Danfoss Automotive on PLUS 1 User guide
Technical Information
Automotive on PLUS+1® for MC-024
powersolutions.danfoss.com
Technical Information
Automotive on PLUS+1® for MC-024
Revision history |
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Aug 2016 |
Updated order numbers |
0202 |
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Dec 2015 |
Converted to DITA CMS and Danfoss layout |
0201 |
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Mar 2012 |
Typos |
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Dec 2011 |
First edition |
0101 |
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2 | © Danfoss | Aug 2016 |
L1120636 | 0202 |
Technical Information |
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Automotive on PLUS+1® for MC-024 |
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Contents |
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General Information |
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General Description, Electric and Electronics......................................................................................................................... |
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Automotive-on PLUS+1 (AoP+1), system description................................................................................................... |
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Automotive on PLUS+1 advanced functions.................................................................................................................... |
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Required Controller.................................................................................................................................................................... |
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Mode Types........................................................................................................................................................................................ |
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Hydrostatic propel methods................................................................................................................................................... |
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Automotive Mode....................................................................................................................................................................... |
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Non-Automotive Mode............................................................................................................................................................. |
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Creep-Automotive Mode......................................................................................................................................................... |
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System modes and selection........................................................................................................................................................ |
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Application Function.................................................................................................................................................................... |
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General customer / sensor requirements.............................................................................................................................. |
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Drive / Creep / Joystick / Rocker and inch pedal........................................................................................................... |
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Pressure inch sensor................................................................................................................................................................ |
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Mode switch A........................................................................................................................................................................... |
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Mode switch B............................................................................................................................................................................ |
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HST / Motor / PPU..................................................................................................................................................................... |
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Pump displacement................................................................................................................................................................. |
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Motor displacement and Brake Pressure defeat (BPD) .............................................................................................. |
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Digital outputs 1, 2, 3, 4.......................................................................................................................................................... |
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Automotive Control connection diagram............................................................................................................................. |
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Technical Specifications |
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Input signals: Power supply – Battery.................................................................................................................................... |
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Input signals: Forward-Neutral-Reverse (FNR) switch...................................................................................................... |
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Input signals: Mode switch......................................................................................................................................................... |
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Input signals: Inch pedal.............................................................................................................................................................. |
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Input signals: Drive/Creep pedal, Joystick and Rocker pedal ....................................................................................... |
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Input signals: Motor speed sensor .......................................................................................................................................... |
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Output signals: Pump displacement control....................................................................................................................... |
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Output signals: Motor displacement and Brake Pressure Defeat (BPD) control..................................................... |
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Output signals: Digital outputs 1, 2, 3, 4................................................................................................................................ |
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CAN Communication: Input and Output signals................................................................................................................ |
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Mating Connectors........................................................................................................................................................................ |
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Customer connector: 1, 2 (C1, C2)...................................................................................................................................... |
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CAN Bus adapter cable................................................................................................................................................................. |
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AC Electrical Data & Characteristics......................................................................................................................................... |
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Supply characteristics............................................................................................................................................................. |
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I/O characteristics..................................................................................................................................................................... |
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Operating characteristics....................................................................................................................................................... |
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Environmental and Protection characteristics............................................................................................................... |
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© Danfoss | Aug 2016 |
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Technical Information
Automotive on PLUS+1® for MC-024
General Information
General Description, Electric and Electronics
Automotive-on PLUS+1 (AoP+1), system description
The Automotive-on PLUS+1 is designed to control a single-path hydrostatic transmission system consisting of one pump and one hydrostatic motor. The flexible system configuration allows use of a wide range of hydrostatic pumps and motor configurations.
The AoP+1 is optimized for use with a hydrostatic motor equipped with Pressure Control Override (PCOR) or Proportional (PROP) valve to control pressure or motor displacement. Additionally a Brake Pressure Defeat (BPD) digital control valve can override the hydraulic pressure control during vehicle decelerating.
Parking Brake, Reverse Motion buzzer, Forward/Reverse-Lamp-Indicator, Retarder output and a Vehicle speed controlled output can be controlled with additional four digital output. All functions may not be available simultaneously.
The AoP+1 can read several analog, digital, and frequency signals representing operator input, system demands, and machine status inputs.
The CAN Comunication Interface (SAE J1939) is used for diagnosis purposes and for information exchanging with other controllers such as engine, or customer-controllers.
Automotive on PLUS+1 advanced functions
The Automotive-on PLUS+1 commands the basic vehicle driving behavior and performance (i.e. acceleration, deceleration, and vehicle speed). The operator selects the driving mode, driving direction, and basic transmission set point command via throttle or Creep/Drive pedal. An additional input, the inch pedal command, can be used to override the basic transmission command.
A number of advanced features can be independantly activated and configured depending upon the application.
Below is a list of the primary advanced functions:
•Engine and Motor Over-Speed Protection
•Engine Anti stall
•Constant Speed Control
•Vehicle Speed Limitation
•Intelligent Operator Presence Detection
•Maximum Motor Torque at Vehicle Start
•Retarder control
Required Controller
The Automotive-on PLUS+1® application is designed for a specific MC024-121 “Automotive on PLUS+1® ” with the order number 11177284.
4 | © Danfoss | Aug 2016 |
L1120636 | 0202 |
Technical Information
Automotive on PLUS+1® for MC-024
General Information
Mode Types
Hydrostatic propel methods
The application software provides 3 different hydrostatic propel methods, defined as mode types, which can be calibrated individually.
•Automotive
Proportional pump (displacement) and motor (displacement or PCOR) control valve current is defined by the Automotive Curve,
•Non-Automotive
Drive-Pedal controlled proportional pump (Displacement) and motor (Displacement or PCOR) control valve current, but Engine RPM independent,
•Creep-Automotive
like “Automotive”, but Creep-Potentiometer limitation of the Automotive Curve of the pump.
Automotive and Creep-Automotive mode types are primarily intended for Wheel Loader and Telescopic Handler applications.
The Non-Automotive mode type is primarily intended for Sweeper, Forestry, and Forklift applications.
Each selectable system mode can be configured as one of the 3 mode types (hydrostatic propel methods) below:
•Automotive Mode
•Non-Automotive Mode
•Creep-Automotive Mode; (combination of Automotive and Non-Automotive)
© Danfoss | Aug 2016 |
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Technical Information
Automotive on PLUS+1® for MC-024
General Information
Automotive Mode
In Automotive Mode the current to the proportional valves is directly controlled by the measured engine RPM. The current is independently parameter configurable for pump and motor in each mode. The Automotive Mode provides good anti-stall behavior due to the load dependent control.
The profile curve (points 0-7) of the Automotive Mode drive curve are set according to the available torque characteristics of the engine, accounting for additional auxiliary power.
Pump drive curve
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The actual current is defined by the automotive curve |
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max. |
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7 |
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Low idle |
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Engine min-1(rpm) |
P003 532E |
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Motor drive curve
De-energized (no current) = Motor at min. displacement
H1B Motor controls M1, M2, K1, K2, T1,T2, P1, P2
The actual current is defined by the automotive curve
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current |
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"STOP" |
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Motor at max. displacement |
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Motor at min. displacement |
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Low idle |
Engine min-1(rpm) |
P003 561E |
De-energized (no current) = Motor at max. displacement
H1B Motor controls L1, L2, D1, D2, E1, E2
The actual current is defined by the automotive curve
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and therefore engine speed dependent |
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Motor at min. displacement |
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Motor at max. displacement |
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constant |
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current |
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"STOP" |
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Low idle |
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Engine min-1(rpm) |
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P301 338E |
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6 | © Danfoss | Aug 2016 |
L1120636 | 0202 |
Technical Information
Automotive on PLUS+1® for MC-024
General Information
Non-Automotive Mode
The Non-Automotive Mode uses an analog input signal from the drive pedal to command vehicle speed.
The pump and motor valve currents are controlled by the system mode profile and are independent of pump speed.
Pump drive curve
max. |
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0 |
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7
6 
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100
Drive pedal position (%) |
P003 533E |
Motor drive curve
De-energized (no current) = Motor at min. displacement
H1B Motor controls M1, M2, K1, K2, T1,T2, P1, P2
constant |
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current |
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"STOP" |
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Motor at max. displacement |
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Motor at min. displacement |
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Drive pedal position (%) |
P003 562E |
De-energized (no current) = Motor at max. displacement
H1B Motor controls L1, L2, D1, D2, E1, E2
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Motor at min. displacement |
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Motor at max. displacement |
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constant |
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current |
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"STOP" |
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100 |
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Drive pedal position (%) |
P301 337E |
© Danfoss | Aug 2016 |
L1120636 | 0202 | 7 |
Technical Information
Automotive on PLUS+1® for MC-024
General Information
Creep-Automotive Mode
Creep-Automotive Mode is a combination of both Automotive and Non-Automotive Mode. Creep Automotive Mode uses an analog input signal (Drive/Creep Potentiometer) to control the pump valve current. The available pump valve current is limited by the automotive curve dedicated to this mode type.
The actual current to the pump valve is the product of the actual engine RPM, the defined automotive curve, and the actual percentage of Drive/Creep Potentiometer input. Creep-Automotive is active above a user defined “Creep Start RPM”, below this RPM the propel system behaves like Automotive-Mode.
The motor valve current follows the automotive curve like in Automotive Mode. Actual engine RPM = 1800 min-1 => IAutomotive-Curve = 1500 mA;
Actual Pedal value = 40%;
Creep Start RPM = 1050 min-1 => ICreepStart = 825 mA; IValve = [(1500-ICreepStart) * 40 / 100] + ICreepStart = 1095 mA
Pump drive curve
<![endif]>Current (mA)
The actual current is defined by the automotive curve and therefore engine speed dependent
max. |
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FNR in neutral = no current |
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FNR in FW or RV = current at |
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Creep Start RPM 1050 rpm |
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1095 |
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825 |
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Dotted line |
represents x % |
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of Drive Pedal stroke, |
the example about 40 % |
Low 1050 min-1 |
Engine rpm |
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idle |
“Creep“ pedal controls |
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current at any engine speed |
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thus controlling vehicle speed |
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point 5: 1500 - 825 = 675 mA |
P003 534E |
8 | © Danfoss | Aug 2016 |
L1120636 | 0202 |
Technical Information
Automotive on PLUS+1® for MC-024
General Information
Motor drive curve
De-energized (no current) = Motor at min. displacement
H1B Motor controls M1, M2, K1, K2, T1,T2, P1, P2
The actual current is defined by the automotive curve
constant |
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and therefore engine speed dependent |
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current |
0 |
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"STOP" |
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Motor at max. displacement |
32˚ |
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Motor at min. displacement |
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Low idle |
Engine min-1(rpm) |
P003 561E |
De-energized (no current) = Motor at max. displacement
H1B Motor controls L1, L2, D1, D2, E1, E2
The actual current is defined by the automotive curve
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and therefore engine speed dependent |
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Motor at min. displacement |
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6˚ (0˚) |
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5 |
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0 |
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Motor at max. displacement |
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constant |
1 |
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current |
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"STOP" |
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Low idle |
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Engine min-1(rpm) |
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P301 338E |
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System modes and selection
The application simultaneously supports up to 4 system modes. The system modes define the basic characteristic of the transmission and are operator selectable via 2 digital inputs: Mode Switch A and Mode Switch B.
Each of the four system modes can be:
•optimized for driving behavior through independent drive curves with individual pump and hydrostatic motor ramping.
•configured as any one of the mode types (propel methods).
The following table describes the relationship between the digital input mode switches and the resulting system modes:
Modes and selection
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System mode |
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Mode 1 |
Mode 2 |
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Mode 3 |
Mode 4 |
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Mode switch A |
Low |
Low |
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High |
High |
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Mode switch B |
Low |
High |
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Low |
High |
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© Danfoss | Aug 2016 |
L1120636 | 0202 | 9 |
Technical Information
Automotive on PLUS+1® for MC-024
General Information
Application Function
Application function description
Description
1.Independent Pump/Motor-Profiling & Ramping
Both the pump and motor can be independently configured for the forward and reverse driving direction. The application software facilitates individual command profiles (8 points) based on pump RPM or drive pedal inputs. Additionally vehicle acceleration timing (1 ramp) and deceleration timing (3 ramps plus 1 error ramp) are independently configurable.
2.4 Selectable System-Modes
The application supports 4 configurable System Modes which are selectable with digital inputs Mode Switch A and Mode Switch B. Each System Mode can be individually configured through Mode Type (Automotive, Creep-Automotive, Non-Automotive) and all advanced functions (e.g. CSD, Antistall, Overspeed Protection, etc).
3.Configurable System-Mode- & Direction-Change
This function allows configuration of an application specific System Mode transition. The System Mode change condition can be dependent on multiple factors including actual FNR Direction, Drive Pedal Input, and Ground Speed.
The vehicle driving direction change can be configured on vehicle speed.
When a momentary FNR switch logic is configured, the driving direction change request is rejected if the vehicle speed is above a predefined speed.
4.Configurable Operator-Presence-Detection (only via CAN-BUS)
In primary configuration, an open seat switch (operator not in the seat), programmable with or without time delay, will trigger vehicle shut down. In secondary configuration, the open seat switch requires an secondary operator presence indicator, such as the release of throttle, drive pedal, or inch pedal, to trigger vehicle shut down
5.Pump Displacement Control:
The software provides a displacement control for NFPE (Non-Feedback Proportional Electric) or EDC (Electrical Displacement Control) pumps. The pump command can be definded by a profile curve which can be dependent on engine speed (Automotive Mode, Creep-Automotive Mode) or the drive pedal (Non-Automotive Mode) The current change (stroke time) is configurable by ramps during initial vehicle set up.
6.Motor Displacement Control: Proportional, Variable-PCOR or Two-Position
The software facilitates Motor Displacement Control for Proportional, Variable PCOR, and Two Position control types. The motor command can be defined by a constant value or a profile curve which can be dependent on engine speed (Automotive Mode, Creep-Automotive Mode) or the drive pedal (Non-Automotive Mode). The motor valve current change (stroke timing) is configured by ramps defined during initial vehicle set up.
7.Motor BPD-Control
The Motor Brake Pressure Defeat Control prevents the activation of the internal motor control pressure compensator (PCOR) during deceleration events. The Motor BPD Control activation can be configured individually for driving direction. For change of driving direction the control timing can be configured as state change or actual motor direction dependent.
8.Brake Test Mode
The Brake Test Mode allows the hydrostatic transmission system to drive against the applied park brake and can be individually configured for each System Mode.
The Brake Test Mode cannot be used during normal operation.
9.Parking-Brake-Control
The Parking Brake Control digitally activates (apply/release) a park brake. Park brake activation can be vehicle speed dependent with additional dependency on:
•Software machine state in STOP mode
•Actual pump valve current below user defined value
•Actual inch pedal command exceeds user defined value.
Delay times for park brake application and release are individually configurable.
10.Reverse-Driving-Direction-Buzzer-Output
The Reverse Driving Direction Buzzer Output controls a buzzer that indicates reverse driving direction. The output logic can be directly controlled by FNR status or by actual propel movement.
11.Forwardand Reverse-Direction-LED Output
The Forward and Reverse Direction LED Output function digitally drives LEDs as driving direction indicators for use in dashboard/display and is directly linked to the FNR status.
12.Fault-Status-Output (Red-LED)
The Fault Status Output provides an output signal of the internal fault status/error code capable of digitally driving an LED.
10 | © Danfoss | Aug 2016 |
L1120636 | 0202 |
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