Sauer-Danfoss Next

Generation Hydrostatic
Transmission Products

/ H1
Agenda

• H1 Program Overview
• H1 Product Overview
• Control
• Performance & Efficiencies
• Functionality & Integration
• Dimensions & Size
HyTron Project –> H1 Product Family
H1 Critical Program Elements

• H1 is a product that will regain and grow HST

market share
– H1 will be the technical benchmark for HST pumps
• H1 is not a revolutionary product but an
evolutionary product
• H1 is a Reliability improvement product
• H1 is a Quality Improvement product
H1 Product Overview
 SPD for H1 Pumps

Variable Pumps
Load Life Curve

A 450 69 89 115 147 180 250

B B400
45 60 100 130 165
45 60 78 100 130 165

CC
30 38 52 68
350 30 38 53 68 SD Servo Pump
20 Rexroth A10/A4

0 50 100 150 200 250

Displacement CC/Rev
H1 Concept Swashplate Pump

• Displacements (20…250cc)
• All units have 9 pistons
• 0-18 Degree Swash Angle
• Reduced Length
• Reduced Power Losses
• Reduced Noise
• Designed & Produced for 250
DPM
• Design optimized for Electrical
Controls
H1 Pump Sectional View
Tandem Concept Drawings
H1 Tandem
43 cm³ and 53 cm³
Designed for Quality & Reliability

• Reaching for 250 Defect Per Million (DPM) “delivered

quality” goal
– HST products today are 2500-3500 DPM
– H1 needs to be 10X better delivered quality than today!
• Reduce # of parts
– EDC: from 90 to 60
– Typical pump (S90): from 190 to 134
• Design around electronic control
– No performance compromises
– Limit assembly cell variation
• Utilize global purchasing and common suppliers
• Deliberate attempt to minimize unwarranted variation
 Designed For Quality & Reliability
• Lower cost repair
– Bi metal valve plate leads to fewer block replacements
– No cast on bronze

“Spring” slipper hold down (wave washer)

• No S90 fixed clearance screws, spacers, and plates
• Mechanical compressed slipper joint stands up to moments of low
inlet pressure

• One piece swashplate

– No bolted or pressed joints
– Diamond milled running face; eliminates lapping contaminants
Designed For Quality & Reliability
• Splined Charge Pump Drive
– More robust than key or pin drive

• High strength tandem front flange

– No flange – housing joint

• Common design across entire (20-250cc)

displacement range
Designed For Quality & Reliability

Bearings

– Swashplate bearing is designed for even load

distribution across all rollers
• Reduces hysterisis
• Longer life
• Reduces brinelling sensitivity to being at one position for
long periods

– New endcap bushing material has higher load capacity

than S90
Designed For Quality & Reliability

• Several FEA´s were

performed to optimize the
needle bearing load
• Comparison to other products
• FEA´s for the hole pump
range (scaling)
• Test was performed to
All rollers have same load!!
compare FEA results to
measurement, fit was very
good
Control
H1 Controls
• H1 is an Electrical Control ONLY!
– EDC
– NFPE
Electric
Electric
– FNR Controls
Controls

• There are NO plans to design

– MDC
– HDC
– NFPH
Proportional Solenoid EDC
– Significantly fewer parts than PCP style will
improve reliability and quality
– Reduced hydraulic losses to existing EDC
• No solenoid losses
– Improved Linearity
– Same Solenoid for EDC and NFPE
EDC Performance (current vs. angle)
• Actual 147 test data
Current EDC vs. H1 EDC

Today‘s EDC H1 Control

• One Control for all
frames
• Proportional solenoids
(industrial standard)
• Less parts
• Supports 250 DPM
• Reduced power losses
• Control supply is
filtered
 H1 – Control Principle
Tension spring

EDC link
Cradle
feedback pin
Feedback link

Seal lock nut Center ring

Eccentric
Control spool
adjustment
H1 Pump Servo System

Servo Piston
• One-piece swashplate
• Robust design
• Center loaded servo
• Simple neutral
adjustment
• Springs parallel to servo
piston
Servo Cylinder • Wear resistant
swashplate bearing
• Reduced number of
Swashplate parts
Performance & Efficiencies
Kit Efficiency Improvements

• Improved L/D piston/bore ratio reduces leakage

• Better optimization of slipper leakage by
improved block and slipper balance.
• All units are 9 piston 18 degree blocks
– M46 today is 7 piston 17 degree
– S90 is 17 degree
– M35/44 is 16 degree
H1 “Improved” Geroter

• Traditional geroter charge

pump

– Pressure balanced port

plates reduce the slippage
leakage across geroter
face
– Increased land width
between drive coupling
and inner member
reduces P-T leakage
– Optimized profile
improves efficiency
across lobes
 H1 147cm³ and 165cm³
Charge Pump Efficiency
H1-165ccm, Efficiency, Charge Pump 34ccm, 22 bar at 1500 rpm, 80°C

1,0 0
0 ,9 8
0 ,9 6
0 ,9 4
0 ,9 2
0 ,9 0
0 ,8 8
0 ,8 6
0 ,8 4
0 ,8 2
0 ,8 0
ETAvo l
0 ,78
0 ,76 ETAhm
0 ,74 ETAto t
0 ,72
ETAvo l_ 9 0 P13 0
0 ,70
0 ,6 8
0 ,6 6
0 ,6 4
0 ,6 2
0 ,6 0
0 ,58
0 ,56
0 ,54
0 ,52
0 ,50
750 10 0 0 12 50 150 0 2000
n [ 1/ min]
More Efficient
• Kits
– Higher piston l/d leading to reduce piston loading and
lower leakage

• Control
– No PCP flow losses

• Servo Piston
– Designed for lower control pressures leading to
reduced charge pump power requirements
 H1 Efficiency
H1-165 - PUMPING- TORQUE EFFICIENCY COMPARISON
Vi=100% Vimax; 2000 RPM;80°C

1,00
0,98
0,96
TORQUE EFFICIENCY

0,94
0,92
0,90
0,88
0,86
0,84
0,82 H1
0,80
0,78 90P130
0,76 90P075
0,74
0,72
0,70
0 50 100 150 200 250 300 350 400 450
DIFF. PRESSURE [BAR]
H1 Efficiency
H1-165 - PUMPING- TORQUE EFFICIENCY COMPARISON
Vi=20% Vimax; 3000 RPM;80°C

1,00
0,98
0,96
0,94
0,92
0,90
0,88
TORQUE EFFICIENCY

0,86
0,84
0,82
0,80
0,78
0,76 H1
0,74
0,72
0,70 90P130
0,68
0,66 90P075
0,64
0,62
0,60
0,58
0,56
0,54
0,52
0,50
0 50 100 150 200 250 300 350 400 450
DIFF. PRESSURE [BAR]
Functionality & Integration
H1 Schematic
 H1
PL and HPRV settings
• Performance improved through separate functionality
- Pressure Limiter, short: PL (adjustable setting)
- High Pressure Relief Valve, short: HPRV (fixed setting)

• HPRV‘s will be set 30-50 bar above PL setting

• Preferred settings for PL+HPRV or HPRV only are:

PL + HPRV HPRV
only
PL HPRV
400 430 400
420 450 420
450 480 450
480 510 480
H1 Control OverRide (COR)

• Destrokes pump with de-energized solenoid.

– Overrides the operator input to the control
– Does not effect loop charge pressure…only control
• Provides additional element of controlling
destroke rate independent of normal control
response
– A pump could destroke slowly… or quickly
• Will be a “control solution”
H1 Control OverRide (COR)

Two Position Solenoid for COR

 H1 Control OverRide (COR)

• Coasting: control is
“dumped” to case
and the servos are
shunted across
orificed spool.
• E-Stop: control is
“dumped” to case
and the servos are
shunted without
orificing.
w/ & w/o orificing
 H1 Integrated Speed Limitation (ISL)

• When is ISL- function required:

– Turbocharged diesel engine with low braking

power is used
– Braking power of the diesel engine is not
adequate for the machine mass and speed (big
mass & speed up > 30 km/h)
– High pressure in the pump has to be limited when
braking, brake pressure acting on the hydraulic
motor should be high
– Mechanical brakes will have less load
 H1 Integrated Speed Limitation (ISL)
• Performance:
– Sufficient deceleration of the vehicle when
braking
– Protect the diesel engine and the hydraulic pump
against over-speed
– Ensures an optimal use of the diesel engines
brake capability
– Provides high comfort of driving because it acts
independent from the operator
– It saves the mechanical brakes
– No additional hydrostatic components or others
(like retarders) are required for this function
H1 Integrated Speed Limitation (ISL)

SCR-Valve (pilot function)

Pressure Regulator Valve

Check valve
H1 Integrated Speed Limitation (ISL)

SCR-Valve (pilot function)

Check Valve
Pressure Regulator Valve
H1 Integral Filters
• Single pumps with integral filters and electrical
dirt detection switches
– Full flow filtration with filter bypass
– Switch energized prior to filter bypass
– Integral filter an option down to 60 cc
H1 Integral Filters

Bypass Function

Pressure
Start 5,3 bar
End 6,4 bar
Dirt detection Function

Pressure
Start 4 bar
End 6 bar
H1 Singles
• All H1 single pumps will be of the same layout
considering the location of all ports and valves so
long as proper wrench clearance can be
maintained
Pressure Sensors
• Evaluated Three Suppliers
– HYDAC
– TI
– Honeywell

• Will use integral

connector

• High Pressure (0-550 bar), Purchased Component

– Charge Sensor also available at 0-55 bar
– ALL Pumps
Dimensions & Size
H1 – 147/165
Dimension comparison
A B (width) D (height)
(length)
H1 147/165 305 270 320
90P130 370 221 284
A4V125 326 280 365

A
H1 Dimension Comparison

90 P 130 H1 147 90 P 180

147/165 Aux Pads

• No pad, A, B, & C pad are • D pad is integrated into

bolt-on adaptors the endcap
 H1
Port and Valve Location (Outline in EDMS)
C2 M4 PL A PL B M5 C1
L2
L4
MB
HPRV B
HD B
CPRV
M3

L1 S
HPRV A
HD A

L3
MA
Sensor Technology
• High Pressure (0-550 bar), Purchased Component
– Charge Sensor also available at 0-55 bar
– All Pumps
• Swashplate Angle Sensor (± 20°) – Production Ready
– Production sensor but with new packaging
– Used with NFPE controls ONLY
• Multi Sensor (Speed + Temp) – Existing Technology
(Giant Magneto Resistance - GMR).
– Motors ONLY: 0-8000 rpm with direction sensing
• Integrated Sensors with Microcontroller “Tron” – Under
development
– No external wires
 Series
Product Type
Frame Size
Rotation

A B
Revision
Description

H1 P 165 R _ _
General Product

D
Control

F
Propel Characteristics

E
Displacement Limitation
Control

G
Endcap Type

H
Mounting Flange
H1 Order Code

J
Input Shaft
Customer
Interfaces

K
Auxiliary Pad

A2 C3 N _ D3 G G2 H2 _
M
Protection Type Side A & B
High Pressure Setting Side A

L 42 L
N
Protection Type Side A & B
System

High Pressure Setting Side B

Protection

42 _ L
S

Charge Pump
M
T

Filtration
V

Charge Relief Pressure Setting

System
Charging

Special Hardware Features

X

Paint & Tag

Special

Features
Hardware

Settings
30 _ NN _NNN_ NNN
Features
Customer