124 Mobile 2006 Gearbox Solutions Bosch Rexroth AG Bosch Rexroth AG Gearbox Solutions Mobile 2006 125

Function Hydrostatics Meet Mechanics

The intelligent combination of hydrostatics and mechanics in gearboxes
significantly increases the operating comfort. At the same time, it allows
for gearbox functions that could not be implemented with purely mechani-
cal or hydrostatic approaches.
Costs
Hydromechanical transmission concepts allow for improved gearbox
efficiencies and a free selection of the speed of the combustion engine.
Besides other advantages, this results in a significantly reduced fuel con-
sumption as well as an increased output of the vehicle. At the end, this
results in lower operating costs.
Todays electronics allows for more closely interlocking hydrostatics with
mechanics and to combine the benefits of both technologies. As a result,
continuous variable speed, power split gearboxes for tractors have establis-
hed themselves in the uppper output classes.
Together with minor modifications to the gearbox, the electronics achieve
a gearbox that can be shifted while driving using the Shift on fly concept
based on a fully hydrostatic transmission that could previously be shifted
only during standstill. It is no longer necessary to stop to change the driving
range.
Frank Schmid
Elchingen (D)
126 Mobile 2006 Gearbox Solutions Bosch Rexroth AG

1 Shift on fly
Price-sensitive applications that cover
a relatively large speed range and, at
the same time, build upon advantages
of a hydrostatic drive, are generally
equipped with idle gearshifts today.
They consist of a variable pump and a
variable motor with series-connected
mechanical gearshift. Using only
minor efforts, it can be used to imple-
ment a gearbox that can be shifted
while driving (Shift on fly).
The Shift on fly technology is also of
interest to applications that are cur-
rently still driven in a mechanical way,
but could profit from the advantages Fig. 1: Application examples for hydromechanical travel drives.
of a hydrostatic drive in the future.
Presently, the drive concept is pri-
marily used in vehicles of up to ap-
proximately 50 kW. The concept is,
however, not limited to these output
classes, but can also be used in larger
machines.

1.1 Applications
Shift on fly is of particular interest
to applications such as telehandlers,
small tractors and municipal vehicles,
which are not only price-sensitive,
but also cover large speed ranges and
can tolerate short interruptions of
the tractive force during the shifting
process.

1.2 Design and function Fig. 2: Test vehicle for Shift on fly at Rexroth in Elchingen.
A detailed description of the
Shift on fly technology and its com-
ponents is available in the specialist
article regarding Telehandlers.
Bosch Rexroth AG
1.3 Advantages
Compared to the hydrostatic idle
gearshift, Shift on fly offers several
advantages:
Convenient driving range change
while driving.
Lower consumption since the hy-
drostatics can be operated in a more
ideal range (improved use and utili-
zation of driving ranges).
Increased productivity and increas-
ing driving comfort since changing
the driving range no longer requires
stopping.
Reliable protection of the gearbox
against maloperation.
Compared to true mechanical gearbox
solutions, additional advantages arise:
Improved consumption through
possible decoupling of the diesel
engine speed from the drive speed
(operation of diesel engine in the
speed range with the best possible
consumption).
Performance benefit through maxi-
mum diesel engine output for all
driving speeds.
Advantages when operating a con-
sumer at the power take-off, which
requires a fixed speed.
High tractive force even at low die-
sel engine speeds.
Sensitive handling.
Reversibility.
Gearbox Solutions
2 Power-split gearboxes
Hydrostatic power-split gearboxes
(as well as pure hydrostatic drives)
belong to the class of continuous vari-
able transmissions (CVT), with all
the advantages offered by this class
of gearboxes. Compared to the pure
hydrostatic drives, the hydrostatic
power-split transmissions feature a
significantly higher efficiency since a
large part of the output is transferred
using the better efficiency of the me-
chanics.
Hence, the hydrostatic power-splitting
combines the advantages of hydrostat-
ics and of mechanics in an ideal way.
2.1 Applications
Presently, hydrostatic power-split
gearboxes are primarily used in trac-
tors starting at approximately 80 kW
and, in the meantime, have firmly es-
tablished themselves in the prime seg-
ment of the upper output classes.
New applications are construction
machinery, telehandlers, municipal
vehicles, reach stackers and generally
all vehicles whose application profiles
consists of frequent stopping and re-
starting or reversing and speeds across
a wide range (work and transport).
Fig. 3: Diagram of a power-split transmission.
Mobile 2006 127
2.2 Design and mode of opera-
tion
With respect to a hydrostatic power-
split gearbox, the input power is
generally divided from a drive (gen-
erally a diesel engine) turning at a
fixed speed: On the one hand onto a
branch with fixed ratio, on the other
hand onto a hydrostatic branch with
variable ratio (Fig. 3). This splitting
resulted in the designation power-
split gearbox. The fixed speed of the
mechanical branch and the variable
speed of the hydrostatic branch are
then added again or superimposed in
a planetary gear set. For this reason,
the designations summation gear-
box and superposition gearbox are
used synonymously. To be precise, this
description refers only to the gearbox
with torque split or input coupled.
If, on the other hand, the planetary
gear set is set up directly after the
diesel engine, it results in a speed split
(output coupled) with a slightly dif-
ferent characteristic.
128 Mobile 2006 Gearbox Solutions
Hydrostatic power ratio and effi-
ciency
The total output of a hydrostatic
power-split gearbox is comprised of
the hydrostatic power ratio (h) and
the mechanical power ratio (m):
h + m = 1 (equation 1)
The overall efficiency of a power-split
gearbox is comprised of the hydro-
static efficiency (hydr) and the me-
chanical efficiency (mech), each with
its ratio of the power:
tot = h hydr + m mech
Equation 1 results in:
tot=h hydr + (1-h) mech
The overall efficiency is, therefore,
dependent upon the hydrostatic
power ratio between the value of the
mechanical efficiency and a mixed ef-
ficiency of mechanical and hydrostatic
efficiency. The general hydrostatic
power ratio measures up to 25 to 40
Percent of the diesel engine output
at full swivel angle of the hydrostat
(Fig. 4).
Since the efficiency of the hydrostat-
ics enters into the overall efficiency
with only this maximum ratio, it is
significantly higher than the efficiency
of torque converter gearboxes or full
hydrostatic travel drives.
Being able to operate the diesel engine
in partial load mode at low speed
and, therefore, at the more favorable
consumption point significantly over-
compensates the efficiency advantage
of a true mechanical gearbox.
Bosch Rexroth AG
1,00
0,75
Hydrostatic output ratio (h)
0,50
0,25
0,00
10 20 30 40 50 60
-0,25 km/h
-0,50
-0,75
-1,00
Fig. 4: Model hydrostatic output ratio above the travel speed.
Fig. 5: Mechanical operating point.
Mechanical operating point For the dimensioning of the gearbox,
this means to place the main operat-
In the diagram shown (Fig. 5), the
ing point of the vehicle as close as
ring gear is not moving when the hy-
possible to this mechanical point
draulic motor is at rest. In this state,
the satellite set functions only as stand (e.g. the speed during power plowing
ratio of the mechanical branch. The for tractors).
vehicle moves at a constant speed.
In this point, no speed and hence no
power is transferred via the hydro-
static branch. The hydrostatic power
ratio h is 0. This results in:
tot 0 hydr + (1-0) mech =>
tot mech
The power transfer occurs purely me-
chanically, which causes the gearbox
to operate at the point of the best ef-
ficiency.
Bosch Rexroth AG Gearbox Solutions Mobile 2006 129

Active standstill (Geared neutral)

In this operating point, the speeds of
the hydrostatic and the mechanical
branch cancel each other out. As a
result, the satellite carrier and the ve-
hicle are standing still (Fig. 6).
Hence, stopping on a slope, even un-
der load, is possible without activat-
ing the brake. This point usually lies
close to that of the negative maximum Fig. 6: Active standstill.

swivel angle of the hydrostat.

2.3 Advantages 130

g/kWh
120
Lower consumption 230

With a mechanical gearbox, a change 110 120

225

Output in % of the output at nominal speed

of the travel speed is accomplished 100
Loading in % of the torque at nominal speed

223,2
by changing the diesel engine speed. 90 100
Every travel speed is permanently as-
signed a certain diesel engine speed 80 230

in a gear. In general, this diesel engine 70 80

240
speed is not the most consumption-
60 250
friendly one for the required power at 260 60
any given time. In partial load mode, 50
the diesel engine could also provide 40 280
300 40
the required power at a lower speed
30 350
and a reduced consumption.
20 400 20
500 600
For this reason, a significant advan-
10
tage of the power-split gearbox con-
sists of the independent adjustability 0
40 50 60 70 80 90 100 110
of diesel engine speed and travel
Engine speed in % of the nominal speed
speed. This allows for reducing the
diesel speed in the partial load mode Fig. 7: Lowering the diesel speed to 60 percent of the nominal speed allows for reducing the
and operating the engine in a more consumption by 14 percent while maintaining the output.

consumption-friendly range (Fig. 7).

Full diesel power at all travel speeds dromechanical power-split gearboxes

Due to the rigid coupling of the diesel since the diesel engine can be oper-
engine speed to the travel speed for ated at nominal speed. This allows the
mechanical gearboxes, it is not pos- full nominal output to be available
sible to utilize the maximum diesel at all travel speeds. In return, signifi-
engine output for speeds with diesel cantly faster acceleration processes
engine speed below the nominal are possible. The output of the vehicle
speed. However, this is possible for hy- increases significantly (Fig. 8).
130 Mobile 2006 Gearbox Solutions Bosch Rexroth AG

Travel speed independent of the die-

130
sel speed g/kWh
120
Examples include PTO shafts or all 230
230
applications for which a fixed speed of 110 120
225

Output in % of the output at nominal speed

the diesel engine is desirable (power 100 223,2

Loading in % of the torque at nominal speed

223,2
take-off).
90 100

Use of a smaller diesel engine 80 230

230

Previous illustrations and character- 70 80

240
istics assumed that the same internal
60 250
250
combustion engines are used for 260 60
hydromechanical travel drives as well 50
as for gearshifts. This is generally pos- 40 280
280
sible, but not always ideal. Yet another 300 40
30 350
350
possible advantage applies primarily
to applications that are dimensioned 20 400 20
500 600
for full load operation: 10
For a stable travel operation, a vehicle 0
requires an increase of the available 40 50 60 70 80 90 100 110
tractive force at decreasing speed. Engine speed in % of the nominal speed

Since the diesel engine speed is per- Fig. 8: Diesel operation at nominal speed allows for increasing the available output by more than
manently coupled with the travel 30 percent.

speed for a mechanical gearbox, this

translates to an increasing torque power increases, and for certain appli- Powered Zero / Geared neutral
characteristic of the diesel engine in cations it is possible to select a smaller The vehicle can be stopped on a slope
the working range while the speed diesel engine at the same maximum without breaking and even under
is decreasing. For this reason, the power (Fig. 9). load.
point of maximum power (maximum
speed) does not provide for the maxi- Improved braking behaviour
mum torque. Based on the diesel, it is possible to
For a hydromechanical travel drive, achieve a higher braking output by
the speed change is achieved via the means of the gearbox. This reduces
hydrostat with fixed diesel engine the wear of the operating brake.
speed and therefore also a constant
power. Since the tractive force is the Hydrostatic reversing
quotient resulting from the power Sensitive and wear-free hydrostatic re-
and the speed (F = P/v), the tractive versing even from higher speeds.
force automatically increases with
decreasing speed and constant power.
This allows for dimensioning a diesel
engine for a hydrostatic superposition
gearbox so that the maximum torque
is achieved close to the maximum
speed. Hence, the achievable output
Bosch Rexroth AG Gearbox Solutions Mobile 2006 131

2.5 Electronics / Software

130
g/kWh The complete gearbox and diesel en-
120
230
230 gine management is carried out elec-
110 120 tronically. For this purpose, Rexroth
225

Output in % of the output at nominal speed

100 offers the controllers from the BODAS
223,2
Loading in % of the torque at nominal speed

223,2
RC program. Among the tasks of the
90 100
electronics are:
80 230
230 Control of the diesel engine.
70 80 Control of the hydrostat (setting the
240
swivel angle to achieve the desired
60 250
250
260 60 ratio of the gearbox).
50
Control of the clutches (purpose:
40 280
280 jerk-free shifting without tractive
300 40
30 350
350 force interruption by controlling
the new clutch before reaching the
20 20
400 500 600 switching point while considering
10 the fill time).
0 Error detection.
40 50 60 70 80 90 100 110
Engine speed in % of the nominal speed
Powered Zero/Geared neutral (ve-
hicle standstill without brake activa-
Fig. 9: With the same maximum torque and nominal speed, the CVT diesel (red graph) achieves tion with closed clutches).
20 percent more output power compared to a diesel with characteristic for gearshift.
Power Reverse (clutch management
during reversing).
2.4 Hydrostatics Using the ideal selection of the rotary
Inch function.
Rexroth offers hydrostatic compact groups and design of the connection,
units for power-split gearboxes. The the hydrostatic transmission achieves Emergency function (limp-home
advantage of this design, in which the efficiencies of up to 85 percent. mode).
pump and the motor are located in
a common housing, lies in the com-
pact dimensions, the reduced weight
compared to that of individual units
and an improved overall efficiency.
The increased efficiency is based on
the optimized and direct connection
of the high-pressure and low-pressure
channels of the pump and motor side.
The rotary groups of the compact
gearbox come from Rexroth standard Fig. 10: Hydrostatic compact unit A40CT.
high-pressure units and ensure high
performance at highest reliability.
132 Mobile 2006 Gearbox Solutions Bosch Rexroth AG

3 Conclusion
Driven by increasing fuel prices and
stricter conditions of the legislator
(Euro 4/5; TIER III/IV), as well as
increased customer demands with
respect to user-friendliness and high
output, hydrostatic drive solutions
continue to gain more and more ac-
ceptance. The most important ad-
vantages are represented by low con-
sumption, user-friendliness and high
reliability.
Based on the large advantages of
these gearboxes, the trend for the
use of power-split transmissions for
tractors continues to gain more and
more acceptance, so that vehicles with
increasingly smaller output classes
are equipped with this technology. A
growing interest in this technology is
also evident in other application areas.
Shift on fly also offers a cost-efficient
alternative for applications with lower
requirements on the drive system.
Dependent upon the demand of the
customer, Rexroth offers individual
components for a previously devel-
oped system or provides support as a
partner for the new development of a
complete gearbox up to mass produc-
tion including dimensioning, devel-
opment, software creation, simulation
and coordination.
Bosch Rexroth AG Gearbox Solutions Mobile 2006 133