Brueninghaus Hydromatik

Hydrostatic Drive Systems for Mobile Concrete Mixers

RE 98050/04.95

Hydrostatic Drive Systems for Drum Drives on Mobile Concrete Mixers

Drives, Control, Movement. A complete transmission system from a single supplier.

High demands are placed today on modern technology when designing drum drives for mobile concrete mixers. High operational safety Easy handling High level of efficiency Environmental acceptability Long service life

Hydrostatic transmissions from Brueninghaus Hydromatik fulfill these requirements by offering the following advantages: k stepless and sensitive setting of drum speed k smooth reversal of drum direction for mixing and emptying

k simplification of mobile mixer design k mounting of internal combustion engine independent of position of drum drive k simple operation of transmission from a number of positions k reduction in noise

The quality of the Brueninghaus Hydromatik products is along with the high level of technologies the reason for content customers worldwide. The certification as to DIN ISO 9001 therefore is the logical result of our extensive quality assurance strategy.

The Mannesmann Rexroth group of companies is able to offer a complete solution for any drive application. Why not talk to our mobile concrete mixer sales department?

Standard Model
conventional design

Our A4V variable pumps are equiped with hydraulic servo control. Actuation is distance dependent by means of a control lever. This permits both the flow and thus the drum speed to be infinitely set between Q0 and Qmax for mixing and emptying.

Hydraulic control, mechanical servo, HW

in 40 30 20 10
1,0 0,8 0,6 0,4 0,2 0,2 0,4 0,6 0,8 1,0

Vg Vg max

10 20 30 40 in

Vg Vg max

Strong end stops of the lever in the pump eliminate the need for further end stops in the cable line for maximum drum speeds. The cable support is mounted on the pump using the special bores provided. Electrical control is also possible if required e.g. for a particular mixing programme or for remote control. For this an amplifier card (a 12 or 24 V PVR, see data sheet RE 95 022) is required together with one or more potentiometers.

Electrical control with proportional solenoid, EP

I in mA 800

Pump speeds down to 500 rpm are permitted with all units.
1,0 0,8

600 400 200 0,6 0,4 0,2 200 400 600 800 I in mA

0,2 0,4 0,6 0,8 1,0

Vg Vg max

Vg Vg max

Standard Model
conventional design

All A4V variable displacement pump sizes are available with SAE-A or SAE-B through drives or with a mounted gear pump (for operation of a conveyor belt, chute or an auxiliary axle on the vehicle). Axial piston pumps may also be mounted onto the through drive for operating the distributor mast on combination mixers/concrete pumps.

Axial piston pumps sizes 71 and 90 are fitted with drive flanges for the steering shaft (standard flange 100 mm dia.).

Components

Series A2F fixed displacement motors in bent axis design are the best choice for the hydraulic motor. These motors are characterised by a high starting torque and long service life. Dimensions correspond to standards for mixers. All motors are equipped with a flushing valve for changing the oil in the main circuit. For further information see data sheet RE 91 001.

Any combination of the following pumps and motors may be used.

en gc n i t un Mo
127 mm 127 mm

g erin

dia

Pum

A4V40 A4V56 A4VTG71

nd ft e a h S 16/32 pitch, 21 splines

16/32 pitch, 21 splines 16/32 pitch, 21 splines with drive flange for cardan shaft 16/32 pitch, 23 splines with drive flange for cardan shaft SAE 1 3/4", 13 splines

r onf i t c ne con ump n o p i t t Suc boos for .

M36x2 external thread M36x2 external thread

Hig

hp

res

ep sur

orts

t of igh ox.) e W pr (ap

pum

3/4" 3/4"

30 kg 37 kg

127 mm

M42x2 internal thread

1"

48 kg

A4VTG90

127 mm

M42x2 internal thread

1"

50 kg

A4VG125

152 mm

M48x2 internal thread

1 1/4"

80 kg

Mo

tor

f Sha

d t en

ing a. unt ing di o M nter ce

127 mm 127 mm 127 mm 127 mm 127 mm

f x.) ht o appro g i We tor ( mo

13,5 kg 18 kg 18 kg 23 kg 23kg

A2FM45 A2FM56 A2FM63 A2FM80 A2FM90 8

16/32 pitch, 21 splines 16/32 pitch, 21 splines 16/32 pitch, 21 splines 16/32 pitch, 21 splines 16/32 pitch, 21 splines

Standard Drum Drives

Either the vehicle engine (secondary power take-off) or a separate drive motor is used to drive the variable pump. In order to reduce noise during filling, mixing and emptying of the drum the vehicle engine is normally run only at low speed (nmax = 1600 rpm), whereas with a separate drive motor speeds of up to 2500 rpm are possible. To achieve the maximum drum speed, the appropriate pump size must be selected.

From the maximum drum speeds the following mixer sizes can be assumed:

The selection of the mixer drive depends mainly on the required torque of the mixer drum. Given a standard drum diameter of 2200 2300 mm we can assume a standard value of 6000 Nm per m3 concrete.

k 4 m3 k 6 m3 k 7 m3 k 8 m3 k 9 m3 k 10 m3 k 12 m3 k Agitation

14 18 rpm 13 16 rpm 12 15 rpm 11 14 rpm 10 12 rpm 9 12 rpm 8 12 rpm 1 5 rpm

This represents the maximum value taking into consideration peaks occuring when starting up the drum after a long journey (setting of concrete). Furthermore the gear ratio of the mixer drive used is also decisive. The gear ratio of the mixer transmission varies considerably from one manufacturer to another, but lies within the range of approx. i = 100 - 160.

Standard transmission for mobile concrete mixer Transmission with 2-stage planetary gear with axially mounted hydraulic motor. Optional secondary power take-off for water pump and speed sensing device. 10

Selection of hydraulic motor

Required drive torque at mixer drum

Capacity of mixer drum (m3)

10 8 6 4 2

As a general rule the drive of a mobile concrete mixer can be selected in accordance with these diagrams.

Example: Mixer drum capacity Drum speed Mixer transmission Drive speed (pump)
Nm 10000 20000 30000 40000 50000 60000 70000
Drum drive torque (Nm)

6 m3 14 rpm i = 141 1500 rpm

36000 Nm = 255 Nm 141 (i transmission) Size 45 Size 56 Size 63 Size 80 Size 90

Operating pressure at hydraulic motor (bar)

450 400 300 200 100

Determination of hydraulic motor (mh = 0,95)

Nm

100

150

200

250

300

350

400

450

500

550

600

Hydraulic motor drive torque (Nm)

selected hydraulic motor Size 56

Selection of hydraulic pump

Output speed hydraulic motor (rpm)

4000 3000

v = 0,95 Determination of Qreq

Size 32

Size 45

Size 56 Size 63 Size 80 Size 90

nmotor = ndrum . itransmission = 14 rpm . 141 = 1974 rpm To obtain a drum speed of 14 rpm a pump drive speed of 1725 rpm is required. A pump drive speed of 1500 rpm gives a drum speed of 1716 rpm /141 = 12.2 rpm.

2000 1974
1716

1000

20

40

60

80

100

120

140

160

180

200

220

240

Motor displacement (l/min)

116,3 4000
Drive speed hydraulic pump (rpm)

v = 0,95 Determination of hydraulic pump

Size 40 Size 56 Size 71 Size 90 Size 125

3000 2000 1725 1500 1000

20

40

60

80

100

120

140

160

180

200

220

240

Pump flow (l/min)

selected hydraulic pump Size 71

On request we can supply exact dimensioning using CAD, stipulating the most suitable hydraulic components. 11

Drives for Low-noise Mobile Concrete Mixers

Hydraulic pumps
It is possible to reduce noise with minimal effect on operating efficiency. Good results were achieved at a drive speed reduction of up to min. 800 rpm. Naturally larger pumps are then necessary which require higher drive torques although this can lead to overloading of the camshaft drive. To prevent this the pump must be fitted with a torque control (applies to pumps > 90 cm3/rev). Our A4VG 125 pump is particularly suitable and is available with the following control characteristics:

HA1

HA2

Camshaft drive not switchable, only part load transferable, Mdmax approx. 600 Nm, short time 720 Nm i = rev 1:1 motor speed, torque limitation necessary when using pumps > 90 cm3/rev.

Operating pressure p (bar)

500

400

300

200

100

0,25 qv max

0,5 qv max

0,75 qv max qv max

Flow qv

Pressure relief valves 450 bar Pressure cut-off 420 bar Start of of speed reduction ~ 300 bar = 600 Nm

Separate motor Pump mounted directly by means of elastic coupling, no torque limitation required

On entering the speed reduction field the drum speed is automatically reduced in accordance with the diagram.

HA1

HA2

Front engine power take-off (FEPTO) Mdmax depending on design characteristics, i = 1:1

12

Hydraulic motors
In these days of environmental awareness large volume radial piston motors are commonly used owing to their reduced noise. They are either an integral part of the mixer transmission or are mounted such that the transmission and the motor build a single unit. At the same time a cooler and pump suction filter are mounted, the housing also being used as an oil reservoir for the hydraulic fluid. The result is an extremely compact unit. Such transmissions demonstrate an i of approx. 7:1 (planetary stage) The highest speed of all rotating parts is less than 100 rpm, making them quieter than conventional mixer transmissions. These transmissions could well be introduced in the long term in standard devices.

"Low noise" mobile mixer transmission

On request we can supply exact dimensioning for devices with these drives using CAD.

13

The New Way

Model with EL constant speed drive (CSD)

The electrical constant speed drive was developed especially for use in mobile concrete mixers. The drive consists basically of the same hydraulic components as with the standard drive, but with the control via a control flow (see characteristic EP, page 5). Proportional solenoids mounted onto the drive (EP control) are used to control pump flow as required. The constant speed function effects a constant drum speed, even with varying speed of the drive motor.
Potentiometer setting
18 Drive speed (rpm)

This drive offers the following advantages for use in mixers: The drum may be set to agitate during travel at a constant drum speed. This has only a minimal effect on the performance of the vehicle. The continuous acceleration and deceleration of the drum with changing vehicle speeds is eliminated. This means less wear of all rotating parts (transmission, hydraulics, drum), longer service life and lower fuel consumption. When accelerating the vehicle no additional power is necessary for simultaneous acceleration of the mixer drum. The power reserve of the prime mover is available for acceleration of the vehicle. This is of particular advantage in vehicles with low engine power and when travelling uphill.

Even mixing of the concrete during travel, with correct metering of the water supply, eliminates the need for additional fuel and wear-intensive mixing at high drum speeds on site before unloading. Even for "kerbstone concreting" the constant drum speed allows even flow of the concrete. The electric CSD also permits complete mixing programmes to be carried out with the aid of additional devices i.e. by setting the no. of drum revolutions and rpm a programme can be produced to include specific intervals during mixing. As a general rule the ELCSD can be easily operated by remote control, as only electrical signals are required to operate the pump. The drum speed can be set by ramps, this method of operation being kinder to the materials.

12

1000

2000 3000 Diesel engine speed (rpm)

This function is brought about by determination of the required pump swivel angle dependent on the pre-selected drum and pump speeds. From these two parameters the electronics calculate continuously the required control flow and changes the pump swivel angle so that the pump flow remains constant, corresponding to the given value.
5 6

1 2

14

Function
See also data sheet RE 95 075 Selection of drum speed can be made from one of two positions. a) By potentiometer (3) in the driver's cab. This is a potentiometer without housing and is mounted on the dashboard. b) By potentiometer (4), which is mounted near the chute at the rear of the vehicle. This is built into a water-resistant rubber housing (type SP, see data sheet RE 95 040). Speed feedback, which has to bear a fixed relationship to the pump drive speed, can be either by means of terminal W (5) on the generator or, if not possible, via the speed sensor on the starting gear ring (6) or elsewhere. If using terminal W as speed feedback an electronic device with a frequency range of 100 - 1000 Hz must be used. If a VDO is used for speed feedback at the starter gearing, electronics with a frequency range of 2000 - 8000 Hz must be used.

Torque limitation
If overloading of the camshaft drive or of the drive motor is to be avoided, then model CSD with torque limitation should be used (see data sheet RE 95 075). The relevant high pressure is measured by a pressure sensor 7 and the torque limited in accordance with the following formula: M = 1,59 x Vg max x p 100

i.e. when the pre-set torque is exceeded the control flow for the pump is reduced, the pump will swivel back and the torque measured is reduced to prevent overloading. The drum speed will automatically be reduced accordingly. Both potentiometers are of the same design (1x with housing, 1x without housing). They are fitted with strong mechanical end stops to prevent overspeeding. Only one potentiometer may be used at any one time. Switchover is by means of switch 2, installed in the driver's cab. After switchover the potentiometer switched on must first be set to the zero position to prevent malfunctioning and accidents. With vehicles in common use today the current max. Md at the camshaft drive is 600 Nm for continuous operation and 720 Nm for short periods. Torque limitation of these vehicles has been shown to be only necessary when using pumps of over 90 cm3/rev (predominantly with lownoise concrete mixers).

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Hydraulic fluids

Our units are equally suitable for use with mineral oil based hydraulic fluids and ecologically acceptable fluids. When using fire resistant hydraulic fluids please consult us.

Please also refer to our recommendations for oils. k Mineral oil based hydraulic fluids see data sheet RE 90 220 k Ecologically acceptable fluids HETG, HEPG, HEE see data sheet RE 90 221 k Axial piston units for use with HF hydraulic fluids see data sheet RE 90 223

Note: Environmentally acceptable fluids are also subject to the relevant regulations regarding disposal.

Brueninghaus Hydromatik GmbH Plant Elchingen Glockeraustrae 2 D89275 Elchingen Telephone (0 73 08) 8 20 Telefax (0 73 08) 72 74 Telex 712 538 Plant Horb An den Kelterwiesen 14 D72160 Horb Telephone (0 74 51) 9 20 Telefax (0 74 51) 82 21 Telex 765 321

Mannesmann Rexroth GmbH D97813 Lohr am Main Telephone (0 93 52) 18 0 Telefax (0 93 52) 18 21 59 Telex 689 418-12