Bosch Rexroth AG e-Load-Sensing Adaptive working hydraulics for tractors | MOBILE 2017 49

Chapter 2: Efficiency

e-Load-Sensing
Adaptive working hydraulics for tractors

Abstract
Hydraulic load-sensing systems have become state-of-the-art technology for tractors.
They combine good energy efficiency with ease of use and functionality. Current
systems are suitable for use in comprehensive machinery management only to a
limited degree, particularly if there is a wide variety of different implements.

With e-load-sensing (e-LS), Bosch Rexroth is presenting the next generation of

hydraulic systems. This enables machine manufacturers to individually, actively
and dynamically optimize the hydraulic system in response to various requirements
relating to the implement and work process. Improved productivity and efficiency
increase the economic benefit of the machine.

New functions allowing automated, monitored workflows are also being introduced
for simplified operation. Tractor manufacturers continue to benefit from the system's
excellent flexibility, reduced installation space requirements, and the possibility of
extended services.

Efficiency
The new e-LS electronic system solution consequently helps to bring machine
manufacturers a step closer to Agriculture 4.0 standards. Optimally coordinated
hardware and software components simplify integration into the machine and reduce
the engineering effort.

Uwe Maier
Sales and Industry Sector Management Tractors

Ulrich Lenzgeiger
System Integration Development

Peter Schmuttermair
System Integration Development
50 MOBILE 2017 | e-Load-Sensing Adaptive working hydraulics for tractors Bosch Rexroth AG

From hydraulic load sensing to an electronic

system solution

From the first open-center solutions to today's load-sensing systems, the trend for tractors
has been toward continually improved energy efficiency, increased flow and improved ease
of use (Fig. 1).

Fig. 1: Evolution of tractor hydraulic systems

Bosch Rexroth is expanding on these advantages with comprehensive machine management

options for the tractor plus attachment. e-LS adapts flexibly and optimally to the specific
pressure, oil flow and reaction time requirements of each individual implement (Fig. 2).

Fig. 2: e-LS range of applications

Bosch Rexroth AG e-Load-Sensing Adaptive working hydraulics for tractors | MOBILE 2017
Future-proof
Hydraulic load-sensing systems (hLS) signal the maxi-
mum load pressure to the variable pump purely by hydrau-
lic means. This is done via a closed signaling circuit with
a shuttle valve chain. The pump controller adapts to the
load pressure plus a differential pressure p; this balances
system losses. The differential pressure p is generally set
at a system-dependent fixed value between 25 and 35 bar.
Similarly, the pressure range is fixed between the standby
pressure pstb and the pressure cut-off or the maximum pres-
sure pmax. A hydraulic damping element just ahead of the
pump tunes the system. A disadvantage of hLS systems is
that these parameters are fixed and then have to work for all
the available tractor options and the numerous implements
that are available on the market. They are consequently a
compromise (Fig. 3).
e-LS replaces the hydraulic LS signaling circuit with an
electronic closed loop control. All the components simul-
taneously signal their demand to the control unit, the ECU.
One advantage of this is that the risk of resonant vibration
in the system is reduced.
Software now enables the system parameters to be indi-
vidually adjusted and varied. The result is that dynamic
system tuning, and consequently dynamic influencing of
performance, is possible.
Fig. 3: Basic configuration of hydraulic LS
51
This can be adapted as required to the respective tractor
model/attachment and/or the operating situation, and it
can be altered at any time. The variance is now provided by
the software.
This allows variation of the minimum pressure pmin, the
differential pressure p, the maximum pressure pmax and
of the swiveling out speed and/or swiveling back speed of
the pump (dynamic response). The standby pressure pstb is
a fixed value that represents the minimum possible pump
pressure. A constant pressure system can be implemented
for certain situations.
The electronic signal acquisition and processing makes it
easy for machine manufacturers to incorporate options or
to enable them as required. This makes it possible to keep
the vehicle continually up to date over time.
The electronic system solution also assists quick and simple
parameterization of the tractor hydraulics during the devel-
opment phase. Furthermore, manufacturers can also imple-
ment functions that would be impossible or very difficult to
implement with a purely hydraulic LS system (Fig. 4).
Efficiency
Fig. 4: Basic configuration of e-LS
52 MOBILE 2017 | e-Load-Sensing Adaptive working hydraulics for tractors
Operating principle
Pressure sensors with a SENT interface determine the
load pressure of the respective consumer and signal it to
an electronic control unit. When directional control valves
are used, it is advisable for economic reasons to compare
the various pressure signals within the block by means of
shuttle valves, and only to scan them electronically with a
pressure sensor at the block outlet. If necessary, each valve
section can be individually fitted with a sensor.
During the operation of, for example, a front loader with a
directional control valve on the tractor, the load pressure
Fig. 5: e-LS with implement connected to the tractors valves
Fig. 6: e-LS with implement with own hydraulics
Bosch Rexroth AG
is measured at the block's LS port. Moreover, sensing can
be carried out at additional signals, i.e. from valves on a
frontloader, and they can be incorporated into the closed
loop control (Fig. 5).
In the case of attachments with their own hydraulics, such
as fertilizer spreaders, the LS pressure can be measured
on the implement itself. If necessary, the pressure signal
is processed in the implement's ECU before the setpoint
value is transmitted to the tractor's control unit, e.g. via
ISOBUS. The advantage of this is faster signal transmission
and a true pressure value reading without any line losses
(Fig. 6).
Bosch Rexroth AG e-Load-Sensing Adaptive working hydraulics for tractors | MOBILE 2017
If the attachment does not have an electronic pressure
signal, the LS connection can be hydraulically connected
to the PowerBeyond, as is already done today. A pressure
sensor on the tractor side converts the hydraulic signal into
a digital one.
Functions with known or predefined pressure values, such
as front axle suspension, do not require a pressure sensor,
and the LS tie-in valves which are currently necessary can
also be omitted. These values can, if required, be generated
in the ECU itself.
All the pressure signals are transmitted to the electronic
control unit where they are processed. Various evaluation
algorithms are available depending on the mode. The con-
ventional procedure is that the maximum load pressure is
determined and then with a delta pressure it is speci-
fied as the setpoint value for the pump controller.
However, the signal to the pump controller can also be
individually adapted to the situation or the operating mode/
attachment. An optional swivel angle sensor on the variable
pump makes additional functions possible, such as power
management or the prioritizing of specified consumers.
Fig. 7: e-LS advantages
53
Modular and scalable
e-LS is a modular system. Intermediate stages on the road
to an all-electronic design continue to allow hydraulic LS
signals to be integrated. The solution can consequently
also be implemented with existing system configurations.
It makes sense to incorporate the directional control valve,
the PowerBeyond port and the front axle suspension into
the basic version electronically. This configuration already
enables many functions to be realized. At this level, the LS
signals from the steering and the trailer brake are still sent
to the variable pump hydraulically.
In the complete buildout, the LS signals from all the com-
ponents are measured electronically by pressure sensors
and an electronically pressure-controlled pump is used.
This eliminates all the hydraulic LS lines and shuttle valves
except the shuttle valves within the block.
Advantages for machine manufacturers and
users
Tractors fitted with e-LS provide measurable advantages
Efficiency
both for end users and machine manufacturers (Fig. 7).
54 MOBILE 2017 | e-Load-Sensing Adaptive working hydraulics for tractors
Increased productivity and flexibility
Optimal system tuning of the tractor and the implements
and the ability to compensate for line losses in the system
lead to higher productivity. The reduced power losses in
standby mode and the variable delta pressure also increase
energy efficiency. Predefined parameter sets for the specific
type of job simplify operation. Enhanced diagnostic options
provide the basis for predictive maintenance and increase
machine availability. Not least, data sets are provided for
monitoring and if necessary recording jobs.
An important side effect: Simplified operation thanks to
predefined system parameters when using same-brand
vehicles and implements increases customer loyalty and
acceptance.
Electronification gives tractor manufacturers new levels of
design freedom, and it speeds up the engineering process.
The system no longer needs rigid, hydraulic LS lines. This
gives designers more installation space, greater flexibility
in how they can arrange the components, and it makes it
easier for them to incorporate optional and/or add-on func-
tions. Moving the system tuning to the software speeds up
the testing and application process.
Fig. 8: e-LS fields of application overview
Bosch Rexroth AG
Evaluation of the collected vehicle data in electronic form
facilitates the validation process and improves the simu-
lation models. Evaluation of the operating data over the
whole life cycle provides important information for continu-
ous product improvements.
The elimination of hydraulic components reduces the amount
and complexity of the installation work. Parameterization of
the hydraulic system is series-specific, or it is customized for
each individual vehicle end of line (EOL) (Fig.8).
Quick diagnosis
The comprehensive electronic pressure, flow and tempera-
ture data enable faster, more accurate and cost-effective
diagnosis of the hydraulic system. The data can be read out
both at the machine itself or online via appropriate cloud
services. Updates over the air improve the hydraulic
system and enable new functions. Calibration over the air
provides manufacturers with a simple way to add specific
new services, such as online problem solving. The pressure,
flow and temperature data can be incorporated for condi-
tion monitoring and predictive maintenance.
Bosch Rexroth AG e-Load-Sensing Adaptive working hydraulics for tractors | MOBILE 2017 55

Energy efficiency improved

Constant delta pressure

The standby pressure of the variable pump has a minimum

Delta pressure [bar]

of approx. 1013 bar as a result of the technical design
and this is used in the case of e-LS. The hydraulic LS re- Delta pressure

quires a much higher standby pressure of 25...35 bar. So Variable

the new Rexroth e-LS solution is significantly more energy-
efficient. If a specific situation requires a higher pressure
than the 1013 bar range, a variable minimum pressure
pmin can be set electronically.

Tractor system
In addition to the variable minimum pressure, the neces- (pressure losses)
sary hydraulic system delta pressure p can be parameter-
ized in a variety of ways with e-LS. This leads to further Oil Flow [l/min]
energy savings.
Fig. 9: Constant delta pressure
Constant value: The delta pressure is constant through-
out the flow range. This is the same as the behavior of a
purely hydraulic LS system. However, the level of this
Variable delta pressure
constant value is variable in the case of the electronic
solution (Fig.9).
Delta pressure [bar]

Variable value: The delta pressure varies according to the

flow; it increases in line with the quantity of oil. Corre-

Efficiency
sponding system characteristic curves, including the Variable
Delta pressure
characteristic curve form and height, can be individually
set up in the ECU, and they may even vary between indi-
vidual consumers. This enables p to be set optimally for
the respective hydraulic system (Fig. 10).
Tractor system
(pressure losses)
If the steering and the brakes are, for example, operated via
a separate Silence gear pump, the variable pump is used Oil Flow [l/min]
solely for supplying the implement hydraulics.
Fig. 10: Variable delta pressure
When driving on roads, for example with a loader wagon,
the variable pump maintains the pressure at the lower
standby pressure. The saved power can be used for the
travel drive, and the noise level and fuel consumption
decrease. On arrival at the unloading point, the minimum
pump pressure is increased to the pressure that is required
for controlling the electric operated directional valves. The
valves can then be actuated and the trailer can be raised
for emptying.
56 MOBILE 2017 | e-Load-Sensing Adaptive working hydraulics for tractors Bosch Rexroth AG

More power
PowerBeyond offset

When using PowerBeyond, e-LS enables a fixed or variable

Delta pressure [bar]

offset to be specified for the PowerBeyond port in addition
to the set delta pressure. This is done to consider the pres- Variable Implement
hydraulic
sure loss via the quick-release couplings and in the imple- (pressure losses)
ment's hydraulic system. This curve is flexible too, both as
a value and in terms of the characteristic curve form, and
it can be individually adjusted to the respective attachment
(Fig. 11).

Tractor system
If the maximum pump pressure is 210 bar and there is a (pressure losses)
pressure loss of 30 bar, a hLS system will have 180 bar avail-
able at the cylinder, e.g. for a dump wagon. If e-LS is used Oil Flow [l/min]

and the dump wagon is connected to the system, this 30 bar

pressure loss can be added to the maximum pressure of the Fig. 11: Variable delta pressure + PowerBeyond offset
pump. The pump then delivers 240bar, and a full 210 bar is
available at the cylinder of the dump wagon. This increases
the lifting power by 16 percent. Alternatively, higher pressure Precise and dynamic
enables a smaller cylinder to be used, which has advantages
in terms of raising and lowering speed. The e-LS system also provides the option of switching to a
constant pressure system when necessary, in particular if
the application involves high requirements in terms of dy-
Sensitive namics and stability combined with high system pressures.
For instance, the rotational speed of the discs of fertilizer
e-LS makes it possible for the first time to flexibly adjust spreaders must be adhered to very precisely. A constant
the maximum pressure during operation to suit individual pressure system may make sense in some such cases.
implements and functions. The manufacturer stores the set-
tings in the software. Internal consumers, such as electro- The reaction rate of the variable pump can be varied, both
hydraulic hitch control or implements, can be designed for for swiveling out and back. Manufacturers can consequently
higher pressures. On the other hand, it may be advisable use software to adjust the pressure build-up speed for a
to limit the pressure in the case of sensitive applications. specific application. This results in differing system behav-
Electronic pressure limitation can apply to the whole sys- iors. It adapts front loader responsiveness and sensitivity to
tem, but it can also be set for each individual valve or each the task in hand. A high level of damping leads to gentler,
individual function. more easily controlled movement, and a more dynamic set-
ting leads to faster processes.
For example, in order to avoid damaging silage bales
through over-compression in the bale gripper, manufactur-
ers can limit the pressure of the bale gripper. When the
bale gripper is actuated, the system only permits the preset
maximum pressure and the compressive force of the grip-
per is hydraulically limited. Following operation of the bale
gripper, the system switches back to normal mode with
a higher permissible working pressure. For short power
boosts, for example breakaway force for a front loader, the
pressure can be overridden to suit the situation.
Bosch Rexroth AG e-Load-Sensing Adaptive working hydraulics for tractors | MOBILE 2017
Large oil flow at low motor speed
Applications such as field end management require a large
quantity of oil at low motor speed. The use of a higher
pump drive ratio enables a larger quantity of oil to be pro-
vided with the same size of pump and at low motor speed.
However, a disadvantage is that the pump can reach a criti-
cal operating point at higher motor speeds. The swiveling
back of the pump at high rotational speeds can prolong this
critical range, and the pump can also be used with a higher
gear ratio. It is throttled back.
The swivel angle sensor, together with the rotational speed,
records the current flow of the variable pump. The use of
electrically controlled directional valves reveals individual
consumer flows. This makes flexible prioritizing of the
consumers according to the situation possible. If necessary
and permissible, it is also possible to limit the maximum
permissible power consumption of the hydraulic system.
This is done either by lowering the maximum pump pres-
sure or, if possible, by limiting the flow requirements.
PR4 pressure sensors with SENT interface measure temper-
ature alongside pressure. This is used for setting tempera-
ture-dependent parameters, and consequently for optimiz-
ing the hydraulic system. In addition, it can also be used
for providing protection against overheating. If a specifiable
maximum temperature is exceeded, the hydraulic power
can be gradually restricted in order to reduce heat build-
up. Limiting the pressure and the swivel angle during cold
starts provides additional protection for the pump.
57
Compact and automatic
In conventional load-sensing systems, hydraulic LS signals
are needed in order to control the variable pump. This is
done either in the valve or, in the case of a function with no
LS pickup, by means of a solenoid valve which generates an
LS signal. The components that are needed for this are now
no longer required.
This saves costs and installation space, and it simplifies
the hydraulic configuration. For example, if the front axle
suspension is activated, e-LS electronically signals the
corresponding demand to the variable pump. The neces-
sary predefined pressure is precisely adhered to, and the
accumulators can be charged. Once the accumulators have
been charged, the pump switches back to standby or a new
current mode.
Predefined operating modes, in particular in connection with
the automatic recognition of the implements (e.g. via RFID),
make the end user's day-to-day work easier. Automatic system
optimizations are also conceivable.
Rotary drives or the actuation of parallel consumers are the
Efficiency
main potential causes of vibrations. The system solution
recognizes these causes and counters them by making a
corresponding adjustment to the pump control parameters
(damping).
58 MOBILE 2017 | e-Load-Sensing Adaptive working hydraulics for tractors
Modular hardware and software
The e-LS scalable system solution consists of pressure sen-
sors, an electronic RC control unit (ECU), valve technology
and an electrically controlled variable pump. The interac-
tion between the hydraulics, electronics, sensor system
and software is specifically coordinated for use in tractors
(Fig.12).
The development of the new SBx4 family of valves already
incorporated the requirements of the new system solution.
The modular control block consisting of additional SBx4
directional valves and an EHRx4 hitch control valve is fitted
with a PR4 pressure sensor.
The elimination of the hydraulic LS connection reduces the
size of the front axle suspension block. The accumulator
charging signal simultaneously triggers a demand to the
pump.
The signals from the PR4 pressure sensors with SENT
interface are read in by the high-performance RC10-10
electronic control unit. The SENT technology improves the
accuracy of signal detection and transmission and is much
more resistant to interference. The sensor transmits a tem-
perature signal alongside the pressure signal.
Fig. 12: Components of the electronic system solution
Bosch Rexroth AG
The basic software processes the sensor and input values
and it actuates the variable pump. Optimal interaction be-
tween the individual components is consequently ensured,
and the engineering workload is reduced. In relation to ap-
plication know-how, the system provides full flexibility.
The e-LS software interface is designed to allow the cus-
tomer to specify the desired setpoint values. The machine
manufacturer's application know-how is therefore protected.
A special intermediate plate allows the A10CNO axial piston
variable pump to process electronic and hydraulic LS sig-
nals. This means that components with hydraulic LS signals
can still be incorporated. An optional swivel angle sensor
on the variable pump extends the range of functions. As a
further enhancement, the system can also be configured
around a purely electrically actuated pump controller.
The DI4 display facilitates simple, intuitive operation. An
optional Bluetooth-to-CAN module (connectivity unit) pro-
vides a connection to a mobile device. An app developed by
Bosch Rexroth enables the hydraulic system settings to be
entered easily using a mobile device. Operating data evalua-
tions are also possible.
Bosch Rexroth AG e-Load-Sensing Adaptive working hydraulics for tractors | MOBILE 2017 59

Summary
The e-LS scalable system solution consists of the new SBx4 family of valves, pressure
sensors, an electronic RC control unit (ECU), a valve system and an electrically controlled
variable pump.

The only way in which manufacturers can achieve efficiency and productivity improvements
is through overarching tractor/trailer management and the interaction between the trac-
tor and its attachment. This requires interconnected processes and optimally coordinated
systems.

e-LS enables the whole hydraulic system to be customized for each specific application
so that fully integrated machine management of the tractor and attachment is achieved.
Parameterization based on flexible software algorithms optimizes the respective work op-
eration, which ensures seamless interaction between the tractor and its attachment.

Predefined modes or automated parameterization processes, e.g. for coupling up the

implement, make operation easier and help the user to achieve maximum work results with
minimal effort.

Bosch Rexroth simplifies the whole engineering process since tractor manufacturers can
fine-tune the hydraulic system via the software. At the same time, the system provides live
operating data throughout the whole life cycle. It consequently doesn't just provide scope
for a one-off optimization on delivery. Instead, it provides comprehensive diagnosis options

Efficiency
and preventive maintenance approaches, thus increasing machine availability. What's more,
the data provides the basis for expanded service and marketing measures.