192 Mobile 2006 Excavators > 10 Tons Bosch Rexroth AG Bosch Rexroth AG Excavators > 10 Tons Mobile 2006

ch Rexroth AG Excavators > 10 Tons Mobile 2006 193

Energy Excavators greater than 10

No or reduced losses during circulation in the neutral position and lower
pressure differentials with Electrohydraulic Flow Matching (EFM) and Tons Better Controllability and
Positive Control improve the energy efficiency of wheeled and crawler
excavators. reduced Energy Requirement
thanks to Electrohydraulics and
Function
EFM and Positive Control systems developed by Rexroth guarantee opti-
Positive Control Multi-Circuit
mum controllability and flexibility while offering high system dynamics and
stability.
Solutions
Energy savings and improved controllability are important drivers for new
hydraulic concepts in wheeled and crawler excavators. With a single-circuit
flow-sharing (LUDV) system, the manufacturer can fully utilize the progress
achieved in the field of electrohydraulics with Electrohydraulic Flow Matching
(EFM) by Rexroth. A Positive Control block for multi-circuit solutions devel-
oped specifically for crawler excavators improves the energy efficiency and
the handling for the operator.

Werner Herfs
Lohr (D)

Co-author:

Andreas Kuhse
Elchingen (D)
194 Mobile 2006 Excavators > 10 Tons Bosch Rexroth AG

1 Electrohydraulic Flow
Matching (EFM)
In the course of the further develop-
ment of the hydraulically pilot operat-
ed single-circuit flow-sharing (LUDV)
system with a p-controlled pump,
the combination of the electrohydrau-
lic (EH) flow-sharing (LUDV) control
valve with an electroproportional
(EP) pump with flow on demand
offers additional possibilities of op-
timizing the system even further and
tailoring it even more flexibly to the
needs of the end customer. The EFM
developed by Rexroth guarantees op-
timum controllability and flexibility
while offering high system dynamics
and stability (Fig. 2). Fig. 1: Excavators and material handling equipment.

1.1 Optimum controllability Hydraulical flow-sharing (LUDV) EFM with flow-sharing (LUDV)
through EH valve control
The electrohydraulic pilot control EH
allows variable control characteristic
curves, priorities and time ramps for
various consumers and applications.
Thanks to its pre-configured software,
it simplifies the flexible adjustment to
manufacturer-specific characteristics
and to the requirements of different
markets. The electrohydraulic pilot
control supports the simple adapta-
tion of additional actuators and can
assume remote controlling of flow
and pressure.

Fig. 2: System comparison of hydraulic flow-sharing (LUDV) and EFM with flow-sharing (LUDV).

It provides mode recognition starting leveling, fine-controlling or

through the evaluation of control shaking of the bucket, and adjusts the
signals. The system is capable of rec- corresponding parameters automati-
Fig. 3: M7-24 control block with electrohy- ognizing the planned working cycle cally (Fig. 3).
draulic (EH) pilot control. of the operator, for example when
Bosch Rexroth AG Excavators > 10 Tons Mobile 2006 195

Slew
250

The electrohydraulic pilot control EH

200
for the slew gear function improves
Deceleration
Pressure [bar]

the controllability significantly, be-

150

Acceleration cause the EH pressure control allows

100
the utilization of various, pre-pro-
grammed characteristic curves during
50 both, acceleration and deceleration of
the slew gear (Fig. 4).
0
-100 -50 0 50 100

Set value [%] 1.2 Improved system character-

istics through flow-controlled
Fig. 4: EH valve control for slew gears.
pump
The electroproportional pump flow
control combines high dynamic
stability with fast response (Fig. 5).
The combination of an electrohy-
draulic (EH) valve control and an
T1 G M A electroproportional (EP), demand-
controlled pump reduces the energy
consumption and improves the emis-
V g max V g min
sion balance.
The valve, pump and diesel engine
A11VO
managements can communicate with
R T2 M1 S
each other via the CAN bus. The
U

Fig. 5: A11VO pump with circuit diagram. evaluation of temperature, set/actual

speed, and current torque of the diesel
engine as well as of the residual torque
still available allows the implemen-
tation of completely new open and
closed loop control strategies in the
excavator, with positive influences
EFM on the energy and emission balance
control (Fig. 6).

Act. engine rpm

Act. engine torque
Remainig torque
Temperature

Nominal engine rpm

Fig. 6: Basic EFM system structure.

196 Mobile 2006 Excavators > 10 Tons
Further energy savings are provided
by the reduction in the circulation
losses, because the high system dy-
namics allows the operation without
a Qmin flow in the neutral/stand-by
mode. Moreover, if only one individ-
ual actuator is operated, the metering
orifice can be fully opened to reduce
pressure losses, because the actuator
velocity is controlled by the pump
flow.
The electronics offer the manufac-
turer numerous options of storing
various requirement profiles for the
excavator in individual modes, thus
simplifying operation. Depending on
the equipment of the system, the op-
erator can change the operating mode
by pre-selecting, for example, Power
Mode, Eco Mode or Noise Control
Mode.
The power request in line with de-
mand cuts the fuel consumption and
reduces the emission of pollutants
and noise. In addition, the more ho-
mogeneous, softer torque pick-up at
the diesel engine diminishes wear.
In the basic configuration of the EFM,
only an additional pump pressure
sensor is required, and thanks to the
use of proven and reliable Rexroth
products, high reliability is ensured
for the use in excavators (Fig. 7).
Additional information on this is
available in the specialist article
regarding Electrohydraulic Flow
Matching.
Bosch Rexroth AG
BODAS
Control device
RC
Pump A11VO
LUDV control Foot pedal
Joystick THE5
block M7-24 THE-NR
Fig. 7: Components in the EFM system.
2 Positive Control system
Multi-circuit Open Center systems
are frequently employed specifically
in crawler excavators having a weight
of more than 20 tons. Control block
M9-25 (Fig. 8) is a further develop-
ment of the proven and rugged system
by Rexroth for the excavator class of
Fig. 8: Positive Control manifold 7M9-25.
20 to approximately 32 tons, which
has been adjusted to todays require-
ments. The circuit implemented in them on to the control spool in the
the M9-25 allows the main actuators directional valve. At the same time,
to be supplied from a separate pump the pumps are swiveled out from Qmin
each. To achieve maximum velocities, towards Qmax in proportion to the
the pump circuits are summated. Due deflection on the control devices. The
to the separation of the two pump increase in flow at different load pres-
circuits, the simultaneous operation sures shows that a Positive Control
of a purely hydraulic design simul-
of various actuators at different pres-
taneously actuates the pump and the
sures can be accomplished fast and in
directional valve spool with the same
an energy-saving manner.
signal and changes relatively quickly
In a Positive Control, the hydraulic over from a load-dependent to a load-
logic, the shuttle valve block, collects independent and hence velocity-con-
the proportional control signals of trolled system (Fig. 9).
the TH control devices and passes
Bosch Rexroth AG Excavators > 10 Tons Mobile 2006 197

2.1 Positive Control with electro-

Actuator 1
hydraulic pump control
A Positive Control system, extended
with pilot pressure sensors and an
electrohydraulic pump control with
the associated electronics, supports
hydraulic pilot control and allows in-
fluencing of the pumps when swivel-
ing in or out. The control characteris-
Fine metering Spool
stroke tics in a Positive Control can therefore
be adjusted depending on the require-
ments, by increasing the dependence
upon the load when the movement is
started, or by swiveling the pump out
according to a linear or progressive
curve (Fig. 10).
The graphic (Fig. 11) shows the struc-
Pilot pressure ture of a hydraulically pilot controlled
Positive Control system with EP-con-
Fig. 9: Operating principle of Positive Control.
trollable pump and pilot pressure
Actuator 1 sensors.

The central control element in a

Positive Control system
With control block 7M9-25, Rexroth
developed a new circuit with the fol-
lowing features:

Fine metering Spool

Pump flow
stroke Q = 2 x 200 to ~ 300 l/min;
Pilot control, hydraulic or electro-
hydraulic.
Rexroth designed the 7M9-25 as
mono-block with seven actuator sec-
tions. The integrated anti-drift valves
for the lifting head side and the arm
rod side is possible. The constructive
design provides simple and cost-effi-
Pilot pressure
cient piping with low p losses.
Fig. 10: Positive Control with electrohydraulic pump control.
198 Mobile 2006 Excavators > 10 Tons Bosch Rexroth AG

2.2 Hydraulic logic and pilot con-

trol circuit in the Positive Control
system
The acquisition of the Oil Control
Group by Bosch Rexroth has led to a Travel drive
GFT + A10VT
complementation and extension of
Control
Rexroths product portfolio of pipe block
burst safety valves and various ac- Slew drive 7M9-25
GFB + A10FD
cessory valves for main and auxiliary
LLC
circuits. New developments include,
for example, the logic control block,
which is also required for the hydrau-
lic Positive Control system, as well
as a compact block with electropro-
portional load-limiting control valve,
electroproportional pressure relief Pump for travel
and implement Hydraulic pilot
valves for limiting the pump flow, and hydraulics BODAS Logic block control devices
A8VO RC TH
various on/off solenoid valves. The
two blocks represent an optimally
Fig. 11: Dual-circuit Positive Control system.
matched solution for the Positive
Control system and reduce the piping
effort remarkably (Fig. 12).

2.3 More economic and flexible

When compared with other Open
Center/Negative Control systems, the Logic block
Positive Control solution by Rexroth
helps the user save energy, because Priority flow divider
circulation losses as well as control
losses when swiveling the pump out
do not incur. Moreover, the system
features reduced pressure losses, Multi-directional valve

because fewer pressure differentials

between the main actuators have to be
compensated for in this multi-circuit Pipe burst safety valve
system. The Positive Control system
ensures efficient operation also in the Pilot control block

non-full-speed range due to the inde-

Fig. 12: Auxiliary blocks and valves for excavator systems.
pendent flow allocation by the pumps
in line with demands. Moreover, it
improves the controllability and pro- The load-dependent distribution of
ductivity through independent valve flow ensures a harmonic motion se-
and pump controls and enhances quence.
non-fatiguing operability.
Bosch Rexroth AG Excavators > 10 Tons Mobile 2006 199

Also when it comes to the slew gear

Diagnostics Slew mode Joystick Display BODAS RC
+ Software
control, manufacturers can carry
DI2

out various working processes faster,

BB-3
ESC F1 F2 F3 F4 F5

better and more cost-effectively by

changing the control characteristic
curves, time ramps and other software
parameters.
Pre-selectable slewing modes relieve
the operator by providing sensitive
a b

X5

I R T1 T2 PS Fa Fa1 Fe MB
starting of the slewing movement and
B
T1 B UB
soft deceleration of the slew gear for
f
n
f

crane operation or pipe-laying tasks.

Maximum acceleration at the output
A
A T2 R

torque that is limited by the inte-

X1 X2 S MA

grated pressure cut-off feature as well

G MH Fs

Motor A2FM Gear GFB

Pump A4VG
as maximum deceleration shorten the
Fig. 13: Principle of the electrical slew gear control. working cycles. This results in an in-
creased handling performance of the
excavator. By way of variable power
3 Electrical slew gear Especially the ease of adapting the
system characteristics to different consumptions, the control shifts pri-
control in the closed circuit orities between the slew gear and the
customer requirements as well as
Another energy-saving potential working hydraulics, thus matching
the greater operating comfort have
can be opened up by the excavator the individual actuator movements to
aroused the interest of more and more
manufacturer due to the increased ef- each other in an optimum way.
manufacturers in electrohydraulic
ficiency of the hydraulic system with
systems.
the help of a closed circuit for the slew
gear.

3.1 Electrical slew gear control

Via the BODAS RC control device the
electroproportional pressure reducing
valves are energized, which control
the pump flow and hence the output
speed under the influence of the load
(Fig. 13).
The characteristics show the pressure/
flow relationship (Fig. 14). Slewing-
back forces of the drive, which result
from the high pressure acting on the
rotary group, result in the load-de-
pendence of the drive system and have
an influence on the acceleration, brak-
ing and fine control behavior.
Fig. 14: Characteristic curve of the electrical slew gear control.
200 Mobile 2006 Excavators > 10 Tons Bosch Rexroth AG

As an alternative to todays standard Apart from the manufacturers of large

drives, the electrical slew gear control
in the closed circuit offers the ma-
chine manufacturer the possibility of
introducing new functionalities and
increasing both, the efficiency of the
machine and the operator comfort.
excavators, producers of handling
equipment and standard excavators
have already recognized and imple-
mented the benefits of this drive con-
cept.

3.2 Separation of slew gear and 4 Conclusion

working hydraulics Rexroth offers different, flexible and
Raising the pressure level opens up powerful drive concepts, which sat-
the possibility of installing smaller isfy the increasing demand of end
slew gear motors. This cuts cost while users for efficient and energy-saving
offering the same output torque, and systems in wheeled and crawler exca-
the manufacturer gains more flex- vators, mining machines or handling
ibility in the component arrangement equipment according to the machine
due to smaller dimensions. The pump class and application. Electrohydraulic
achieves the maximum slewing veloc- systems and Positive Control multi-
ity also at a reduced flow. This results circuit solutions by Rexroth offer
in lower flow losses. Rexroths A4VG promising potentials.
variable displacement pump with
integrated pressure cut-off ensures
acceleration of the slew gear without
throttling losses. A more favorable
heat balance allows the installation
of a smaller and consequently less
expensive cooling system. Instead of
converting the kinetic energy into
heat when decelerating, the pump
supports on the diesel engine and
powers other actuators that are oper-
ated simultaneously. Depending on
the load cycle and the operator, fuel
savings of up to ten percent can be
achieved. In addition, the separation
of the slew gear and the working hy-
draulics prevents mutual influences in
the case of movements performed in
parallel.
Bosch Rexroth AG Excavators > 10 Tons Mobile 2006 201