ISOBUS for Trailed Sprayers Implementation and Experience
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1 ISOBUS for Trailed Sprayers Implementation and Experience by Willy Peeters John Deere - NETHERLANDS 1. Introduction Development of the ISOBUS application for trailed sprayers started in Before that, the trailed sprayers had electronics to control the different sprayer functions from external partners, mostly partners that also supplied the competitors with electronics and software. With approximately 125 competitors in Europe, the main market for John Deere trailed sprayers, it is important to be able to supply a solution that works to all customers, regardless of tractor brand but one which also gives the features and solutions that create differentiation from competitors. ISOBUS is a generic communication protocol which allows the implementation of features on top of ISOBUS, for enhanced functionality and features which are designed to work with John Deere equipment, and specifically Green-on-Green solutions for John Deere. 2. History In order to understand how the development of ISOBUS for trailed sprayer went, it is important to know about the history of the trailed sprayers within John Deere. The John Deere trailed sprayer factory is located in Horst, Netherlands. The factory joined John Deere through an acquisition by Deere & Company exactly 20 years ago. The acquisition was announced at the Agritechnica in Until then, the factory was a private held company, Machine Fabriek Gebroeders Douven BV. This company was founded in 1947 (Fig. 1) and it holds long history with building sprayers. The factory had vast portfolio of products. Apart from trailed sprayers, 3-point linkage sprayers (mounted sprayers), orchard sprayers and other small sprayer related machines were also manufactured. The factory had a small development team, of around four engineers who were primarily concerned with the development of the structures such as frames, sprayer booms and tanks. Many components used on the machines like valves, hydraulics and sprayer nozzles, were purchased at the same suppliers used by competitors. Over the years, the electronics has become increasingly important but without expertise on electronics and software, the electronics to control the sprayer functions were purchased at suppliers also used by competition (Fig. 2). This reliance makes differentiation more challenging. When John Deere acquired the factory in 1997, development of the first real John Deere Sprayer, the 800-series began. This machine was introduced in 2000 and until that time, the sprayers from Douven were delivered under the John Deere brand name, eg the 600-series. These machines obviously still used the controls and electronics from the Douven time. With the development of the 800-series, new electronics were also developed to have better integration and cooperation within John Deere. At that time, the Greenstar 4 system (Fig. 3) was the base for this. The factory was not yet integrated within John Deere as it is today and with the lack of electronic experts in Horst, this development was again done with a non-deere partner. These electronics however were developed for the John Deere trailed sprayers, not anymore an off the shelf solution just branded differently. 1
2 The logic used (software) was however not owned by the John Deere Horst factory. The specifications were only developed together with the supplier. This turned out to be a major challenge when doing the ISOBUS development. Between 2002 and 2005 it became very clear that the Deere specific Greenstar 4 system would not be the solution for the future. As an implement, the sprayers are connected to a different brand of tractors, not only John Deere. Customers having non-deere sprayers wanted and still want to use their on board displays to operate the implement. Due to the complex operation of a sprayer, an operating device such as joystick switches must be added to the system and adding a Greenstar 4 system additionally is costly and complex. Also in that timeframe, development and focus on ISOBUS became strong. John Deere developed the GS2100 and GS2600 displays which were ISOBUS. This lead to the decision in 2005 to start the development of the ISOBUS control for John Deere Horst sprayers, not only trailed but also for mounted sprayers as they share the same electronics. It was also decided to integrate section control based on GPS by using the ISOBUS Taskcontroller, which was at the time not available on the server side in the John Deere Displays. 3. Development, initial challenges As written earlier, John Deere Horst did not have the specification from the software as used on the Greenstar 4 systems. There was also no electronics or software expertise in Horst present. This gave a major challenge on how to develop the ISOBUS application. As John Deere Horst was at the time less integrated with the self-propelled sprayer factory in Des Moines (US), developing this together with them was also no option. Based on the Greenstar 4 application, an extremely basic specification was written. It was only four pages long and specified the major functions of the sprayer with limited detail: Rate control, ensuring the set rate is maintained based on target rate, ground speed and spray boom width; Hydraulic control, ensuring the spray boom can be folded and unfolded and automatic drawbar steering control; Air pressure control for TwinFluid systems, ensuring the air pressure is set correctly based on the fluid flow and desired droplet size. As there was limited experience within John Deere with implements and ISOBUS, Horst got in contact with the implement factory in France, Arc le Gray. They produce balers and also they were developing an ISOBUS solution. They were already working with an external supplier for both the hardware and the software. This external partner was working for other John Deere facilities (eg Mannheim). Very important also that they worked exclusive for John Deere and not for any other competitor from John Deere. Based on the four pages of specification and after very good discussion, John Deere Horst also decided to start the development of ISOBUS with this supplier. This would allow developing ISOBUS sprayer application software exclusively for John Deere Horst sprayers. Working together with previous suppliers would mean a risk of revealing application specifics/features that could end up in competitor s software which is not wanted of course. Given the amount of I/O s needed, together with the partner a number of controllers were reviewed as potential sprayer controller. It became quickly clear the sprayer was very demanding regarding the number of I/O s and no single controller was available to handle all the I/O s. Developing a specific 2
3 sprayer controller for John Deere Horst was/is no option as in the world of electronics the volume is low and development cost are very high. A base controller was selected that was also used on Tractors as engine controller. Slight modifications were necessary on how the board was populated but this did not require much testing, nor high development cost. As the selected controller did not have enough outputs, a controller was selected with 10 outputs that would be added to the system. Up to 6 were added to the system, depending on the machine configuration (Fig. 4). This controller was already in use by John Deere on different product (eg combines) so it passed all the required quality test and we could just re-use the part. With the expertise of the supplier regarding hardware and hardware available within John Deere and the Horst expertise on what components and functions are required on the sprayers, a very cost effective system setup was selected as both selected controllers were used within John Deere in high volume. As a small unit, John Deere Horst would never have been able to use controllers this cost effective. Since the selected supplier was already working on ISOBUS for the John Deere balers, knowledge was already present on the foundations of the ISOBUS communication and the Operating System the John Deere controller run on, JDOS. The supplier is also well involved in the ISOBUS standard development The real application software was of course a major challenge as the limited specifications were by far not enough to fully develop application software. However, Horst did not have software expertise or specs, the Horst team knew very well how the sprayer works and should work. The Horst team at the time involved was small. 2 Product Engineers, 1 Product Support engineer and 1 Marketing expert. This allowed to work very close together and define required detail in a very short time to allow continuous development. The supplier would only develop the software, they did not do the ISOBUS user interface (Fig. 5). This must be done by Horst. The John Deere tool to create the so called Object Pool was available to use but Horst had to learn it. The tool has some nice features inside that built on the ISOBUS communication but that are not allowed by the standard. Some of this was learned the hard way. 4. Development, challenges As with all developments that start with limited spec, all kinds of different challenges came up during the development. Many related to the spraying application but also many specifically related to ISOBUS. 4.1 Operating system John Deere are using their own operating system on the controllers, JDOS. During the implementation several aspects of JDOS had to be reviewed and updated because of the ISOBUS implementation for the Horst sprayers. As per ISOBUS standard multiple sizes of screens must be supported, the scaling algorithm had to be updated to ensure all worked well with non-deere displays using a different screen resolution, Deere displays use the 480x480 resolution. Mapping of proprietary colours gave issues, some graphics were not visible anymore because the proprietary colours were mapped to black instead of a standard colour close to the proprietary colours. For very ISOBUS specific items like the Taskcontroller, the development was not final and was finalised during the implementation of the Taskcontroller. Also the loadable language feature (see 3
4 later) required updates on JDOS. 4.2 Taskcontroller As mentioned earlier, it was decided to use the Taskcontroller for section control, map based spraying and documentation of the job done based on GPS. John Deere had a proprietary protocol already in use but this would not allow working with non-deere equipment. At project start, the Taskcontroller was not developed yet and the sprayer was the first to use this within John Deere as an implement. A tool to create the resource with the Taskcontroller objects was under development but not finalized. Especially here, the very close cooperation between the JDOS support group, the implementation group of the Taskcontroller server in the display and the Horst group made it work in a relative short period. With the introduction of section control via the Taskcontroller also the limitation of the physical hardware were found. The section can be commanded on and off in a very short time, sometimes within 20 seconds. On many machines motorized ball valves were used which require a runtime to open or close of 750 msec. This resulted in very nervous behaviour and issues with the hardware. Provisions in the application software had to be made to ensure the physical limitation of the application hardware were respected. 4.3 User Interface John Deere is using the development tool JDGui for the User Interface. With the tool the Object Pool is created which is later loaded to the display. The basics for the ISOBUS User Interface were more or less copied over from the self-propelled sprayers and modifications were made to tune it to the trailed and mounted sprayer for Europe. The John Deere Horst sprayers have many different configurations so many objects on the User Interface must be handled dynamically, depending on machine configuration. The ISOBUS standard has provisions in place for this but it is very difficult to keep an overview on what needs to be shown with which machine configuration. After a while this was realized and an extensive document was created to show/document these relations. As the self-propelled sprayers use a similar User Interface, some nice features were adopted. As the tool accepted them and also the John Deere display accepted this, the understanding was that it was no issue doing it in this way. When the software with these modification was connected to a non- Deere display, the whole Object Pool was rejected. It took 4 hours to find out what the real issue was. It turned out that objects were used in a way that was not allowed by the standard. We learned than also that the John Deere display is more friendly to Deere equipment than to non-deere equipment. To non-deere it reacts the same as competitive display by really checking against the ISOBUS standard and rejecting when issues are found. It was requested to modify the checking mechanism and make it per the standard also for John Deere equipment. The JDGui tool has a way to check for items not per the standard but it is a manual process and thus forgotten sometimes which is than learned the hard way. 4.4 Languages For equipment in Europe, it is a mandatory, legal requirement to deliver with the equipment an Operators Manual in the native language. Expectation and in many cases a legal requirement is that also the User Interface is in the native language. At the project start, 14 and today 22 different languages had to be incorporated. The ISOBUS standard has a provision inside for this. When the display is set to a different languages, it send out a language command and the application can then upload the strings for the selected languages. When the 4
5 requested language is not available, the application will remain in English, even when the display itself is using the selected language. Target during design was to have as few text strings as possible. However, warning and failure messages require real text to ensure the user understand the warning. Some strings are very small, like units but some are real text, like information to the user about a failure. The first release of software already had 950 text stings. All needed to be translated into 14 different languages and then stored in the controller. Due to the large Object Pool and the high amount of strings, issues came up with the amount of available memory inside the controller. In the Greenstar 4 system, the languages could by the user. 3 different languages could be loaded. This was not possible (yet) in the ISOBUS implementations as done in Deere but not all languages could be stored inside the controller and no bigger memory for he chosen controller was available. In the ISOBUS standard is a section called File Server. This section allows to transfer a file from one device, like a USB stick to another device, like a controller. However, at the time the standard was still under development and with that, officially not available. It was still decided to build into the Deere display s (Fig. 6) and the Deere sprayer a part of the Fileserver so the languages could be loaded and deleted by the user on demand. This also gave the flexibility to correct a language and give it to the customer without a real software release and all the consequences this has (eg lab testing, field testing etc). Also here a very close cooperation was required between the operating system development team, the display development team and the sprayer development team. The disadvantage of this approach was that a customer without a Deere display could not easy update/exchange a language. Therefore in parallel, development of implementing the Fileserver logic in the John Deere Service Advisor tool was started. This allowed a Deere technician to upload/exchange a language on non-deere tractor/display. The concept works well but can be complex, especially when a tractor is having 2 displays which both have the support of the Fileserve in. The sprayer can only connect to one and with both on the bus, issues have been seen and reported. A detailed manual had to be created to explain what to do for which configuration/combination of displays. A full, per ISOBUS standard implementation of the Fileserver should resolve this. 5. Plugfest and Certification From the beginning, the goal was to have the ISOBUS software certified. This proves the software is per the standard and should allow working with other parties without issues. As it is very difficult to check the ISOBUS application with non-deere parties, the so called Plugfest is a very important part of the process to validate the software is working with non-deere system. The Plugfest is an event where the agricultural industry comes together and connect systems of different brands together to see if things work as intended (Fig. 7). So a John Deere Sprayer controller is connected to a CNH display and (depending on what level of implementation both have) the different aspects of ISOBUS are tested like the User Interface and the Taskcontroller. The Plugfest is a real engineering event and all parties have a good drive to resolve issues together, no finger pointing if something does not work but jointly analyse the issue and come to a conclusion on root cause. The event is held 2x per year, once in Europe and once in the US. John Deere Horst has participated until last year on both events. Many issues were found during these event that cannot and will not be found during the in-house development. Analysing the issues looking from two sides really help to solve the issues. 5
6 The first years of development the validation was mainly on the User Interface (the VT). When this was stable, the main validation was on the Taskcontroller. Issues were found between manufacture also because the standard was not fully clear/defined. During Plugfest it was found that left and right were mixed up by the display compared to the sprayer because the interpretation from the standard was different. As the certification does not test the actual machine operation, very likely this would not have been found during a certification. In 2007 the John Deere Horst sprayer was the first John Deere implement that was certified by an external certification agency, DLG in Germany (Fig. 8). As only the first test was done with a full machine, the next certifications were done with only the main components. To prove the sprayer is ISOBUS compliant, a certification was done for a new software release that went on production machines. Certification however is a challenge as also a revision of the software because of a revision that is triggered by a change in the logic for controlling the machine, no relation with ISOBUS requires a renewal of the certification. 6. Current status The ISOBUS software as developed started in 2005 is still in use. In 2012 a new hardware platform was introduced using a main controller with more outputs but still with the additional modules for more outputs (Fig. 9). The main controller has more memory which allowed now to have all the 22 languages fixed installed into the controller and thus resolve the issue of the loadable languages, drawback is that translation updates require a software revision. After the AEF (Agricultural Electronic Foundation) was established, the certification as done by DLG was replaced by the AEF test. The AEF test covers different aspect of the ISOBUS standard and has documented tests. Major benefit of the test is that the requirements are now all clearly written down and a tool has been created with the test that is available for the developers to test against in every stage of the development in their own work area. Still, the Plugfest is very important as also the AEF test does not cover all issues that can be present. The goal of John Deere Horst is to be present at at least one Plugfest to test against real non-deere hardware. The sprayer was also again the first John Deere implement to pass the AEF certification test in February 2015 for UT1.0 (the VT part of the ISOBUS standard). This year in February the certification was extend by having the UT1.0, the TC-BAS and TC-GEO (the Taskcontroller) (Fig. 10). This year, Horst is working on implementing the ISOBUS AUX-N part. A tractor with Aux-N functionality makes functions available for devises to use. Currently, many tractors have a joystick with buttons for driving and these buttons can be made available to operate an implement. Today, a John Deere multi-function lever (joystick) is delivered with the machine (the switchbox used at start of the ISOBUS implementation was replaced with this device). Tractor can end up with having 2 operating joystick in the cab which is not convenient. Challenge for a user is however to map his most used function to his tractor device. The John Deere multi-function lever has 25 function as buttons available but very few if none on board tractor Aux-N devices have so many functions available. An additional, mandatory ISOBUS feature that is required to support is the ISB, the Implement Stop Button. This feature allows the user to operate a ISB button somewhere in the tractor and with that brining the implement in a defined state without accessing the implement application on the display. After 1 January 2018 the sprayer will face some additional challenge regarding certification. Per AEF 6
7 requirements, all components must meet the minimum conformance. Some components used today (like the controllers for additional output) do not meet that and cannot meet it because the software design does not have the required messages available. As these controller are already for a long time in use, it is nearly not possible (without major efforts) to update the software to meet these minimum requirement. Until 2018 the components are allowed because they were part of the older DLG certification. Another challenge for certification after 1 January 2018 is the Ground Isolation. The requirement is that there is a resistance of 100 kohm between the ECU ground and the Battery ground at the ISOBUS connector of the sprayer. As the controllers are today not designed with ground isolation (both grounds are connected together inside the controllers) it needs to be investigated what the exact status is for the different machine configurations. Certification after 1 January 2018 will need some more review and investigation of possible options to still meet the AEF requirements without developing new controllers. John Deere is also delivering non-isobus sprayers. However, the communication is fully ISOBUS and the difference with a real ISOBUS machine is that the connector to the tractor is more simple (and thus less costly), power is coming from the 3-pole tractor outlet socket (less power available) and the wiring is always independent of the tractor (no integration). These machines are in base with a very simple VT which cannot do section control and documentation. However, the display can easy be replaced by a display that has section control and documentation capabilities 7. Outlook to the future As mentioned above, meeting current AEF requirements will give challenges. Specifically for sprayers a major challenge is the transition to a new hardware platform with a new operating system. This new operating system must have again all the ISOBUS layers inside and functioning per the ISOBUS standard. Likely the bigger challenges is to update/upgrade the standard to allow high speed ISOBUS. Today, many implements (including sprayers) are equipped with camera systems which today require separate wiring apart from the ISOBUS wiring. The speed of the current ISOBUS specifications per ISO11783 does not allow to add the camera communication to the implement bus, it would be overloaded. Also on the sprayer itself are many developments ongoing that require much more communication between the tractor, the sprayer and other devices. individual nozzle control instead of control by section (Fig 11). This means for example controlling based on GPS 72 nozzles instead of 12 sections for a 36m spray boom. Currently already used by different manufacturers but no standard communication protocol defined; variable rate control per nozzle (Fig. 11).This means for each nozzle the speed and position is calculated and based on target rate the nozzle is controlled regarding the output. Also already in use by some manufacturers without standard protocol; direct injection. This means the sprayer has multiple small pumps that are controlled. System are known with 4 to 6 pumps. Also already in use by some manufacturers without standard protocol. In many cases, the display or another controller on the tractor is handling many of the functions mentioned above. The sprayer (and in this case more specific the trailed sprayer) is executing the function but the decision logic is not on the sprayer. The current Baud rate of 250 kbs will not be able to handle this as far more messages are required to control these new features. 7
8 It is important that the industry groups like the AEF quickly defines and finalizes a standard for high speed ISOBUS. For implements (especially in Europe with multi brand tractors) such a standard is important to ensure the implement is compatible with other brands then their own. It must be avoided that each manufacturer develops again something by themselves. Past has proven that this does not work on the long run. The current protocols will have to be reviewed in combination with high speed ISOBUS Still, the standard allows to implement features that use the ISOBUS protocol but have clear brand specific advantages. Unlike some statements, ISOBUS is not a fully open system in which everybody on the bus can see and understand what is being send. For the user/customer it is important (again, especially in Europe) that he can use his equipment with multiple brand implements and tractors without the need to end up with multiple displays and controls in the cab. 7. Conclusions Implementation of ISOBUS has been and still is a very interesting journey which is very important for the John Deere trailed sprayers. With the great cooperation between the different John Deere facilities and the external partner it was able to implement it even when John Deere Horst did not have specialists on the engineering department in Horst. 8
9 FIGURES Figure 1 History Figure 2 Sprayer controls before ISOBUS 9
10 Figure 3 Greenstar 4 system Figure 4 First generation ISOBUS architecture 10
11 Figure 5 User interface Figure 6 Fileserver Loadable languages 11
12 Figure 7 Plugfest Figure 8 DLG certification 12
13 Figure 9 Second generation ISOBUS architecture Figure 10 AEF certification 13
14 Figure 11 Variable rate nozzle (John Deere ExactApply tm ) 14
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