s1x generic speed control system description - danfossfiles.danfoss.com/documents/s1x generic speed...

MAKING MODERN LIVING POSSIBLE

System Description

S1X Generic Speed ControlSystem

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Revision history Table of revisions

Date Changed Rev

August 2015 Danfoss Layout 0600

September 2004 E

October 2001 D

System Description S1X Generic Speed Control System

2 BLN-96-0401-E • Rev 0600 • August 2015

OverviewDescription..........................................................................................................................................................................................4Features................................................................................................................................................................................................4System Components....................................................................................................................................................................... 4

S1X MicrocomputerLED Overview.....................................................................................................................................................................................5

System Block DiagramSystem Block Diagram.................................................................................................................................................................... 6

Theory of OperationGeneral................................................................................................................................................................................................. 7Modes for Travel Speed Setpoint............................................................................................................................................... 7Non Automotive Mode...................................................................................................................................................................7

FNR Set............................................................................................................................................................................................7Automotive Mode............................................................................................................................................................................ 7

RPM Set...........................................................................................................................................................................................7FNR RPM......................................................................................................................................................................................... 8

Drive Direction...................................................................................................................................................................................8Gear and Ramp Selection.............................................................................................................................................................. 8All Range Antistall Control............................................................................................................................................................ 9Speed Calculation Modes..............................................................................................................................................................9

SIMPLE_NORMI_MODE : 0........................................................................................................................................................9SIMPLE_CALC_MODE : 1...........................................................................................................................................................9DIESEL_MODE : 2.........................................................................................................................................................................9DRUM_1_MODE : 3..................................................................................................................................................................... 9DRUM_2_MODE : 4.....................................................................................................................................................................9DRUM_1_DIESEL_MODE : 5.................................................................................................................................................. 10DRUM_2_DIESEL_MODE : 6.................................................................................................................................................. 10

Constant Speed Drive...................................................................................................................................................................10CSD Open Loop......................................................................................................................................................................... 10CSD Closed Loop.......................................................................................................................................................................10CSD Open Loop and Closed Loop...................................................................................................................................... 10

Special Roller Features................................................................................................................................................................. 10Vibration ON/OFF Control..................................................................................................................................................... 10Waterflow Control.................................................................................................................................................................... 10

System Connection DiagramSystem Connection Diagram.....................................................................................................................................................11


Contents

BLN-96-0401-E • Rev 0600 • August 2015 3

Description

The Danfoss Speed Control System combines the capabilities of modern digital electronics with theworldwide proven Danfoss axial piston pump series and bent axis motor series to enhance machineperformance.

The microprocessor-based S1X provides flexibility and is designed for the future. The control conceptcontains several individual selectable functions such as: ramp drive control, antistall, CSD, brake andspeed calculation. Additional to these standard drive modules special roller features like water controland vibration ON/OFF are implemented.

With easy-to change parameters (in software) it is possible to make an individual setup for different kindof machine types.

Features

• Environmentally hardened for mobile applications

• Supply voltage 12 V DC or 24 V DC

• Proportional Valve or EDC

• Analog direction or digital direction

• Software changes without hardware operations

• Wide range of system configuration options

• Easy to service

• Flexible ramp module

• 4 Software gears with different ramps

• Constant speed drive

• Antistall function

• 7 different kind of speed calculations

• Vibration ON/OFF control

• Waterflow control

• CAN J1939 connection

• Different Brake functions

System Components

• S1X-46-G2 Amp K164 S1X Electronic CAN

• Manual Graphic Interface, english


Overview

4 BLN-96-0401-E • Rev 0600 • August 2015

LED Overview

1 14

15 28

29 42

1 S1X

2 Mounting slots

3 AMP connector

4 Diagnostic LED red Error check

(STATUS) Lights up if an error is detected.

5 Diagnostic LED yellow Software check

(MODE) Flashes with approx. 0.5Hz (slow) if the program is running fine.

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.edom putes ni fi gnihsalf oN

6 Diagnostic LED green 5V DC internal

(SYSTEM) Lights up if 5VDC internal is O.K.

7 Diagnostic LED green Battery after ignition switch

(POWER) Lights up if the battery voltage is connected after ignition.

32 1

4

5

67

123,5

8,58,5

10,5

10

10

9

174

155

55

60,2555,75

POWER

SYSTEM

MODE

STATUS

S01697b


S1X Microcomputer

BLN-96-0401-E • Rev 0600 • August 2015 5

System Block Diagram

CSDmodule

Ramp &State

machine

Rampcontrol

logic

Speeddependent

release(Vibration)

Status outputramp control

Antistall switch

A

D

A

D

Timer

Timer

Timer

DI

DI

Batt.12VDC

+ -

Emergency stopV

t

Voltage regulator

Cycle controlmodule(Water)

Diesel RPMsetup

Cyclerelay

(Water)A

D

F

10A

Speedcalculation

module

RS232interface

for SUSMIC-DIA 1 to 4

Drive mode switchFNR Set/RPM Set

Setpointcalculation

logic

Antistallmodule

Engine Rpm

Wheel Rpm (Option)

Wheel Rpm (Option)

Hydrostaticgear switch1st/2nd gear(Option)

DI

Speeddependent

module(Vibration)

Ramp controlON/OFF

CAN Bus

S01718b

Rv

R v

cw

Speed limitationsetpointpotentiometer

Rv

R v

cw

Control handleDrive setpointAnalog FNR

Automatic/Standbybrake switch ordigital FNRReverse switch(Option)

Rv

R v

cw

Auxiliarysetpointpotentiometer

Engine

PPU Diesel RPM

EIF

DI

DI


System Block Diagram

6 BLN-96-0401-E • Rev 0600 • August 2015

General

CSDmodule

Ramp &State

machine

Timer

Timer

Engine

PPU Diesel RPM

Drive mode switchFNR Set/RPM Set

FNRSetpoint

calculationlogic

Antistallmodule

Engine Rpm

Wheel Rpm(Option)

Motorcurve

(Option)

(Option, if one motor system)

Control handleDrive setpointMCH43BMS100

FNRto engine

setointSetpoint

generation

S01823

Modes for Travel Speed Setpoint

The system can work with three different setpoint modes. With a drive mode switch it is possible to selectbetween a non automotive mode and an automotive mode.

Non Automotive Mode

FNR Set

This is the basic mode for the application.

The drive setpoint depends on the setting of the control handle and the speed limitation potentiometer.The speed limitation potentiometer sets the max. output current to the drive pump in order to give theoperator of the machine the best possible range and resolution over the hand lever. The bidirectionalmobile control handle generates the drive direction signal.

Typical application is vehicle with a diesel engine running full power to fulfil auxiliary functions likecutting, planning or harvesting. In that case the speed of the vehicle is set by the speed setpoint lever(FNR).

Automotive Mode

There are two different automotive modes available:

RPM Set

This mode is the classic automotive mode, where the drive setpoint is generated by the engine rpm. Themaximum speed can be limited through the speed limitation potentiometer. Typical example for this isthe transport drive in higher speed, where no external functions are active. A droop of the enginereduces by principle the setpoint of the pump.


Theory of Operation

BLN-96-0401-E • Rev 0600 • August 2015 7

FNR RPM

The setpoint of the control handle generates a virtual setpoint of the engine. The engine uses amechanical link between the handle or pedal. In case of droop, an antistall module can compare theengine speed setpoint through the control handle and the actual speed of the engine. The maximumspeed can be limited through the speed limitation potentiometer.

Drive Direction

The drive direction signal is given by the bidirectional mobile control handle (FNR). If a direction switch isrequired, the switch must work like a control handle. A simple digital direction switch may be usedinstead of the above. No neutral position is required. An analog signal of 2.5V at the control handle inputis defined as neutral, 3.5V at the control handle input are defined as forward and 1.5V at the controlhandle input are defined as reverse.

Gear and Ramp Selection

For each hydrostatic gear, the ramp times for acceleration and deceleration can be set individually.

Ramp Parameters

S01748_11e

Acceleration Deceleration

Ramp Up

Ramp T1 Up

Ramp T1 Down

Ramp Down

Ramp PT1 TAU Down

Ramp PT1 TAU Up

As shown above the ramps have an adjustable exponent, linear and PT1 delay part. These parts can beset different for acceleration and deceleration.


Theory of Operation

8 BLN-96-0401-E • Rev 0600 • August 2015

All Range Antistall Control

The antistall module is to be activated if necessary. If active, it starts working below a predefined dieselRPM limit, or above a predefined engine load value EEC2 (CAN). It controls the output current to pumpwithout overloading diesel engine. Depending on the droop and the control parameters the swashplateangle is descreased.

Transient Response of the Antistall Controller

0 t

ΙΙ100%

RPM

0 t S01748_08e

Speed Calculation Modes

SIMPLE_NORMI_MODE : 0

In this mode, a simple speed calculation is done. In the setup, there are maximum values for speed ineach gear. The vehicle speed is dependent on setpoint to max. speed in each gear. No PPU is necessary,no motor data or gear ratio data are necessary. No constant speed possible, speed setpoint is the same asactual speed.

SIMPLE_CALC_MODE : 1

In this mode, the calculation of speed works with motor data and ratios. The pump volume and the wheeldiameter gives the speed setpoint. No constant speed possible, speed setpoint is the same as actualspeed.

DIESEL_MODE : 2

In this mode, the Diesel RPM is in the calculation. All other data works as the same, as in 1.Constant speedis without effect, antistall is possible.

DRUM_1_MODE : 3

The real vehicle speed in this mode is calculated with the wheel motor RPM. The gear ratio and the wheeldiameter belong to the calculation of the real vehicle speed. The speed setpoint is calculated from enginerpm and lever position. CSD (Constant Speed Drive) compares the speed of the setpoint with the actualvalue by the wheel PPU. The antistall controller output is the setpoint for CSD.

DRUM_2_MODE : 4

Same logic than in DRUM_1_MODE. In this mode, there are 2 PPUs for the speed to calculate the correctspeed in curves. The vehicle speed is the average of both speeds.


Theory of Operation

BLN-96-0401-E • Rev 0600 • August 2015 9

DRUM_1_DIESEL_MODE : 5

For constant speed drive, it is necessary, to use a setpoint for speed, and an actual speed to compare in aclosed loop system. The setpoint works with mode 2, the actual speed works with mode 3. The CSDspeed setpoint is dependent on the diesel engine. The antistall controller output is the setpoint for CSD.

DRUM_2_DIESEL_MODE : 6

For constant speed drive, it is necessary, to use a setpoint for speed, and an actual speed to compare in aclosed loop system. The setpoint works with mode 2, the actual speed works with mode 4. The CSDspeed setpoint is dependent on the diesel engine. The antistall controller output is the setpoint for CSD.

Constant Speed Drive

The CSD function can be activated independent or additional to the antistall function. The CSD functioncan work in three different modes.

CSD Open Loop

This constant speed mode is possible if an engine PPU is installed. A reduction of an engine rpm could beused as an increased displacement for the pump.

Possible speed mode: DIESEL_MODE

CSD Closed Loop

The closed loop mode needs a speed detection. This is done by one or two wheel PPU´s. The speed iscalculated with the number of pulses per revolution, the gear ratios and the wheel diameters. Thismeasured vehicle speed can be compared with a speed setpoint and controlled by a closed loop CSDfunction.

Possible speed mode: DRUM_1_MODE

DRUM_2_MODE

DRUM_1_DIESEL_MODE

DRUM_2_DIESEL_MODE

CSD Open Loop and Closed Loop

This mode needs a measured speed detection and a engine speed detection. The closed loop functionmust compensate less difference.

Possible speed mode: DRUM_1_DIESEL_MODE,

DRUM_2_DIESEL_MODE.

Special Roller Features

Vibration ON/OFF Control

The ON/OFF control depends on the actual vehicle speed. Parameters for start at low speed and stop athigh speed can be set individually for each gear.

Waterflow Control

The ON/OFF time is calculated depending on potentiometer setpoint and actual vehicle speed.


Theory of Operation

10 BLN-96-0401-E • Rev 0600 • August 2015

System Connection Diagram

Gear switch (Option)

A

B

C

D

EDC Propel pump

Proportional valves(Option)

FNR_SET/RPM_SET (FNR_RPM)Drive mode switch (Option)

Status ramp control

CAN Bus Terminals

Vibro output (Option)

VORWÄRTSFORWARD

RÜCKWÄRTSREVERSE

S1Emergency stop

PPU Diesel RPM

PPU front left

PPU front right

Contact capability min. 6A

Malting fuse 10A

Max. 3,25A each pin

Optional not installed

Position shown : 1st/2nd gear

Alternate FB channel configure by software

Position shown : FNR_SET

= Option

*

512791a

1

2

3

Position shown: Antistall OFF4

5

6

Optional supplied by ASC

Position shown: Ramp control ON Used as FNR forward switch position shown: Neutral

7

8

9 Used as brake switch position shown: Standby brake Used as FNR reverse switch position shown: Neutral

10

11

! Important use ONLY ONE

*

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

AMP connector, 42pin

Sensor (-)

Digital Input 0

Digital Input 1 *

Digital Input 2

Digital Input 3 *

High Current 0 (+)

High Current 1 (+)

High Current 0 FB (-) *


Low Current 0 FB (-)

Low Current 1 FB (-) *

nc

RS232 Ground

Sensor (+)

Battery (-)

PPU Input 0

PPU Input 1

PPU Input 2

PPU Input 3 *

RS232 TxD

RS232 RxD

High Current 4 (+) *




High Current 2 (+)


Battery (+)

Battery (-)

nc

Analog Input 0

Analog Input 1



nc

nc

CAN High

CAN Low

CAN Shield

Digital Output 0

Digital Output 1 *

Battery (+)

Ramp control switch orDigital FNR forward switch

1

F1

2

Batt.12V DC

+ -

TerminalsBatt. (-)

TerminalsBatt. (+)

3

Automatic/Standby switch orDigital FNR reverse switch

9

Rv

R v

cwAuxiliary setpoint potentiometer (Option)

TerminalsSensor (+)

Rv

R v

cwInch setpoint potentiometer

Rv

R v

cw

Control handledrive setpoint

TerminalsSensor (-)

Rv

R v

cwSpeed limit setpoint potentiometer

Water pump(Option)

SUB-D Diagnostic connector(female), 9pin

123456789

10

Antistall switch

!11

3

!11

5 7

5 7

8

4

6


System Connection Diagram

BLN-96-0401-E • Rev 0600 • August 2015 11

Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic andelectronic components. We specialize in providing state-of-the-art technology and solutionsthat excel in the harsh operating conditions of the mobile off-highway market. Building onour extensive applications expertise, we work closely with our customers to ensureexceptional performance for a broad range of off-highway vehicles.

We help OEMs around the world speed up system development, reduce costs and bringvehicles to market faster.

Danfoss – Your Strongest Partner in Mobile Hydraulics.

Go to www.powersolutions.danfoss.com for further product information.

Wherever off-highway vehicles are at work, so is Danfoss. We offer expert worldwide supportfor our customers, ensuring the best possible solutions for outstanding performance. Andwith an extensive network of Global Service Partners, we also provide comprehensive globalservice for all of our components.

Please contact the Danfoss Power Solution representative nearest you.

Local address:

Danfoss Power Solutions GmbH & Co. OHGKrokamp 35D-24539 Neumünster, GermanyPhone: +49 4321 871 0

Danfoss Power Solutions ApSNordborgvej 81DK-6430 Nordborg, DenmarkPhone: +45 7488 2222

Danfoss Power Solutions (US) Company2800 East 13th StreetAmes, IA 50010, USAPhone: +1 515 239 6000

Danfoss Power Solutions Trading(Shanghai) Co., Ltd.Building #22, No. 1000 Jin Hai RdJin Qiao, Pudong New DistrictShanghai, China 201206Phone: +86 21 3418 5200

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies toproducts already on order provided that such alterations can be made without changes being necessary in specifications already agreed.All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

BLN-96-0401-E • Rev 0600 • August 2015 www.danfoss.com © Danfoss A/S, 2015

Products we offer:

• Bent Axis Motors

• Closed Circuit Axial PistonPumps and Motors

• Displays

• Electrohydraulic PowerSteering

• Electrohydraulics

• Hydraulic Power Steering

• Integrated Systems

• Joysticks and ControlHandles

• Microcontrollers andSoftware

• Open Circuit Axial PistonPumps

• Orbital Motors

• PLUS+1® GUIDE

• Proportional Valves

• Sensors

• Steering

• Transit Mixer Drives

Comatrolwww.comatrol.com

Schwarzmüller-Inverterwww.schwarzmueller-inverter.com

Turolla www.turollaocg.com

Hydro-Gearwww.hydro-gear.com

Daikin-Sauer-Danfosswww.daikin-sauer-danfoss.com

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