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Hydraulic and Electronic Control SolutionsConcrete Pump Truck

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Hydraulic and Electronic Control Solutions Concrete Pump Truck

C O N C E P T P H A S E I N Q U I R Y

• Detailedprojectplan

• Technicalsystemspecification

• Differentsystemproposals

• Evaluationandselectionofapproach

P R O J E C T S P E C I F I C A T I O N

Withdecadesofdevelopment,Chinahasbecomethelargestmarketforconcretespumpequipmentintheworld,whereanumberofsuppliersarecompetingfiercely.Thecustomershaveincreasinglyhigherexpectationfortheequipment.Inadditiontolowfuelconsumption,highperformanceandhighreliability,intelligentandprecisecontrolsareplayingmoreimportantrolesinthismarket.

Facedwithamorecompetitivemarketandevergrowingexpectationsfromendusers,pumpequipmentmanufacturersneedtointegrateresourceandfocusoncustomerstomeetthemarketdemandsconstantly.

Asthegloballeaderinmobilehydraulics,DanfossPowerSolutionstartedtoworkwiththeleadingpumptruckenterpriseinGermanyoverthreedecadesago.Thequal-ityhydraulicandelectroniccontrolproductsandsolutionsprovidedbyDanfosswillenableyoutodevelopmorecompetitivesystemstofulfillneedsofspecificcustomers.

Hydraulic and Electronic Control Solutions Concrete Pump Truck

• Sizingandselectionof

compatiblecomponents

• AdvancedsimulationtestsandsystemFMEA

• Installationinprototype

• Real-lifeworkconditiontestsat

Danfoss’on-sitetest-track

• Carefulsystemperformanceanalysisfor

optimizationandtrouble-shooting

• Finalreview

• Finalreport

• Documentation

• Start-uphelp

D E S I G N I M P L E M E N T A T I O N R E L E A S E

Focus on Customer and Join hands for a Better Future

Closed Pumping Systemxxx

PVG32LoadSensingProportionalValve

Series45AxialPistonOpenCircuitPump

SNPGearMotor

ControlValveforFlushingandMixing

SGMFanDriveGearMotor

OMH500OrbitalMotor

VMROrbitalMotor

DP700GraphicDisplay

PLUS+1®

MC050Microcontroller

Sensor(TemperatureandPressure)

© BlueGraphicsConceptbyDanfoss

SNMFlushingDriveGearMotor

Series90AxialPistonTandemPump(180+180cc /130cc)

Diagram for Pumping System (Closed Pumping System)

Diagram for Arm System

Series45AxialPistonOpenCircuitPump

ControlValveforFlushingandMixing

CAN Bus

(VMP)

Proportional

Terminal(DP700)

Microcontroller(PLUS+1®)

valve group

Motor

(PVG32)

to SupporterVariable pump

CAN BusProportional

Terminal(DP600)

Microcontroller(PLUS+1®)

Motor(VMR)

valve group(PVG32)

To SupporterVariable pump

RemoteController

Third-party

RemoteController

Third-party

(S90PV180)

Auxiliary pump

Microcontroller(PLUS+1®)

Terminal(DP700)

Fan Drive Gear Motor (SGM)

(Series 45)

Tandem piston pump

CAN Bus

Gear motor(SNM)

Gear pump(SNP)

Motor

Switch Over Cylinder

Position sensor Position sensor

Position sensor

Drive Cylinder

Drive Cylinder

Position sensor

Accumulator

(OMH)

Motor(OMH)

(S90PV180)

Auxiliary pump

FFH Valve

Microcontroller(PLUS+1®)

RemoteController

Third-party

Terminal(DP600)

Multi-wayValve

(Series 45)

Tandem piston pump

CAN BusOil Tank

Gear motor(SNM)

Gear pump(SNP)

Motor

Switch Over Cylinder

Position sensor

Position sensor

Position sensor

Position sensor

Drive CylinderDrive Cylinder

Accumulator

(OMH)

Motor(OMH)

Fan ControlValve

Fan Drive Gear Motor (SGM)

Fan ControlValve

Oil Tank

FFH Valve

Maulti-wayValve

Diagram for Pumping System (Open Pumping System)

Microcontroller(PLUS+1®)

RemoteControllerThird-party

Terminal(DP700)

Drive cylinder

Oil Tank

Drive cylinder

Sensor

Sensor

Sensor

Sensor

Main Valve Group

Swing CylinderValve Group

AuxiliaryValve Group

Cooling Control Valve

Engine

CAN bus

Change Piston Valve

Fan Drive Gear Motor (SGM)

Auxiliary Pump(Series 45)

Gear Pump(SNP)

Tandem Open Circuit Piston Pump(D1P193+D1P193)

Gear Motor(SNM)

l Closed Pumping System Solution:S90seriesclosedpumpingsystemcanmeetavarietyofcontrolrequirements, includingpumpcapacity,regularandreversepumping,constantoutput,highpressureoverflow,reversingimpact mitigation,etc..Theintegratedflushingvalves,shuttlevalvesandotherfunctionalmodulesmakethecustomersystem moreconcise.

l Open Pumping System Solution:UndertheleadershipofthemostexperiencedpistonpumpR&Ddirectorfrom Germany,DanfosshasdevelopedD1P193,anopenhigh-pressurepistonpumpwithhighquality, whichhasgonethroughlong-termverificationinpumptruckunderharshconditions.Thecontrolfunctionofthe pistonpumpcanfullysatisfytherequirementsofthepumpingsysteminapumptruck,includingthecontrolof Electricdisplacementcontrol,Powercontrol,Pressurecompensatedcontrol,etc..

l S Valve Swinging System Solution: S45seriesvariableopenpumpshaveintegratedconstantpressurecontrolsfor long-timehigh-pressureoperatingconditions.

l Mixing System Solution:OMHSeriesOrbitalmotorscanworkunderhigh-torquedemandedbythesystem.

l Flushing System Solution:QualitySNPgearboxesandSNMgearboxesmakethesystemmorereliable.

l Developspecificsolutionsbasedoncustomerdemandstopromotethecompetitivenessoftheirproducts.

High EfficiencyA

B

C

Whentheoilpumpforpumptruckadoptsthemostcommonly-usedoperatingparameters(pressure:35bar–300bar,rotationalvelocity:1500rpm–2500rpm),itwillstayinhighlyefficientworkingrange,withatotalefficiencyover85%.Comparedwithcurrenttechnology,highefficiencyoilpumpcanreducefuelconsumptionby3%-5%foreachpumping.

0.9

0.85

0.8

0.75

0.7

0.65

0.6

0.55

A

S90

0.5

500 1000 1500

50º 80º

2000 2500 500 1000 1500 2000 2500

0.30

0.25

0.20

0.15

0.10

0.05

0.00 dp min

dp 100dp 200dp 300dp 350dp m

indp 100dp 200dp 300dp 350

dp min

dp 100dp 200dp 300dp 350

dp min

dp 100dp 200dp 300dp 350

A

S90

nCoretechnologycreatesvaluesforcustomers–Theclosedpump,speciallydevelopedbyDanfossplantinGerman forpumpingsysteminpumptruck,hasthefollowingfeatures:

Pumping, Swinging, Mixing, and Flushing System

High Reliability and Long Service LifeForover3decades,Danfosshasemployedstrictzero-defectprocessesand“longservicelife”conceptinEurope,toeradicateanylosscausedbyfaultsandofferalong-livedpumptruck“heart”toourcustomers.Thehighreliabilityandlongservicelifeofitsproducts,whichourGermanplanttakesgreatpride,arewell-proveninawiderangeofrigorconstructionenvironmentsandwidelyrecognizedbythemarket.

Quick Pump Control Reversing TechnologyAccordingtonumerouscomparisontests,theaveragereversingtimeofDanfosspumpsis0.222s,8%fasterthan0.242sofourcompetitors’.Thisadvantagenotonlysavesfuelconsumptionforourcustomer,butalsopromotesconcreteflowability,andthusdecreasestheimpactofflowpulsecausedbyconcretereversing.

EfficiencyComparisonCurve

S90PV180TandemPump

ReversingTimeComparisonCurve

A

B

C

PVED-CC

PVE

PVHC

V310072.A

PVE

Electronics

NC Solenoid valve

Pilot oil supply

B port Oil A port

PVB

PVM

Neutral spring

PVBS

NO solenoid valveLVDT

P -> A

PVG32

PVED-CC

Microprocessoradd-onmoduleSimpleAnaloguemodule

PVG32

Arm SystemDeveloped specially for pump truck, PVG32 arm serves as the proof of customer-oriented R&D concept of Danfoss.

Thevalvehasthefollowingfeatures:

l Flow control technology, independent of load: Bettermaneuverabilityforoperator,resultinginbettercontrollabilityofarms.

l LS load sensitive control technology: Reducefuelconsumptionandprolongservicelifeofhydrauliccomponents.

l Advanced electro-hydraulic proportion control technology: Maketheoperatingspeedofarmsunderfreecontrol.

Low-Cost PlanThisplancancutOEMpurchasingcostwithoutimpairingtheperformanceofarmvalvesonthemarket.

nDetailedcustomerrequirements–Danfossselectsthreearmvalveplansforpumptruck.

Advanced Control PlanUnlikearmvalvecontroltechnologyavailableoncurrentmarket,PVEarmvalvesadoptclosedloopcontrolstoreducemagnetichysteresisinherenttoelectromagnetfrom20%to1%andsignificantlypromotecontrolaccuracy.Moreover,thepriceperformanceratioofthisplanishigher,asitscostisequivalenttothoseofcommonproductsonthemarket.

More Advanced Digital Control Plan-ThisplancanbeusedwithCAN-BUS,enablingcustomersto developmoreintelligentandhigherlevelequipment.

-ThisplancanbeequippedwithSIL2certifieddigitaldriver PVED-CX(uptoEUorUSSafetyStandards),enablecustomers expandbusinesstoEuropeanorUSmarket.

A

B

C

PLUS+1GUIDEServiceTool

Electronic Control System

Tailored to concrete pump truck, the electronic control system has a number of advantages, including excellent performance, clear objective, strong applicability, high reliability and so on.

An Excellent Performance-Amainfrequencyof150MHZbringsaboutultra-fastoperating speedandpowerfuldataandalgorithmprocessingability, whichcancompleteawholeprocedurescanningcyclein1msonly.

-PWMcontrol,withaminimumofresolutionof0.1mA, greatlyupgradestheoperabilityandsmoothness.

-12digitA/Dconversionraisethemeasurementaccuracy andcontrollability.

Clear Objective-Provenfunctionalmodulesinpumptruckcontrolsoftware facilitateprogramming,codeunderstanding,andfunctional addition.

-PowerfulServiceToolMonitoringSoftwareprovidesmore convenientgraphicaldebugging,parametermodification andsystemmonitoringfunctions.

-Themagnetichysteresisremovalfunctionspeciallydesignedfor proportionalvalveinpumptruck,whenusedwithPVG32valve group,willimprovetheaccuracyandstabilityofarmoperation.

PLUS+1®Microcontroller Heavy-LoadPressureSensor

Standard/ExtendedTemperatureSensorfor

FluidandGas

DPSeriesGraphicDisplay

ElectronicControlSystemComponentsforPumpTruck

Better extensibility and High Reliability-AssembleandaddI/Omoduleaccordingtocustomerdemands, tomeetthecustomizationneedsfordifferentpumptrucks.

-ReserveaCANBUSinterface,tofacilitatetheGPRScommunication withBUSremotecontroller.

-ConformtorequirementsonIP67protectiondegree,vibration, impactandelectroniccompatibilitystipulatedbyapplication standardsinconstructionengineering.

SoftwareFunctionsandTestData

ExpansionModuleandOne-offEncapsulationRequirement

Asforsteeringproducts,weprovidestandardsteeringdevice,electro-hydraulic steering components,mini-steering gear,dedicatedsteeringgear,flowamplifier,etc.,whichcoversallapplication needs, including common two-wheel steering,four-wheel steering, articulated steering, and automaticsteeringcontrolledbysensorsorsatellitesignals. ThesteeringsystemsolutionsprovidedbyDanfossaretakingtheleadinthemarketandhavesetthebenchmarksfor reliable, safe and comfort control systems for off-road vehicles. We provide independent and ready-to-usecomponents,whichcanbeusedinhighlyefficientsteering,mobile,operatingandcontrolsystems.

Our well-proven valve products, with reliable quality andmodularized design concept, can be used in almost everycircumstance. Weprovideloadsensitive,electroniccontrolproportionalvalves,aswellasproportionalvalvesindependentofload.With our valve products, you can adopt various controlmethodstosatisfythemostdemandingrequirements,whilekeepingthesystemoperatingstablyanddurably.

S T e e r i n g C O m P O n e n T S a n d S y S T e m S

V a l V e S

H y d r O S T a T i C S

We can provide solutions applications of low, mediumand high output, including single and double-side drivingsystemsandencloseddrive. Our products contains the best-in-class axial−flowvariablesinglepistonpumpandtandempump,SIL2certifiedvehicledrivemodeproducts(H1AC),axial-flowpistonfixeddisplacementmotor anddoubledisplacementmotor,bentAxis variable displacementmotor, complete pump system,mixerproducts,axial-flowvariablepistonpumpforworkingsystem,etc..

One of the Industry’s Broadest Product PortfoliosOur aim is to be the best partner in mobile hydraulics.Based on 45 years’ experience in off-highway vehicles, we can provide expertise in a great variety of industries, including but not limited to construction, agriculture, material handling, road construction, lawn care, forestry, as well as multi-functional purpose-built vehicles

Our product portfolio includes various high performanceelectronic products used for off-highway vehicles.We canoffer a series of standard as well customized products,includingsoftware,handle,PLUS+1controller,sensor,displayand GPS device.With these products and PLUS+1 controlplatform,youcanestablishavehiclecontrolsystemquickly,cutdevelopmentcost,andputyourvehiclesonthemarketinshortertime.

Inorbitalmotormarket,wecanprovidethewidestrangeofhighquality,durable,efficientand reliableproducts,whichare able to endure high axial force and radial force andprovidehighstart-uptorqueandstableoutputtorque.Theshaftsealscanwithstandhighpressure,somotorscanhavelongerservicelifeeveninadverseoperatingenvironment.

m O b i l e e l e C T r O n i C C O m P O n e n T S a n d S y S T e m S

O r b i T a l m O T O r S

yOur STrOngeST ParTner in mObile HydrauliCS

One of the Industry’s Broadest Product Portfolios

The increasingly rigor regulations on motor exhaust emission and the launch of new european safety regulations will have influence design and development of almost all off-road vehicles. in order to help our customers to address the above and other industrial challenges, we provide intelligent solutions, including various hydraulic products, electronic control components, and vehicle control recommendations. The comprehensive measure makes us the best partner of your business.

L1421108_Rev BC_Mar 2015

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 to products 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.

About Danfoss Power Solutions

Danfoss Power Solutionsisaglobalmanufacturerandsupplierofhigh-qualityhydraulicandelectroniccomponents.Wespecializeinprovidingstate-of-the-arttechnologyandsolutionsthatexcelintheharshoperatingconditionsofthemobileoff-highwaymarket.Buildingonourextensiveapplicationsexpertise,weworkcloselywithyoutoensureexceptionalperformanceforabroadrangeofoff-highwayvehicles.WehelpOEMsaroundtheworldspeedupsystemdevelopment,reducecostsandbringvehiclestomarketfaster.

DanfossPowerSolutions–yourstrongestpartnerinmobilehydraulics.

Products we offer:• BentAxisMotors• ClosedCircuitAxialPistonPumpsandMotors• Displays• ElectrohydraulicPowerSteering• Electrohydraulics• HydraulicPowerSteering• IntegratedSystems• JoysticksandControlHandles

• MicrocontrollersandSoftware• OpenCircuitAxialPistonPumps• OrbitalMotors• PLUS+1®GUIDE• ProportionalValves• Sensors• Steering• TransitMixerDrives

Whereveroff-highwayvehiclesareatwork,soisDanfossPowerSolutions.Weofferyouexpertworldwidesupportforensuringthebestpossiblesolutionsforoutstandingperformance.AndwithanextensivenetworkofGlobalServicePartners,wealsoprovideyouwithcomprehensiveglobalserviceforallofourcomponents.

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

Danfoss Power Solutions (US) Company2800East13thStreetAmes,IA50010,USAPhone:+15152396000

Danfoss Power Solutions GmbH & Co. OHGKrokamp35 D-24539Neumünster,GermanyPhone:+4943218710

Danfoss Power Solutions ApSNordborgvej81DK-6430Nordborg,DenmarkPhone:+4574882222

Danfoss Power Solutions Trading(Shanghai) Co. Ltd.Building#22,No.1000JinHaiRdJinQiao,PudongNewDistrictShanghai,China201206Phone:+862134185200