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curtis科蒂斯 1220 电动转向助力控制器说明书

Manual

Model 1220

Electric Steering Controller

for Brushed PM Motor

Read Instructions Carefully!

Specifications are subject to change without notice.

? 2015 Curtis Instruments, Inc. ? Curtis is a registered trademark of Curtis Instruments, Inc.

Curtis Instruments, Inc.

200 Kisco Avenue

Mt. Kisco, NY 10549

https://www.wendangku.net/doc/9f12203108.html,

CONTENTS CONTENTS

1. OVERVIEW (1)

2. INSTALLATION AND WIRING (4)

Mounting the Controller (4)

High Current Connections (5)

Low Current Connections (5)

(6)

Wiring

Controller

(8)

Input/Output

Speci?cations

3. PROGRAMMABLE PARAMETERS (10)

(11)

Program

4. MONITOR MENU (23)

5. COMMISSIONING (27)

6. DIAGNOSTICS AND TROUBLESHOOTING (37)

7. MAINTENANCE (41)

appendix a Vehicle Design Considerations

appendix b Programming Devices

appendix c Speci?cations, 1220 Controller

FIGURES / TABLES

FIGURES

fig. 1: Curtis 1220 controller (1)

fig. 2: Mounting dimensions, Curtis 1220 controller (4)

fig. 3a: Wiring diagram, using motor encoder for position feedback (6)

fig. 3b: Wiring diagram, using analog pots for position feedback (7)

fig. 4: Command signal flow (12)

fig. 5: Steer command map (13)

fig. 6: Position feedback signal flow, with analog pot (15)

fig. 7: Position feedback signal flow, with encoder (16)

fig. 8: Steering sensitivity map (22)

TABLES

table 1: Programmable parameter menus (11)

table 2: Functions menu (22)

table 3: Monitor menu (23)

table 4: T roubleshooting chart (38)

t able C-1: Speci?cations, 1220 controllers .........................................C-1

OVERVIEW The Curtis Model 1220 controller is designed to drive a brushed permanent magnet motor for electric power steering (EPS). The 1220 performs as the steering system controller, interpreting the steering command input and wheel position feedback, then driving the steering motor to move the steered wheel(s) to the desired position. The steering motor must be speed reduced to get the high torque required to rotate the drive wheel. Typically this is done with a gearbox around 50:1 and a chain or gear with an additional reduction of around 4:1. The steering command comes either from a linear potentiometer or an analog voltage sen-sor. The wheel position feedback comes either from a linear potentiometer, an analog voltage sensor, or an encoder with a home switch. 1

1 — OVERVIEW

Fig. 1 Curtis 1220 electric steering controller.

The 1220 works only with Curtis AC traction controllers with embed-ded VCL. A “handshake” with the traction controller is required at startup to enable operation.Intended applications are material handling vehicles such as reach trucks, order pickers, stackers, “man up” warehouse trucks, and other similar industrial

vehicles.

1 — OVERVIEW

Advanced Motor Control

3Absolute position control mode.

316 kHz PWM switching frequency ensures silent operation.

3Advanced PWM techniques produce low motor harmonics,

low torque ripple, and minimized heating losses, resulting

in high efficiency.

3Configurable homing methods, center offset, and end-stop

protection.

324 V, 40 A 2-minute current rating.

324 V nominal supply voltage.

Maximum Safety

3Dual steering command inputs and dual analog position

inputs for redundant check.

3Fault output can be used to turn off traction controller’s

main contactor or interlock connection.

3Steered wheel position (angle) output can be used to limit

the traction motor speed.

3Following error check ensures the wheel position tracks

the steering command.

3Power On Self-Test: FLASH, ALU, EEPROM, software

watchdog, RAM, etc.

3Power On Hardware Check: Motor Open, Motor Short,

and MOSFET short.

3Periodic Self-Tests: EEPROM parameters, Motor Open,

and command and feedback devices.

Unmatched Flexibility

3Integrated hourmeter and diagnostic log functions.

3Curtis 840 Spyglass can be connected to show traction

and steering information such as BDI, hour meter, fault,

traction speed, and steered wheel angle.

3+5V low-power supply for input sensors, etc.

3Curtis 1313 handheld programmer and 1314 PC

Programming Station provide easy programming and

powerful system diagnostic and monitoring capabilities.

3External Status LED driver gives instant diagnostic

indication.

Robust Reliability

3 Intelligent thermal cutback and overvoltage/undervoltage

protection functions maintain steering while reducing traction speed until severe over/under limits are reached.

3 Standard Mini-Fit Molex Jr. and Faston terminals provide

proven, robust wiring connections.

3 Electronics sealed to IP65.

3 Reverse polarity protection on battery connections.

3 Inputs protected against shorts to B+ and B-.

Familiarity with your Curtis controller will help you install and operate it prop-erly. We encourage you to read this manual carefully. If you have questions,

please contact your local Curtis representative.

1 — OVERVIEW

The Curtis Model 1220 does not satisfy EN1175-1:1998+A1:2010 Article 5.9.6 as it is not a Category 3 device under EN ISO13849-1:2008. It should not be used on any vehicle within the scope of Machinery Directive 2006/42/EC that will be operated within the European Economic Area (EEA).

2 — INSTALLATION & WIRING

INSTALLATION AND WIRING MOUNTING THE CONTROLLER

The 1220 controller can be oriented in any position, but the mounting location should be carefully chosen to keep the controller clean and dry. If a clean, dry mounting location cannot be found, a cover must be used to shield the controller from water and contaminants.

The outline and mounting hole dimensions are shown in Fig. 2. The con-troller should be mounted by means of the two mounting holes at the opposing

corners of the heatsink, using M4 (#8) screws.

You will need to take steps during the design and development of your end product to ensure that its EMC performance complies with applicable regulations; suggestions are presented in Appendix A.

The 1220 controller contains ESD-sensitive components. Use appro-priate precautions in connecting, disconnecting, and handling the controller. See installation suggestions in Appendix A for protecting the controller from ESD damage.

2 — INSTALLATION & WIRING: High Current Connections

CONNECTIONS: High Current

Four 1/4” Faston terminals are provided for the high current connections.

The motor connections (M1, M2) and battery connections (B+, B-) have one terminal each.

CONNECTIONS Low Current

The low current connections are made through three connectors: J1, J2, and J3.

2 — INSTALLATION & WIRING: Controller Wiring

CONTROLLER WIRING

As shown in the wiring diagrams (Figs. 3a, 3b), the 1220’s keyswitch power

must go through the traction controller so that when the keyswitch is turned

off both controllers turn off. The fault output (Pin J3-1) must be able to shut

down the traction system in the case of a serious fault, in order to meet inter-

national safety requirements.

Fig. 3a Basic wiring diagram, using motor encoder for feedback device.

2 — INSTALLATION & WIRING: Controller Wiring

These wiring diagrams (Figs. 3a, 3b) show generic applications and may not

fully meet the requirements of your system. You may wish to contact your local

Curtis representative to discuss your particular application. Array

Fig. 3b Basic wiring diagram, using position feedback pots for feedback device.

2 — INSTALLATION & WIRING: I/O Signal Specifications

INPUT/OUTPUT SIGNAL SPECIFICATIONS

The electrical characteristics of the input/output signals wired to the J1, J2,

and J3 connectors are described below.

KSI(pin J1-5)

The keyswitch (KSI) must be connected to B+ via a switch. This pin feeds the

internal power supply and can be used for general on/off and for the power

supply to the Fault Output pin.

Input current at Nominal Battery Voltage (50 – 200 mA) + Fault Output current

Digital inputs(pins J1-4 and J3-2)

The digital inputs must be connected to B+ via a switch, or they can be driven

by outputs from other systems.

Input current at Nominal Battery Voltage approx. 0.2 – 0.7 mA (depending on

nominal battery voltage

Input filter R-C time constant max 5 ms

Max LOW threshold voltage 5.0 V

Min HIGH threshold voltage 12 V

De-bouncing time (in software) 10 – 25 ms

Analog inputs(pins J1-3, J1-6, J1-11, J1-13)

The analog inputs are used for analog input commands from any analog input

device, e.g., potentiometer, Hall sensor.

Input resistance (to B- ground) 50 kΩ± 10%

Input current (wheel in center position) max 100 μA ± 10%

Input filter R-C time constant max 5 ms

Voltage range 0 – 5.5 V

Minimum resolution 12 bit

Steer Motor Encoder inputs(pins J1-2, J1-9)

These inputs are used for the A and B signals of the Steer Motor Encoder device.

Input current (to Encoder Ground) 1.5 mA ± 20%

Input filter R-C time constant 1 μs

Max LOW threshold voltage 0.5 V

Min HIGH threshold voltage 2 V

+5V Supply(pin J1-7)

This pin is the power supply connection to the Command Input Device and

the Position Feedback Device.

Command supply voltage +5 V ± 10%

Maximum current draw 70 mA

2 — INSTALLATION & WIRING: I/O Signal Specifications Pot Low(pins J1-10, J1-14)

The Command and Feedback Pot Low pins are connected to I/O GND. They are not protected against short circuits to B+.

Fault Output(pin J3-1)

The Fault Output has independent supervision via the MCU, and can be used for power supply of the traction main contactor coil. This output has reverse polarity protection.

Max output current 1.5 A

Max voltage drop (to KSI) at 1.5 A 2 V

Steering Angle Output(pin J1-12)

This pin will output an analog signal to the traction controller for traction speed limit.

Analog output range 5 – 9 V ± 10% (2.5 V when not ready)

Max ripple voltage (p-p) 0.2 V

Max output current 5 mA

Programmer connections(J2 connector)

The Curtis programmer plugs into the 4-pin connector, J2.

Rx is the data input connection to/from the programmer.

Input pull down resistance (to B- ground) 5 kΩ± 10%

Tx is the data input connection to/from the programmer.

Logic Level O:

Min output sink current 2.8 mA

Max output voltage at current < 2.8 mA 0.6 V

Logic Level 1:

Min output source current 0.4 mA

Max output voltage at current < 0.4 mA 3.5 V

3 — PROGRAMMABLE PARAMETERS

PROGRAMMABLE PARAMETERS The 1220 controller has a number of parameters that can be programmed using a Curtis 1313 handheld programmer or 1314 Programming Station. The pro-grammable parameters allow the steering performance to be customized to ?t the needs of speci?c applications. The programmable parameters are grouped into nested hierarchical menus, as shown in Table 1. We strongly urge you to read Section 5, Initial Setup, before adjusting any of the parameters. Even if you opt to leave most of the parameters at their default settings, it is imperative that you perform the procedures outlined in Section 5, which set up the basic system characteristics for your application .

3 — PROGRAMMABLE PARAMETERS: Command Device Parameters

Fig. 4

The normalization map takes Command Analog 1 in volts and maps it to Steer

Command in percent. Command Analog Left may be set higher or lower than

Command Analog Right. Command Analog Center must be between Command

Analog Left and Command Analog Right. Assuming Command Analog Left is

less than Command Analog Right, the three points of the normalization map

are defined (from left to right in the diagram above) as:

X = Command Analog Left and Y = -100%

X = Command Analog Center and Y = 0%

X = Command Analog Right and Y = 100%.

3 — PROGRAMMABLE PARAMETERS: Command Map Parameters

A command map is used in the input command signal flow to compensate for steering geometry differences between vehicles (steered wheel on the left side, middle, or right side).The command map menu contains 14 parameters defining an 8-point map that modifies the steer command input. The first point (Left Stop (deg)) always defines the steer command input of -100% and the last point (Right Stop deg)) always defines the steer command input of 100%.

Although any map shape can be set up, it is recommended that the map al-ways be set so that a Steer Command of zero % equals a Steer Command

(deg) of zero .

3 — PROGRAMMABLE PARAMETERS: Feedback Device Parameters

Encoder Phase A

Feedback Pot Low +5V Position Encoder Input

(Position Feedback Device = 1 or 2)Encoder Phase B

If encoder position feedback is used, an encoder and a home switch are required. The electrical requirements for the encoder are as shown.

Position Analog 1(primary)Feedback Pot Low

+5V

Position Analog Input (Position Feedback Device = 0)Position Analog 2 (redundant)

Channel A

Channel B

360° electrical (1 cycle)

> 66 μs

180° ±18°

90° ±30°

3 — PROGRAMMABLE PARAMETERS: Feedback Device Parameters

The normalization map takes Position Analog input in volts and maps it to Wheel Position in percent. Position Left Stop may be set higher or lower than Position Right Stop. Position Center must be between Position Left Stop and Position Right Stop. Assuming Position Left Stop is less than Position Right Stop, the three points of the normalization map are defined (from left to right in the diagram above) as:

X = Position Left Stop and Y = Left Stop (deg)X = Position Center and Y = 0%X = Position Right Stop and Y = Right Stop (deg).

The wheel position is aligned to the current steer command position upon inter-lock. The left stop, center, and right stop points are programmable parameters. Angular rotation is limited by means of programmable left stop (deg) and right stop (deg) parameters in the Command Map.

3 — PROGRAMMABLE PARAMETERS: Feedback Device Parameters