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Risk assessment

W

Warning

It is the OEMs responsibility to perform a hazard and risk analysis of the complete steering system and

add the necessary risk-reducing measures.

Operation Manual

PVED-CL Controller for Electro-Hydraulic Steering, Version 1.38

Safety Considerations

 

©

 Danfoss | May 2016

11025583 | AQ00000216en-US0302 | 15

Summary of Contents for pved-cl

Page 1: ...Operation Manual PVED CL Controller Electro Hydraulic Steering Version 1 38 powersolutions danfoss com...

Page 2: ...2010 Major changes For PVED CL software release 1 38 CA 05 May 2007 Major changes For PVED CL software release 1 28 BA 01 Nov 2006 First edition For PVED CL software release 1 26 AA Operation Manual...

Page 3: ...peration 14 Vehicle Speed Sensor 14 Closed loop Operation 14 Analogue Input Sensors Joystick or Wheel Angle Sensor 14 Risk assessment 15 Configuration and Adjustment Configuration and Adjustment 16 Pa...

Page 4: ...be acquired 32 Analogue Interface 32 AD Signal Interface Requirements 33 Scaling Analogue Signals 33 Linear Transfer Characteristic 3 Point 33 Non Linear Transfer Characteristic 5 Point 34 Scenario 34...

Page 5: ...e Noise due to Frequent Pressure Build up 58 Magnetic Valve Control 58 Steering by High Priority Steering Device Open Loop Steering by High Priority Steering Device Open Loop 60 Functionality Tree 60...

Page 6: ...s with Fixed Ramp Times 82 Example 82 Example 83 Select Ramps with Ramp Time Related to Vehicle Speed 83 Example 85 Example 85 Anti jerk Ramp Parameter Tuning Guide 86 Soft Cushion End stop 86 Spool D...

Page 7: ...xample on Resolving a Fault 101 Solution 101 Troubleshooting 101 Typical Fault Sources 101 J1939 Diagnostic Interface 102 AD1 and or AD2 Short circuit 104 Missing CAN Sensor Set points 104 Redundant W...

Page 8: ...higher focus along with higher demands for automation new technologies are necessary to take on this challenge The new technologies are using electro hydraulics combining hydraulic power with electro...

Page 9: ...teering pressure up to 250 bar PVG 32 Proportional valve Flow capacity up to 120 l min Max steering pressure 350 bar Please contact Danfoss for further information PVG 100 Proportional valve Flow capa...

Page 10: ...no steering before it can switch to the requested steering device In case the operator wants to switch to a higher priority steering device controller the switch will happen instantaneously This mean...

Page 11: ...ith GPS laser or row guidance controllers Variable steering ratio actuator dependant Lower steering ratio during load cycle Variable steering ratio speed dependant The higher driving speed the higher...

Page 12: ...ol The PVED CL conforms to CAN bus standard J1939 Relevant J1939 compliance issues are explained in PVED CL Communication Protocol 11079551 For details on parameter changes refer to Changing Default P...

Page 13: ...Steering Device Steering wheel sensor SASA CAN Mapping a Steering Device Anti Drift knob position control Vehicle Speed Dependent Sensitivity Actuator Dependent Sensitivity Soft End Stop Anti Jerk Fix...

Page 14: ...ve correctly and the data field is within the valid range Therefore W Warning It is the OEMs responsibility to establish a reliable vehicle speed signal to the PVED CL The provider of the vehicle spee...

Page 15: ...rform a hazard and risk analysis of the complete steering system and add the necessary risk reducing measures Operation Manual PVED CL Controller for Electro Hydraulic Steering Version 1 38 Safety Con...

Page 16: ...ustomize the EHPS EH system to a particular vehicle Parameters are used to e g map steering devices and sensors compensate for non linearity in steering signals and to control the functionality featur...

Page 17: ...g device 5 20 24 Low priority steering device 5 25 29 High priority set point controller 5 30 34 Example on program layout for high priority steering device Set point to Flow command Ramp Limitation C...

Page 18: ...on page 112 What is the program parameter index for Steering sensitivity selector Sse for the steering wheel program 4 Sse Steering wheel device is defined as device number 1 The index for program num...

Page 19: ...The PVED CL provides max vehicle speed thresholds for each steering device The default values are chosen for robustness reasons to create a region rather than a point Device Index Default Value range...

Page 20: ...ages between 0 and 5V to digital signals 10 bit Executing the steering software monitoring for discrepancies with fixed time intervals Output the main spool position setpoint Controlling the LED color...

Page 21: ...PVED controls the spool movement inside the valve Yellow The magnetic valves are temporary disabled due to the power saving feature or until the PVED is operated The magnetic valves can also permanen...

Page 22: ...DC 0 to 5 VDC into 0 1023 10 bit Available baud rates to CAN Kilo bit s 125 250 500 AD1 2 input impedance Approximately 1MOhm Max analogue signal source impedance 100 kOhm Protection Grade of enclosu...

Page 23: ...on time at installation time in a PVED CL replacement situation or in performance fine tuning situations The PVED CL is calibrated to the valve by a dedicated valve transfer function having 7 paramete...

Page 24: ...ation can be configured to jump between over the dead band This resembles servo valve operation and gives a fast steering response In PVED CL closed loop operation mode the spool will always jump over...

Page 25: ...p Parameter holding information about the maximum flow capacity of the valve ClosedLoopXspOffset Spool position offset which is added to spool position set point in closed loop mode only The offset en...

Page 26: ...g ratio applications the dead band and steering ratio will vary slightly Similarly in auto steering mode the flow for correcting the steered wheels may vary from smooth corrections to more jerky corre...

Page 27: ...de in PVED CL Communication Protocol 11079551 on how to set the PVED CL in calibration mode 2 The valve auto calibration command shall be sent from the MMI controller 3 A wheel angle sensor shall be i...

Page 28: ...detected spool set points results in the open loop software dead bands values XspCalibrationOffset is a parameter value and is used for both left and right spool direction XspCalibrationOffset paramet...

Page 29: ...Valve auto calibration procedure 1 Issue the start valve auto calibration command from a MMI 2 Monitor valve auto calibration status messages Optionally enable status set 1 for detailed monitoring of...

Page 30: ...red steering accuracy can be obtained when using the PVED CL in closed loop mode such as auto steering The vehicle shall follow the path within the expected precision with small steering actuator move...

Page 31: ...re noise levels from the analogue wheel angle sensor The wheel angle sensor AD noise shall not exceed 4 counts when observed via Status set 1 see Status in PVED CL Communication Protocol 11079551 High...

Page 32: ...steering wheel using the EHPS valve with hydraulic back up Other parameter conflicts are mentioned appendix Program Parameters on page 112 A mapped device can be de activated by means of sending a Dev...

Page 33: ...ght and neutral and even intermediate values if desired Scaling is done by sample value to calculation domain transfer characteristics Two different transfer characteristics are available for each AD...

Page 34: ...eered wheel is precisely in between neutral and right or left end stop respectively 0 Sampled AD value Scaled value Margin Short circuit AD1 2 _1000_Right AD1 2 _Neutral AD1 2 _1000_Right AD1 2 _500_R...

Page 35: ...ion value as a result of aging or temperature of the electronic circuits To select compensation in PVED CL or not use parameter AnalogChannelCompensation Compensation can be applied to either input or...

Page 36: ...s the criteria the previous selected device remains On power up all devices are normally in their rest position which means that no device is selected The magnetic valve is disabled while no device is...

Page 37: ...ering device 319 100 0 200 Steering by Low priority steering device 419 100 0 200 Steering by High priority external set point controller 519 100 0 200 Changes to parameters of non present steering de...

Page 38: ...rtTime parameter defines the time in ms that the no steering wheel activation confidence timer shall reach before the noise gate will floor any steering wheel input to 0 As long as the confidence time...

Page 39: ...Sse 3 Open loop sensitivity related to steering actuator position with fixed ramp times Open loop sensitivity related to steering actuator position no ramps applied Open loop sensitivity related to v...

Page 40: ...s normally set equal to the angle related to elasticity However any set value greater than zero leads to slower steering responds Therefore to minimize these effects the steering wheel sensor shaft an...

Page 41: ...inear to 10 max progressive Qm 1y27 1000 0 to 1000 100 flow at CL or CR port Steering Sensitivity Sensitivity is set individually for each program and can be either fixed or variable Sensitivity can d...

Page 42: ...t be set at 1 Sts0 1y10 400 20 to 1200 A steering ratio of 400 equals to 4 00 steering wheel turns to move the steering actuator from YL to YR left to right end lock position Select a Sensitivity with...

Page 43: ...etween two table coordinates is found by linear interpolation The relation is equal for negative speeds 200 300 400 500 0 340 360 380 420 Sts0 400 Sts3 400 Sts4 400 Sts5 400 Ve Vehicle speed 1 unit 0...

Page 44: ...closing the valve oil flow An instant cylinder movement stop starts the articulating masses to oscillate until all kinetic energy is dispatched into heat by the shock valves or by the friction between...

Page 45: ...mance Set up fast ramp down time Tfr before tuning this parameter Setting YsetFr to 1000 eliminates the effect of the fast ramp down Typical settings are 500 800 Use trial and error Example A value of...

Page 46: ...ort at a slight reverse port flow request Typically YAbortDownRamp needs be increased to avoid unintentional down ramp aborts as this will infer a jerk on the driver Tra 1y35 1 1 to 1000 ms Ramp down...

Page 47: ...en the ramp up time is set larger than the inherent ramp down time of the main spool See Technical Data on page 22 for these ramp times Trh Sets the ramp up time to open the valve from zero to max por...

Page 48: ...y Tra shall be significantly smaller than the slow down ramp to get any effect Example A value equal to 500 means that the driver needs to steer out 500 1000 of maximum flow before the slow down ramp...

Page 49: ...to slow down the actuator speed when approaching the end lock electronically The red line in the figure below shows how the actuator is slowed down near the end lock position The black line in the fi...

Page 50: ...ding on the flow request The backlash parameter has no impact for these Tolsout values Dead band Hold and Proportional Control Setting Tolsout between 21 and 30 000 ms defines the maximum time where t...

Page 51: ...c valve bridge is enabled when the PVED CL receives a non zero flow request Symbol Index Default Value range Magnetic valves off delay time 115 30 000 1 to 30 000 ms If Qm is set to 0 then the magneti...

Page 52: ...applied Open loop sensisitivity related to vehicle speed with fixed ramp times Open loop sensisitivity related to vehicle speed no ramp times applied Open loop Cp 0 Fixed Sr 1 Var Sr 2 Control princip...

Page 53: ...ng wheel sensor shaft and underlying mechanics as shown below must be designed as stiff as possible Sensor Steering wheel Since this parameter only effects changes in the set point stability problems...

Page 54: ...o vehicle speed is normally used to optimize steering controllability at higher driving speeds The values correlation is normal closely related to the present vehicle dynamics of the individual vehicl...

Page 55: ...ring actuator from YL to YR left to right end lock position See chapters Mapping steering signals and J1939 Vehicle Speed to acquire vehicle speed Create the Set point The transfer function provides t...

Page 56: ...rkVol scales the feed forward in order to get the specified number of steering wheel turns within the end locks It represents the stroke volume between the mechanical end locks in cm3 Kp must be tempo...

Page 57: ...w capacity per 0 1 positional error Qm 1y27 1000 0 to 1000 0 0 100 0 of max port flow Off 1y28 100 0 to 1000 0 0 100 0 of max port flow StrkVol 707 600 10 to 8000 ccm In order to ensure convergence ch...

Page 58: ...ow command exceeds the threshold The default values mean that if a flow request from the controller is less than 5 of max port flow has occurred for 3 seconds the spool returns to neutral Tclpout Sets...

Page 59: ...nge Magnetic valves off delay time 115 30 000 1 to 30 000 ms Operation Manual PVED CL Controller for Electro Hydraulic Steering Version 1 38 Steering by Steering Wheel Closed Loop Danfoss May 2016 110...

Page 60: ...s applied Open loop sensitivity related to vehicle speed with fixed ramp times Open loop sensitivity related to vehicle speed no ramp times applied Open loop Cp 0 Fixed Sr 1 Var Sr 2 Control principle...

Page 61: ...direction or CW Max input signal for activating the steering device into the left direction or CCW Qr requested port flow 1 unit 0 1 of Max port flow P005 210E Db Sets a dead band in the middle regio...

Page 62: ...ed 1 unit 0 1 km h Fixed sensitivity program 0 Sts0 Sts1 Sts2 Sts3 Sts4 Sts5 Vehicle speed dependant non linear program 2 Vehicle speed dependant non linear program 3 Vehicle speed dependant linear pr...

Page 63: ...tantly used since variable Yact remains 0 Sts1 Sets the linear gradient between steering angle and requested port flow for steering at the minimum turning radius Symbol Index Default Value range Sse 3...

Page 64: ...ed port flow when the vehicle is driving at 50 00 of the speed defined by parameter Vesm Sts5 Sets the linear gradient between steering angle and requested port flow when the vehicle is driving at 100...

Page 65: ...rom zero to max port flow The time applies for both ports To gain the best performance the ramp up time shall be set larger than the inherent ramp up time of the main spool See Technical Data on page...

Page 66: ...s to a certain steering wheel RPM Typical values are 100 300 to have the abort down ramp possibility and to avoid unintentional abort of the down ramp due to steering wheel activation due to vibration...

Page 67: ...set larger than the inherent ramp down time of the main spool See Technical Data on page 22 for these data Trh Sets the ramp up time to open the valve from zero to max port flow when the vehicle speed...

Page 68: ...ra shall be significantly smaller than the slow down ramp to get any effect Tra is the ramp down time applied when the slow down ramp is aborted This rampdown time shall typically be much lower than t...

Page 69: ...st jerks shall be tuned away with the ramp up time Tro and ramp down time Tfo 7 Finally the YAbortThrehold and Tra may be adjusted Consider how many steering wheel RPM is needed to abort the down ramp...

Page 70: ...1000 1000 Values smaller than 0 will be set equal to the positive equivalent YL 3y08 1000 1000 1000 Values greater than 0 will be set equal to the negative equivalent Off 3y28 50 0 to 1000 0 0 100 0...

Page 71: ...30 000 ms Magnetic Valves OFF Control Magnetic valves off delay time disables the magnetic valve bridge after a time specified in ms when the flow request is 0 otherwise it remains enabled This param...

Page 72: ...ring actuator Sse 2 Related to vehicle speed Sse 3 Open loop fixed sensitivity with no ramps applied Open loop sensitivity related to steering actuator position with fixed ramp times Open loop sensiti...

Page 73: ...nit 0 1 of steering actuator at the left end lock position P005 212E Defaults db 0 Lx 0 Xysat 1000 YR 1000 YL 1000 db Sets a dead band about the middle region of the signal The parameters prevent self...

Page 74: ...on Steady State Error on page 56 for information on accuracy The default value fits to steering systems with a lock to lock time of 2 seconds at max port flow Qm Sets the maximum port flow It effects...

Page 75: ...for a longer period of time and the user wishes to eliminate the risk of unintentional device activation System Requirements The device enable disable control functionality is only functional if the...

Page 76: ...the reception of first command message Otherwise the device disable state will change back to its last state Boot up State of Steering Device The boot up enable disable state of the device can be con...

Page 77: ...en loop sensitivity related to vehicle speed with no ramps applied Closed loop Fixed sensitivity no ramps possible Closed loop Cp 255 Fixed Sr 1 No Sr 0 Var Sr 2 Control principle switch Sensitivity s...

Page 78: ...direction or CW Max input signal for activating the steering device into the left direction or CCW Qr requested port flow 1 unit 0 1 of Max port flow P005 210E Db Sets a dead band in the middle regio...

Page 79: ...eed 1 unit 0 1 km h Fixed sensitivity program 0 Sts0 Sts1 Sts2 Sts3 Sts4 Sts5 Vehicle speed dependant non linear program 2 Vehicle speed dependant non linear program 3 Vehicle speed dependant linear p...

Page 80: ...l be constantly used since variable Yact remains 0 Sts1 sets the linear gradient between steering angle and requested port flow for steering at the minimum turning radius Symbol Index Default Value ra...

Page 81: ...ted port flow when the vehicle is driving at 50 00 of the speed defined by parameter Vesm Sts5 Sets the linear gradient between steering angle and requested port flow when the vehicle is driving at 10...

Page 82: ...own curve The default value is a linear ramp Tro Sets the ramp up time to open the valve from zero to max port flow The time applies for both ports To gain the best performance the ramp up time shall...

Page 83: ...to steer out 500 1000 of maximum flow before the slow down ramp is aborted 500 again corresponds to a certain steering wheel RPM Typical values are 100 300 to have the abort down ramp possibility and...

Page 84: ...set larger than the inherent ramp down time of the main spool See Technical Data on page 22 for these data Trh Sets the ramp up time to open the valve from zero to max port flow when the vehicle speed...

Page 85: ...p is aborted This rampdown time shall typically be much lower than the slow ramp down time Tfo in order to gain any increased steering responsiveness Typical value is half the value of Tfo or Tfh time...

Page 86: ...d Consider how many steering wheel RPM is needed to abort the down ramp Secondly adjust Tra to reduce the jerk when aborting the down ramp Obviously Tra needs to be less than the down ramp time Tfo to...

Page 87: ...position and back so called jumps at small flow requests The flow request is 0 while moving the high priority steering device within the steering device dead band db see Set point Transfer Function on...

Page 88: ...D CL receives a non zero flow request Symbol Index Default Value range Magnetic valves Off delay time 415 30 000 1 to 30 000 ms Resolving a Steering Control Conflict On systems utilizing a PVED CL an...

Page 89: ...sensitivity with fixed ramp times Related to position of steering actuator Sse 2 Related to vehicle speed Sse 3 Open loop fixed sensitivity with no ramps applied Open loop sensitivity related to stee...

Page 90: ...activating the steering device into the left direction 1 unit 0 1 of steering actuator at the right end lock position 1 unit 0 1 of steering actuator at the left end lock position P005 212E Defaults d...

Page 91: ...iving at low high vehicle speed and reversed gear robustness to changes in damping dead times Moreover Kp is closely related to valve capacity stroke volume See section Steady State Error on page 56 f...

Page 92: ...steering devices when only the steering wheel device is in use for a longer period of time and the user wishes to eliminate the risk of unintentional device activation System Requirements The device e...

Page 93: ...isable state will change back to its last state Boot up State of Steering Device The boot up enable disable state of the device can be configured with a parameter and can be changed via the SetParamet...

Page 94: ...n in the parameter table below Other parameters mentioned in this chapter can be used with default values and should only be adjusted if the performance needs fine tuning Symbol Index Default Value ra...

Page 95: ...the valve and will therefore not have any effect Ampl Factor that amplifies the set point Used if the steered angle is always too small or too larger It applies to both sides hence if the angle is too...

Page 96: ...ual vehicle model The Sts value is used to amplify the input signal as described in Set point Transfer Function on page 78 The correlation is defined by seven parameters All Sts parameters may be set...

Page 97: ...ng control conflict between the OSP and the PVED CL implementing EHPS type 1 systems only The default value disables this functionality i e the magnetic valve bridge is enabled at all times The magnet...

Page 98: ...ring detection of SASA steering wheel position changes Symbol Index Default Value range StwDxActivationThreshold 64022 5 0 to 4095 StwActivationTimeout 64023 0x7FFFFFFF 0 to 0x7FFFFFFF Default is also...

Page 99: ...to the PVED CL error handler that any fault related to the High priority steering device shall bring the PVED CL into reduced state and change the high priority steering device functionality as follow...

Page 100: ...eed on page 46 Program transition will ignore vehicle speed condition rule See System State on page 19 Symbol Index Default Value range VSReducedModeAllowed 64012 0 0 FALSE 255 TRUE False infers that...

Page 101: ...PVED CL in calibration mode Troubleshooting The PVED CL software performs diagnostic checks on the CAN bus interface analogue sensors magnetic valve bridge interface internal hardware peripherals and...

Page 102: ...s joysticks etc do not match and causes a small output flow when the device is activated 3 PVED CL neutral spool position calibration is incorrect and needs re adjusting mechanical valve defect 4 Auto...

Page 103: ...10106 1083 AD1 short circuit to VCC 3 0 Yes 10108 1084 AD2 short circuit to GND 4 0 Yes 10107 1084 AD2 short circuit to VCC 3 0 Yes 10109 611 Missing sensor set points 14 0 Yes 10210 10212 10215 1021...

Page 104: ...presented as standardized J1939 73 Suspect Parameter Numbers SPN The sub set is limited to interface related faults which are typically causing most troubles AD1 and or AD2 Short circuit Each of the t...

Page 105: ...can be ignored by using the knowledge of the actual sensor mapping SPN PVED CL Error Code Possible root cause 612 10104 The primary steered wheel angle sensor set point and the redundant steered wheel...

Page 106: ...er to retrieve the EHPS error code and apply the table with PVED CL error codes to locate the error source The user shall locate the last entered error entry which is either the last error code before...

Page 107: ...ax Spool position at right side of neutral 300 1000 EH OSPE 400 1000 EHPS 25 748 ClosedLoopXspOffset Auto calibration set point offset 0 300 25 750 Ktol Tolerance parameter for plausibility check and...

Page 108: ...5 Temperature histogram interval 4 936 Temperature histogram interval 5 937 Temperature histogram interval 6 938 Temperature histogram interval 7 939 Temperature histogram interval 8 940 Temperature h...

Page 109: ...owed 255 0 64012 VSReducedModeAllowed Reduced mode switch for the vehicle speed sensor signal 64013 HPStdReducedModeAllow ed Reduced mode switch for the high priority steering device 64014 LPStdlReduc...

Page 110: ...user defined 65051 BaudRate The CAN bus physical baud rate 250 65055 AD1_500_Left Value of the analogue AD 1 between extreme left and neutral U16 30 957 300 65062 AD1_500_Right Value of the analogue A...

Page 111: ...n joystick potentiometer other U8 No device connected 0 0 Analogue device on AD1 1 Analogue device on AD2 2 CAN based device 4 65103 LowPrioritySteeringDeviceInterface Low priority steering device con...

Page 112: ...mm 65120 OSPSize Size of hydraulic steering unit in cm3 20 1200 20 65121 ValveType Defines type of the valve PVED CL is mounted on EHPS 1 EH 2 1 65122 SteeringType Used for Auto steering algorithm sel...

Page 113: ...ime at vehicle speed 0 1y21 3y21 4y21 5y21 1 1000 1 Trh Ramp up time at vehicle speed Verm 1y22 3y22 4y22 5y22 Tfo Ramp down time at vehicle speed 0 1y23 3y23 4y23 5y23 350 Tfh Ramp down time at vehic...

Page 114: ...ernal set point controller Range Default High Priority Low Priority Kp SIGNED16 Proportional gain for closed loop 108 308 408 508 0 200 50 Full_Strk SIGNED16 Fastest steering device input minimum to m...

Page 115: ...d Detection of steering request with a steering device 10 of maximum activation speed 119 319 419 519 0 2000 50 100 100 100 P_Ve_Transit_Threshold SIGNED16 Vehicle speed Threshold value to allow new p...

Page 116: ...DK 6430 Nordborg Denmark Phone 45 7488 2222 Danfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 Danfoss Power Solutions Trading Shanghai Co Ltd Building 22...

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