H1-Automotive-Control

H1-Automotive-Control
AGENDA

• Introduction
– NFPE vs AC Pump

• Automotive-Systems AC-1 & AC-2

• Outline & Connection-Overview

• Speed- and Angle-Sensor

• Innovation & Advantages

• Product Development Strategies

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 H1-Automotive-Control
Introduction: AC vs NFPE
AC NFPE

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H1-Automotive-Control
Automotive-System-1.x (AC-1)
• 4 Selectable Transmission-Modes
• Automotive
• Creep-Automotive

• Hydrostatic-Braking (Inching)
• Engine Over-Speed Protection
• HST-Motor Over-Speed-Protection (Pump or Motor)
• Constant-Speed-Control (RPM)
• Adjustable Drive-Control
• Parking-Brake or Backup-Alarm
• CAN-Interface
• Engine-Controller, PLUS1-Devices, Service & Diagnosis

Know-How in Motion™
H1-Automotive-Control
Automotive-System-2.x (AC-2)
• 4 Selectable Transmission-Modes
• Automotive
• Creep-Automotive
• None-Automotive

• Hydrostatic-Braking (Inching)
• Engine Over Speed Protection
• HST-Motor Over-Speed-Protection (Pump or Motor)
• Pump-Angle-Control
• Constant-Speed-Control (Flow or RPM)
• Anti-Stall-Control (RPM)
• Adjustable Drive-Control
• Parking-Brake or Backup-Alarm
• CAN-Interface
• J1939-Engine-Interface, PLUS1-Devices, Service & Diagnosis

Know-How in Motion™
H1-Automotive-Control
Running or Pipeline Applications

• Wheel Loader • Dumper

– PV: H1-P45 & H1-P078 w/ AC-1 – PV: H1-P78 w/ AC-1
• Telescopic Handler • Airport luggage vehicle
– PV: H1-P45 w/ AC-1 – PV: H1-P78 w/ AC-1
– PV: H1-P78 w/ AC-2

• Forklift • PTR Roller

– PV: H1-P78 w/ AC-2 – PV: H1-P78 w/ AC-1
• Pick a back forklift
– PV: H1-P45 w/ AC-2

• Municipal vehicle
– PV: H1-P45 w/ AC-2

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H1-Automotive-Control
AGENDA

• Introduction
– NFPE vs AC Pump

• Automotive-Systems AC-1 & AC-2

• Outline & Connection-Overview

• Speed- and Angle-Sensor

• Innovation & Advantages

• Product Development Strategies

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H1-Automotive-Control
Outline

Transparent
Plastic-Plug
Plastic-
Proportional
Housing
Solenoid

Grey-Cast-
Iron

Control-Override- Angle-
Solenoid Sensor
Know-How in Motion™
H1-Automotive-Control
Connection-Overview: CCx-Connectors
Customer-
Connector 1
Customer-
Connector 2

Customer Connectors have to be wired

Know-How in Motion™
by the customer
 H1-Automotive-Control
Connection-Overview: Pump-Connectors

CAN- Pressure- Pump- Speed-

Bus Transducer Valves Sensor
Blind-Connector
Connectors are wired
assembled
by Sauer-Danfoss
by Sauer-Danfoss

Know-How in Motion™
H1-Automotive-Control
AGENDA
• Introduction
– NFPE vs AC Pump
– Innovations & Advantages
– Key Environmental

• Automotive-Systems AC-1 & AC-2

• Outline & Connection-Overview

• Speed- and Angle-Sensor

• Innovation & Advantages

• Product Development Strategies

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H1-Automotive-Control
H1-Speed-Sensor

• Customized design for H1-Pumps (H1-AC only) and Motors

• Plastic molded housing w/ metal flange
• Extended functionality / Reduced variation
• 2 Speed signal & 1 Direction signal & Case temperature
• Works in different electrical modes PNP and NPN
• Wire fault detection, Reverse polarity & over voltage protection

• ASIC (Application Specific Integrated circuit)

• Reduced number of components & Improved reliability

• Powder Metal Target Ring

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H1-Automotive-Control
H1-Angle-Sensor

Sensor

Magnet

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H1-Automotive-Control
H1-Angle-Sensor

• Customized design for H1-Pumps (H1-AC only)

• Plastic molded housing w/ metal inserts for bolts

• Magnet carrier mounted to swash-plate

• AMR-technology (Anisotropic Magneto Resistive)

• Measurement of field direction in field saturation
• Not sensitive to field strength changes/degradation

• Functionality
• 2 swash angle signal (analog)
• Wire fault detection, Reverse polarity & over voltage

protection

• ASIC (Application Specific Integrated circuit)

• Reduced number of components & Improved reliability

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H1-Automotive-Control
AGENDA

• Introduction
– NFPE vs AC Pump

• Automotive-Systems AC-1 & AC-2

• Outline & Connection-Overview

• Speed- and Angle-Sensor

• Innovation & Advantages

• Product Development Strategies

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H1-Automotive-Control
Innovations

• Mechatronic As Part Of Transmission-Pump

– Electronic Swash-Plate-Angle-Sensing
– RPM-Measurement integrated
– Control-Over-Ride (COR)

• External Safety Certification for SIL-2 (IEC 61508)

– PLUS+1 Software Tool-Chain
– Complete Automotive Controller

• Simulation-Based Development Strategy

• Vibration Protection Level of 500g

• 100% Lead-Free and RoHS-Compliance (2002/95/EG)

• Assembling and Programming inside HST-Production-Flow

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H1-Automotive-Control
Advantages

• No Customer End-Of-Line Setup For Transmission

– Extended factory tests and program cycles
– Plug and Perform <<< 100% Compatibility >>>

• Generic Application Strategy

+
– Flexible applicable w/ high performance
– Prepared for future enhancement

• Less Assembly-Effort & -Cost

– Reduced controller space
– Mechanical interface 100% equal to NFPE-, EDC- and FNR-Control

• Application Prepared For Simulink-Integration

– Dynamic Vehicle Simulation

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H1-Automotive-Control
AGENDA

• Introduction
– NFPE vs AC Pump
– Innovations & Advantages
– Key Environmental

• Automotive-Systems AC-1 & AC-2

• Outline & Connection-Overview

• Speed- and Angle-Sensor

• Product Development Strategies

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H1-Automotive-Control
Safety Strategy
• Controller:
– Intelligent Watch-Dog
– Internal Analog-Injection-Channel & Temperature-
Measurement
– Redundant Reference-Voltage-Measurement (2,5V)
– Redundancy for critical inputs
– Redundant Shut-Off for critical outputs
– FLASH- and RAM-Memory Checks

• Control:
– Control Override Valve Option

• Certifiable for SIL-2 according IEC 61508

– H1-Automotive-Control (Part 1-3) (Cost: € 30.000.-)
– PLUS+1-Software-Tool (Part3) (Cost: € 50.000.-)
Know-How in Motion™
H1-Automotive-Control
Design Strategy

• HW-Design:
– PCB is vibration absorbed mounted and glued (RAPID Y16)
– No electronic- components inside gluing-material
– Components for temperatures up to 125°C
– PCB is separately coated (HUMISEAL 1H2O)
– Housing-Material (GRIVORY HTV-5H1)

• SW-Design:
– Tool-Supported requirement and specification tracking
– Tool-Supported application-development and -testing
– Proven Kernel usage
– Diverse programming of DSP and PIC

Know-How in Motion™
H1-Automotive-Control
Qualification Strategy

• HW-Qualification:
– PVPR (Product Verification Plan and Report)
• Derived from GS-0027 and HPP-187
– Hydrostatic Test-Stand-Validation
– Highly-Accelerated-Lifecycle-Test (HALT) – Cycles
• Thermal Step Stress
• Rapid Thermal Transition
• Combined Environment
– 100-Day-Cycle-Test
• Min. 1000 positive temperature-cycles
• Temperature-Range -50°C to +125°C
– 12-Month Field-Test w/ Pilot-Customer

Know-How in Motion™
H1-Automotive-Control
Qualification Strategy

• SW-Qualification:
– TUEV-Audit of whole implementation & documentation
– Development & Verification via Hardware-In-The-Loop
– Automated Function-Testing
• XLS-Vector-Tool of PLUS+1
– Automated Integration-Testing
• LabVIEW/Teststand from National Instruments

• System-Qualification:
– 12-Month Field-Test-Phase
• Pilot-Customer: KRAMER, BELOS, MOFFET/KOOI, Bergmann

Know-How in Motion™
H1-Automotive-Control

Know-How in Motion™