benchmanager installation guide

BenchManager

Installation and Configuration Guide

Wenco International Mining Systems Ltd.

2014 Wenco International Mining Systems Ltd. All rights reserved.

100 - 10271 Shellbridge Way, Richmond, B.C. V6X 2W8 Canada

email: [email protected]

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All other products or company names are used for identification purposes only, and may be

trademarks of their respective owners.

2/25/2014

What's in this Manual

This document contains information on installing and configuring BenchManager.

Intended Audience

This document is intended for those responsible for installing and configuring the

Wenco system programs. This includes Wenco Technical Services personnel and

may include mine site system administrators.

BenchManager

2014 Wenco International Mining Systems Ltd. i

Table of Contents

....................................................................................................................... 1Chapter 1: Overview

.............................................................................................................................. 1About BenchManager

.............................................................................................................................. 2System Requirements

....................................................................................................................... 3Chapter 2: Installing BenchManager

.............................................................................................................................. 3Install BenchManager on the MDT

....................................................................................................................... 4Chapter 3: Configuring BenchManager

.............................................................................................................................. 4Step 1: Configure the Bench.ini and AGSConfig.ini Files

.............................................................................................................................. 12Step 2: Configure Registry Keys and WLAN Communications

.............................................................................................................................. 14Step 3: Start Wenco MDT and BenchManager Software

.............................................................................................................................. 14Step 4: (Only ALIGN-installed Shovels/Backhoes) Calibrate ALIGN Feature

.............................................................................................................................. 15Step 5: (If Using MDT5) Make Sure MDT3\Dispatch Buttons is Removed

.............................................................................................................................. 15Step 6: (If Using Fleet Awareness) Set Up Proximate Equipment Display

....................................................................................................................... 17Chapter 4: Upgrading BenchManager

.............................................................................................................................. 17Step 1: Back Up the Bench.ini and AGSConfig.ini Files

.............................................................................................................................. 17Step 2: Install and Configure Upgrade

.............................................................................................................................. 19Step 3: Update Wenco Parameters

....................................................................................................................... 20Appendices

.............................................................................................................................. 20Appendix 1: BenchManager Registry Keys

.............................................................................................................................. 21Appendix 2: AGS Installation for Shovels and Backhoes

.............................................................................................................................. 33Appendix 3: BenchManager Offset Measurements

BenchManager

2014 Wenco International Mining Systems Ltd. 1

Chapter 1: Overview

Chapter 1: Overview

About BenchManager

BenchManager is a high-precision GNSS equipment-tracking

system that provides bench elevation monitoring and ore

quality control for loading and grading units. BenchManager

uses onboard graphical real-time displays that show

equipment orientation over the mine plan. Dig block

coordinates, ore quality information, and digital terrain model

files (DTM) are sent to BenchManager from the host computer

system, and work performance data is returned from

BenchManager.

Use BenchManager to:

load designs and maps that are transferred to the

BenchManager unit from the dispatcher office.

display a visual map so that the equipment unit operator

can see a realtime display of the current ramp, dump,

blast perimeters, hazardous areas, real-time floor, and

face positions.

transmit information about the working area back to the

dispatch office for surveyors and engineers to use.

BenchManager


Chapter 1: Overview

System Requirements

The mine system must have the following installed in order to

use BenchManager:

a configured Wenco Server (see the Wenco Server

Installation Guide for information on the Wenco

applications and services required on a Wenco Server).

any RTK-compatible GPS Base Station.

a Mesh radio network for transmitting GPS corrections

and maps, and for receiving back the current floor and

face positions.

Wenco's BenchView software (see the BenchView

Installation Guide for information on installing and

configuring BenchView and the FTP Server for

BenchView/BenchManager communications).

In addition, installation on the equipment unit requires:

a GPS enclosure to house the Novatel dual frequency

GPS receiver and power supply.

a GPS Antenna to receive positioning messages from

satellites.

a Mesh Antenna/WLAN AntennaAntennex 3dB gain

antenna for communication with the radio network.

a Mobile Data Terminal (MDT) touchscreen computer

and display with Wenco MDT software and Wenco

BenchManager software installed to store data and run

BenchManager.

(only if you are using MOBA or Novatron pitch and roll

sensors) one of either:

a PEAK PC104+ board installed in the Octagon C2,

or

a ruggedized PEAK dongle cable connected to a

USB port on the Octagon C2.

BenchManager


Chapter 2: Installing BenchManager

Chapter 2: Installing BenchManager

Install BenchManager on the MDT

The BenchManager software is installed after the MDT

software has been installed. Exit from the MDT software

before running the BenchManager installation.

To install the BenchManager software:

1. Browse to the BenchManager folder on the network or

USB drive and double-click setup.exe.

2. Click Next at the Welcome screen.

3. Choose Accept on the License Agreement screen,

and click Next.

4. Click Install.

5. Click Finish.

BenchManager


Chapter 3: Configuring BenchManager


Step 1: Configure the Bench.ini and AGSConfig.ini Files

For each machine with BenchManager software installed, the

configuration file should be completed before the hardware is

installed on the equipment.

1. Use Windows Explorer to open the Bench.ini file

(located in the C:\Program

Files\Wenco\BenchManager\Config folder).

2. Refer to the BenchManager Parameters.xls document

to configure the Bench.ini parameters.

Below are the CRITICAL Bench.ini parameters that

must be modified. (Parameters not listed here have

default values that work for most situations.)

Note: Units of Measure (UOM) are defined by the

transformation settings under [local_grid]. All offset

measurements must be measured in the UOM used by

the site.

Parameters Common to All Equipment Types

Section ParameterParameter

OptionsComments

[App] elevation_unit= feet, meter

[Vehicle] gps_height_offset= float value

Difference between

the local datum and

the MSL (Mean Sea

Level) datum.

[Vehicle] antenna_height_offset=negative float

value

Vertical offset from

the GPS antenna to

the ground.

[Vehicle] toe_radius=positive float

value

(Defined as

dig_radius in the

BenchView

Equipment Editor.)

Used to display the

mined out area, it is

the distance to the toe

of the slope.

The toe radius will

vary from machine to

machine, based on

the equipment size.

BenchManager



[Vehicle] crest_radius=positive float

value

(Defined as

crest_buffer in Wenco

Configuration

Manager.)

Distance to the crest

of the slope with

respect to the center

of the machine.

[Tilt] type= blank: Select this

if you are not

using a pitch and

roll sensor.

GPS: On a loader

or dozer, this

uses the change

in elevation to

measure the

pitch. On a

shovel, this uses

the rotation of the

shovel to

measure pitch

and roll.

MOBA: This uses

the pitch and roll

sensor by MOBA.

It must be must

be aligned with

the direction of

travel and

installed on a flat

surface.

Note: There are

additional INI

parameters to

set for MOBA

that are listed in

the [MOBA]

section of the

BenchManager

Parameters.xls

file. See the

BenchManager

Parameters.xls

file for details

and options.

Novatron: These

are the same

BenchManager



sensors used for

the Arm

Geometry

system. See

Appendix 2:

AGS Installation

for Shovels and

Backhoes of the

BenchManager

Installation

Guide for

installation

instructions in or

on the cab.

Note: There are

additional INI

parameters to

set for Novatron

that are listed in

the [Novatron]

section of the

BenchManager

Parameters.xls

file. See the

BenchManager

Parameters.xls

file for details

and options.

[Local Grid] cmeridian=positive or

negative integerUTM central meridian.

[Local Grid] k1= float value

Local coordinate

transformation scale

factor.


Local coordinate


factor.

[Local Grid] shiftx= float value

Local coordinate

transformation shift in

easting.


Local coordinate


factor.


Local coordinate


factor.

[Local Grid] shifty= float value Local coordinate

BenchManager



transformation shift in

northing.

[Local Grid] map_orgx= float value

Easting coordinate

that defines the origin

of the cut/fill grid.

[Local Grid] map_orgy= float value

Northing coordinate

that defines the origin

of the cut/fill grid.

Parameters Specific to Shovels/Backhoes


OptionsComments

[Vehicle] type=

shovel

backhoe

[Vehicle] machine_width=positive float

value

Used to calculate the

four corners' position

of the vehicle. It

defines the width of

the rectangle from the

center of the

machine.

This is required for

exclusion zone

detection.

[Vehicle] rear_length=positive float

value



of the vehicle. It

defines the rear

length of the

rectangle from the

center of the

machine.

This is required for

exclusion zone

detection.

[Vehicle] boom_length=

float value

Scraper: negative

float value

Other types:

Measured from the

center of rotation/

center of the machine

to the bucket center.

It is also used to

define the proximity

BenchManager



positive float

value

rectangle around the

center of the

machine.

[Vehicle] dx= float value

Offset from the GPS

antenna to the center

of the machine.

[Vehicle] dy= float value

Offset from the GPS


of the machine.

[Vehicle] dxr= float value

(Used in NovAtel

ALIGN GPS only.)

Offset from the

remote GPS antenna

to the center of

rotation.

(Shovels and

backhoes use

hdg_corr instead.)

[Vehicle] dyr= float value

(Used in NovAtel

ALIGN GPS only.)

Offset from the

remote GPS antenna

to the center of

rotation.

(Shovels and

backhoes use

hdg_corr instead.)

Parameters Specific to Loaders/Dozers


OptionsComments

[Vehicle] type=

dozer

loader

[Vehicle] machine_width=positive float

value



of the vehicle. It

defines the width of

the rectangle from the

center of the

machine.

BenchManager



[Vehicle] rear_length=positive float

value



of the vehicle. It

defines the rear

length of the

rectangle from the

center of the

machine.

[Vehicle] wheel_width_offset=positive float

value

Offset from the center

of the machine to the

center of the track or

wheel.

[Vehicle] wheel_length_offset=positive float

value

Distance from the

center of the machine

forward to the front of

the wheels or track.

[Vehicle] dx= float value

Offset from the GPS


of the machine.

[Vehicle] dy= float value

Offset from the GPS


of the machine.

[Vehicle] dxr= float value

(Used in NovAtel

ALIGN GPS only.)

Offset from the

remote GPS antenna

to the center of

rotation.

(Shovels and

backhoes use

hdg_corr instead.)

[Vehicle] dyr= float value

(Used in NovAtel

ALIGN GPS only.)

Offset from the

remote GPS antenna

to the center of

rotation.

(Shovels and

backhoes use

hdg_corr instead.)

BenchManager



AGS Parameters


OptionsComments

[Vehicle] AGSInstalled=1 - the vehicle

has AGS installed

Indicates whether or

not the vehicle has

AGS installed.

[Vehicle] joint_offset_hori=positive float

value

Horizontal distance

from the vehicle

center to the boom

joint.

[Vehicle] joint_offset_vert=positive float

value

Vertical distance from

the ground to the

boom joint.

3. Refer to the BenchManager Parameters.xls document

to configure the AGSConfig.ini parameters.

Below are the CRITICAL AGSConfig.ini parameters that

must be modified. (Parameters not listed here have

default values that work for most situations.)

Notes:

Measurements will be provided by the site

surveyors.

For the MachineName parameters, all options

are listed in the .ini file. These are your only

options.

Parameters Specific to Backhoes with AGS

(Be sure to modify the parameters associated with the correct model type.)

Section Parameter Parameter Comments

BenchManager



Options

[] BoomLength= float value

Measured on the boom

from the cab pin to the arm

pin.

[] ArmLength= float value

Measured on the arm from

the boom pin to the bucket

pin.

[] BucketLength= float value

Measured on the bucket

from the arm pin to the

bucket teeth.

[] BucketSensorDirectMount=F - mounted

on linkarm

Indicates whether the

bucket sensor is mounted

directly on the bucket or on

the linkage arm.

[] BaseLength= float value

Distance from

arm_bucket_pivot to

arm_linkage_pivot.

[] LinkageLength= float value

Distance from

arm_linkage_pivot to

linkage_transmit_pivot.

[] TransmitArmLength= float value

Distance from

linkage_transmit_pivot to

transmit_coupler_pivot.

[] CouplerLength= float value

Distance from

transmit_coupler_pivot to

arm_bucket_pivot.

[] BaseAngle= float value

Angle from

boom_arm_pivot to

arm_bucket_pivot to

arm_linkage_pivot.

[] Bucket_CouplerAngle= float value

Angle from bucket_teeth to

arm_bucket_pivot to

transmit_coupler_pivot.

BenchManager



Parameters Specific to Shovels with AGS

(Be sure to modify the parameters associated with the correct model type.)


OptionsComments

[] BoomLength= float value

Measured on the boom

from the cab pin to the arm

pin.

[] ArmLength= float value

Measured on the arm from

the boom pin to the bucket

pin.

[] BucketLength= float value

Measured on the bucket

from the arm pin to the

bucket teeth.

[] BucketSensorDirectMount=T - mounted

on bucket

Indicates whether the

bucket sensor is mounted

directly on the bucket or on

the linkage arm.

Step 2: Configure Registry Keys and WLAN Communications

Use the registry to configure the BenchManager Server

WLAN address:

1. Start regedit.

2. Go to the registry key:

HKEY_LOCAL_MACHINE\Software\Wenco\BenchMan

ager.

MDT4: You need to enter the Server A WLAN IP

Address, Server B WLAN IP Address, and WLAN

Subnet Mask registry entries manually. Configure

the BenchManager Registry Keys .20

BenchManager



MDT5: The Server A WLAN IP Address, Server B

WLAN IP Address, and WLAN Subnet Mask

registry entries are automatically set when the MDT5

resynchronizes. Check that the BenchManager

Registry Key values are correct.

3. Go to the WLAN subkey:

HKEY_LOCAL_MACHINE\Software\Wenco\BenchMan

ager\WLAN. Make sure that the values under this

registry key are set correctly.

Note for MDT4: For MDT4 installations, this setting

can be updated using the Field Configuration

Editor (an icon for the Field Configuration Editor

is installed onto the desktop). Start the Field

Configuration Editor, click the BenchManager

WLAN tab, and add a checkmark to the Active

checkbox. Then enter the IP Address where the

BenchView Service is located. For more

configuration information, see here .

20

20

BenchManager



Step 3: Start Wenco MDT and BenchManager Software

To start the MDT and BenchManager software:

1. Start the MDT software. The Badge In screen displays

briefly.

2. The BenchManager screen displays for a few seconds.

Note: Do not interfere during the startup process. Wait

until the BenchManager screen displays.

3. The display switches back to the MDT Badge In

screen. Badge in to the MDT.

Press the button on the MDT screen to switch

to the BenchManager screen.

Press the button on the BenchManager screen to

switch to the MDT screen.

Step 4: (Only ALIGN-installed Shovels/Backhoes) Calibrate

ALIGN FeatureNotes:

This procedure is only for shovels and backhoes with

ALIGN GPS installed.

The operator must be granted the ALIGN Calibration

privilege before performing the calibration.

To perform manual calibration:

1. On the GPS tab of the Position Data menu, uncheck

the Use ALIGN checkbox.

2. Have the operator rotate the shovel until the center of

rotation (COR) is calculated.

The appearance of the shovel graphic on the

BenchManager screen indicates that the COR is

calculated.

3. Stop rotation and shovel movement. Keep the shovel

stationary for about 10 seconds to ensure that the

ALIGN data is stable.

4. On the GPS tab of the Position Data menu, press the

Calibrate ALIGN button.

5. If the calibration procedure is successful, the Calibrate

ALIGN button turns green. To use ALIGN, check the

BenchManager



Use ALIGN checkbox.

Automatic calibration: BenchManager

automatically calibrates ALIGN if all of the following

conditions are met:

INI::align_auto_calibration = 1, and

the shovel has rotated wide enough to find the

center of rotation and then stopped, and

either:

the ALIGN has not already been calibrated,

or

the previous calibration failed

(i.e., INI::hdg_corr does not exist, or is equal

to -9999.9).

You can do manual calibration regardless of the INI::

align_auto_calibration setting. However, automatic

calibration can only occur when INI::

align_auto_calibration = 1.

Step 5: (If Using MDT5) Make Sure MDT3\Dispatch Buttons is

RemovedIf BenchManager is working with MDT5, make sure that the

registry key

HKEY_LOCAL_MACHINE\Software\Wenco\MDT3\Dispatch

Buttons is removed.

This key contains pre-defined dump/material dispatches,

which are supported in MDT4 but not MDT5. With this key,

BenchManager displays a Next button that brings up a set of

dump/material dispatch buttons.

Step 6: (If Using Fleet Awareness) Set Up Proximate

Equipment DisplayYou can configure the Wenco system to display proximate

equipment in BenchManager.

To configure BenchManager to display proximate

equipment:

1. Configure PitNav, by completing all steps of the PitNav

Installation and Configuration Guide. Pay special

attention to:

Chapter 3: Obtain a Fleet Awareness for PitNav

license for your mine site. The Proximate Awareness

BenchManager



feature is not available with a simple PitNav license.

2. Start BenchManager from each MDT5.

3. In BenchManager's Tools menu, add a checkmark to

Show Proximate Vehicles.

BenchManager


Chapter 4: Upgrading BenchManager


Step 1: Back Up the Bench.ini and AGSConfig.ini Files

Before upgrading BenchManager, it is a good idea to create a

backup of the Bench.ini file for the equipment unit.

To create a copy of the Bench.ini file:

1. Browse to the c:\program

files\Wenco\BenchManager\Config folder.

2. Copy the Bench.in file to a new location.

Step 2: Install and Configure Upgrade

To upgrade BenchManager:

1. Install the new software by following the instructions in

Chapter 2 of this document.

Note: It is no longer necessary to uninstall the

previous version of the application before running the

updated installation kit.

2. Open the c:\program

files\Wenco\BenchManager\Config\bench.ini file to

confirm that the file contains the same information as

before the upgrade.

3. Check the WLAN settings by following the instructions

in Chapter 3.

4. Check the readme file in the installation folder to see if

new configuration items have been added to the bench.

ini file since the last installation. If there are new items

you will need update the installed version.

To update the bench.ini file:

a) Open the updated default version of the bench.ini

file from the \program files\Wenco\BenchManager\

ConfigDefault folder.

b) Open the configured version of the bench.ini file

from the \program files\Wenco\BenchManager\

Config folder.

c) Compare the entries in the two versions of the file.

d) Copy any new configuration items from the updated

default version to the configured version.

[FTP] section: For bv_repository_path, enter the

folder where the BenchView repository files are saved.

Enter the folder that is configured in the Wenco

Configuration Manager parameter: Repository

BenchManager



Directory.

Example:

If the Wenco Configuration Manager Repository

Directory parameter setting is: \Wenco FTP

Site\BenchView\Repository

Then in the bench.ini file, the

bv_repository_path=\BenchView\Repository

BenchManager



Step 3: Update Wenco Parameters

If you are upgrading the BenchManager software, there may

be an update of Wenco Parameters that needs to be

installed on your system.

Wenco Parameters are configuration settings that are used

with Wenco applications. Each time there is new Wenco

Parameters release that is relevant for your mine, Wenco

Technical Services will send you a file containing the Wenco

Parameters update.

Note: The WencoDB Home editor Software Version History

displays the version and installation date of WP updates.

To update the Wenco system using the latest Wenco

Parameters:

1. Copy all of the files from the Wenco Parameters

installation kit or zipped file to the

:\WencoWP folder on your Wenco

server. In the Two Server Model, copy the files onto

the Operational Server. In the Four Server Model,

copy the files onto the Operational Services Server.

2. Double click on WencoParameters.exe in the

:\WencoWP folder to start the

Wenco Parameters Installer.

Notes:

Refer to the Wenco Parameters Installer Guide

document for information about using the Wenco

Parameters Installer.

A readme file with release notes is included with

each Wenco Parameters release.

BenchManager


Appendices

Appendices

Appendix 1: BenchManager Registry Keys

The BenchManager registry keys are located in the registry

under:

HKEY_LOCAL_MACHINE\Software\Wenco\BenchManager

Name Default Description

Interface WLAN

Defines the radio modem

configuration used by the

BenchManager system.

Server A

WLAN IP

Address These registry entries are set by

the MDT5 when it resynchronizes

to the database. The value is the

same as the value in the Wenco

Configuration Manager >

System parameter with the same

name.

Server B

WLAN IP

Address

WLAN

Subnet

Mask

BenchManager\WLAN Subkey


Host

Address

IP Address of the BenchView

Service computer.

BenchManager will automatically

upate the host address when it

detects a server switch.

Refresh

Interval120000

If the MDT unit has not seen any

traffic for the defined time (in

milliseconds), then the unit

invokes a ping cycle in order to

establish that the Host is still

functioning and is aware of the

units location.

BenchManager


Appendices


UDP Port 40003

Identifies the port on which the

BenchManager sends and

receives WLAN Messages. This

should be the same as the port

used for the BenchView Service.

Ack Timeout 1500

For every transmitted message,

Ack Timeout specifies the

duration (in milliseconds) that

BenchManager waits for an Ack

message to arrive. The Ack

message confirms that the

outgoing message has been

received by the target application.

Maximum

Retries3

For every transmitted message, if

BenchManager does not receive

an Ack message within the Ack

Timeout duration,

BenchManager retransmits its

message. Maximum Retries

defines the maximum number of

times BenchManager will try to

retransmit it.

Appendix 2: AGS Installation for Shovels and Backhoes

AGS Hardware Installation

There are five stages for installing hardware for the Wenco

Arm Geometry System (AGS):

1. Survey the Shovel or Backhoe

2. Lay Out the Boom and Arm Sensors

3. Weld the Brackets

4. Run the Cables

5. Install and Terminate the Cables

Step 1: Survey the Shovel or Backhoe

Having accurate dimensions of the shovel/backhoe is

essential for BenchManager to precisely position the shovel

bucket. Below is a description of survey measurements

required to configure a Wenco AGS shovel/backhoe system.

21

23

26

26

27

BenchManager


Appendices

Shot Location Comment

Four or more shots

on the circular ring

on the undercarriage

Use to determine the center of rotation.

One shot on the

center line of the

bucket

Use this point and the center of rotation point from above to

determine the center-line of the machine.

One shot on top of

each GPS antenna

One shot on the

boom joint

Use to determine the boom joint height above ground.

One shot on each

pivot point on the

arm

Use to measure components of the arm. Take shots for each of

the pivot points (P1 to P5) as illustrated in the image below and the

backhoe bucket image on page 9. Survey shots on arm:

Survey shot locations:

One or two shots at

the track level below

the boom joint

Used to determine the elevation difference between the GPS

antenna and the ground. A shot on both sides of the machine near

the center of rotation is best.

BenchManager


Appendices

Step 2: Lay Out the Boom and Arm Sensors

Once the surveyor has taken the above measurements, the

surveyor has enough information to mark reference points on

the boom and arm. Use a felt or grease pen to mark these

reference lines.

Notes:

When mounting the sensor on the linkage (see sensor

ID 101 picture below), the terminated end of the sensor

MUST be pointing parallel along the line from P4 to P3

(i.e., towards the piston coupler).

The sensors must be mounted on the left side of the

machine.

Boom layout (sensor ID 103):

Lay out two points just in front of the cab along the

line between the boom-joint and the joint

connecting the boom to the arm (P5). The welders

will use this line as a reference to place the AGS

sensor base plate. The base plate must be parallel

to this line, and as close to the boom joint as is

practical (which is just in front of the cab). Refer to

the pictures below.

BenchManager


Appendices

Arm sensor layout (sensor ID 102):

Lay out two points along the line from P5 to P1 that

defines the arm length. The welders will use this as

a reference line. The sensor mounting plate must

be placed parallel to this reference line. Just above

point P5 is the preferred location. Refer to the

pictures below.

BenchManager


Appendices

Cab sensor (sensor ID 105):

The cab sensor must be located on a flat surface

somewhere on the body/cab of the shovel. Refer to

the pictures below for a typical installation.

Linkage Sensor (sensor ID 101):

The bucket sensor will most commonly be placed

on the linkage assembly near the bucket. It must

be placed in a plane parallel to the plane of the

boom and arm sensors. The boom and arm

sensors are placed on the left side of the machine.

The bucket sensor is placed on the inside of the

right-hand linkage assembly. It is in the same

orientation as if it were on the outside face of the

linkage on the left side of the machine. It is not in

the same plane as the other sensors but it is

parallel to the plane of the boom and arm sensor.

BenchManager


Appendices

A good location for the linkage/bucket sensor is on

the inside of the linkage assembly. Refer to the

pictures below.

Step 3: Weld the Brackets

Have a welder weld the brackets in place as shown in the

pictures above.

Step 4: Run the Cables

Cables are fastened with cable ties to existing hoses and

cables as shown in the pictures above. Whenever possible,

fasten the cable to rigid (stationary) hydraulic lines. Have a

qualified person operate the machine and observe its

movements prior to attaching the cable, to ensure proper

routing.

BenchManager


Appendices

Step 5: Install and Terminate the Cables

Install and terminate the cables, following the steps below.

1. Install cables as noted in Step 4: Run the Cables and

cut to required length.

2. Slide on crimp sleeve (provided in the plastic bag

attached to the cable).

3. Slide on heat shrink (provided in the plastic bag

attached to the cable).

4. Remove approximately 2 inches of stainless steel outer

braid.

5. Remove approximately 1.5 inches of cable jacket.

6. Use coax crimpers to crimp the sleeve over the outer

braid.

7. Terminate the connector according to the

manufacturer's instructions (located on the bag).

Note: Sensor cables are coded by color to match the

BenchManager


Appendices

color-coded positions on the back of the M12 connectors.

Wire ColorM12 Connector Position

Color

RED RED

BLACK BLACK

BLUE BLUE

WHITE WHITE

GREEN GREY

BROWN NOT USED

BenchManager


Appendices

AGS Software Installation

Configuration parameters for the AGS are set in two

configuration files:

Bench.ini : parameters relevant to the vehicle.

AGSConfig.ini : parameters relevant to the AGS.

The parameters should be set from measurements gathered

during the installation of the AGS sensor hardware (refer to

the document BenchManager Parameters.xls).

30

31

BenchManager


Appendices

Bench.ini Parameters

Note: The information about the parameters below is added

as of BenchManager version 3.5.2007. The measurements

are in meters or feet, depending on the site.

Bench.ini

Vehicle AGS Parameters

Parameter Comment

AGSInstalledSet to 1 to indicate that the AGS is installed on

the vehicle.

joint_offset_hori

Horizontal distance from the vehicle center to

the boom joint.

This will generally be the same for each model.

joint_offset_vert

Vertical distance from the ground to the boom

joint.

This will generally be the same for each model.

under_scoop_offsetAdjust the candidate bucket elevation by this

amount.

The following parameters define the Bucket Zone used to trigger bucket detection. They

should be adjusted after the AGS accuracy has been confirmed.

horizontal_dig_limitDo not calculate a bucket if the bucket is this

distance away from the boom joint.

min_forward_distanceThe bucket must move forward in the zone at

least this distance.

scoop_heightThe bucket must move upwards in the zone at

least this distance.

vertical_limitDo not calculate a bucket if the bucket is this

distance above the boom joint.

vertical_trigger

Start calculating the bucket if the vertical

distance from the boom joint exceeds this

value.

BenchManager


Appendices

AGSConfig.ini Parameters

Notes:

The information about the parameters below is added as

of BenchManager version 3.5.2007.

The following parameters are only required if

BucketSensorDirectMount=F:

BaseLength, LinkageLength, TransmitArmLength,

CouplerLength, BaseAngle, Bucket_CouplerAngle.

The measurements are in meters or feet, depending on

the site.

AGSConfig.ini

AGS Parameters

Parameter Comment

MachineName

Set this value to one of the predefined

configurations in the file (e.g.,

Hitachi_EX3600_Backhoe).

BoomLengthMeasured length between the pins on the

boom.

ArmLength Measured length between the pins on the arm.

BucketLengthMeasured value between the pin on the bucket

and the tip of the teeth.

BucketSensorDirectMount

Set to T if the sensor is mounted on the bucket

usually shovels.

Set to F if the sensor is mounted on the linkage

arm usually backhoes.

BaseLengthP1P4: Measured length between the bucket

pin (P1) and the linkage pin on the arm (P4).

LinkageLength

P4P3: Measured length between the arm pin

(P4) and the transmit pin (P3) on the linkage

arm.

TransmitArmLengthP3P2: Measured between the linkage pin (P3)

and the coupler pin (P2) on the transmit arm.

CouplerLengthP2P1: Measured length between the transmit

pin (P2) and the bucket pin (P1) on the coupler.

BaseAngle

A2: Measured angle from the boom pin (P5) to

the bucket pin (P1) to the linkage pin (P4) on

the arm.

Bucket_CouplerAngle A1: Measured angle from the bucket teeth to

BenchManager


Appendices

the bucket pin (P1) to the transmit pin (P2) on

the coupler.

BenchManager


Appendices

Appendix 3: BenchManager Offset Measurements

BenchManager Shovel Offset Measurements

The following descriptions refer to the diagrams shown above

and below. Record all measurements in meters. Convert to

feet afterwards if required.

Note: The recommended location of the GPS antennas is

to the rear of the machine to minimize shadowing from the

pit wall. The locations shown above are just for illustrative

purposes.

The following parameters are inserted into the Bench.ini

configuration file.

BenchManager


Appendices

Measurement Description

dx

Distance from the center of the machine rotation to the

center of the Master GPS antenna as shown above. Take

note of whether the antenna is on the left (negative value)

side or right (positive value) side of the machine. The GPS

Master-GPS Remote diagram above shows the GPS

antenna on the left side of the machine.

dy

Distance from the center of rotation to the center of the

Master GPS antenna as shown above. Take note of

whether the GPS antenna is forward (positive value) of the

center of rotation or to the rear (negative value). The GPS

Master-GPS Remote diagram above shows the GPS

antenna to the rear of the machines center of rotation.

dxr

Distance from the center of rotation to the remote antenna.

The GPS Master-GPS Remote diagram above shows the

remote antenna on the right side of the machine.

dyr

Distance from the center of rotation to the remote antenna.

The GPS Master-GPS Remote diagram above shows it

forward of the center of rotation.

antenna_height_offset (J)

Distance from the phase center of the GPS antenna to the

bottom of the tracks (ground level). The bottom of the GPS

antenna shows the offset from the base of the antenna to

the phase center of the antenna. Enter this as a negative

(-) value.

boom_length (D)Estimated distance from the center of rotation to the

cutting edge of the shovel bucket.

rear_lengthDistance from the center of rotation to whatever is sticking

out the furthest at the back of the machine.

toe_radius (B + C)

Estimated distance from the center of rotation to the toe of

the slope. This is usually the same value as the

boom_length or a little longer.

crest_radius

Estimated distance from the center of rotation to the crest

of the digging face. The distance from the toe of the slope

to the crest can be calculated by knowing the slope of the

pit wall and its height. For example:

Slope = 1:3

Height = 15 meters

Toe to Crest distance = 15 * 1/3 = 5

crest_radius = boom_length + 5

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Appendices

To measure dx, dy using a tape measure

To determine the correct heading of the machine based on a

center of rotation calculation, we need to know the location of

the GPS antennas with respect to the center of rotation.

Unfortunately, the center of rotation is not easily defined.

What is more easily defined is the center-line of the shovel.

1. Measure the perpendicular distance from the center of

the antenna to the center-line of the shovel. This should

be accurate to within a couple of centimeters if care is

taken. This is the dx measurement.

2. Now measure the perpendicular distance from the

antenna center to the center of rotation as best you can.

This is not as obvious to locate. This is your dy

measurement. You can refine this measurement later

once BenchManager is running (see step 4 below).

3. Enter these values into BenchManagers ini file as dx

and dy.

4. To refine the dy measurement:

a) Run BenchManager in COR (center of rotation)

mode.

b) Go to the Tools page and look at the Radius label.

This displays the calculated radius (R) from the

COR to the antenna. Take note of this value and let

it calculate two or three times.

c) Take the average radius value and calculate dy

using Pythagorass formula:

dy = sqrt(R^2 - dx^2)

BenchManager


Appendices

BenchManager Loader Offset Measurements

The following descriptions refer to the diagrams shown above.

Record all measurements in the same units as the coordinate

system.

Note: Locations of the antennas shown above are for

illustrative purposes only. Try to place the Master receiver

near the center-line of the machine.


dx

Distance from the center of machine to the center of

the GPS antenna as shown above. Take note of

whether the antenna is on the left (negative) side or

right (positive) side of the machine. The diagram

above shows the Master GPS antenna on the left

side of the cab.

dy

Distance from the center of the cab to the center of

the GPS antenna as shown above. Take note of

whether the GPS antenna is forward (positive) of the

cab center or rear (negative) of the cab center. The

diagram above shows the Master GPS antenna to

the rear of the cab center.

dxrDistance from the center of rotation to the remote

antenna.

dyrDistance from the center of rotation to the remote

antenna.

antenna_height_offset (C)

Distance from the phase center of the GPS antenna

to the bottom of the tracks (ground level). The

bottom of the GPS antenna shows the offset from

the base of the antenna to the phase center of the

antenna. Enter this as a negative (-) value.

boom_length

Distance from the center of the cab to the cutting

edge of the loader bucket. The cut/fill is calculated

here. Wheel_width_offset is also used to determine

where the cut/fill is calculated (see below).

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Appendices

wheel_width_offset (B/2)

Distance from the center of the loader to the center

of the wheels, or, half of dimension B in the

cross-sectional diagram shown above. Cut/fill values

are calculated at two locations on each side of the

machine based on these offsets.

rear_length

Distance from the center of the cab to whatever is

sticking out the furthest at the back of the machine.

In the diagram above, it is the fender.

machine_width Width of the loader bucket as shown above.

toe_radius

Estimated distance from the center of the cab to the

toe of the slope. This is usually the same value as

the boom_length or a little longer.

crest_radius Estimated distance from the center of the cab to the

crest of the digging face.

BenchManager


Appendices

BenchManager Bulldozer Offset Measurements

The following descriptions refer to the diagrams shown above.

Record all measurements in metres. Convert to feet

afterwards if required.

Note: These measurements apply when there is only one

antenna.


dx

Distance from the center of the machine to the

center of the Master GPS antenna as shown above.

Take note of whether the antenna is on the left side

or right side of the machine. The diagram above

shows the GPS antenna on the right side of the cab.

dy

Distance from the center of cab (the crease in the

roof of the cab) to the center of the GPS antenna as

shown above. Take note of whether the GPS

antenna is forward of the cab center or rear of the

cab center. The diagram above shows the GPS

antenna to the rear of the cab center.

antenna_height_offset (J)

Distance from the phase center of the GPS antenna

to the bottom of the tracks (ground level). The

bottom of the GPS antenna shows the offset from

the base of the antenna to the phase center of the

antenna

wheel_length_offset

Distance from the center of the cab to the cutting

edge of the dozer blade. The cut/fill is calculated

here. Wheel_width_offset is also used to determine

where the cut/fill is calculated (see below).

wheel_width_offset (A/2)

Distance from the center of the dozer to the center of

tracks, or, half of dimension A in the cross-sectional

diagram shown above. The cut/fill values are

calculated at two locations on each side of the

machine based on these offsets.

rear_length

Distance from the center of the cab to whatever is

sticking out the furthest at the back of the machine.

In the diagram above, it is the ripper. If the machine

BenchManager


Appendices

does not have a ripper, then just measure to the limit

of the machine.

machine_width (B) Width of the dozer blade as shown above.

BenchManagerChapter 1: OverviewAbout BenchManager System Requirements

Chapter 2: Installing BenchManagerInstall BenchManager on the MDT

Chapter 3: Configuring BenchManagerStep 1: Configure the Bench.ini and AGSConfig.ini FilesStep 2: Configure Registry Keys and WLAN Communications Step 3: Start Wenco MDT and BenchManager Software Step 4: (Only ALIGN-installed Shovels/Backhoes) Calibrate ALIGN FeatureStep 5: (If Using MDT5) Make Sure MDT3\Dispatch Buttons is RemovedStep 6: (If Using Fleet Awareness) Set Up Proximate Equipment Display

Chapter 4: Upgrading BenchManagerStep 1: Back Up the Bench.ini and AGSConfig.ini FilesStep 2: Install and Configure UpgradeStep 3: Update Wenco Parameters

AppendicesAppendix 1: BenchManager Registry KeysBenchManager\WLAN Subkey

Appendix 2: AGS Installation for Shovels and BackhoesAGS Hardware InstallationStep 1: Survey the Shovel or BackhoeStep 2: Lay Out the Boom and Arm SensorsStep 3: Weld the BracketsStep 4: Run the CablesStep 5: Install and Terminate the Cables

AGS Software InstallationBench.ini ParametersAGSConfig.ini Parameters

Appendix 3: BenchManager Offset MeasurementsBenchManager Shovel Offset MeasurementsBenchManager Loader Offset MeasurementsBenchManager Bulldozer Offset Measurements

benchmanager installation guide

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