TRAX_ECU_CA387809_LIUGONG_R1_V1_20100310

CARRARO Engineering & Innovation Power Trains Engineering CA387809 REV 1 TRAX ECU / Carraro TLB2 transmission LIUGONG Functional Specification this document refers to software p/n CA387808 rev 1 application p/n CA387807 rev 1 hardware p/n CA339360 rev 2 DOCUMENT INFO Last modified: 10-Mar-10 Customer: LIUGONG Application: Backhoe loader Transmission model: CARRARO TLB2 Powershift p/n 387792 Content: TRAX specification for TLB2 / LIUGONG BHL vehicle DOCUMENT OWNER Guido Albertin guido_albertin@carraro.com Tel: +39 049 9219119 Carraro S.p.A. Fax: +39 049 9289119 Via Olmo 37 http://www.carraro.com 35011 Campodarsego (Pd) - Italy PRIVACY INFORMATION This document may contain information of a sensitive nature. This information should not be given to persons other than those who are involved in the project or who will become involved during the life cycle. DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 2 of 18 Confidential DOCUMENT REVISION HISTORY Doc. Version Author Date Changes V1 G. Albertin 10-Mar-10 First release V2 V3 V4 V5 V6 V7 V8 V9 DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 3 of 18 Confidential 1. TRAX ECU Connections schematic TRAX ECU Overtemperature Lamp switch TEMPERATURE SENSORGND +15 signal 43 25 +15 HALL-EFFECT SPEED SENSOR N.O. PRESSURE SENSOR SWITCH 44 53Engine Alternator signal GND 9 38 S13 VALVE S24 VALVE 27 55 CANBUS (OPTIONAL) 7 2 28 56 SERIAL RS232 DB9 FEMALE CONNECTOR (OPTIONAL) 3 2 5 +15 (UNDER KEY) 29 34 5 8 10A fuse 1 +30 (DIRECT TO BATTERY) 1A fuse 2 CIRCLE KICKDOWN CRAB DECLUTCH VEHICLE 20 48 21 49 Shifter Lever GearCmd01 GearCmd02 FWD RVS 18 46 19 47 GEAR SHIFT MODULATION PROPORTIONAL PWM VALVE 1 GEAR SHIFT MODULATION PROPORTIONAL PWM VALVE 2 6 13 7 41 FWD PROPORTIONAL PWM VALVE RVS PROPORTIONAL PWM VALVE 3 12 4 40 4WD VALVE39 DIFFLOCK SWITCH HDL VALVE 11 DIFFLOCK LAMP +15 (UNDER KEY) 4WD LAMP 42 “AUTOMATIC MODE” OPT. DASHBOARD LAMP +15 (UNDER KEY)+15 50 BRAKE SWITCHES Right BrakeLeft Brake 4WD 22 +15 “TRANSMISSION STATUS” OPT. DASHBOARD LAMP 14 +15 (UNDER KEY) DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 4 of 18 Confidential 2. TRAX pinout configuration TRAX PIN TRAX PIN Description Configuration Connection 01 Logic Supply +12 +12v battery Direct to battery 02 Power supply +12, group A +12v battery (PWM 1-2 Supply) Battery under key 05 Power supply +12, group B +12v battery (PWM 3-4 Supply) Battery under key 08 Power supply +12, group C +12v battery (Digital Outputs Supply) Battery under key 34 Power Supply +12 +12v battery under key Battery under key 17 Logic ground Battery GND Sensors Ground 29 Power supply ground Battery GND Direct to battery 18 Digital input 01 Pull-down Forward input command 46 Digital input 02 Pull-down Reverse input command 19 Digital input 03 Pull-down GearCmd01 input command 47 Digital input 04 Pull-down GearCmd02 input command 20 Digital input 05 Pull-up Crab input command 48 Digital input 06 Pull-up Circle input command 21 Digital input 07 Pull-up Declutch input command 49 Digital input 08 Pull-up Kickdown input command 22 Digital input 09 Pull-down 4WD switch 50 Digital input 10 Pull-down Brake input switch (SX and DX) 23 Digital input 11 Pull-down Unused 51 Digital input 12 Pull-down Unused 43 Temperature input NTC Transmission oil temperature sensor 44 Analog input 01 Pull-up, configured as digital in Transmission pressure switch (threshold: 10 bar) 16 Analog input 02 Undefined Unused 45 Analog input 03 Undefined Unused 54 Analog input 04 Undefined Unused 25 Frequency Input 01 Hall, pull-up Hall effect sensor P/N 339307 53 Frequency Input 02 No pull-up Engine Speed Signal (alternator “W” signal/speed sensor) 28 RS232 TX Serial connector d-sub 9-way male housing female pins 56 RS232 RX Serial connector d-sub 9-way male housing female pins 27 CAN: CAN_H CAN HIGH Can bus connector / DEUTSCH 3-way 55 CAN: CAN_L CAN LOW Can bus connector / DEUTSCH 3-way 03 PWM 01 Output PWM Forward valve command 12 PWM 01 Current Current input Forward valve current feedback 04 PWM 02 Output PWM Reverse valve command 40 PWM 02 Current Current input Reverse valve current feedback 06 PWM 03 Output PWM PWM 1st/3rd valve command 13 PWM 03 Current Current input PWM 1st/3rd current feedback 07 PWM 04 Output PWM PWM 2nd/4th valve command 41 PWM 04 Current Current input PWM 2nd/4th current feedback 09 Digital output 01 Source digital out DIGIT Valve 1st/3rd 37 Digital output 02 Source digital out unused 10 Digital output 03 Source digital out Unused 38 Digital output 04 Source digital out DIGIT Valve 2nd/4th 11 Digital output 05 Source digital out HDL valve 39 Digital output 06 Source digital out 4WD valve 42 Digital output 07 Sink (switch to ground) digital out Automatic lamp (optional) 14 Digital output 08 Sink (switch to ground) digital out Transmission status lamp (optional) DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 5 of 18 Confidential 3. Transmission and driveline characteristics 3.1. TLB2 CA387792 drawing 3.2. Driveline parameters Parameter Value Forward/Reverse ratio 1 Rear/front PTO ratio 41/51 Input/output 1st gear ratio 5.533 Input/output 2nd gear ratio 3.360 Input/output 3rd gear ratio 1.532 Input/output 4th gear ratio 0.810 Rear axle ratio 17.077 Rolling wheel circumference [m] 3.931 Phonic wheel teeth number 51 Output sensor frequency to rear output speed [rpm/Hz] 1.1765 Output sensor frequency to vehicle speed [kph/Hz] 0.0138 Alternator pulse frequency to engine speed [rpm/Hz] 4.115 DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 6 of 18 Confidential 4. Transmission sensors (for reference) 4.1. Speed Sensor (p/n 339307) DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 7 of 18 Confidential 4.2. Temperature Sensor (p/n 635446) DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 8 of 18 Confidential 4.3. Pressure Sensor Switch (p/n 339785) DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 9 of 18 Confidential 4.4. Control Valve, p/n 357938 4.4.1 Drawing, 2D 4.4.2 Control Valve Solenoids • 4 proportional solenoids, internally protected with double zener diode, voltage:12V, max current sink (each): 0.9 Amps • 4 digital on/off solenoids, internally protected with double zener diode, voltage:12V, max current sink (each): 1.68 Amps 4.4.3 Valve diode electrical schematics CONNECTORS: 1st, 2nd, 3rd, 4th, FWD, RVS, 4WD,HDL • Receptacle: DEUTSCH DT04-2P • Mates with (plug): DEUTSCH DT06-2S DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 10 of 18 Confidential 5. TRAX ECU connection and placement 5.1. TRAX ECU Outline Dimensions 5.2. TRAX Installation clearance requirements TRAX Female Connector 192.5 mm 18 5 m m ca 35 m m Clearance required to engage/disengage the female connector 35 mm DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 11 of 18 Confidential 5.3. TRAX ECU Connector Details Connector: Framaton 56 pins P/N 211PL562L0011 Mates with : Framaton 56 pins P/N 211PC562S0009 DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 12 of 18 Confidential 6. Application Specification 6.1. Introduction This section describes shortly what the Electronic Controller is supposed to accomplish: 1. reading inputs from vehicle. 2. drive transmission for proper operation. 3. reading and sending data through the CAN bus (optional) and serial line (optional). 4. preserve transmission from damage. 6.2. Transmission Management TRAX controller is responsible of the following transmission management tasks: • Drive proportional solenoids for FWD/RVS management, using a certain pressure modulation to engage the clutches • Drive proportional solenoids for 1st, 2nd gear engagement, using a certain pressure modulation to engage the clutches • Drive proportional solenoids AND digital valves for 3rd,4th gear engagement, using a certain pressure modulation to engage the corresponding clutches • Understand what the operator wants to do: move the vehicle, change a gear etc • Under request, shift the gears automatically, without specific user command • Calculate the vehicle speed, understanding the transmission output shaft speed via frequency caught by the transmission speed sensor 6.3. Lever and shift management 6.3.1 Lever management • FWD and REV signals are catched by pins 18 and 46, with direct connection to the shifter. Lever position FWD RVS Forward ON (12V at pin 18) OFF (0V at pin 46) Neutral OFF (0V at pin 18) OFF (0V at pin 46) Reverse OFF (0V at pin 18) ON (12V at pin 46) Not valid ON (12V at pin 18) ON (12V at pin 46) • For safety reason TRAX controller will not engage any gears if engine was started with F- N-R Shifter NOT in neutral. Gear will be engaged when lever is put back in neutral and then moved in forward or reverse position. • Moving the shifter to F position will make the vehicle moving in forward direction. Moving the shifter to R position will make the vehicle moving backwards. DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 13 of 18 Confidential 6.3.2 Shifter management • Shifter position logic: o Position 1: manual mode, 1st gear engaged (if speed compatible with 1st gear) o Position 2: manual mode, 2nd gear engaged (if speed compatible with 2ndgear) o Position 3: manual mode, 3rd gear engaged (if speed compatible with 3rd gear) o Position 4: Automatic mode selected • GEARCMD01, GEARCMD02 are sensed by lever electrical signals, with the following bit logic: Shifter position GEARCMD01 GEARCMD02 Position 1 ON (12V at pin 19) OFF (0V at pin 47) Position 2 OFF (0V at pin 19) OFF (0V at pin 47) Position 3 OFF (0V at pin 19) ON (12V at pin 47) Position 4 ON (12V at pin 19) ON (12V at pin 47) • Manual mode when the operator selects the position 1, 2, or 3 of the shifter, the system works in manual mode and tries to engage the corresponding gear. Before executing gear change, a speed congruency check is performed by the system: if current speed is higher than a certain (configurable, look at “Max Speed” on next figure) threshold then gear change is not performed until speed is compatible with the selected gear (see “Downshift speed protection”). • Automatic mode is activated with shift lever in 4th position; manual selection of 4th gear is thus not possible. Default gear engaged with vehicle at rest is 2nd gear. Speed 1st 2nd 3rd 4th Ammisible range UpShift DownShift Max speed 1st Max speed 2nd Max speed 3rd 3rd-4th threshold 4th-3rd threshold 3rd-2nd threshold 2nd-3rd threshold 2nd 3rd 4th DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 14 of 18 Confidential FROM TO Speed (kph) 2nd 3rd 7.6 3rd 4th 17 4th 3rd 12.7 3rd 2nd 6.2 6.4. Downshift speed protection To protect the transmission during downshift operations at high speed, the downshift speed protection feature references to the following table: GEAR Max Speed (kph) 3rd 26.5 2nd 10.2 1st 8.3 6.5. Higher gears inhibition In some conditions 3rd and 4th gear engagement are not permitted by TRAX ECU: • In Reverse direction, Automatic mode 4th gear engagement is inhibited. • Crab steering signal (if present) active inhibits 3rd and 4th gear engagement. • Circle steering signal (if present) active inhibits 4th gear engagement. 6.6. Kickdown Kickdown button operates as follows: • Sequential up and down shifting from 2nd to 1st and back from 1st to 2nd. • Can be armed with 2nd gear engaged and vehicle speed below 8.5 kph. • Available irrespective of shifter position (F, N or R). • Kickdown is cancelled shifting the gear selector (to 1st, 2nd, 3rd or auto). • Kickdown is cancelled if exceeding 5.5 kph with 1st gear engaged in automatic mode. • Kickdown is armed with the rising front (off to on) of a toggle switch (a-stable). • Activation/deactivation speed thresholds are programmable. 6.7. Declutch • When active, transmission master clutches will be disconnected. • When released, selected (FNR) transmission master clutch modulated in order to transmit power. • Toggle switch (a-stable), active when closed. DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 15 of 18 Confidential 6.8. Hydraulic differential lock (HDL) • Source output to be connected through external stable switch to valve. • Output enabled (+12V) with 1st or 2nd engaged gear. 6.9. Four wheel drive (4WD) • Four wheel drive hydraulic circuit works in negative way: 4WD is engaged with valve not energized. • Four wheel drive is engaged either: o when relevant operator input command switch is ON (stable switch). o when operator brakes (full braking, both right and left braking circuit in pressure) and vehicle is in 3rd or 4th gear. This is a safety feature. DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 16 of 18 Confidential 7. Faults management 7.1. Definitions Fault: A defect in a circuit or wiring caused by imperfect connections, poor insulation, grounding, or shorting. A sensor fault occurs when sensor is broken or not correctly connected. Warning: when an abnormal operation condition occurs, i.e. transmission oil temperature too high, not admitted operator input command, etc. 7.2. Faults and Warnings Warnings and faults of this application are managed by the control unit according to the following operating modes: • When a warning or a fault occurs a DTC numeric code is generated by the control unit and stored on memory with ECU working timestamp and with number of occurrences of the event. • Faults and warnings memory log is readable with a PC and a client program “SERVICE TOOL for TLB transmissions” via RS232 serial communication (not provided). • When a warning or fault occurs, the event will be handled by the controller in order to protect safety of the operator but it will try to maintain the possibility to move the vehicle (Limp Home Mode). If the fault is critical, to protect the transmission the controller shuts off all outputs (Neutral). • Possible reactions to a fault code: - Neutral: all controller outputs OFF, unable to operate the transmission, vehicle down - Limp Home Mode 1: FWD/REV allowed without any modulation; 1st gear only - Limp Home Mode 2: FWD/REV allowed without any modulation; 2nd gear only Error/fault codes are displayed with a numeric code (called DTC, Diagnostic Trouble Code) of two digits (except DTC:2, no errors): the first digit will be represented with a long pulse, the second digit with a short pulse, i.e. if you see 4 long blinks and 2 short blinks, then the active DTC is 42. The higher priority currently active blinking code will be transmitted continuously. DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 17 of 18 Confidential 7.3. Diagnostic Trouble Codes (DTC) table DTC ID Description Reaction Auto Lamp T.Status Lamp 2 DTC_NOERROR Everything OK None STD OFF 21 DTC_MAINRING_PRESS_FAIL Charge pressure is not detected when engine speed is above 700 rpm for 10 seconds Neutral OFF OFF 23 DTC_SPDENG_FAIL Charge pressure switch is closed with no engine speed detected by the TRAX controller. None STD OFF 25 DTC_FNRLEVER_ERR FNR lever input pattern error Neutral OFF Blinking Code 32 DTC_TEMP_HIGH Temperature Signal: temperature too high None STD Blinking Code 33 DTC_TEMP_LOW Temperature Signal: temperature too low None STD Blinking Code 36 DTC_TEMPSENS_FAIL Temperature signal erratic or incorrect. None STD Blinking Code 42 DTC_TEMPSENS_LOW Temperature sensor input (Pin 43) is shorted to a ground. None STD Blinking Code 43 DTC_TEMPSENS_HIGH Temperature sensor input (Pin 43) is open circuited or shorted to a voltage above 5 volts. None STD Blinking Code 53 DTC_PWRSUPP_HIGH Battery voltage (Pin 34) voltage above 16 volts for 2.5 seconds None(3) STD OFF 54 DTC_PWRSUPP_LOW Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds with engine speed above 900 rpm None(3) STD OFF 57 DTC_PWM12_OVERCUR Power supply (Pin 2), forward FWD drive (Pin 3), or RVS drive (Pin 4) drive shorted to ground Neutral OFF Blinking Code 58 DTC_PWM34_OVERCUR Power supply (Pin 5), PWM 1 drive (pin 6), or PWM 2 drive (pin 7) drive shorted to ground Neutral OFF Blinking Code 59 DTC_DO12_OVERCUR_ALL Digital power outputs supply (pin 8) does not have power. Limp Home 2 BLINKING (2) Blinking Code 61 DTC_DO12_OVERCUR First / Third shift solenoid shorted to ground Limp Home 2 BLINKING (2) Blinking Code 62 DTC_DO34_OVERCUR Second / Fourth shift solenoid shorted to ground Limp Home 1 BLINKING (1) Blinking Code 63 DTC_DO56_OVERCUR 4WD / Difflock solenoid shorted to ground None STD Blinking Code 64 DTC_DO78_OVERCUR Auto / T. Status Lamps shorted to supply None STD Blinking Code 71 DTC_PWM1_OVERFEED FWD input (Pin 12) feedback circuit is reading current without command. Neutral OFF Blinking Code 71 DTC_PWM1_ERRCURR_HIGH FWD solenoid is drawing more current then commanded. Neutral OFF Blinking Code 72 DTC_PWM1_NOFEED FWD input (Pin 12) current is too low with command present. Limp Home 2 BLINKING (2) Blinking Code 72 DTC_PWM1_ERRCURR_LOW FWD solenoid is drawing less current then commanded Limp Home 2 BLINKING (2) Blinking Code 73 DTC_PWM2_OVERFEED RVS input (Pin 40) feedback circuit is reading current without command. Neutral OFF Blinking Code 73 DTC_PWM2_ERRCURR_HIGH RVS solenoid is drawing more current then commanded Neutral OFF Blinking Code 74 DTC_PWM2_NOFEED RVS input (Pin 40) current is too low with command present. Limp Home 2 BLINKING (2) Blinking Code 74 DTC_PWM2_ERRCURR_LOW RVS solenoid is drawing less current then commanded Limp Home 2 BLINKING (2) Blinking Code 75 DTC_PWM3_OVERFEED First and third shift modulation solenoid input (Pin 13) feedback circuit is reading current without command. Neutral OFF Blinking Code 75 DTC_PWM3_ERRCURR_HIGH First and third shift modulation solenoid is drawing more current then commanded Neutral OFF Blinking Code 76 DTC_PWM3_NOFEED First and third shift modulation solenoid input (Pin 13) current is too low with command present. Limp Home 2 BLINKING (2) Blinking Code 76 DTC_PWM3_ERRCURR_LOW First and third shift modulation solenoid is drawing less current then commanded Limp Home 2 BLINKING (2) Blinking Code 77 DTC_PWM4_OVERFEED Second and fourth shift modulation solenoid input (Pin 41) feedback circuit is reading current without Neutral OFF Blinking Code DRAFT 2010-03-04 TRAX_ECU_CA387809_LIUGONG_R1_V1 Page 18 of 18 Confidential command 77 DTC_PWM4_ERRCURR_HIGH Second and fourth shift modulation solenoid is drawing more current then commanded Neutral OFF Blinking Code 78 DTC_PWM4_NOFEED Second and fourth shift modulation solenoid input (Pin 41) current is too low with command present Limp Home 1 BLINKING (2) Blinking Code 78 DTC_PWM4_ERRCURR_LOW Second and fourth shift modulation solenoid is drawing less current then commanded Limp Home 1 BLINKING (2) Blinking Code 88 DTC_SERIALLINEERROR Serial Line communication problem. None STD OFF 89 DTC_MINORINTERNALERROR Internal TRAX failure, restart