Modul Sy215c9m3ks

SANY HEAVY MACHINE CO.
,LTD
SY215C9M3KS principle and application of electric system
SANY HEAVY MACHINE CO.,LTD
为中国贡献一个
世界级品牌
R&D Academy of Mid-Excavator Co.
Composer ：Yunfei Xiong Check： Approve：

>>> 为中国贡献一个世界级品牌 <<<
Catalogue
一、 electric system and circuitry
二、principle and structure of main parts
三、control theory of excavator
1
1、 electric system and circuitry
starting loop
Electric appendant
Engine EGR controller
Main controller
Display KC-MB-20
CAN Bus
Engine Controller ECM
power supply
controller E battery
power
power supply
2
1、electric system and circuitry
1.2 electric circuitry （1）

Main controller
KC-MB-20
CAN bus
Relay
battery Starting mtor
fuse
off
on
switch
starting signal
generator
励磁 battery

1.2 electric circuitry （2）
Power
singal
starting
singal
Main
主控制器
controller
KC-MB-20
KC-MB-20
4

1.3 generator
While rotor rotated, its line of magnetic shear the line of force which supplied by three –
phase wilding , three –phase wilding is separated 120 degrees with each other .three –
phase wilding generated the induced emf, named alternating current . The value have a
direct proportion with number of phase wilding , rotate speed of rotator and the
magnetic
battery
5

1.4 Starting motor work principle(1)
上启
Power
电动 starting
signal
信信 signal
号号
启动信号输出
starting signal out
Power delay output
Main controller
KC-MB-20
6

1.4 Starting motor work principle(2)
Startup control principle
Armature powered(rotate)
Start forbidden relay Start electromagnetics
switch push startup gear to the left
gear left into flywheel shell Crank rotated Engine started
stop control principle
A. power off forbidden relay Electromagnetics switch reset by the spring Coil power off
gear go to the right and disconnect to the fly wheel Motor shutdown
B. Motor work(velocity get to120-400rpm) To protect the motor ,the gear go to the
right and disconnect to the fly wheel
Start switch
7
1.5 preheated circuitry- Inlet air preheated

（ECU）the temp of cold water and the heat them, inlet air and fuel also
Engine
controller
Control signal
Inlet air heat
8

1.5 preheated circuitry-fuel heat
The temp of fuel is 0±4℃,it will be heated

by the system, and it will be stop at the
temp of 15±4℃
Power on
24V
gnd
9

1.6 speed control
Main controller assemble the signal of the accelerator、schema of the display 、pilot，give
the control signal of engine speed by CAN Bus, so then engine controller to adjust the rank
level to change the velocity of the engine
10

1.7 power off circuitry
Power
on
KC-MB-20
11
1.7 power off delay circuitry
Power
on
KC-MB-20
12

1.8 air condition circuitry
13

1.9 Fuse box
14

1.10 Display Electric control schematic principle
15

1.10 Electric control schematic principle
16

1.10 Body Harness schematic principle
17
二、 principle of electric system component
2.1 sensor
1、pressure sensor(voltage）
KPP：0 Mp-----0.5V
50Mp----4.5V
1.1、 pump pressure sensor 1.2、 pilot pressure sensor
operated Relation between pressure(P) and voltage(E)operated Relation between pressure(P) and voltage(E)
18
2.1 sensor
2、fuel level gauge（resistance）
KPP ：Max resistance---88±3 Ω 0%
Min resistance --（1-5）Ω 100%
3、hydraulic oil temp sensor（current）

KPP：
level gauge：-25℃~100℃；
out signal：4mA~20 mA
4mA--25℃，
20 mA--100℃；
Work voltage：24VDc；
4、fuel filer pressure sensor
19
2.2 proportional valve

Switch valve
There are six pieces valve(switch and
Key Performance Parameter : resistance 34 Ω proportional),and there are another two
Proportional valve proportional pieces at the pump, they can
adjust the flow of the pump.K3v112
Key Performance Parameter, frequency：80HZ
pump curse like this:
resistance 17.5 Ω
20
2.3 generator
①Alternator
. Alternator include coil SC、FC，diode-D,T1,T2，ZD and resistance
.Port B connect to B by path: B->R->RF->(R)->(R1) .
21
2.3 generator
When the battery relay is in the ON state, The transistor base is energized, The collector and emitter are
conduction, The excitation coil is grounded
At the begin ,current go to the coil FC, and then The rotor rotates，The stator coil generates alternating
current
There is a current through the coil, The voltage generated by the coil is increased, Excitation current
increases, The rotor voltage is further increased Charge the battery
voltage stabilizer
The excitation voltage is greater than the set value
The transistor is turned off
22
2.3 generator
Repeat the above procedure, The voltage generated by the rotor is reduced, Stable system voltage
The engine comes with an alternator 24V,50A

the alternator has an Silicon rectifier and regulator ，L: Neutral line，B:Power output，E: ground
wire. The generator does not have a voltage output, L is 0V. Charging alarm lighted. The battery
supplies power to the generator. The supply current becomes an excitation current.
So that the generator can generate electricity quickly. generate electricity。Voltage of L is 28.7V.
Charging alarm is shut.
23
2.4 battery
role:
24V power
like an accumulate, there two 12v batteries in series 20T:there are
two 12V,120AH batteries in series 30T:there are two 12V,150AH
batteries in series.
1. engine starting, supplied power for motor and the electric
system 2.generator don't work or voltage is low , the battery
supply power for system.
3.stabilize the system voltage, protect electric parts
notes:
your battery is maintenance-free , and just to check the battery work status from the
battery windows.
white: there are need to change the battery black: you need to charge the battery
green: the battery is ok
generator charge them auto, when starting the system, the voltage is 28.5V
24
二、principle of electric system component
2.4 battery
6qw-120:120t
6:there are 6 cell(every one 2V)

Q: lead accumulator used in the car
w: maintence-free
120:rated capacity
t: charge-discharge number
Ah: Short for unit name of capacity of battery (amper/hour),Capacity (Ah)=I*t, I current, t
time。
CAA： starting current(Temp:-17.8--28.9), It can get the valve of current in some case，
the battery supplies current valve，when the battery is full and the voltage decrease 7.2V
in 30S. cold starting current is total current.
note: the fist starting is fail ,you need to wait for 15s to start the second one. the second
starting is fail ,you need to wait 15m， if three are fail ,you must to diagnose the
machine.
25
2.5 Battery relay
Key switch control the delay on or off. To turn on or off the power supply，in this way, it
Increase system security.
working principle
The relay has four wiring points，Winding and fork. the coil is energized and the fork is
pulled together. The system is powered on. Relay contacts disconnect. Circuit can be
specified as closed Directly measure the output resistance
26
2.5 battery delay
To check the delay:
1、short the circuit of the delay

2、measure the resistance of the delay
The valve of the resistance :
55Ω-OK
27
2.6 throttle knob
Principle:
It like a sliding resistance，there
are three wires :red（50），yellow（0）
Blue(506),It`s output is 0-5V.
Diagnosis:
Twist the knob , measure the voltage
of 506.
Resistance：the resistance between 0

and 50 is 50K Ω
28
2.6 throttle knob

voltage：5V
resistance：5K
OperatingVoltage:5V
Standard resistance:5K Ω
Resistance gauge :0.18KΩ-0.2K Ω
Percentage of resistance change:3.6%-4.0%
PER
voltage
29
2.7 CAN bus and components
The communication base on the CAN bus，All the parts is connected by CAN bus-
Display，Main controller, Engine control 、Air-condition controller , Power supplier
and so on. All of them share the message by bus, so there are an simply interactive.
EGR controller
Main controller
KC-MB-20
30
2.7 parts in Can bus circuit-power management

circuit-power management：
1）The box integrate the fuse box and delay ,and manage it by can bus.
2）the output port is given the overload protection，and we can get the
work station of the output by CAN bus. Shown on the display, so it is very
easy to diagnose.
3） Electrical current ≤5A, the port is driven by MOS， Electrical current
＞5A, the port is driven by delay，this way is very reliability 。
4）The Max current is 30A each circuit，and the total Max current is 200A.
5）It control the electric system with main control and display by CAN bus.
6）the box can clamp the voltage at the in and out port. Decrease surge,so
it can protection the circuit.
31
2.7 parts in Can bus circuit-power management
circuit-power management drawing
32
2.7 parts in Can bus circuit-display
Display：
1）Give information of power-management, It
can check the system easy and fault diagnose.
3）Enlarge memory from 8K to 32K
5）the showing is more humanistic
Display
33
三、 Control principle of excavator

3.1control chart
Engine-pump compound control
Pump control
Valve control
Control system Engine pre-heat/over heat alarm
Oil low level alarm
Auto idling / Speed increase
GPS function

3.2 control chart
35

3.3 Pump control
Main controller supplies the speed signal according the gear, engine
controller test the signal , there are no signal 1 sec, the speed decrease
100spm，there are no signal for 5sec， the engine will come into idling.
The pump adjust the output according the power curve by PID，so the
engine gain the economy diesel consumption.
model
Current
Gear- Current unitary Valve of
gear current Current Current PID pump
Current
Initial torque Torque
PID
Torque
feedback
36
三、Control principle of excavator

3.3Pump control
Pump power control
1.The controller adjusts the

displacement of the pump
according to the pilot pressure.
2.The controller monitors the
pressure change and adjusts the
displacement by PQ curve.
3.The controller compares the
constant power curve and
selects the small value output.
37

3.3pump control
there are three electromagnetic valves.

one is used to control ppc, and one is to
control high and low speed changing. the
last one is to control pump
38

3.3pump control
According to the matching relationship

between the engine and the pump, gear
setted point, torque PID and stall feed
forward to real-time, and then by current PID
to control torque output
controller adjust the pump pressure as PQ curve by current，

another ,there an especial case, the engine can get pressure of air to
adjust the torque. H work model， the pump give high pressure ,then the
pump control the power of pump output closely.
39

3.3pump control
40

3.3pump control
41

3.4Engine-pump compound control
42

Function:
operator can select work model , so that the give the
required engine power and pump torque.
there are four work model: S, L, B, H, use these
model, you need to select relative button.
the pump can consume all the power from the engine, also
this process is defined by engine speed, throttle, pump work
model.
43

Function:
operator can select work model ,
so that the give the required
engine power and pump torque.
there are four work model: S, L,
B, H, use these model, you need
to select relative button.
the pump can consume all the
power from the engine, also this
process is defined by engine
speed, throttle, pump work
model.
model: S, L, B, H
output percentage of work model
in the four work model.

Engine speed follow the
anchor in the pq curve
44

four work models
in the four work model. engine speed follow the anchor in the pq curve
the pump load and pressure become higher, engine speed will down. but main will keep the engine work
around the anchor.so the engine will decrease output, when the pump load go small and pressure
become small. The engine will increase.
45

3.5 Valve control
46

3.5 Valve
Bucket confluence
Speed switch
Pilot lock
option
option
option
47

3.5 valve control
1. Bucket flow control
function
. Control the pump base on bucket pilot
Process
Main controller get the bucket digging and dump pilot information from the joystick, then it control the
confluence core
48

3.5Valve control
Swing priority
Function:
flow go through Arm core ,go to the swing motor fist.
Process
Main controller get the signals from front pump, arm and swing, then the system limits the flow of the arm parallel oil
follow, swing motor get the pump power, so there are no influence on the swing control when arm digging
requirement
Swing pressure sensor give the signal
Arm pressure sensor give the signal
49
3.5 Valve control
Boom priority ,condition: Boom go to moving,

the Boom get the pressure and current fist
50
Engine starting protection
Starting protection function

The port Engine Start Signal is on, the main controller give the Engine Start output ,and
then ePower output signal is set ON(1)
Engine Start output will keep 10sec.
The counter will collect the number of starting, the number is 3 or big then 3, the engine
starting output will be limited or 30sec. The speed of engine is higher 650rpm, the
number will be reset
51
3.7 engine oil pressure protection
Low Engine oil pressure protection

The delay of engine oil pressure is set off for low pressure , the speed is higher 800 rpm,
the speed of engine is limited fist gear.
52
3.8 GPS
GPS communication function

Lock the machine follow the GPS signal
1 class: control current is set 0A of the main pump, it is the min current of pump
2class: the speed of engine is set idling max speed.
53
54

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SANY HEAVY MACHINE CO.

SY215C9M3KS principle and application of electric system

SANY HEAVY MACHINE CO.,LTD

R&D Academy of Mid-Excavator Co.

Composer ：Yunfei Xiong Check： Approve：

一、 electric system and circuitry

二、principle and structure of main parts

三、control theory of excavator

1、 electric system and circuitry

Engine Controller ECM

1、electric system and circuitry

1.2 electric circuitry （1）

battery Starting mtor

1、electric system and circuitry

1、 electric system and circuitry

1、 electric system and circuitry

Power delay output

1、 electric system and circuitry

1、 electric system and circuitry

1.5 preheated circuitry- Inlet air preheated

Inlet air heat

1、electric system and circuitry

The temp of fuel is 0±4℃,it will be heated

1、 electric system and circuitry

1、electric system and circuitry

1、electric system and circuitry

1.7 power off delay circuitry

1、electric system and circuitry

1、electric system and circuitry

1、 electric system and circuitry

1、electric system and circuitry

1、electric system and circuitry

二、 principle of electric system component

二、 principle of electric system component

3、hydraulic oil temp sensor（current）

二、 principle of electric system component

2.2 proportional valve

二、 principle of electric system component

二、 principle of electric system component

The transistor is turned off

二、 principle of electric system component

The engine comes with an alternator 24V,50A

二、 principle of electric system component

二、principle of electric system component

6:there are 6 cell(every one 2V)

二、principle of electric system component

2.5 Battery relay

二、principle of electric system component

2.5 battery delay

To check the delay:

1、short the circuit of the delay

二、principle of electric system component

2.6 throttle knob

Resistance：the resistance between 0

二、 principle of electric system component

2.6 throttle knob

二、principle of electric system component

2.7 CAN bus and components

二、principle of electric system component

2.7 parts in Can bus circuit-power management

二、principle of electric system component

2.7 parts in Can bus circuit-power management

circuit-power management drawing

二、principle of electric system component