144 Mobile 2006 Wheel Loaders Bosch Rexroth AG Bosch Rexroth AG Wheel Loaders Mobile 2006 145

Costs All Inclusive Clever Drive

Also in the wheel loader compact class, the wish for more driving comfort
is growing however, with heavy focus on the costs. This includes an
increasing demand for continuous acceleration to 40 km/h while main-
taining the full startup tractive force all for very little additional costs in
comparison to a standstill gearbox. Working together with leading gear-
box and axle manufacturers, Rexroth offers the cost efficient Shift on fly
shifting concept, which is based on the widely used standstill gearbox.
Function
The market demands an increasing level of sophistication in the compat-
ibility of the wheel loader in standard vehicles as well. At the same time, it
is important for manufactures to distinguish themselves from the competi-
tion. Electronic drive management is establishing itself as a solution to
this issue. For the fast and simple implementation of electronic drive man-
agement, Rexroth offers a number of standardized and tested software
modules which the manufacturer can customize with his own parameter
sets. Using these modules and in combination with other compatible soft-
ware packages, he can quickly and affordably improve the functionality of
the wheel loader.
Systems for Wheel Loaders
Today, wheel loaders are indispensable in the mining industry, in building
construction and civil engineering as well as in many other industries. Con-
sidering them to be a driving force for travel drives, Rexroth places wheel
loaders among its core applications in mobile hydraulics and offers inno-
vative products and systems, such as the Automotive Drive and Anti Stall
Control (DA) for hydrostatic travel drives as well as steering and electronic
systems. Today and in the coming years, topics such as energy consumption,
noise emissions and improved efficiency at lower operating costs will be in-
cluded in manufacturers specification books.
Rexroth recognized this trend early on, and now offers a number of new
developments. In the area of travel drives, these include the new series of
A4VG axial piston pumps and A6VM axial piston motors, a new gearbox
solution for fast-moving loaders of the compact class as well as a standard
software system for automotive travel. With working hydraulics, focus lies
on the new Electrohydraulic Flow Matching (EFM) system, a bypass priority
valve for steering systems and the M1-25 throttle control block for the low-
cost sector.

Michael Frasch
Elchingen (D)

Michael Schulte
Lohr (D)

Thomas Krumrey
Horb (D)

Julien Daligand
Vnissieux (F)

Martin Sykora
Elchingen (D)
146 Mobile 2006 Wheel Loaders Bosch Rexroth AG

1 New pumps and mo-

tors: highest efficiency,
maximum availability
For wheel loaders of the compact class
(material weight up to approximately
7 Tons), a hydrostatic travel drive is
used due to its advantages which in-
clude characteristics such as a large
conversion range and open construc-
tion. In the last few decades, power
density in travel drive components
has increased constantly. Currently,
pressure settings of up to 490 bar are
Sizes 30 45 65 85 110 145 210 280
common. As a result, the require-
ments placed on the components in Pressure increase by 50 bar Reduction of the sealing joints
the model A4VG axial piston pumps (450/500 bar) Improvement in flexibility
and model A6VM bent axis motors Speed increase of up to 12% Optimization of noise
are increasing as well. Rexroth is Increase in efficiency Optimization of the quality standard
meeting these demands with a new Increase in power density
generation of products.
Fig. 1: Axial piston pump A4VG, series 40.
The A4VG of series 32, with a nomi-
nal peak pressure of 450 bar (nominal
pressure 400 bar), has been com-
pletely reengineered. The new series
40, with a peak pressure of 500 bar
(nominal pressure 450 bar), fulfills
the markets increased demands. The
optimization of critical components
such as the swasher bearing, whose
carrying capacity has been increased
by 30 percent, leads to longer service
life. Moreover, a new housing concept
results in the need for fewer sealing
joints, whereby the already existing
and proven controller range has been Sizes 28 60 80 110 140 170 200
retained and expanded especially for
applications with electronic closed Pressure increase by 50 bar Improvement in the startup efficiency
(450/500 bar) Increase in the control range
loop controls (Fig. 1).
Speed increase of up to 16% Retain the proven features Controller
For model A6VM axial piston motors, Increase in efficiency range
which have also been reengineered, Increase in power density Optimization of the quality standard
the new series 71 is now available with
a 9-piston rotary group. This is char-
acterized by increased speed endur- Fig. 2: Axial piston motor A6VM, series 71.
Bosch Rexroth AG
ance strength, modifications to meet
increased pressure values and im-
proved starting performance (Fig. 2).
For the user, this development means
not only a 25 percent higher power
density but also longer motor service
life and, thus, increased availability of
the wheel loader.
The optimization of the sizes
(Fig. 1 and 2) for the two series fo-
cuses on space requirements. Users
can now use two compact units and
achieve the same output power. The
higher pressure values apply for all
sizes of the new series. Particularly
in combination with the new AS/
DRCD standard software (see chapter
3), the transfer of the diesel engine
power has been improved, especially
for the partial load cases. Instead of
the still common combination of
A4VG71 and A6VM140, the new
series allow users to install a pump
with 65 cm/rev and a motor with
110 cm/rev. This solution results in
considerable savings in space while
maintaining the same power and gives
the designer more freedom in the de-
sign of the drive train.
2 Intelligent drive concepts
for fast moving wheel
loaders
Together with renowned gearbox
manufacturers, Rexroth has, for years,
been developing solutions for drive
power up to 250 kW. With regards
to reduced energy consumption and
increased driving comfort, the hy-
drostatic travel drive has now also
established itself in the utility class up
to 130 kW. The various drive concepts
Wheel Loaders
contain a number of new features
which will be discussed in the follow-
ing.
2.1 Shift on fly new drive con-
cept in the compact class
Since mid-2005, a new transmis-
sion concept is available under the
name shift on fly: a modified two-
gear standstill gearbox whose shift-
ing mechanism has been expanded
through the addition of a synchroni-
zation device. Using the shifting de-
sign which Rexroth has registered for
patent, the driver can now shift gears
while driving. As a result, the driver
no longer needs to select the driving
range before beginning to drive. Due
to the extremely compact construc-
tion of this transmission concept,
which takes only slightly more space
than a splitter gearbox, it is particu-
larly well suited for the fast-travel
versions of the compact class (Fig. 3).
chapter 3). Rexroth first tested and
The nominal sizes of the standard de-
optimized the new concept in its own
vices (20 km/h version) can generally
Fig. 3: DANA 367 shift on fly gearbox.
Mobile 2006 147
be used due to the variety of available
gear ratios.
Another component of the new con-
cept is the AS/AGSD (Application
Software/Automated Gear Shifting,
Version D) standard software. Dur-
ing the development of the software,
which was created with BODAS-de-
sign, Rexroth ensured that the system
could be realized with minimal ad-
ditional work. As a result, the previ-
ously installed A4VG pump with DA
control system can still be used. On
the motor, an A6VM with electric-
proportional EP control system is
used. The A6VM motor as well as the
switching valve for gear shifting are
controlled by the smallest control-
ler from the Rexroth program, the
BODAS RC2-2 (Fig. 4). The modular
design of the software makes pos-
sible optimum integration in the
AS/DRCD travel drive software (see
experimental vehicles. The shifting
quality, which is comparable to that of
a power shift, performed convincingly
during subsequent use in various cus-
tomer vehicles.
Due to the available transmission ra-
tios, an optimal efficiency characteris-
tic exists over the entire driving range
from 0 to 40 km/h. Without penalties
in tractive effort with respect to the
20-km/h version, as is common for
gearboxes with high-angle units, the
loader reaches the required 40 km/h.
Additional information on shift on fly
gearboxes is available in the specialist
article regarding Telehandlers.
148 Mobile 2006
Classical DA
Travel Inching
direction pedal
Diesel engine A4VG.DA
Gearbox management
Hydro motor management
Diagnostics
Fig. 4: Shift on fly gearbox, schematic structure.
2.2 Summation gearbox with
clutches
Two-motor summation gearbox with
one clutch
A two-motor summation gearbox is
currently available from two manu-
facturers for wheel loaders up to
130 kW. For this purpose, Rexroth
offers a hydraulic base solution AS/
AGSF as well as a comfortable, elec-
tronic drive management system AS/
DRCD+AGSE as standard software.
One advantage of the two-plus-one
concept is the external mounting
of the hydraulic motors. Through
optimum combination of the sizes,
it is possible to select the ideal drive
for a wide range of power classes. In
addition, the components are very ac-
Wheel Loaders
Gearbox management
Diagnostics, Gear Gear
parameterization selection control
process monitoring lamp
RC2-2
+ AS/AGSD
Speed
4/2 Valve
A6VM.EP
through the use of modern electron-
ics. In particular, two-gear power
shifts in the class up to 130 kW are an
cessible. Unlike integrated solutions,
in which the entire gearbox must be
removed, this approach guarantees
brief down times should service be
required and even allows repairs on
working site.
Two-motor summation gearbox with
three clutches
This drive concept, which features two
additional clutches, has been on the
market for years. It runs successfully
in loaders with drive power up to 200
Solutions.
kW. Through optimized gear shifting
as well as the Rexroth software, which
has been tested and proven in series
use, it is possible to pass through the
entire driving range between 0 and
40 km/h without any interruption in
Bosch Rexroth AG
tractive force and at optimal power
utilization. A stronger version for
drive power of up to 250 kW is cur-
rently in duration testing.
Various comparison tests have shown
that both systems demonstrate better
driving comfort and up to 30 percent
less fuel consumption than drives
with torque converters. Moreover,
diesel engines and coolers can be opti-
mally positioned due to the open de-
sign. This leads to further advantages
for the design of motor cover and
counterweight.
2.3 Other hydrostatic drive
concepts
In the future, hydrostatic drives with
power shifts will regain importance
alternative to summation gearboxes.
The speed-dependent modulation of
the clutches can keep the interrup-
tions in tractive force to a minimum.
For larger power classes, power split
gearboxes are currently on every-
ones lips. Used only in agricultural
machines up to now, they are cur-
rently being considered by nearly all
manufacturers for use in construction
machinery such as wheel loaders in
which a large portion of the operat-
ing time involves driving. More in-
formation on this is available in the
specialist article regarding Gearbox
Bosch Rexroth AG Wheel Loaders Mobile 2006 149

For the creation of a complete travel

drive which is matched to Rexroth
components, the AS/DRCD (Applica-
tion Software/DRive Control, Version
with
D) standard software was developed.
traction
effort This software represents the electronic
interruption i1, i2 variant of a travel drive control of
i1, i2, i3
the hydraulic DA control system. The
2-speed power shift gearbox 3-speed power shift gearbox
AS/DRCD is designed for controlling
without a variable pump (A4VG, A10VG) in a
traction
closed hydraulic circuit with electric
effort
interruption direct-controlled DE / EV control and
i1, i2, i3
up to two variable motors (A6VM)
Summation gearbox Switchable
option with coupling summation gearbox
with electric proportional EP control.
Instead of variable motors, it is pos-
Drive rating in kW 60 120 250
sible to use multiple fixed motors (e.g.
Drive speed in km/h 25 40 40
A2FM) (Fig. 6 and 7).
Fig. 5: Overview of hydrostatic drive concepts.

3 AS/DRCD The intelli-

gent standard software for
travel drives
Increased competition, stricter envi-
Acceleration pedal

ronmental requirements, higher sys-

Special function
Special function

operating states

Travel direction

Teach function
Speed limiting

tem complexity and shorter develop-

Acceleration

PC software
Seat switch
Inch pedal

behaviour

ment times lead every manufacturer

Lights for

BODEM
to pose the question: How do I meet
all of these demands? Emergency Ignition
off lock
speed senor or Diagnostics
RS232

The Rexroth product program BO- Power

socket

DAS (BOsch Designed Application supply

System) was developed in response
of diesel engi-
Diesel engine

Temperature

to precisely this question. The system

ne via CAN

Speed sensor
speed via
via CAN

consists of hardware components (RC

controllers, input devices, displays, RC4-4 controller
with DRCD software
sensors), a development environment,
tools for diagnostics and program-
ming as well as a standard software li-
brary for valve and fan control, travel
drives and speed controls, to name
just a few. Engine Variable pump Variable motor A6VM...EP
A4VG...DE/EV or fixed motor A2FM /A10FM
or A10VG...DE

Fig. 6: AS/DRCD schematic structure.

150 Mobile 2006
Acceleration
Teach curve
pedal
Inch pedal Inch function
Output speed
Diesel temperature
Diesel engine speed
Fig. 7: Method of operation of the DRCD, schematic representation.
In particular, the AS/DRCD travel
drive control is characterized by the
following features:
Automotive travel:
The hydrostatic drive with travel
drive control makes possible a level of
comfort similar to that experienced in
an automobile. The variable pump is
controlled in proportion to the deflec-
tion of the acceleration pedal. After
the pump has been fully swiveled out,
the variable motor is adjusted from
the maximum displacement to the
minimum displacement. The load-
dependent travel behavior of the AS/
DRCD drive control has the advan-
tage that the driver has a better feel
for the driving status and conditions.
With increasing load, the vehicle
slows or becomes sluggish. Examples
here include beginning to climb after
traveling on a flat stretch or the differ-
Wheel Loaders
Travel behaviour
(hard, medium, soft)
Travel behavior Time ramps
Put-up Time ramps
Load limiting control
Overheating protection
Diesel protection
Speed limiting
ence between a loaded and an empty
vehicle.
Selectable travel modes:
Unlike the classic DA control system,
up to three parameterizable travel
modes are available in the AS/DRCD.
Using the three different travel modes,
the driver can adapt the travel behav-
ior of the vehicle to the current work
conditions (e.g. transport driving,
precise maneuvering, working).
Integrated load limiting control:
The integrated load limiting control
prevents overloading of the diesel
engine. Depending on the permis-
sible speed drop of the diesel engine
specified in the parameter set, in the
event of overloading, the power input
of the variable pump and of the vari-
able motor are reduced by the load
limiting control so that both units
are operated for as long as possible
Bosch Rexroth AG
Direction
switch
Control of
Evaluation
variable pump
Control of
Evaluation variable motors
in the optimum efficiency range. By
comparing the set and actual speeds,
a speed drop in the diesel engine can
also be detected in the underload
range.
Reversing operation:
Reversing from full speed is possible.
The reversing behavior can be param-
eterized.
Inch function:
The inch function enables decoupling
of the vehicle speed from the accelera-
tion pedal position, and, thus, from
the diesel engine speed. The pump
control current and, thus, the swivel
angle are reduced independent of
the pedal path via a potentiometer in
the brake pedal and/or separate inch
pedal. The transition between hydrau-
lic and mechanical braking can be set
freely.
Bosch Rexroth AG
Speed limiting:
The permissible maximum speed of
the vehicle can be parameterized. In
this way it is possible, for example,
to permanently set country-specific
maximum vehicle speeds prior to de-
livery. During running operation, the
maximum speed can also be steplessly
limited by the driver using a potenti-
ometer. This simplifies driving with
attachments such as sweepers.
Protection of the diesel engine:
Depending on the connection variant,
the AS/DRCD protects the diesel en-
gine from overheating.
Safety functions:
Checks of the start condition, such as
the default travel direction in neu-
tral and seat switches, are available as
safety functions. Moreover, the analog
inputs and proportional outputs are
monitored for wire break and short
circuits. Error states can also be dis-
played by an error lamp.
Diagnostic facilities:
Process variables and error messages
are recorded and can be displayed via
the BODEM diagnostic software.
All Rexroth standard software pack-
ages have undergone a risk analysis
and are programmed according to
CMMI level 2.
4 Working hydraulics
4.1 EFM Electrohydraulic Flow
Matching
Electronics will play an increas-
ingly important roll for working
hydraulics as well. The advantages of
Wheel Loaders Mobile 2006 151
todays variable pump systems with 1-circuit LUDV with
flow sharing (LUDV) control blocks flow-controlled pump
should continue to be used and addi- (= system with active
pump control)
tional useful data generated by means
of electronics. The EFM from Rexroth
fulfills these requirements (Fig. 8). Valve with
downstream
pressure balance
With the base system shown here
(without sensors), users can fully
exploit the following advantages in a
wheel loader:
Functionality
Faster response times
Custom adaptation of the wheel
Fig. 8: EFM schematic representation.
loader to the drivers wishes
(characteristics, ramps, resolution)
Rexroth offers all components neces-
Prioritization of a consumer
sary for the EFM system including
(e.g. in the event of undersupply)
hardware, software and sensors from
Easy to mount a single source. All components are
Noise reduction (no oil circulation optimally designed for one another
in the cabin) and are adjusted to the users machine
Energy savings in independent op- by means of the software. The EFM
eration (reduction of the differential basically consists of an M6 control
pressure) block with electrohydraulic control,
Furthermore, other additional func- an A10VOEP/53 variable pump, a
tions are possible through the use of 4THEF5 electronic pilot control de-
sensors: vice with EC4000 handle, an RC con-
Parallel guidance of the bucket with troller with EFM software as well as
Z-kinematics the sensors for an extended system.
Cradle equipment
Active RSM (Rexroth Stability Mod-
ule)
Variable, electronic power control
of the A10VO variable pump
End-position damping of the cyl-
inder
Bucket return guide (return-to-
dig)
Stroke length limiting
152 Mobile 2006 Wheel Loaders
Series M6 control block:
The M6 control block was developed
especially for wheel loaders larger
than 60 kW. The double monobloc
has already proven itself on the mar-
ket in sizes 15 (200 l/min) and 22 (350
l/min) and can be expanded with in-
dividual disks.
The M6 (Fig. 9) convinces with its
technical features such as flow sharing
(LUDV) control, the hydraulically or
electrically switchable float position,
integrated pilot oil supply, regenera-
tion of high-flow and low-flow as
well as the secondary pressure-relief
valve for all consumers.
Fig. 9: Control block M6-22.
A10VO axial piston pump, series 53:
Series 53 is a further development of
series 52, which is already well known
on the market. It is equipped with an
expanded controller range and the
possibility of an EP electric-propor-
tional volume flow control, which is
used for the EFM system. Series 53
is available in sizes 28, 45, 63 and 85
[cm/rev]. The pressure level remains
constant, i.e. the nominal pressure
pnom is 250 bar and the peak pressure
pmax is 315 bar.
Bosch Rexroth AG
The advantages of compact series 53 4THEF5 electronic pilot control de-
include (Fig. 10) vice with EC4000 grip:
High precision The 4THEF5 electronic pilot control
Highly economical device is available in various versions
EP electric volume flow control with analog or PWM signal, CAN bus
or power PWM. The 4THEF5 fulfills
Lower noise level
protection class IP67 (including elec-
tronics) and is tested to five million
cycles. At customers request, two
micro controllers can be integrated in
order to achieve certification accord-
ing to SIL 2 (Fig. 12). The EC4000
multifunction handle can be mounted
Fig. 10: A10VO electro-proportional variable
pump with EP control.
With the EP electro-proportional
control, the A10VO pump swivels out
in proportion to an increasing current
value. This is shown using an example
in Figure 11. Fig. 12: 4THEF5 electronic joystick.
100
on all hydraulic and electronic pi-
Swivel angle [%]
lot control devices available in the
Rexroth product program (Fig. 13).
Depending on the customers desires,
it can be extended with a number of
0
Imin Solenoid current [mA] Imax different functions. These include
Fig. 11: Characteristic of EP control. pushbuttons, three-position switches
in a variety of different ergonomic de-
signs, for example as travel direction
I = Imax Vg max switches. Moreover, the user can also
select a proportional signal for a third
I = Imin Vg min
axis with an output signal between 0.7
I = 0 mA Vg min V and 4.3 V or a proportional PWM
signal for direct actuation of propor-
tional valves (e.g. the FT-DRE2 pro-
portional pressure reduction valve).
Bosch Rexroth AG
Fig. 13: Handle EC4000.
RC controllers with software:
The BODAS RC controllers (Fig. 14),
which are designed and manufac-
tured by Bosch in accordance with
the demanding requirements from
the automotive industry, are available
in four standard sizes. In addition to
the testing criteria standard in the
automotive industry, the controllers
are also subjected to additional load
tests for off-highway applications. The
number of inputs and outputs can
be increased with the RCE extension
module. The controllers are equipped
with additional monitoring options
for detecting and rectifying external
and internal errors. Application-de-
Fig. 14: BODAS RC Controller.
pendent safety requirements, which
arise, for instance, as the result of a
risk analysis, are covered.
The BODEM diagnostics software
is used for the diagnostics and pa-
rameterization of the software pro-
grammed with the BODAS-design.
The system behavior can be individu-
ally modified. Causes of errors are
precisely displayed. Thus, the require-
ments for a complete service concept,
including calibration and testing at
the end of the conveyor belt as well as
maintenance, are met.
A free demo version of the diagnostic
software for troubleshooting is avail-
able on the Internet. In addition to
displaying the contents of the error
memory, it can also display the pro-
cess data.
Steering
LAGU
Axial piston pump
2x A10VO
Fig. 15: Full-current priority valve.
Wheel Loaders Mobile 2006 153
Sensors:
Rexroths product portfolio includes
all sensors required for the EFM sys-
tem, including sensors for pressure,
force, angle, temperature and speed.
They are all especially designed for
demanding use in construction and
agricultural machines, appropriately
tested and, have performed reliably
for years in a broad range of applica-
tions in series production.
Bypass priority valve for steering
systems
Another new development especially
for wheel loaders larger than 14 tons
drops the flow resistance in systems
in which steering and working hy-
draulics are supplied by one or more
pumps (Fig. 15).
The priority valves currently avail-
able on the market are arranged in
the primary current of the pump(s)
and, when necessary, divert the neces-
Priority
valve
LPS
Control block
M6-22
154 Mobile 2006 Wheel Loaders
sary flow from the steering system.
If the steering is not actuated, the
entire flow flows through this priority
valve, leading to a drop in pressure.
To minimize this drop in pressure,
the priority valve is dimensioned for
the pump flow. Nevertheless, this loss
in pressure is approximately 10 to 15
bar (Fig. 16). For this reason, Rexroth
patented a solution which functions
with flow sharing (LUDV) control
blocks (SX, M6, M7). With this solu-
tion, the priority valve is not located
in the primary current, but instead
in the bypass. Oil flows through the
priority valve only when the steering
system is actuated. As a result, there
are no pressure losses over the priority
valve if not actively steering. Another
advantage is the fact that the size of
the priority valve is independent of
the maximum steering volume, op-
timizing installation space and costs
(Fig. 17).
Short-circuit
valve
pressure
balance
Port Steering
LS Pressure
Steering
Fig. 17: Circuit diagram for priority function.
The priority valve is a special com-
bination at pressure balance and a
short-circuit valve. The function
is dependent on two different load
states, i.e. depending on whether the
working hydraulics (as subordinate
consumer) or the steering (as primary
consumer) has the greater load pres-
Bosch Rexroth AG
Steering
LAGU
Priority
valve
LPS
Control block
M6-22
Axial piston pump
2x A10VO
Fig. 16: Bypass priority valve.
sure. This solution leads to significant as the wheel-loader-specific features,
savings for the user, as pressure losses such as four positioning pistons for
are prevented while the steering is the lifting frame and anti-cavitation
inactive. Because the valve size is de- function. Additional features, such
fined by the steering quantity, savings as e.g. double connections for lifting
can also be achieved. frame and bucket, are optional.
Control block M1-25:
International markets, with their
varying requirements, demand flex-
ible solutions. A special and growing
market, for wheel loaders as well, is
Asia. Technology, requirements and
market prices differ considerably from
those in Europe and America. Never-
theless, this market is interesting. It
is for this reason that Rexroth devel-
oped a special M1-25 throttle control
block mainly for applications in wheel
loaders and dozers. The block oper- Fig. 18: Control block M1-25.
ates with a maximum pressure pmax
of 250 bar and delivers a maximum
flow Qmax of 340 l/min (Fig. 18). The
M1-25 control block meets the re-
quirement of the Asian market as well
Bosch Rexroth AG Wheel Loaders Mobile 2006 155

5 Conclusion
The wheel loaders ability to lay claim
to a successful market position is
greatly dependent on factors such as
fuel consumption, exhaust gas and
noise emissions, availability and cost
effectiveness. Rexroths modern drive
and control concepts contribute to the
reduction of the life-cycle costs and
will continue to help keep wheel load-
ers a competitive working machine in
the future. The new developments in
the areas of travel drive and working
hydraulics are essential factors in the
optimization of driving comfort while
simultaneously reducing operating
costs which demonstrate the potential
they still hold even 50 years after the
invention of the wheel loader.