Introduction, August 2012

© Blue Graphics Concept Sauer-Danfoss© Blue Graphics Concept Sauer-Danfoss

Manual Component Sizing

Introduction, August 2012

Introduction, May 2012

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Agenda

1. Introduction

2. Calculation steps of manual component sizing

3. Exercise

4. Further informations

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You must know driveline requirements ....Manual Component Sizing

Wheeled Vehicles Tracked Vehicles

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Manual Component Sizing… before you can size a HydroStatic Transmission

The customer has to define all the Vehicle and Driveline Requirements before it‘s possible to size a Hydro Static Transmission, short: HST

Vehicle Weight (un-/loaded) Engine Power and Speed Static and Dynamic Wheel Radius Working and Transport Speed Gradeability at Transport Speed Pull Force Auxiliary Pump(s) Final Gear Supplier and available ratios Limitations on Pressure Duty Cycle

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Manual Component SizingRequired Pull Force=Tractive Force+.....

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Manual Component SizingRequired Pull Force=Tractive Force+Rolling Resistance+.....

Rolling Resistance

FRR =m × g × fRR

FRR = Rolling Resistance[N]m = weight [kg]g = gravity [9,81 m/s2]fRR = rolling coefficient [-]

_________________________________________________

Rolling Resistance fRR (rubber tyre)Wet Soil/Mud 0,20Loose Soil 0,12Grassy Field/Dry Cropland 0,08Packed Soil 0,05

Dry Asphalt/Concrete Road 0,02

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Manual Component SizingRequired Pull Force=Tractive Force+Rolling Resistance+Gradeability

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Manual Component SizingCorner Power

𝐇𝐒𝐓𝐑𝐚𝐭𝐢𝐨=𝐏𝐂𝐏𝐄

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Manual Component SizingCorner Power definiton for Fixed and Variable Motor

Vg × ∆p × ŋmech.motor

20∏ rev rated speed

9550PC MF = X

X

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Manual Component SizingCorner Power of Vehicle

Once again .....

Corner Power is the multiplication of maximum pull force with the maximum vehicle speed.

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Manual Component SizingOverview for Motor Corner Power

Motor Corner Power (CP) > required Application Corner Power (CP)

Series Size/Type Max. Working Pressure Rated Speed CP at 450 bar* CP at 420 bar* CP at 380 bar*

[ccm/rev] [bar] [rpm] [kW] [kW] [kW]

90

055 MF

450

3900 161 150 136

075 MF 3600 203 189 171

100 MF 3300 248 231 209

130 MF 3100 302 282 25590 055 MV 450 4600 190 177 160

H1B

060 MV

450

5900 266 248 225

080 MV 5300 318 297 269

110 MV 4800 396 370 334

160 MV 4250 510 476 431

250 MV 3650 685 639 578

* to be reflected of the H1 Pump working pressure capabilities!

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Manual Component SizingMotor Torque and Wheel Torque

* also Sprocket (e.g. Dozer) or Drum (e. g. Roller) radius

*

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Manual Component SizingFinal Gear Ratio and Maximum Motor Speed

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Manual Component SizingPump Sizing

Most of Vehicles using as „State of the Art“ mainly Variable Bent Axis Motor‘s to fulfill OEM-Demand‘s regarding selectable drive modes like this

Wheeled Vehicle Working Speed in a range of 5,5-7,5 km/h Transport Speed in a range of 20, 25,35 and 40 km/h

Tracked Vehicle Working Speed up to 10-12 km/h Transport Speed 20 up to 40 km/h

For this reason it‘s necessary to define the size of Variable Piston Pump as well in the following way …

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Manual Component SizingPump Sizing

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Your calculated pump size must be compared what we haveavailable today in Series H1P and Series 90

Series Size Rated Speed Working Pressure Working Pressure Working Pressure [ccm] [rpm] [bar] [bar] [bar]

H1P

45 3400 420 54 38060 3500 420 68 38069 3500 450 78 450 89 3300 450

100 450 115 3200 450 130 450 147 3000 450 165 450

90

42 4200

450

55 390075 3600

100 3300130 3100180 2600250 2300

Awareness!Selected pump size inconjunction with releasedworking pressure (see table)must be matched withmotor corner power. Re-check it‘s a must!

Have a care!

Pump Sizing

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Manual Component SizingMinimum Displacement at maximum Vehicle Speed

If you has selected the pump you can calculate the requiredminimum displacement for the motor at transport speed andmake a re-check again for the requested working speed …..

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Vehicle Corner Power higher compared w/ Motor Corner Power

What can we do in such case???(Remember: H1B250 685 kW at 450 bar as example)

Two-speed Gear Shift Shift on Stop (simple solution) Two-speed Power Shift Gear Shift on Fly* Two Motor System Shift on Fly (0°-degree capability w/ clutch)*

Remark *• higher demand for the Control System of Pump & Motor• compensation/synchronization of HST during shifting required

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Application: Wheel-Loader

Technical Data:

Wheel Radius 0,487 mPower for Propel System 49 kWat engine speed 2200 rev/minCustomer Requirements: Tractive Force 44500 NWorking Speed 6 km/hTransport Speed 20 km/h


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Manual Component SizingCorner Power of Vehicle

𝐏𝐂=𝟒𝟒𝟓𝟎𝟎𝐍∗𝟐𝟎𝐤𝐦 /𝐡𝟑𝟔𝟎𝟎∗𝟎 ,𝟗𝟓∗𝟎 ,𝟖𝟓 =𝟑𝟎𝟔𝐤𝐖

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Motor Selection



90

055 MF

450

3900 161 150 136

075 MF 3600 203 189 171

100 MF 3300 248 231 209

130 MF 3100 302 282 25590 055 MV 450 4600 190 177 160

H1B

060 MV

450

5900 266 248 225

080 MV 5300 318 297 269

110 MV 4800 396 370 334

160 MV 4250 510 476 431

250 MV 3650 685 639 578

Motor Corner Power (CP) > required Application Corner Power (CP=306 kW)



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Motor Torque

𝐓𝐌=𝟖𝟎𝐜𝐦 ³∗𝟒𝟓𝟎𝐛𝐚𝐫∗𝟎 ,𝟗𝟓

𝟐𝟎∗𝛑 =𝟓𝟒𝟒𝐍𝐦


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Wheel Torque

𝐓𝐖=𝟒𝟒𝟓𝟎𝟎𝐍∗𝟎 ,𝟒𝟖𝟕𝐦=𝟐𝟏𝟔𝟕𝟐𝐍𝐦


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Final Gear Ratio

𝐢𝐆=𝟐𝟏𝟔𝟕𝟐𝐍𝐦𝟓𝟒𝟒𝐍𝐦 ∗ 𝟏

𝟎 ,𝟖𝟓=𝟒𝟔 ,𝟖𝟕


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Maximum Motor Speed


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Pump Size Selection


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Pump SelectionYour calculated pump size must be compared what we haveavailable today in Series H1P and Series 90


H1P

45 3400 420 54 38060 3500 420 68 38069 3500 450 78 450 89 3300 450

100 450 115 3200 450 130 450 147 3000 450 165 450

90

42 4200

450

55 390075 3600

100 3300130 3100180 2600250 2300

Awareness!Selected pump size in

conjunction with releasedworking pressure (see table)

must be matched withmotor corner power. Re-check it‘s a must!

Have a care!


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New Motor Selection

Motor Corner Power (CP) > required Application Corner Power (CP=306 kW)



90

055 MF

450

3900 161 150 136

075 MF 3600 203 189 171

100 MF 3300 248 231 209

130 MF 3100 302 282 25590 055 MV 450 4600 190 177 160

H1B

060 MV

450

5900 266 248 225

080 MV 5300 318 297 269

110 MV 4800 396 370 334

160 MV 4250 510 476 431

250 MV 3650 685 639 578



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Motor Torque

𝐓𝐌=𝟖𝟎𝐜𝐦 ³∗𝟒𝟐𝟎𝐛𝐚𝐫∗𝟎 ,𝟗𝟓

𝟐𝟎∗𝛑 =𝟓𝟎𝟖𝐍𝐦


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Final Gear Ratio

𝐢𝐆=𝟐𝟏𝟔𝟕𝟐𝐍𝐦𝟓𝟎𝟖𝐍𝐦 ∗ 𝟏

𝟎 ,𝟖𝟓=𝟓𝟎 ,𝟏𝟗


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Maximum Motor Speed

𝐫𝐞𝐯𝐌𝐦𝐚𝐱=𝟐𝟎𝐤𝐦/𝐡∗𝟓𝟎 ,𝟏𝟗𝟎 ,𝟑𝟕𝟕∗𝟎 ,𝟒𝟖𝟕 =𝟓𝟒𝟔𝟕𝐦𝐢𝐧−𝟏


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Revise Maximum Motor Speed

Maximum Motor Speed (5467 rev/min) > Rated Speed (5300 rev/min)?Select a larger motor, here: H1B110



90

055 MF

450

3900 161 150 136

075 MF 3600 203 189 171

100 MF 3300 248 231 209

130 MF 3100 302 282 25590 055 MV 450 4600 190 177 160

H1B

060 MV

450

5900 266 248 225

080 MV 5300 318 297 269

110 MV 4800 396 370 334

160 MV 4250 510 476 431

250 MV 3650 685 639 578



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𝐓𝐌=𝟏𝟏𝟎𝐜𝐦 ³∗𝟒𝟐𝟎𝐛𝐚𝐫∗𝟎 ,𝟗𝟓

𝟐𝟎∗𝛑 =𝟔𝟗𝟗𝐍𝐦

Motor Torque


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Final Gear Ratio

𝐢𝐆=𝟐𝟏𝟔𝟕𝟐𝐍𝐦𝟔𝟗𝟗𝐍𝐦 ∗ 𝟏

𝟎 ,𝟖𝟓=𝟑𝟔 ,𝟒𝟖


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Final Gear Ratio

𝐢𝐆=𝟐𝟏𝟔𝟕𝟐𝐍𝐦𝟔𝟗𝟗𝐍𝐦 ∗ 𝟏

𝟎 ,𝟖𝟓=𝟑𝟔 ,𝟒𝟖


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Maximum Motor Speed

𝐫𝐞𝐯𝐌𝐦𝐚𝐱=𝟐𝟎𝐤𝐦/𝐡∗𝟑𝟔 ,𝟒𝟖𝟎 ,𝟑𝟕𝟕∗𝟎 ,𝟒𝟖𝟕𝐦=𝟑𝟗𝟕𝟒𝐦𝐢𝐧−𝟏


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Revise Maximum Motor Speed

Maximum Motor Speed (5467 rev/min) > Rated Speed (5300 rev/min)?Select a larger motor, here: H1B110



90

055 MF

450

3900 161 150 136

075 MF 3600 203 189 171

100 MF 3300 248 231 209

130 MF 3100 302 282 25590 055 MV 450 4600 190 177 160

H1B

060 MV

450

5900 266 248 225

080 MV 5300 318 297 269

110 MV 4800 396 370 334

160 MV 4250 510 476 431

250 MV 3650 685 639 578



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Pump Size Selection

𝐕𝐠𝐏=𝟏𝟏𝟎𝐜𝐦 ³∗ 𝟔𝐤𝐦 /𝐡𝟐𝟎𝐤𝐦/𝐡 ∗𝟑𝟗𝟕𝟒𝐦𝐢𝐧

−𝟏

𝟐𝟐𝟎𝟎𝐦𝐢𝐧−𝟏∗ 𝟏𝟎 ,𝟗𝟓=𝟔𝟐 ,𝟕𝟓𝐜𝐦 ³


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Pump Selection

Your calculated pump size must be compared what we haveavailable today in Series H1P and Series 90


H1P

45 3400 420 54 38060 3500 420 68 38069 3500 450 78 420 89 3300 450

100 420 115 3200 450 130 420 147 3000 450 165 420

90

42 4200

450

55 390075 3600

100 3300130 3100180 2600250 2300

Awareness!Selected pump size inconjunction with releasedworking pressure (see table)must be matched withmotor corner power. Re-check it‘s a must!

Have a care!


H1P

45 3400 420 54 38060 3500 420 68 38069 3500 450 78 420 89 3300 450

100 420 115 3200 450 130 420 147 3000 450 165 420

90

42 4200

450

55 390075 3600

100 3300130 3100180 2600250 2300


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Minimum Displacement at maximum Vehicle Speed

𝐕𝐠𝐌𝐦𝐢𝐧=𝟔𝟎𝐜𝐦 ³∗𝟐𝟐𝟎𝟎𝐦𝐢𝐧−𝟏∗𝟎 ,𝟗𝟓

𝟑𝟗𝟕𝟒𝐦𝐢𝐧−𝟏=𝟑𝟏 ,𝟓𝟔𝐜𝐦 ³


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Maximum Working Speed

𝐒𝟏𝐫𝐞𝐚𝐥=𝟔𝟎𝐜𝐦 ³∗𝟔𝐤𝐦 /𝐡𝟔𝟐 ,𝟕𝟓𝐜𝐦 ³ =𝟓 ,𝟕𝟒𝐤𝐦/𝐡


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Further Information

Link to Navigator > Sales Propel > Subsystems Propel

• Further sizing information sorted by application


http://navigator.network.int/stellent/idcplg?IdcService=GET_DYNAMIC_CONVERSION&RevisionSelectionMethod=LatestReleased&dDocName=intralp_d_pp_tst_s

Introduction, August 2012

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