Sauer-Danfoss Electrohydraulics Overview

Sauer-Danfoss Electrohydraulics
Global Business Unit and its Operations

Neumünster operation Almhult operation

Central EU operation

ICT Nordborg
operation operation
Minneapolis operation

Italdigit operation

Existent
Planned
 Sauer-Danfoss Electrohydraulics
Global Business Unit and its Operations
• Minneapolis
– Global products
– Applications support for Americas and Asia
• Neumünster
– Global products
– Applications support for Europe
• Älmhult
– Global products
– Applications support for Scandinavia, part of SAS since Jan. 2000
• ICT
– Global products
– Applications support for Western EU-EH
• Italdigit
– Global products
– Applications support for Southern EU-EH
• France as part of Southern EU-EH, under investigation
• Germany as part of Central EU-EH, under investigation
• Nordborg w/Danfoss based Products, under investigation
– Software group is now part of EH GBU
– Handles remain in PVG GBU
Sauer-Danfoss Electrohydraulics
Minneapolis Operation
Minneapolis History

• Honeywell, Mobile Controls Center

1968 - 1981

• Sundstrand Corporation, Mobile Controls

1982 - 1988

• Sauer-Sundstrand, Electrohydraulics
1989 - 1999

• Sauer-Danfoss, Electrohydraulics
2000
Minneapolis Headcount
• Marketing/Customer Service 18 • Operations 135
– Sales support
– Purchasing
– Applications
– Material handling
– Product management
– Market development – Manufacturing planning
– Advertising/product – Assembly/test
literature – Repair
• Engineering 55 • Accounting/Administration 12
– EH Valve engineers – Accounting
– Hardware/software – Secretarial
engineers
– Plant engineering
– Process engineers
– Technicians
– Design/drafting
– Quality technicians
– Team Leaders
Minneapolis
Revenue History and Projections
$50,000

$45,000

$40,000 Revenue $$ History

Revenue $$ Projections
$35,000
Revenue ($ in 000's)

$30,000

$25,000

$20,000

$15,000

$10,000

$5,000

$0
1976

1978

1980

1982

1984

1986

1988

1990

1992

1994

1996

1998

2000
Year
 Electrohydraulic Capabilities

• Design and manufacture of

electrohydraulic interface
devices, used on
hydrostatic pumps and
motors
• Design and manufacture of
electronic devices and
systems, used for vehicle
drive and motion systems
• Develop system software
• Provide control system
applications support
Precise Fluid Power Control Products
Inputs Controllers Outputs Information

Membrane Switches
2 x 24 Displays
Foot Pedals
S2X
Servovalves
Steer Wheels

Custom
Displays
Joystick S1X
FNR Switches

Electric
Displacement
SX
Controls Data Log
Rotary Position Gravity

Proportional
Valves
Ultrasonic
Software
Speed ON/OFF
Encoder
 Grade/Slope & Steering Control

• Grade/Slope Controllers
• Servo Valves
• Microcontrollers
• Level Sensors
• Position Sensors
• Control Panels

Pavement Planers Concrete Pavers Asphalt Pavers

 Ratio Control (Applicators)

• Speed Sensors
• Electrical Displacement
Controls
• Micocontrollers
• Displays

Asphalt Fertilizer Spreaders Combines Chip Spreaders

Distributors
 Load, Speed & Automotive Control

• NFPE/Electrical Displacement
Controls
• Microcontrollers
• IHCs (Transit Mixer, 1-RPM)

Forklifts Transit Mixers Ditchers

 Dual Track Control

• Joysticks
• Electrical Displacement
Controls
• Microcontrollers
• Rotary Position Sensors

Crawler Crawler Snow Harvesters

Loaders Tractors Groomers
 Anti-Spin

Microprocessor based solution

Normally open 2-way proportional valves
Restricts the offending motor(s)
Automatic, no operator input
Steering compensation
Anti-Stall

Microprocessor based solution

Powerful control algorithm
Easy to calibrate
Rpm
 Multi-Wheel Steer

Microprocessor based solution

Maneuverability
Eliminates tie rods

Front Crab
Steer Steer

Zero
Radius
Radius
Steer
Steer
 Sauer-Danfoss

Microcontroller Overview
Microcontroller Overview

• Fastest growing part of our business

• 90% of current engineering activity
dedicated to microcontroller systems
– 70% of this is software
• Customers are accepting this technology
because users are demanding the features
that only electronics can provide
• Mobile microelectronics are much more
reliable today than 10 years ago
Microcontroller Overview
S-D Micros Shipped

35000

30000

25000

20000

15000

10000

5000

0
'88 '89 '90 '91 '92 '93 '94 '95 '96 '97 '98 '99 '00 '01
Microcontroller Overview
• Current OTP (One Time Programmable) Product
Offerings

IHC
(Transit Mixer – 1 RPM Drum Control)
FDC
Microcontroller Overview
• Current Field Programmable Product Offerings

SX / MC200 Susmic10 / S1X

S2X
General Features
• Design for the mobile market
– Rugged die cast housings
– 9-32VDC operations
– Sealed connectors
– Washdown protected
– EMI/RFI protection to 100 V/m
– Tested to harsh shock and vibration standards
– CAN 2.0b standard when included
General Features
• Standard 4 LED Diagnostics
– Power Proper 9-32VDC supply
– System Proper internal 5VDC power
– Mode Operating system status
– Status Used to display application error codes

• Product differentiators
– Ruggedized electronics
– Software expertise
 Microcontroller I/O Comparison
Lower Tier Middle Tier Upper Tier
SX SX MC200 S1X S2X/ MC400
(w/CAN) MC300 (planned)
Analog Inputs 2 2 3 2 5 6

PPU/Analog Inputs 2 1 2 4 4 6

Digital Inputs 3 3 3 4 9 9

Servo Outputs 0 0 0 2/0 4 0

(low current)

PWM Outputs 2 2 4 2/4 4 12

(high current) (2 pairs) (6 pairs)

Digital Outputs 1 1 0 0 0 2
(on/off)

CAN No Yes No No Yes Yes

RS232 Yes Yes Yes Yes Yes Yes

Processor Motorola Motorola Motorola Intel Intel 196/ Siemens 167

HC08 HC08 HC08 196 Siemens 167

Program Memory 64K 64K 64K 128K 128K/1000K 1000K

SX Microcontroller

• Released in 1999
• Low end microcontroller
– Low number of I/O
– Uses an 8-bit Motorola processor
• Typically offered with pre-programmed software
solutions called “personalities”
– One price for hardware and software
– Pricing depends on software complexity (e.g. $700 list
for joystick shaping, $880 list for Bi-directional PID)
 MC200 Microcontroller

• Released in 2000
• Modification of the SX micro to include
(4) proportional PWM outputs
– No CAN capabilities
– No digital output
• Uses same 8-bit microprocessor as SX
• Offered with personalities
– Dual axis hall-ball joystick output amplifier
– Low end dual path control
S1X Microcontroller

• Updated version of the

Susmic 10/12/16 microcontrollers
– Both versions still built
• Uses a 16-bit Intel 196 processor
• Custom software applications only
S2X Microcontroller

• DC2 design update in 1998

– DC2 developed in 1990-91
• Uses a 16-bit Intel 196 processor
• Additional features:
– Integrated 4 character LED
– Integrated function keypad
• Custom software applications only
MC300 Microcontroller (Planned Product)

• Pin for pin compatible with S2X and

DC2
• Processor and memory upgrade for
S2X
– Infineon 167 microcontroller
– 1Meg memory vs. 128K
– Required to implement more complex
CAN based controls (extended J1939
support)
• Available 2Q 2001
• Custom software applications only
 MC400 Microcontroller (Planned Product)

• Available 4Q 2001
• Uses a 16-bit Siemens 167 processor
• 12 PWM outputs
• Incorporates many new features
– Deutsch connectors
– Optional PVG valve drivers (up to 12)
– Optional keypad and display like S2X
• Custom software applications only
Sauer-Danfoss

Software Overview
Background
• Sauer-Danfoss microcontroller software
originally accomplished with standard line
coding techniques
– PLM
– C
• Some C-code libraries developed for
common control algorithms
– PID
– Anti-stall
Background
• GPI - dos based user interface
Background
• This technique had some limitations
– Applications firmly tied to a single software
engineer
– Lengthy development time
– More susceptible to software bugs
– Outdated user interface
– Difficult to grow and support the business
• Change in methodology was required
– 1997 - Sauer-Danfoss began developing object
based programming tools with a new user
interface
– This has evolved into SauerWare
SauerWare
• Features include :
– Application more independent of the programmer
• Common programming techniques among software
engineering team
– Standard control object library
– Increased platform independence
• Objects work on most all micro-controllers
– Shorter project development time
– Greatly enhanced user interface - WebGPI
• Version 1.0 officially released July 13th, 2000
Standard vs. Custom Software Solutions
• Standard solutions (generally lower volume applications)

– Smaller micros offer “drop-in” software

solutions (personalities)
– Limited I/O  limited options
– Single function solutions (load control, speed control,
automotive control, etc.)
• Custom solutions (generally higher volume applications)

– Larger micros provide more options

– Total machine control
– Custom prepared software
• License fees, development time
• Can also have custom solutions on smaller micros
 SX/MC200 Personalities
• What are they?
– SX and MC200 controllers offered with pre-
programmed software solutions called
personalities
– Common applications offered as “drop-in”
solutions
– Available today!!!
• No software development lead times
– One price and part number for hardware
and software
– Pricing depends on software complexity &
hardware
• $700 list for SX, 1-axis joystick shaping
• $880 list for SX, Bi-directional PID
• $750 list for MC200, 2-axes joystick shaping
• $950 list for MC200, dual path controller
SX/MC200 Personalities
• Each personality has various output
current options
– These are hardware configured
• As an example – SX Joystick shaping
– 1090367 - 100ma EDC output
– 1090362 - 240ma EDC output
– 1090368 - 2amp proportional valve output
SX/MC200 Personalities
• Personalities intended to handle most
machine configurations / options
– Example: F-N-R control handle for both
direction and command vs. F-R switches for
direction and control handle for command
– These type of options are configurable where
possible
SX/MC200 Personalities
• User interface is WebGPI
• Each application (personality)
requires individual driver files
– Available on CD as separate 109…. #
• File structure is automatically
created… but is important!

Required driver folder

SX/MC200 Personalities
• Each personality created with
Sauer-Danfoss software object
library
– All have similar look and feel
– All PID, accel/decel, valve parameter,
etc. screens are the same in all
applications
• Each personality has a complete
user manual
– Available within WebGPI
Personality User Manuals
• The best source of detailed application
information
– Theory of Operation
– Configuration and tuning
– WebGPI screen explanations
– Trouble shooting guide
• Error Code information
– System wiring diagram
 SX/MC200 Personalities
• What do I need to order for a SX/MC200
personality?
– For each machine :
• SX Controller - 1090280 (NFPE personality)
• Mating connector - K23334
– One time :
• WebGPI communication software – 1090381 ($325 net)
• NFPE personality drivers – 1090506 ($20 net)
• Programming cable – KW02025
 SX/MC200 Personalities

• What is available now?

– SX Joystick shaping
• Single axis amplifier w/ramping
– SX Bi-directional PID speed control
• Closed loop speed control w/input ramping
– SX Uni-directional PID speed control
• Closed loop single direction speed control (e.g. generator applications)
– SX NFPE automotive
• Automotive control w/inching for NFPE pumps
– SX Load control
• Optimize H.P. delivery to work tool by varying vehicle’s propel (e.g.
trencher applications)
– SX J1939 Fan drive controller
• Reversing fan control w/temp data from J-1939 bus
 SX/MC200 Personalities
• What is available now? (cont.)
– SX Anti-stall
• Propel control limited by engine droop
– SX Closed-Loop leader follower
• Speed matching w/ratio input (e.g. ratio conveyer
speed to propel speed)
– SX Dual mode EDC automotive
• Automotive and displacement control modes for EDC
pump
– SX Position control (PID)
• Closed loop actuator position control (e.g. position
steering cylinder)
– MC200 dual axis joystick controller
• Dual axis amplifier w/ramping
– MC200 dual path controller
• Provide the basic propel and steering control for a
wide range of open loop dual path machines
SX/MC200 Personalities

• Future (2001) applications include:

– SX Uni-directional PID speed control w/feed-
forward
• Closed loop single direction speed control for
systems with rapidly changing engine RPMs (feed
forward signal, from engine PPU, is added
algebraically to PID to minimize error signal)
 Custom Applications
• Though the SX/MC200 personalities are best suited for
distribution, custom software solutions are possible on
these and higher tier platforms:
– Requires a detailed “Statement of Work” describing the
software to be assembled
• All fault conditions/handling need to be included
– Very close cooperation from all parties required (partnership)
– There will be some minimum quantity requirements for
Sauer-Danfoss to accept a project
– There will also be a software license fee that is dependent on
the software complexity ($5,000-$30,000+)
• Yes, software has value ; it certainly has cost
• We base our fees on $100/hr, this compares to $150+ for private
contactors
Custom Applications
• Statement of Work
– Required to know what to quote
– Avoids ‘creeping elegance’
– All fault conditions/handling need to be included
• Not just how the machine is supposed to work
• What needs to happen when something goes wrong
– More thought up front will pay off at the end of a
project
Custom Applications
• Procedure
1. Initial customer consultation (basic requirements)
a) Initial Statement of Work
2. Sauer-Danfoss “Inquiry” meeting
a) Review application (complexity, quantity, etc.)
b) Accept/decline project
c) Estimate time and license fee
3. Customer quotation
4. If P.O. is issued
a) Detailed Statement of Work to begin project
 SauerKernel
• Common operating system that allows us to
transport application software across our field
programmable platforms
• Link between the hardware and application
software:
– Real Time Operating System:
• Byte Bos (exclusive to S-D’s 167 and 196 processors)
– Interrupt handler (collects information form the
processor to feed the application program)
– Reads and writes to the application I/O
– WebGPI interface
System Control Structure
Application

Application Template

Write: DigOut, PWMOut, E 2, CAN, Display

Read : DigIn, AnalogIn, FreqIn, E2, CAN

Register (Objects and Packages)

Control Package Library
(i.e. Antispin, Dualpath, Steering, NFPE)

Kernel Driver
Display J1939
Replacement
Objects Package (Option)

Objects or Components Library

(i.e. Pot3, Ramp, Profile)

Kernel Operating System Kernel Jump Table

Built in Hardware

Kernel State
HC08 API 196RTOS 167RTOS WebGPI Protocol Stack
Machine

I/O - Driver
(i.e. ReadAD, WritePWM)
ISR Stub Table

Hardware

Microsoft Internet Exlorer 5.5

Sauer-Danfoss WebGPI

Application Template
Standard Control Package and Conponent Screens
Application Specific Screens

Application Specific Simulation Screens Application Specific Automatic Test Patern (XML)
Sauer-Danfoss

WebGPI Overview
WebGPI
• Shipped as a product (1090381)
• $325 for single user license
• Version 1.01 now supports IE5.5
WebGPI - features
• WebGPI application interface
– performance parameter adjustment
– on-line parameter help
– application configuration
– data logging
– Troubleshooting
– application file downloading
– parameter uploads
– offline application interface
– user manuals (application
and WebGPI)
 Controller Information

WebGPI
Tool button bar

Welcome Screen
WebGPI - main screen
Real time data points Functional block diagram

Screen menu
WebGPI - main screen
• Functional Block Diagram
– Graphical representation of software
– Logical interface of software objects
– Each object has fault reporting to aid in
troubleshooting
– Key real time / real world data points
included
WebGPI - parameter screen
Numerical parameter entry Graphical parameter entry
 WebGPI - parameter screen
• Features:
– Most objects have a corresponding
parameter screen
– These are consistent throughout all
applications
– Examples include
• Acceleration and deceleration parameters
• Analog input calibration values
• PID control parameters
• Valve current characteristics
– Help available for individual parameters
WebGPI - data logging
Graph / data options Data logging controls Graph legend

Real time data graph

 WebGPI - data logging
• Features:
– Logged parameters selected from main screen
– Data logged to file on host PC
– One logged variable can be selected as a
trigger to store data sample
– Time, date and SW part number stamp
included
WebGPI - application downloading
File type selection Download status

Download instructions
WebGPI - application downloading
• Features:
– Upgrading application software
– Changing software defaults
– Upgrading software kernel (operating
system)
– On-line instructions
– Graphical download progress display
WebGPI - hardware debug mode
Input status System data

Output simulation
WebGPI - hardware debug mode
• Features:
– View results as manipulate inputs
and outputs - independent of
application software
– Valuable tool for debugging system,
wiring, etc.
WebGPI - Sauer-Danfoss link
Link to Sauer-Danfoss web site
 WebGPI - directory structure
• Directory structure on your PC
– File structure is automatically created
during installation… but is important :
– WebGPI folder must contain application
folders
• Where WebGPI folder is located is not critical

This structure is required

 WebGPI - support
• E-mail: WebGPI-Support@Sauer-Danfoss.com
– For: WebGPI only (not application)
– Include in e-mail:
• PC info. (e.g. processor, RAM and hard-disk available memory)
• Windows environment (e.g. 98, NT)
• Microsoft Internet Explorer version #
• Helpful screen shots (press <Prt Sc> and then paste into e-mail)
– Response: within 7 business days
– Goal: Create a “Frequently Asked Questions” database that can be
accessed through our Sauer-Danfoss Webpage.
Product Marketing Structure
Global Product
Management

Microcontrollers Sensors Man Machine Interfaces Servovalves

Dan Ricklefs Dave Shelstad Glenn Whiteley Bob Ertz/Bill Welscher

Sales Sales Sales Sales

Engineering Engineering Engineering Engineering
Operations Operations Operations Operations
Marcom Marcom Marcom Marcom

Global Global Global Global

Product Product Product Product
Planning & Planning & Planning & Planning &
Implementation Implementation Implementation Implementation

EH Global Marketing Communications

•EH Sales Tools, Sauer-Danfoss N.A. marcom
•Kim Hagemo, Susanne Nelson

Applications Support/Key Accounts

Jim Reed / Steve Dougherty

Electrohydraulics Systems Customer Applications and Service Support

MTS – Marketing Technical Services (Lynn, Larry, Chet)

Product Technical Support

Dale Wraspir, Rick Hicks, Bob Ertz