Sauer-Danfoss Next

Generation Hydrostatic
Transmission Products

/ H1
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Standard H1 applications
Agenda

• H1 Program Overview
• H1 Product Overview
• Control
• Performance & Efficiencies
• Functionality & Integration
• Dimensions & Size

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HyTron Project –>
H1 Product Family

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Project Scope

• Expanded use of electronics, valves and new technologies

(design & mfg) will enable higher product functionality…
and improve the opportunity for reduced installed system
cost.
– Sensors for: speed, temperature, pressure,
& swash plate angle (NFPE only)
• Initial Launch:
no sensors available
• Future:
Sensors become integral to pump control (electronic PL, swash control, power
control, etc)
– Pump & motor to be a node on the CAN bus
– Integrated & expanded functionality
(ISL + integral control + sensor)

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Project Scope

• The project will cover pumps (PV), motors (MF, MV),

controls and integral electronics (HW, SW) for closed circuit
applications.

• The products and systems are designed for

“Medium and High Power” strategic markets on a worldwide
global base (Americas, EU and APAC).

• The project will result in a new product portfolio for our

worldwide medium and high power closed circuit
applications.

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Project Scope

• Servo controlled pumps from 20cm³ to 250cm³

Motor (constant and variable motors)

• Variable and constant swash plate motors (up

to 60cm³ swash plate technology)

• Variable motors 60cm³ to 250cm³ bent axis

technology with 0°-Option

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H1 Pumps

Which servo controlled pumps

will have tomorrow?

H1 Product Overview

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Available H1 pumps

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 H1 Concept
Swashplate Pump

• Released:
– H1P045/053
– H1T045/053
– H1P078
– H1P147/165

• Available 2. Q 2008
– H1P115/130

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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

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H1 Pump sectional View

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 H1 Pump
end cap sectional view

• HPRV + CPRV PL Pressure Limiter

PL

Charge
Bypass
HPRV

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Tandem Concept Drawings

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H1 Tandem
43 cm³ and 53 cm³

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Designed for
Quality & Reliability

• One piece swashplate

– No bolted or pressed joints
– Diamond milled running face;
eliminates lapping contaminants

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Designed for
Quality & Reliability

• Splined Charge Pump Drive

– More robust than key or pin drive

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 Designed for
Quality & Reliability

• High strength tandem front flange

– No flange – housing joint

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 Designed for
Quality & Reliability

• All H1 single pumps (20-250cm3) will be

of the same layout considering the location
of all ports and valves so long
as proper wrench clearance
can be maintained

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Designed for
Quality & Reliability

Bearings

– Swash plate bearing is designed for even load distribution

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

– New end cap bushing material has higher load capacity than
S90

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H1 Pump

Controls

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H1 Controls

• H1 is designed for an Electrical Control

– EDC
– NFPE
– FNR
Electric
Electric
Controls
Controls
• There are NO plans to design
– MDC
– HDC
– NFPH

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Proportional Solenoid EDC

– Significantly fewer parts than PCP style will improve

reliability and quality
– Reduced hydraulic losses
• No solenoid losses
– Improved Linearity
– Same Solenoid for EDC and NFPE

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EDC Performance
(current vs. swash plate angle)

• Actual 147 cm3 test data

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H1 – Control Principle

Tension spring

EDC link
Cradle
feedback pin
Feedback link

Seal lock nut Center ring

Eccentric
Control spool
adjustment

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H1 Pump Servo System

• One-piece swashplate
Servo Piston
• Robust design
• Center loaded servo
• Simple neutral adjustment
• Springs parallel to servo
piston
• Wear resistant swashplate
bearing
Servo Cylinder
• Reduced number of parts

Swashplate

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H1 Pump

Performance & Efficiencies

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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

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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

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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

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H1 Pump

Functionality & Integration

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H1 Schematic

Animation
Animation

Charge
Bypass
PL HPRV

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H1 HPRV function
Charge, Bypass, Relief

• Charge closed loop

Back to H1
Scematic

Back to H1
Endcap
Sectional
View

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H1 HPRV function
Charge, Bypass, Relief
• Bypass (for moving the vehicle) Back to H1 Back to H1
Scematic Endcap
!NOT for TOWING! Sectional
View
forward backward

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H1 HPRV function
Charge, Bypass, Relief
• High Pressure Relief function

Back to H1
Scematic

Back to H1
Endcap
Sectional
View

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H1
Pressure Limiter function
• Pressure Limiter

Back to H1
Scematic

Back to H1
Endcap
Sectional
View

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Options

• H1 Control OverRide (COR)

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H1 Control OverRide (COR)

Two Position Solenoid for COR

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 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

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 H1 Control OverRide (COR)

• Destrokes pump with de-energized solenoid.

– Overrides the operator input to the control
– “No driver present” >>> no vehicle movement
– 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 > coasting (e.g. forklift truck, avoid loosing the load) or
quickly >emergency stop (any vehicle quick stop)

• Will be a “control solution”

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Options

• Filtration

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 H1 Integral Filters

• Single pumps with integral filter and

electric dirt detection switch
– Full flow filtration
with filter bypass

– Switch energized prior

to filter bypass

– Integral filter an option

down to 60 cc

– Remote filtration

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H1 Integral Filters

Electric contamination
indicator, 4 bar

Bypass Function

Pressure
Start 5,3 bar
End 6,4 bar

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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

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H1 Pump

Dimensions & Size

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H1 – 147/165
Dimension comparison

A B (width) D (height)
(length)
H1 147/165 333 270 320
90P130 370 221 284
A4V125 326 280 365

A
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H1 Dimension Comparison

90 P 130 H1 147/165 90 P 180

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H1 Dimension comparison

BR90P130
Competitior
125cc
364

HyTron Frame D (147/165)

445

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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

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H1 Angle Sensor

• Angle sensor based on existing

production sensor
• Integrated into sweet point of
swashplate thru the control
housing (AC only)
• Sensor redundancy (SFMEA)
provided by 2nd chip
• Deutsch connector orientated
vertically from pump
– Automotive micro snaps into angle
sensor

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 H1 Pump

Customer References

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H1 – 147 cm3 - EDC
Komatsu Forest

• 220 machines
• Since Jan 2006

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 H1 – 165 cm3 – EDC
Claas

• 300 combines
running since 2004

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