# © Blue Graphics Concept Sauer-Danfoss Manual Component Sizing Introduction, August 2012 Introduction, May 2012.

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© Blue Graphics Concept Sauer-Danfoss Manual Component Sizing Introduction, August 2012 Introduction, May 2012

2 Agenda 1.Introduction 2.Calculation steps of manual component sizing 3.Exercise 4.Further informations

3 You must know driveline requirements.... Manual Component Sizing Wheeled Vehicles Tracked Vehicles

4 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

5 Manual Component Sizing Required Pull Force=Tractive Force+.....

6 Manual Component Sizing Required Pull Force=Tractive Force+Rolling Resistance+..... Rolling Resistance F RR =m × g × f RR F RR = Rolling Resistance[N] m = weight [kg] g = gravity [9,81 m/s 2 ] f RR = rolling coefficient [-] _________________________________________________ Rolling Resistance f RR (rubber tyre) Wet Soil/Mud 0,20 Loose Soil 0,12 Grassy Field/Dry Cropland 0,08 Packed Soil 0,05 Dry Asphalt/Concrete Road 0,02

7 Manual Component Sizing Required Pull Force=Tractive Force+Rolling Resistance+Gradeability

8 Manual Component Sizing Corner Power

9 Manual Component Sizing Corner Power definiton for Fixed and Variable Motor V g × ∆p × ŋ mech.motor 20∏ rev rated speed 9550 P C MF = X X

10 Manual Component Sizing Corner Power of Vehicle Once again.....  Corner Power is the multiplication of maximum pull force with the maximum vehicle speed.

11 Manual Component Sizing Overview for Motor Corner Power Motor Corner Power (CP) > required Application Corner Power (CP) Series Size/TypeMax. Working PressureRated SpeedCP at 450 bar*CP at 420 bar*CP at 380 bar* [ccm/rev][bar][rpm][kW] 90 055 MF 450 3900161150136 075 MF3600203189171 100 MF3300248231209 130 MF3100302282255 90055 MV4504600190177160 H1B 060 MV 450 5900266248225 080 MV5300318297269 110 MV4800396370334 160 MV4250510476431 250 MV3650685639578 * to be reflected of the H1 Pump working pressure capabilities!

12 Manual Component Sizing Motor Torque and Wheel Torque * also Sprocket (e.g. Dozer) or Drum (e. g. Roller) radius *

13 Manual Component Sizing Final Gear Ratio and Maximum Motor Speed

14 Manual Component Sizing Pump 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 …

15 Manual Component Sizing Pump Sizing

16 Manual Component Sizing Your calculated pump size must be compared what we have available today in Series H1P and Series 90 SeriesSizeRated SpeedWorking Pressure [ccm][rpm][bar] H1P 45 3400 420 54 380 60 3500 420 68 380 69 3500 450 78 450 89 3300 450 100450 115 3200 450 130450 147 3000 450 165 450 90 424200 450 553900 753600 1003300 1303100 1802600 2502300 Awareness! Selected pump size in conjunction with released working pressure (see table) must be matched with motor corner power. Re-check it‘s a must! Have a care! Pump Sizing

17 Manual Component Sizing Minimum Displacement at maximum Vehicle Speed If you has selected the pump you can calculate the required minimum displacement for the motor at transport speed and make a re-check again for the requested working speed …..

18 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

19 Application: Wheel-Loader Technical Data: Wheel Radius0,487 m Power for Propel System49 kW at engine speed2200 rev/min Customer Requirements: Tractive Force44500 N Working Speed 6 km/h Transport Speed 20 km/h Manual Component Sizing

20 Manual Component Sizing Corner Power of Vehicle

21 Motor Selection Series Size/TypeMax. Working PressureRated SpeedCP at 450 bar*CP at 420 bar*CP at 380 bar* [ccm/rev][bar][rpm][kW] 90 055 MF 450 3900161150136 075 MF3600203189171 100 MF3300248231209 130 MF3100302282255 90055 MV4504600190177160 H1B 060 MV 450 5900266248225 080 MV5300 318 297269 110 MV4800396370334 160 MV4250510476431 250 MV3650685639578 Motor Corner Power (CP) > required Application Corner Power (CP=306 kW) * to be reflected of the H1 Pump working pressure capabilities! Manual Component Sizing

22 Motor Torque Manual Component Sizing

23 Wheel Torque Manual Component Sizing

24 Final Gear Ratio Manual Component Sizing

25 Maximum Motor Speed Manual Component Sizing

26 Pump Size Selection Manual Component Sizing

27 Pump Selection Your calculated pump size must be compared what we have available today in Series H1P and Series 90 SeriesSizeRated SpeedWorking Pressure [ccm][rpm][bar] H1P 45 3400 420 54 380 60 3500 420 68 380 69 3500 450 78 450 89 3300 450 100 450 115 3200 450 130 450 147 3000 450 165450 90 424200 450 553900 753600 1003300 1303100 1802600 2502300 Awareness! Selected pump size in conjunction with released working pressure (see table) must be matched with motor corner power. Re-check it‘s a must! Have a care! Manual Component Sizing

28 New Motor Selection Motor Corner Power (CP) > required Application Corner Power (CP=306 kW) Series Size/TypeMax. Working PressureRated SpeedCP at 450 bar*CP at 420 bar*CP at 380 bar* [ccm/rev][bar][rpm][kW] 90 055 MF 450 3900161150136 075 MF3600203189171 100 MF3300248231209 130 MF3100302282255 90055 MV4504600190177160 H1B 060 MV 450 5900266248225 080 MV5300318 297 269 110 MV4800396370334 160 MV4250510476431 250 MV3650685639578 * to be reflected of the H1 Pump working pressure capabilities! Manual Component Sizing

29 Motor Torque Manual Component Sizing

30 Final Gear Ratio Manual Component Sizing

31 Maximum Motor Speed Manual Component Sizing

32 Revise Maximum Motor Speed Maximum Motor Speed (5467 rev/min) > Rated Speed (5300 rev/min)? Select a larger motor, here: H1B110 Series Size/TypeMax. Working PressureRated SpeedCP at 450 bar*CP at 420 bar*CP at 380 bar* [ccm/rev][bar][rpm][kW] 90 055 MF 450 3900161150136 075 MF3600203189171 100 MF3300248231209 130 MF3100302282255 90055 MV4504600190177160 H1B 060 MV 450 5900266248225 080 MV5300 318297269 110 MV4800 396 370 334 160 MV4250510476431 250 MV3650685639578 * to be reflected of the H1 Pump working pressure capabilities! Manual Component Sizing

33 Motor Torque Manual Component Sizing

34 Final Gear Ratio Manual Component Sizing

35 Final Gear Ratio Manual Component Sizing

36 Maximum Motor Speed Manual Component Sizing

37 Revise Maximum Motor Speed Maximum Motor Speed (5467 rev/min) > Rated Speed (5300 rev/min)? Select a larger motor, here: H1B110 Series Size/TypeMax. Working PressureRated SpeedCP at 450 bar*CP at 420 bar*CP at 380 bar* [ccm/rev][bar][rpm][kW] 90 055 MF 450 3900161150136 075 MF3600203189171 100 MF3300248231209 130 MF3100302282255 90055 MV4504600190177160 H1B 060 MV 450 5900266248225 080 MV5300318297269 110 MV4800 396 370 334 160 MV4250510476431 250 MV3650685639578 * to be reflected of the H1 Pump working pressure capabilities! Manual Component Sizing

38 Pump Size Selection Manual Component Sizing

39 Pump Selection Your calculated pump size must be compared what we have available today in Series H1P and Series 90 SeriesSizeRated SpeedWorking Pressure [ccm][rpm][bar] H1P 45 3400 420 54 380 60 3500 420 68 380 69 3500 450 78 420 89 3300 450 100 420 115 3200 450 130 420 147 3000 450 165 420 90 424200 450 553900 753600 1003300 1303100 1802600 2502300 Awareness! Selected pump size in conjunction with released working pressure (see table) must be matched with motor corner power. Re-check it‘s a must! Have a care! SeriesSizeRated SpeedWorking Pressure [ccm][rpm][bar] H1P 45 3400 420 54 380 60 3500 420 68 380 69 3500 450 78 420 89 3300 450 100 420 115 3200 450 130 420 147 3000 450 165 420 90 424200 450 553900 753600 1003300 1303100 1802600 2502300 Manual Component Sizing

40 Minimum Displacement at maximum Vehicle Speed Manual Component Sizing

41 Maximum Working Speed Manual Component Sizing

42 Further Information LinkLink to Navigator > Sales Propel > Subsystems Propel Further sizing information sorted by application Manual Component Sizing