Engins · Hydraulique

Real-time hydraulic monitoring via PCAN-USB

The problem

An international Asian construction equipment manufacturer wanted to increase the operational reliability and maintainability of its 35-ton class excavators. These machines, used in mines, on large construction sites, and in civil engineering, are fitted with complex hydraulic systems that control the precise movements of the boom, arm, and bucket.

Until then, operators and technicians had only limited access to the actual condition of these components. Problems often only became apparent once the part was already worn or damaged. Diagnostics also required proprietary systems that were difficult to integrate into the existing infrastructure. Every unplanned machine stoppage led to significant costs — a single excavator alone can generate several thousand euros of added value per hour.

The solution

The engineers chose PEAK-System's PCAN-USB CAN interface, establishing a standardized link between the machine's internal CAN bus and an industrial laptop, used in the cab or in the maintenance container.

1. A reliable bridge to diagnostics

The excavator comes factory-equipped with a CAN bus that cyclically transmits all sensor data (hydraulic pressure, pump speed, oil temperature). The PCAN-USB connects via a service port, forming a reliable bridge between the machine and the diagnostic PC.

2. Diagnostic software via PCAN-Basic

The software developed by the manufacturer accesses raw data via the PCAN-Basic API, processes it, and presents it in a user-friendly interface: pressure in the boom and bucket cylinders, main circuit oil temperature, pump speed as a function of engine load. Comparing target and actual values detects deviations early and helps plan maintenance.

3. Rugged, mobile, and real-time

Compact plastic housing, opto-isolated version offering galvanic isolation up to 500 V, ISO 11898-2 high-speed CAN channel (5 kbit/s to 1 Mbit/s), 42 µs timestamp resolution, extended temperature range from -40 °C to +85 °C: all assets suited to harsh job-site conditions.

"The 42 µs timestamp resolution was decisive for accurate diagnostics: it makes it possible to detect even fast pressure spikes in the hydraulic lines."

The result