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powersolutions.danfoss.com
Hydraulic and Electronic Control SolutionsConcrete Pump Truck
Best Partnerfor a future of intelligence
Quality products and systems indicate lower maintenance cost and longer service life. Our global network and quick response will support smooth running of your equipment.
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 <- Retract towards PVE
Extend away from PVE ->
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