Danfoss Propel Controller Solutions Automotive Control PC-AC Application guide
System Description
Propel Controller Solutions
Automotive Control PC-AC
www.danfoss.com
System Description
Propel Controller Solutions
Revision history Table of revisions
Date Changed Rev
July 2020 Added PC-AC SP content 0201
March 2019 First edition 0101
2 | © Danfoss | July 2020 AB298174786006en-000201
System Description
Propel Controller Solutions
Contents
Basic information
Propel controller system overview.............................................................................................................................................4
Functional safety
Standards.............................................................................................................................................................................................5
PC-AC
Basic functions...................................................................................................................................................................................6
Advanced functions.........................................................................................................................................................................6
PC-AC SP
Basic functions...................................................................................................................................................................................7
Advanced functions.........................................................................................................................................................................7
System design....................................................................................................................................................................................9
PC-AC 2MT
Basic functions................................................................................................................................................................................ 10
Advanced functions......................................................................................................................................................................11
System design.................................................................................................................................................................................12
Functions
Function overview.........................................................................................................................................................................14
Propel functions............................................................................................................................................................................. 14
Protections
Engine control and protection..................................................................................................................................................18
Gearbox control and protection...............................................................................................................................................19
Auxiliary functions
Propel controller
Controller specification................................................................................................................................................................21
General dimensions...................................................................................................................................................................... 22
Pin assignments..............................................................................................................................................................................23
Mode Types.................................................................................................................................................................................14
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...................................................................................................................................................16
Hydromotor overspeed protection....................................................................................................................................16
Electronic Pressure Limiter (ePL).........................................................................................................................................16
Electronic pressure compensator over ride (ePCOR)...................................................................................................16
Load limiter.................................................................................................................................................................................16
Hydraulic-System overheat protection............................................................................................................................ 17
Vehicle constant-speed-drive (CSD).................................................................................................................................. 17
Cruise control.............................................................................................................................................................................17
Filter on drive pedal.................................................................................................................................................................17
Vehicle speed dependent ramps........................................................................................................................................17
Semi-Automatic calibration function................................................................................................................................17
1939-CAN engine interface...................................................................................................................................................18
CAN user interface....................................................................................................................................................................18
Engine speed control.............................................................................................................................................................. 18
Engine anti-stall protection.................................................................................................................................................. 18
All range engine overspeed..................................................................................................................................................18
All range engine overspeed with retarder.......................................................................................................................18
Cold start protection............................................................................................................................................................... 18
Gearbox control........................................................................................................................................................................ 19
Shift monitoring control........................................................................................................................................................ 19
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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:
P
c
S
max
Corner Power (kW)
max Vehicle Speed (km/h)
ղFD Final drive efficiency (-)
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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
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EN ISO 13849-1:2015 Safety of machinery- Safety-related parts of control systems- Parts 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
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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
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EU 167/2013 Agricultural and Forestry vehicles (Tractor directive)
•
EU 1322/2014
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EU 68/2015
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EU 96/2015
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EU 208/2015
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EU 1788/2016
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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
Advanced 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.
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:
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Engine and motor over-speed protection
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Engine anti-stall
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Constant speed control
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ECO fuel saving mode
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Vehicle speed limitation and flow limiter
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Intelligent operator presence detection
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Electronic swash plate control
•
Temperature compensation and overheat-protection
•
Maximum motor torque at vehicle start
•
Engine speed dependent retarder control
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Cruise control
•
User defined I/Os
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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.
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•
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•
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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
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Safety controlled vehicle start protection
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Operator presence detection
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Software based pressure protection
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Hydraulic system overheat and low temperature protection
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Hydromotor overspeed protection
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SIL2 compliant
Performance functions
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ECO fuel saving mode
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Vehicle speed limitation
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Dynamic brake light, automatic park brake, reverse buzzer and vehicle speed controlled output
functions
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Advanced CAN J1939 interface
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System Description
Propel Controller Solutions
PC-AC SP
Engine control and protection
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•
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Gearbox control and protection
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•
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CAN J1939 engine interface
Engine speed control via drive pedal with safety controlled monitoring function
Engine over speed and cold start 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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