Simrad DD15 User manual

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Manual
Simrad DD15
Direct Drive
English
www.busse-yachtshop.de | [email protected]

MANUAL
SIMRAD DD15
Direct Drive
20222303A English
www.busse-yachtshop.de | [email protected]

Simrad DD15 Direct Drive
220222303 / A
About this document
Rev Date Written by Checked by Approved by
06.04.06 NG IK ThHA First edition
© 2006 Simrad AS. All rights reserved.
No part of this work covered by the copyright hereon may be reproduced or
otherwise copied without prior permission from Simrad AS.
The information contained in this document is subject to change without prior
notice. Simrad AS shall not be liable for errors contained herein, or for incidental
or consequential damages in connection with the furnishing, performance, or use
of this document.
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Introduction
20222303 / A 3
Contents
1SYSTEM DESCRIPTION...............................................5
1.1 General .................................................................................................. 5
1.2 How to use this manual......................................................................... 6
1.3 Performance .......................................................................................... 7
1.4 Compatibility in 12 Volts...................................................................... 8
2CONSTRUCTION .........................................................9
2.1 Electric Motor ....................................................................................... 9
2.2 Planetary gearbox.................................................................................. 9
2.3 Electro magnetic clutch....................................................................... 10
3INSTALLATION.........................................................11
3.1 Mechanical mounting.......................................................................... 11
Reducing noise and vibrations ...................................................12
Feedback unit mounting.............................................................13
Direct drive in combination with rack and pinion system .........15
Direct drive in front of pedestal .................................................17
3.2 Electrical connections ......................................................................... 18
3.3 Test the system....................................................................................19
4MAINTENANCE.........................................................20
5TECHNICAL SPECIFICATIONS ..................................21
Draglinks ....................................................................................22
Spare Parts..................................................................................22
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Simrad DD15 Direct Drive
4 20222303 / A
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System description
20222303 / A 5
1SYSTEM DESCRIPTION
1.1 General
The DD15 Direct Drive is a very strong and compact autopilot
drive and more efficient than hydraulic and most electro-
mechanical autopilot drive units. It is powerful (the max. output
torque of 150 Kgm is equivalent to 150 Kg force on the end of a
1 meter steering tiller) and is build for 24 hours per day
continuous operation with a total weight of only 12 Kgs. The
combination of the flat wound (pancake) electric motor with the
efficient planetary and spur gearbox results in an extremely
efficient drive unit to keep the battery charging time to the
minimum. The drive can be used on boats from 30 to 45 feet
l.o.a. (or up to 150 Kgm rudder torque) equipped with a
mechanical steering system that can be back driven. Due to the
electro mechanical clutch, the direct drive can be back driven
with the force of a finger tip leaving the mechanical steering as
sensitive as without drive unit.
The DD15 includes the Simrad RF300 Rudder Feedback unit
with transmission link and 10 m (30 feet) of cable. It transforms
the angular travel of the rudder to a digital signal read by the
autopilot steering computer.
Figure 1-1 Simrad DD15 Direct Drive (with RF300)
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Simrad DD15 Direct Drive
6 20222303 / A
1.2 How to use this manual
This manual is intended as a reference guide for correctly
installing the Simrad DD15 Direct Drive.
Please take time to read the manual to get a thorough
understanding of the use of the drive and the connection to an
autopilot system.
Figure 1-2 Basic autopilot system
This illustration shows the minimum number of components for
a working autopilot configuration.
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Construction
20222303 / A 7
1.3 Performance
The performance table shows the relation between the consumed
power and the output power. The “rudder torque midships” line
shows the output torque against the needed amperage at
midships rudder and the “rudder torque full rudder” line shows
the output torque against the needed amperage at full rudder. The
“hard over time” line shows the hard over time (time to travel
72° of rudder travel) of the drive relative to the output torque.
The table also presents the strength of the drive unit related to
man power. The unit is much stronger than a human being and
can last much longer. One should note however that when the
unit is operated in the dark grey zone, the trim of the boat is not
at its best and the sails should be adjusted to achieve lower
rudder torques. The below table shows that the Simrad direct
drive will steer the yacht even in the worst possible conditions.
As the drive will mostly operate in the light grey zone but not
continuously, the average power consumption on 12 volts is 2
amps.
hardovertime
ruddertorquefull rudder
rudder torque midships
0
1
2
150145
140135
3
4
5
6
7
8
9
10
11
12
13
[
Amp ]
high steering forces,
not manageable by hand power
medium to high steering forces,
manageable for a helmsman for a few minutes
light to medium steering forces,
manageable for a helmsman for a few hours
Drive output torque
[Kgm ]
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130
2
4
6
8
10
12
14
16
18
20
22
24
[HO-time
]
Figure 1-3 DD15 Direct Drive performance table
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Simrad DD15 Direct Drive
8 20222303 / A
1.4 Compatibility in 12 Volts
The following table shows the maximum rudder torques at
amidships and full rudder that can be achieved with the Simrad
direct drive in combination with the autopilot computer. The
hard over time (HO-time) states the time it takes the drive to
travel the full 72 degrees of rudder travel when the speed control
of the autopilot is set to maximum speed.
Autopilot computer
12 Volt version. Max. Output (Amp.) Rudder torque amidships
(Kgm)
Rudder torque
full rudder
(Kgm)
Simrad AC10 (J3000X) 12 73 140
Simrad AC20 (J300X) 20 80 150
Note Even if the AC10 Autopilot Computer is capable of driving the
unit almost to its full power, the AC20 version will have the
necessary extra power when the unit is operating to its extremes.
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Construction
20222303 / A 9
2CONSTRUCTION
This assembly drawing shows a cross section of the direct drive.
The drive can be separated in 5 main parts: The electric motor,
the two step spur gearbox, the planetary gearbox, the electro-
magnetic clutch and the final spur reduction gearbox. The
Simrad direct drive has multiple advantages over existing
integrated drive units. These advantages will be explained per
section of the drive:
2.1 Electric Motor
The flat wound electric motor (pancake motor) used in the
Simrad direct drive is carefully selected for this application.
Pancake motors have multiple advantages over normal electric
DC motors:
•A large flat wound rotor to achieve a high starting toque and
an immediate response to the autopilot speed control signal.
•A motor efficiency of 72,5% to achieve a minimal power
consumption and maximal mechanical power output
(compared to max. 50% efficiency of a normal DC motor).
•Compact main dimensions compared to achievable output.
•Aluminum motor housing in stead of sheet steel plate to
avoid corrosion.
2.2 Planetary gearbox
To achieve a correct rudder travel speed (hard over time) the
electric motor has to be reduced in speed with a factor 750:1.
Some autopilot drive producers use a worm reduction box, but
the efficiency is extremely low as the gears rub each other. The
Simrad direct drive uses a combination of a planetary gearbox
and spur gear sets (one small gear and one big gear). The
planetary gearbox has following advantages:
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