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System Description
Propel Controller Solutions
Automotive Control PC-AC
www.danfoss.com
System Description
Propel Controller Solutions
Revision history |
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July 2020 |
Added PC-AC SP content |
0201 |
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March 2019 |
First edition |
0101 |
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2 | © Danfoss | July 2020 |
AB298174786006en-000201 |
System Description |
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Propel Controller Solutions |
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Contents |
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Basic information |
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Propel controller system overview............................................................................................................................................. |
4 |
Functional safety |
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Standards............................................................................................................................................................................................. |
5 |
PC-AC |
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Basic functions................................................................................................................................................................................... |
6 |
Advanced functions......................................................................................................................................................................... |
6 |
PC-AC SP |
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Basic functions................................................................................................................................................................................... |
7 |
Advanced functions......................................................................................................................................................................... |
7 |
System design.................................................................................................................................................................................... |
9 |
PC-AC 2MT |
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Basic functions................................................................................................................................................................................ |
10 |
Advanced functions...................................................................................................................................................................... |
11 |
System design................................................................................................................................................................................. |
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Functions |
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Function overview......................................................................................................................................................................... |
14 |
Propel functions............................................................................................................................................................................. |
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Mode Types................................................................................................................................................................................. |
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Automotive Transport Mode................................................................................................................................................ |
15 |
Non-Automotive Work Mode (FCMD)............................................................................................................................... |
15 |
ECO fuel saving mode............................................................................................................................................................. |
15 |
Mode transition control.......................................................................................................................................................... |
15 |
Start Protection......................................................................................................................................................................... |
15 |
Quick stop in automotive mode......................................................................................................................................... |
16 |
State and direction change................................................................................................................................................... |
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Hydromotor overspeed protection.................................................................................................................................... |
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Electronic Pressure Limiter (ePL)......................................................................................................................................... |
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Electronic pressure compensator over ride (ePCOR)................................................................................................... |
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Load limiter................................................................................................................................................................................. |
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Hydraulic-System overheat protection............................................................................................................................ |
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Vehicle constant-speed-drive (CSD).................................................................................................................................. |
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Cruise control............................................................................................................................................................................. |
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Filter on drive pedal................................................................................................................................................................. |
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Vehicle speed dependent ramps........................................................................................................................................ |
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Semi-Automatic calibration function................................................................................................................................ |
17 |
Protections |
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Engine control and protection.................................................................................................................................................. |
18 |
1939-CAN engine interface................................................................................................................................................... |
18 |
CAN user interface.................................................................................................................................................................... |
18 |
Engine speed control.............................................................................................................................................................. |
18 |
Engine anti-stall protection.................................................................................................................................................. |
18 |
All range engine overspeed.................................................................................................................................................. |
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All range engine overspeed with retarder....................................................................................................................... |
18 |
Cold start protection............................................................................................................................................................... |
18 |
Gearbox control and protection............................................................................................................................................... |
19 |
Gearbox control........................................................................................................................................................................ |
19 |
Shift monitoring control........................................................................................................................................................ |
19 |
Auxiliary functions |
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Propel controller |
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Controller specification................................................................................................................................................................ |
21 |
General dimensions...................................................................................................................................................................... |
22 |
Pin assignments.............................................................................................................................................................................. |
23 |
© Danfoss | July 2020 |
AB298174786006en-000201 | 3 |
System Description
Propel Controller Solutions
Basic information
The Propel Controller Solutions are designed to support single path hydrostatic transmissions systems.
Danfoss offers several solutions for the propel system to cover vehicle corner power ranges up to 1800 kW. All of these propel system solutions combining proven hardware like PLUS+1® Safety Controller and H1 hydraulic pumps and motors with reliable software developed according to current safety standards.
With the pre-installed application software and easily changeable control parameters, it is possible to tailor the vehicle's driving behavior to the individual requirements of the customer.
Propel controller system overview
Definition of vehicle corner power
Where: |
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Pc |
Corner Power (kW) |
Smax |
max Vehicle Speed (km/h) |
FD |
Final drive efficiency (-) |
4 | © Danfoss | July 2020 |
AB298174786006en-000201 |
System Description
Propel Controller Solutions
Functional safety
The Propel Controller Software is designed to control a single-path transmission system consisting of one pump and one (or two) hydrostatic motor(s). The propel controller and the application software needs to fulfill the safety requirements according to machine directive (2006/42/EC).
PLUS+1® PC controllers are advanced elements of the PLUS+1® family of mobile machine management products. The design of this general purpose safety controller includes features required for sophisticated machine control strategies. It is equally suited for use in safety related or general machine control applications.
These controllers have dual processors with the secondary processor having access to all controller inputs and supervisory control of outputs. These controllers support smart digital inputs. Current measurement capability has been added to some multifunction inputs. Device outputs can be individually controlled by the secondary processor.
The Safety Manual of the propel controller solutions (available by request from your local Danfoss representative) is intended to guide the system integrator concerning functional safety. The document describes a possible implementation of the needed safety functions.
Standards
Type A Standards
Cover aspects applicable to all types of machines
•IEC 61508 functional safety of electrical/electronic/programmable electronic safety-related systems
Type B Standards
Cover particular safety and ergonomic aspects of machinery
•ISO 15998 Controller for earth moving machinery
•EN ISO 13849-1:2015 Safety of machinery- Safety-related parts of control systemsParts 1 & 2
•ISO 25119 Agriculture machinery (former EN 16590)
Type C Standards
Machine safety standards dealing with detailed safety requirements for a particular machine or group of machines
•ISO 20474-2017, former DIN/EN 474 Earth moving machinery
•EN 1459-1:2017 Rough-terrain trucks – Safety requirements and verification – Part 1: Variable-reach trucks
•EN 4254:2013 Agricultural machinery – Safety – Part 1: General requirements
•EU 167/2013 Agricultural and Forestry vehicles (Tractor directive)
•‒ EU 1322/2014
‒EU 68/2015
‒EU 96/2015
‒EU 208/2015
‒EU 1788/2016
© Danfoss | July 2020 |
AB298174786006en-000201 | 5 |
System Description
Propel Controller Solutions
PC-AC
The propel controller application PC-AC is designed to control a single-path hydrostatic transmission system consisting of one pump and one motor. The hydrostatic pump is equipped with two proportional valves.
In the PC-AC system the hydrostatic pump can be controlled in pressure dependent (NFPE) or pressure independent (EDC) pump control mode.
The PC-AC system is optimized for use with a hydrostatic motor equipped with a proportional (PROP) valve to control pressure or motor displacement.
The Danfoss patented Flow Controller Motor Displacement (FCMD) allows the software to change the control command according to the system flow. Which brings advantages in controllability, engine power utilization and system load dependency.
Parking brake valve, reverse motion buzzer, forward/reverse lamp indicator, a retarder valve and a stabilizer valve can be controlled by additional digital outputs.
The PC-AC system can read several analog, digital, and frequency signals representing operator input, system demands, and machine status inputs.
The CAN Communication Interface is used for diagnosis purposes and for information exchanging with other controllers such as engines, other Danfoss power solutions or customer controllers.
Basic functions
The PC-AC 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.
Advanced functions
A number of advanced features can be independently activated and configured depending on the installed application software package. Below is a list of the primary advanced functions:
•Engine and motor over-speed protection
•Engine anti-stall
•Constant speed control
•ECO fuel saving mode
•Vehicle speed limitation and flow limiter
•Intelligent operator presence detection
•Electronic swash plate control
•Temperature compensation and overheat-protection
•Maximum motor torque at vehicle start
•Engine speed dependent retarder control
•Cruise control
•User defined I/Os
6 | © Danfoss | July 2020 |
AB298174786006en-000201 |
System Description
Propel Controller Solutions
PC-AC SP
The PC-AC SP system is dedicated for use with one hydromotor which is mounted on a two speed syncronizer gearbox. A syncroniser allows gear change while driving (SpeedShift).
The SpeedShift function will control and monitor the two speed gearbox. The hydrostatic components are controlled according the requirements to perform a fast and smooth gear change.
A proportional controlled hydromotor with 0° and de-energized minimum displacement is required for SpeedShift. The 0° position of the hydromotor is monitored with a MBS 1250 pressure sensor in port M4 (min. servo chamber).
The gear stage is not linked to a system mode; a gear change is possible for all 4 system modes. It can be automatically or manually triggered. The software will ensure a gear change is only applied if it is possible and safe (dependent on vehicle speed, acceleration/deceleration, and temperature).
The CAN Communication Interface is used for diagnosis purposes and information exchanging with other controllers such as engines and other Danfoss power solutions or customer controllers.
Basic functions
The PC-AC SP offers the same basic function like the PC-AC. It controls basic vehicle driving behavior and performance (i.e. acceleration, deceleration, and vehicle speed). Additional it controls the two speed gearbox. The operator selects the driving mode, driving direction, driving gear and the transmission set point via throttle or creep/drive pedal.
•Four system modes, selectable by the driver for different drive behavior
•Independent pump/hydromotor profiling and ramping for each system mode
•Independent pump/hydromotor profiles in first and second gear operation
•Electric drive pedal
•Electronic inching
•Load dependent pump displacement control (automotive)
•Proportional hydromotor displacement control by flow (FCMD)
•User defined I/Os
Advanced functions
Protection and safety functions
•Safety controlled vehicle start protection
•Operator presence detection
•Software based pressure protection
•Hydraulic system overheat and low temperature protection
•Hydromotor overspeed protection
•SIL2 compliant
Performance functions
•ECO fuel saving mode
•Vehicle speed limitation
•Dynamic brake light, automatic park brake, reverse buzzer and vehicle speed controlled output functions
•Advanced CAN J1939 interface
© Danfoss | July 2020 |
AB298174786006en-000201 | 7 |
System Description
Propel Controller Solutions
PC-AC SP
Engine control and protection
•CAN J1939 engine interface
•Engine speed control via drive pedal with safety controlled monitoring function
•Engine over speed and cold start protection
Gearbox control and protection
•Approved by gearbox manufacturer
•Shift valve control (automatic or manual triggered)
•Gear detection
•Measure hydromotor M4 pressure for 0° detection (with start up and plausibility check)
•Fault management
8 | © Danfoss | July 2020 |
AB298174786006en-000201 |
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