki et a1, 364/551 ,,,, __ 340/52 sensed parameters. A Control reC€iV€S an identi?cation code and selectively illuminates one or more of a plurality of gauges and symbols in response to the identi?cation code. 4,497,057 1/1985 Kato et a1. .... .. . 371/29 A plurality of warning lights are each associated with a 4,521,885 6/1985 Melocik 6'1 a1---- -- 371/29 4,551,801 11/1985 Sokol ................ .. 364/424 4,583,176 4/1986 YEIHBIO et a1. .................. .. 364/431.“ switch-type input. A display selectively indicates a pin code for each switch_type input having a fault condition The indicator lights having an associated switch_type input in the (List Continued on next page_) fault condition are ?ashed. A device selectively indicates a pin code in response to each diagnosable input having a present or a previous fault condition. FOREIGN PATENT DOCUMENTS 3837592A1 5/1990 60-107109 of 1985 Germany . Japan . 2 Claims, 17 Drawing Sheets / so ‘7 MACHINE 42 \. IDENTIFICATION / 52 SERVICE CLEAR BFtlGHTNESS [?sh/é‘! mpur INPUT SWITCH SELECT Ill-"l “I 34 “° 38 I 31: art jl/ \ /V (é‘étt tn} 34th.. @m? El [El ms 4F /\ 43 -> 46-> E?bmg?c I '3'" — — — SENSORS ’ 11 new mm mm ~11 5,453,939 Page 2 US. PATENT DOCUMENTS 4,667,176 5/1987 4,694,408 9,1987 Zaleski ____ u 4,975,848 12/1990 Abe 61:11. ........................ .. 364/42403 4’977’389 12/1990 364,551 5,019,799 5/1991 Matsuda .................................. .. 340/52 shufnshl '''‘‘ ' ' ' " 340/461 Osh1age (it al. ....................... .. 340/438 4,748,843 6/1938 schafer et a1_ ____ __ 73/1173 5,034,889 7/1991 Abe .................................. .. 364/424.04 4,809,177 4,811,240 2/1989 Windle 6t a1. ................... .. 364/424.01 3/1989 B31101! 6131. ................ .. 364/424.01 X 5,041,980 5,050,080 8/1991 Maddock er a1. ................ .. 364/43103 9/1991 Abe .................................. .. 364/424.04 4,812,744 3/1989 4,815,824 3/1989 Shawl“ Havel . . . . . .. . . . . . . .. 324/115 5,091,858 2/1992 350/336 5,150,609 9/1992 Ebner BI a1. ......................... .. 73/1173 4’843’557 6/1989 Ina etal 4,862,395 8/1989 Fey e161. 4,896,276 1/1990 ..... .. 364/550 4,926,331 5/1990 Windle B131. Paielli 364'431'77 5,157,610 10/1992 Asano et a1. ..................... .. 364/424.03 ..... .. 364/561 5214 582 5,1993 Gm 364,431.12 364,424 03 - 4,939,652 4,967,143 Saglimbeni 61 a1. 3 Y ------ - 5,257,190 19/1993 Crane ~ 364424-03 364/42404 5,313,388 5/1994 Cortis -------- - 364/424-04 10/1990 Raviglione et a1. ................. .. 324/731 5,327,344 7/1994 Hoffman et a1- ................. -- 364/424.03 7/1990 Steiner ............ .. .. 364/42404 3 US. Patent Sep. 26, 1995 Sheet 1 0f 17 5,453,939 [I I] QB I] U @U U I] EEIU FI / 3634 / §“%8 g/E'miCI) <1: 38 3 ‘I2 9CRBB3E0D3c/anVI GEE B 8 35%! 6§ r/ k\ 2 / 30 / a 33 US. Patent Sep. 26, 1995 Sheet 2 0f 17 /////z’ 5,453,939 U.S. Patent Sep. 26, 1995 Sheet 4 of 17 5,453,939 US. Patent Sep. 26, 1995 r_H_ (Em. Sheet 5 of 17 m.E Emu 5,453,939 PCmmv s a 8\“_r B _H_ 5%(/8Q K x mm US. Patent Sep. 26, 1995 Sheet 6 of 17 [I] ‘5 E [II-CHE] aw Um @w mm mm 5,453,939 US. Patent Sep. 26, 1995 5,453,939 Sheet 7 of 17 m5 m {X (w gmm. 5/ mglwsCum ?aw (AVQ QEé/t/\muma‘ \ / US. Patent Sep. 26, 1995 Sheet 8 of 17 5,453,939 FLEJEIE READ THE IDENTIFICATION CODE ARE TURN SIGNALS USED ON THIS VEHICLE? READ THE TURN SIGNAL INPUTS V IS THE RIGHT RN TURN SIGNAL ON? N THE RIGHT Tl?l'uRNolNDlcATOR 4 I IS THE LEFT TURN SIGNAL ON‘? L ‘ . I US. Patent Sep. 26, 1995 Sheet 9 of 17 5,453,939 PLE_EI:I_ IS THE HIGH BEAM INDICATOR USED ON THIS MACHINE? READ THE HIGH ‘ BEAM INPUT IS THE HIGH BEAM ON? TURN ON THE HIGH BEAM INDICATOR I IS THE ' ETARDER INDICATOR USED ON THIS ACHINE READ THE RETARDER INPUT IS THE RETARDER ON‘? TURN ON THE RETARDER INDICATOR ‘ I US. Patent Sep. 26, 1995 Sheet 10 0f 17 5,453,939 $112.15 |:_ IS BRIGHTNESS CONTROL PHOTOCELL ONLY? CONTROL BRIGHTNESS IN RESPONSE TO PHOTOCELL OUTPUT IS BRIGHTNESS ' CONTROL SPST? Y EXECUTE LOGIC FOR SPST BRIGHTNESS CONTROL SWITCH EXECUTE LOGIC FOR SPDT BRIGHTNESS CONTROL SWITCH US. Patent Sep. 26, 1995 Sheet 11 0f 17 5,453,939 FLEJEIEI. IS THIS A LOW WARNING STYLE GAUGE ? TURN ON LOWER GAUGE OUTLINE I TURN ON UPPER GAUGE OUTLINE I ENABLE UPPER WARNING SEGMENTS I I READ GAUGE DATA I MAP GAUGE DATA TO SEGMENT DATA I READ SINGLE/FILL INPUT I BUILD AND TRANSMIT SENSOR DATA MESSAGE ENABLE LOWER WARNING SEGMENTS US. Patent Sep. 26, 1995 @ Sheet 12 of 17 5,453,939 :::.I__:-_EIE_ #I 550 TURN ON THE APPROPRIATE SYMBOL IS THE GAUGE IN SINGLE SEGMENT MODE’? IS THIS A LOW WARNING STYLE GAUGE? IS THE GAUGE IN A LOW WARNING CONDITION? FLASH THE LOW WARNING SEGMENTS I IS THIS A HIGH WARNING) STYLE GAUGE- ILLUMINATE INDICATING SEGMENTS 4 N IN IISIIQEI (IIv'ZUFICi?NG CONDITION? Y 1 FLASH THE HIGH ILLUMINATE WARNING SEGMENTS AND ALL THE INDICATING SEGMENTS INDICATING SEGMENTS I 1 US. Patent Sep. 26, 1995 Sheet 13 of 17 5,453,939 ..:"_T.. E IS THIS A LOW WARNING IS THE GAUGE IN A LOW WARNING STYLE GAUGE? CONDITION? FLASH A LDW WARNING SEGMENT ILLUMINATE A SINGLE INDICATING SEGMENT I IS THIS A HIGH WARNING STYLE GAUGE? IS THE GAUGE IN A HIGH WARNING CONDITION? FLASH A HIGH WARNING SEGMENT I ILLUMINATE A SINGLE INDICATING SEGMENT US. Patent Sep. 26, 1995 5,453,939 Sheet 14 0f 17 4-1.5 -EE READ THE HARNESS IDENTIFICATION CODE I READ ALL INPUTS I PERFORM SYSTEM DIAGNOSTICS IS THE SYSTEM IN SERVICE MODE ‘.7 DISPLAY FAULT CODES AND STATUS IS SERVICE INPUT GROUNDED ? DISPLAY NEXT FAULT CODE AND STATUS SOUND THE ALARM FOR 0.5 SECONDS I DISPLAY INPUT PIN NUMBER US. Patent Sep. 26, 1995 HAVE ANY Sheet 15 0f 17 Y DISPLAY THE INPUT olHAilij?Tlgpéil?seAg PIN # FOR ALL CHANGED TATUS? > FAULT CONDITIONS 1 IS THE SYSTEM IN STATUS MODE ? FLASH ALL INDICATOR LIGHTS CORRESPONDING TO INPUTS THAT ARE NOT GROUNDED I DISPLAY PIN # FOR ALL SWITCH INPUTS THAT ARE NOT GROUNDED I STEADILY ILLUMINATE INDICATOR LIGHT CORRESPONDING TO DISPLAYED PIN # SOUND HORN FOR 0.5 SECOND I DISPLAY INPUT # FOR SWITCH INPUTS THAT CHANGED STATUS 5,453,939 ‘ US. Patent Sep. 26, 1995 Sheet 16 of 17 5,453,939 FLE__I_[:IE_ IN NUMEFIlC Baggy N RESET TIMER SET PARAMETER NUMBER TO ZERO SCROLL ACTIVE? TIMER EXPIRED? INCREM ENT PARAMETER # N V RESET TIMER 'N DISPLAY CURRENT PARAMETER # I DISPLAY CURRENT PARAMETER DATA US. Patent Sep. 26, 1995 Sheet 17 of 17 5,453,939 Flaulljh; IS THIS A GAUGE PAHAM ETER? IS THE PARAMETER ENGINE SPD? IS THE PARAMETER VEHICLE SPD? NK THE GAUGE OUTLINE __>_._ TURN ON THE RPM ISO SYMBOL F + Y IS THE SPD INUAIGIFJSQC TURN ON THE l'KMH" ISO SYMBOL ‘ @D T TURN ON THE "MPH" ISO SYMBOL _>__ 5,453,939 1 2 COIVIPUTERIZED DIAGNOSTIC AND MONITORING SYSTEM particularly large off-highway work vehicles, are becoming increasingly complex in their design thus making it more TECHNICAL FIELD and more di?icult for service personnel to locate defects in machine sensors and systems. This is particularly true of intermittent defects not resulting in a breakdown of a system or the vehicle but which interfere with its operation. The invention relates generally to a computerized moni toring and diagnostic system, and more particularly, to a A major frustration when troubleshooting electrical prob monitoring and diagnostic system having a plurality of operating modes. lems on a large work vehicle is caused by intermittent 10 BACKGROUND ART problems. Typically, the operator reports some symptom to a technician and before the technician can get to the machine the problem is no longer present. If the condition is not present it is helpful for the techni In a variety of engine-powered vehicles, monitoring and diagnostic devices are employed to detect the presence of various undesirable operating conditions, such as overheat ing of the engine, low oil pressure, low fuel, and the like, and cian to re-create the fault condition. In many cases the fault condition is caused by a short to ground potential or an open circuit. To recreate these fault conditions, the technician manipulates the wire harnesses or wire connectors to deter indicators are provided to warn the operator of such condi tions. These instruments are typically connected to various tions on the vehicle via a wire harness and/or a communi mine the point at which the fault has occurred. Prior art systems have indicated when fault conditions are present. In connection with such systems, the technician cation link. In many applications, these instruments are also connected to electronic control systems, for example elec tion is present. In troubleshooting intermittent problems sensors and switches for monitoring or controlling condi must view a visual display to determine whether the condi tronic engine controls, electronic transmission controls, and when the fault condition is not currently present, the tech the like. nician must manipulate wire harnesses and connectors to Most prior art systems have included dedicated instru 25 recreate the fault and thus cause the fault indication to be displayed. When the fault condition is present, the techni ments in which the functions and conditions of the vehicle cian must manipulate wire harnesses and connectors and to be monitored or diagnosed, as well as the particular observe whether the manipulations eliminate the fault and sensors provided on the vehicle, are identi?ed in advance. thus cause the fault indication to disappear. Therefore, the instruments are speci?cally designed for and hence “dedicated” to the monitoring or diagnosing of those 30 In many cases, however, the machine is of su?icient size particular vehicle functions and conditions in response to that the technician must leave the area of the diagnostic tool signals from pre-identi?ed sensors. Accordingly, such “dedi~ to recreate the fault condition. Therefore, any visual indi cated” instruments generally cannot be readily modi?ed to cator provided by the diagnostic tool is not visible to the technician. To effectively troubleshoot the electrical system accommodate different machines, different sensors and/or different conditions and functions. Rather, such instruments on such a large machine, typically two or more technicians are generally limited to use with a particular vehicle type or are required and repair expenses are thus greatly increased. Similarly, the vehicle may not be repairable immediately if only a single technician is available. In addition, these machines typically include switch-type inputs that are either in an open voltage or grounded model for which the instrument has been designed. However, it is advantageous for these instruments to be usable in connection with many different machines. Lower costs are achieved and less warehousing space is required if a single instrument can be manufactured which can be used condition. One of the voltage conditions is de?ned as a fault condition. In most cases, the fault condition is de?ned as the in many different applications. Similarly, service time is reduced if software changes are avoided when an instrument is moved from one machine to another. Some prior art systems have provided for standardized open voltage condition thus whenever the wire between the 45 sensor and the display is severed or disconnected, a fault condition is indicated. Similarly, if the switch-type input is monitoring systems that are usable in connection with a connected to a switch-type sensor, the switch-type sensor variety of machines, for example the system shown in US. disconnects the sensor output from ground potential when Pat. No. 4,551,801 issued to Sokol on Nov. 5, 1985. While the sensed parameter exceeds a warning level. being an improvement over dedicated systems, this moni toring system is still relatively in?exible and requires the for each switch-type sensor that is in a fault condition. Each Some prior art systems have illuminated a warning light addition or subtraction of monitoring modules and the use of warning light is associated with one of the switch-type sensors and is illuminated when the display input associated with that switch-type sensor is indicating a fault condition. decals to indicate the parameters being shown by each display module. One area of desired ?exibility is for each gauge in the instrument to be capable of indicating parameters having a 55 advantageous to also indicate the pin number of the input associated with the switch-type sensor. Optimally, the tech nician should be able to determine the pin number of each of the warning lights indicating a fault condition even though there are more than one of such warning lights. This would allow technicians to more readily identify the fault condition and associate the sensor having the fault condition high warning level, for example engine temperature, and also parameters having a low warning level, for example brake ?uid pressure. Prior art systems required the use of decals to indicate that the gauge was indicating the level of a parameter having either a high or low warning level and/or the use of a separate warning light to show that the param eter was outside the normal operating range. To maximize system ?exibility, it is advantageous for the instrument to be capable of performing a number of diag nostic functions in addition to displaying parameter values and indicating warning conditions. Today’s machines, and While adequate for many purposes, in other cases it is to the relevant connector pin. While troubleshooting some diagnosable sensor prob 65 lems, it is sometimes di?icult to determine whether a sensor is producing a signal that is truly representative of the actual level of the sensed parameter. This often results in techni