Professional Documents
Culture Documents
Stefan Ley
Elchingen (D)
Edwin Harnischfeger
Lohr (D)
Co-authors:
Ingo Pulch
Witten (D)
Fernando Da Silva
Horb (D)
170 Mobile 2006 Tracked Vehicles Bosch Rexroth AG
1 Requirements for
tracked vehicles
The primary requirements on the
Working hydraulics
hydrostatic travel and working drives
are characterized by constantly grow- Electronics
ing performance needs and the ever
increasing demand for cost effective-
ness:
Compact dimensions of the com- Hydrostatic travel drive
ponents.
High power density.
Fan drive
Lower mass.
Planetary gear
Long service life.
Optimal transfer of the diesel en-
gine power.
FIg. 1: Drive modules for tracked vehicles.
Ability to accept increasingly larger
external forces.
High dynamics and simultaneously
sensitive operation.
User friendly, simple operation. - Crawler loaders
- Bulldozers
Fulfillment of the necessary safety
requirements in accordance with
the legal specification and norma-
tives.
Cost effectiveness for production - Trench diggers
and operation. - Tracked carriers
A4VG /32
variable motors (Fig. 5) for the opti-
145
BR32
140
ccm
BR40
110
110
100
85
71
in 2007.
65
56
45
50
40
28
280
the roller bearing
250
The increase in the load ratings of the 250
roller bearings of the rotary groups
215
200
by an average of 30 percent under 200
170
comparable operating conditions is A6VM /63
160
150
reflected in a direct ratio of 1:1 in the BR63
140
ccm
150
BR71
service life or, in other terms, makes
115
107
greater reserves available for new de- 100
85
80
signs. This extension of the service life
60
55
Controller
rstellpumpe
Variable pump RC-
RC Steuergert
0VO/A11VO
A10VO/A11VO
Diesel speed signal
Development cycle
planetary gear as consistent construc- Delivery quality
The reduction in TCO begins in the tion principle also ensures a short- Minimizing the procurement and
design phase with the selection of the ened design (Fig. 10). assembly costs also contribute to re-
components which are to be used. ducing the TCO. The pre-assembled
Through a very compact design of the Reduction in the diameter drive unit, consisting of gearbox and
drive unit, it is possible for the manu- The use of solid-forged and hardened hydraulic motor, is supplied from a
facturer to optimally use or to reduce annular gears results in a reduction single source. A high production and
the existing installation space of his of wall thicknesses and, thus, of the assembly quality as well as a 100 per-
device. diameter compared to other solutions cent final inspection are the basis for
while maintaining the same torque the high delivery quality. Inspected
Reduction of the overall length and painted as a single unit, the device
capacity. The main bearing with ta-
The optimized matching of hydraulic pered-roller bearing also considerably can be directly installed in the work-
motor and gearbox with respect to in- shortens the installation space com- ing machine.
stallation space is ensured through the pared to other bearing designs.
use of A6VE/A2FE plug-in-motors.
Through the mergence of motor and In addition, up to five planets in the
gearbox, the A10VT motor series of- main level ensure the transfer of high
fers the most compact drive solution torques and, thus, a high power den-
for the application. sity or for a further reduction of the
annular gear diameter with respect to
Solid-forged planetary spiders in- the use of three planets.
crease strength and allow for reduc-
tions in material compared to cast
pins. A cantilevered mount of the
Bosch Rexroth AG Tracked Vehicles Mobile 2006 175
Field reliability
Tractive
Field reliability and a long product Mass Power effort Vmax Travel drive
service life are the result of extensive (t) (kW) (kN) (km/h) 2x Gearbox 2x Motor 2x Pump
the basis for the design and construc- 5.0 50 60 12 GFT 9 T2 2000 A10VT 45 A10VG 45
tion of the gearbox. The use of high 6.5 60 70 12 GFT 13 T2 4000 A6VE 55 A4VG 56
quality and robust face seals facilitate 90 12 GFT 17 T2 4000 A6VE 55 A4VG 56
high output speeds, resulting in a very 9.0 70 140 12 GFT 26 T2 1000 A6VE 80 A4VG 71
reliable and field-tested seal concept. 12 75 160 10 GFT 40 T2 9000 A6VE 107 A4VG 90/105
90 180 12 GFT 40 T2 9000 A6VE 160 A4VG 90/105
Gearbox selection table 16 150 250 11 GFT 65 T2 1000 A6VE 160 A4VG 105/140
As examples, figures 11 and 12
show independent of the device Fig. 11: Gearbox selection for crawler loaders and bulldozers.
weight class which gearboxes can be
used for crawler loaders and bulldoz-
ers (Fig. 11) or in ski-slope groomers Mass Power Tractive
effort Travel drive
(Fig. 12). (t) (kW) (kN) 2x Gearbox 2x Motor 2x Pump
5.0 130 50 GFT 13 T2 4000 A2FE 56 A4VG 71
A2FE 63
A6VE 55
bile equipment.
Set speed
Moreover, Rexroth offers a library of Variable motor
application software, such as a DPCA Engine Variable pump A6VM...EP or
A4VG...EP A6VE...EP
(Dual Path Control Version A) two-
Fig. 13: Typical configuration for two-circuit travel dirve control.
circuit drive control, specially adapted
for use in track-driven vehicles
(Fig. 13). In addition, a synchronization con-
trol for the controlled straight-ahead
4.1 DPCA track control standard travel and an electronic load-limiting
software control are integrated in the two-cir-
DPCA is an easily adaptable soft- cuit travel drive control. The speed
ware and hardware packet for drive control keeps the speed ratio between
management of reversible, hydraulic, the left and right drive constant dur-
two-circuit travel drives, such as those ing straight-ahead travel and while
used in tracked vehicles. It is used to steering, i.e. in every operating condi-
control a vehicle with separate drives tion. The load-limiting control pre-
for the left and right side of the ve- vents overloading of the diesel engine
hicle. By means of a joystick with two during increased hydraulic power
axes, separate setpoint specifications input for instance when driving up
are set for the travel behavior and the inclines or while moving dirt.
steering function. For safety reasons,
The DPCA track control is available as
both setpoint specifications are set re-
vehicle-specific, parameterizable stan-
dundantly via an analog value and the
dard software (Fig.14).
CAN bus. By deflecting the joystick
over a palpable resistance, the coun-
ter-rotation for maneuvering on the
vertical axis can be activated.
Bosch Rexroth AG Tracked Vehicles Mobile 2006 177
Emergency stop
tion book. Application programmers Pump
right
with detailed application knowledge Safety
are available at Rexroth for this pur- switch
pose. Motor
left
Steering
CAN setpoint behavior
It is also possible for customers to Setpoint steering linear/
analog progressive
program the BODAS controllers avail- Motor
right
able from Rexroth. In this case, the
Emergency
programmers can assemble various stop
software modules from the extensive Fig. 14: Method of operation of the two-circuit travel dirve control.
BODAS software library. Or, they
can create the entire software in the
C programming language and opti- Application software
mize the software for specific devices
(Fig. 15). Standard software modules with specific
optimizable parameters
Special functions of the M6 control Tilting Lifting cylinder Rear mounted Angular control
ripper
block
Next to the features of the M6 control
blocks mentioned above, additional
Ma1
Ma2
Ma3
Ma4
Pst3
Pst5
A1
A2
A3
A4
B1
B2
B3
B4
L3
L5
MP L1 Pst1
P
T
functions can be integrated:
3 3
1
Fast motion function (Fig. 19) 1
L4
L6
Mb1
Mb2
Mb3
Mb4
Pst4
Pst6
tion, the connection between the lift-
ing cylinder on the rod side towards
the tank is blocked while the plate is
lowered. The quantity of oil which Fig. 19: Fast motion and unloading functions.
7 Accompanying mea-
sures for reducing the
TCO Project planning
To ensure that the Rexroth compo-
nents also function error-free in the Checking the operating parameters
application, the operating parameters
are determined during prototyping Commissioning
and, if necessary, potential improve-
System inspection
ments in the device periphery (e.g.
cooler, filter, piping or hydraulic oil
Device acceptance
specification) displayed so that the
life cycle of the units corresponds to
Original service parts
the requirements of the end customer.
Operating parameters here include, Repair service
above all, temperatures as well as
operating and case pressures. In ad-
Fig. 23: Accompanying measures for regarding the TCO.
dition, oscillations can also be taken
into account.
For this purpose, Rexroth makes
available experienced measurement
and application technicians for com-
missioning and device acceptance in
order to make possible definite as-
sessments of the application data and
functions (Fig. 23).
8 Conclusion
Efficiency, cost effectiveness and reli-
ability of the solutions are in the fore-
ground at Rexroth in order to further
extend the high standard in innova-
tion and quality. The product portfo-
lio is continuously developed further
on the basis of the cornerstones: envi-
ronment, energy, costs and function.
Furthermore, Rexroth is a reliable and
dependable partner for everything
from project planning to series sup-
port and service.
Bosch Rexroth AG Tracked Vehicles Mobile 2006 183