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consumption in the Stockholm city Figure 3 shows the principal behavior Area = Area
thermal losses
= Thermal Loss
1
power-split transmission which used
a regenerative brake system with high- 12: The accumulator is loaded and
4
units to store nearly all kinetic energy. gas through volume reduction.
In addition to the improved accelera- This results in an increase in Gas Gas
volume
Volume
tion behavior, fuel savings of over 20 the temperature of the gas. Fig. 3: Charging/discharging process for the
percent were achieved during opera- hydraulic bladder accumulator.
23: Rest phase: the gas releases heat
tion [3], [4], [5]. to the surrounding environ-
ment; the pressure drops while
the volume remains constant.
34: Discharging the accumula-
tor: The accumulator pressure
drops as the volume increases.
As this occurs, the temperature
drops as well.
41: Rest phase: The gas pressure
increases as ambient heat is ab-
sorbed.
54 Mobile 2006 Hydrostatic Regenerative Brake System (HRB) Bosch Rexroth AG
Because the thermal losses during A pressure sensor is used to control 4 System components
the rest phase are greater than what the braking torque and operating state The system components required
is gained during the charge process, transitions. for the HRB include components
the area in Figure 3 is identical to the which are serial or modified serial
thermal losses. components from the Rexroth line of
SHP
products. This guarantees high avail-
3.2 System variants for various PH ability and reproducible series quality.
vehicle classes Through the variety of components,
Rexroth offers two basic concepts for Rexroth is able to offer system solu-
the HRB: V DBV
tions which are customized for the
given application. This is illustrated
Add-on systems by a few examples:
For applications without hydrostatic
K Lift truck
travel drive, for example garbage P/M
pump (P/M), which is coupled with multi-motor drives as well as hydro- Lift truck 20 Liter
the output drive, charges the high- mechanical power-split transmissions. Garbage truck 50 Liter
pressure reservoir (SHP). The high- During normal travel, all four logic
pressure reservoir drives the motor valves are closed. Depending on the
(P/M) during acceleration. During the mode, valves LC1,4 or LC2,3 open.
intervening phases, the 2/2 directional For acceleration, the high-pressure
valve (V) is closed. In addition, a pres- reservoir is discharged to the low-
sure-relief valve (DBV) safeguards the pressure reservoir via the hydraulic
accumulator. motor. During braking, the motor
functions as a pump and charges the
high-pressure reservoir from the low-
pressure reservoir.
Bosch Rexroth AG Hydrostatic Regenerative Brake System (HRB) Mobile 2006 55
In addition to the mass of the vehicle 5.1 Add-on system for garbage The simulation results show that
itself, the surface on which the vehicle trucks fuel savings of up to 30 percent
is driven and the speed to which it is The simulation of an HRB add-on are achieved with the HRB system
accelerated, the operational cycle of system for a garbage truck used for (Fig. 8). The simulation also clearly
the vehicle also plays an important household waste is based on the fol- illustrates the faster accelerations
roll in the size the fuel savings. A lowing cycle parameters (Fig. 7): The which are obtained when starting us-
garbage truck starts at one stopping typical deceleration/acceleration is ap- ing the hybrid drive. Thus, the vehicle
point, accelerates and brakes again prox. -0.65 / +1.4 m/s2, with a maxi- with HRB reaches the next stopping
at the next stopping point. For a gar- mum speed of 25 km/h. The distances point faster. Alternatively, it would be
bage truck (weight 26 tons, power between stops ranges between 30 and possible to use a smaller combustion
205 KW, average fuel consumption 100 m depending on the route. engine while maintaining the same
driving 10l/h) which accelerates to acceleration (downsizing).
25 km/h between collection points,
the fuel savings vary between 15 and 50 m
30 percent depending on the distance
between the collection points. The
influence of the travel path between
the loading and unloading of goods
is of great significance for a lift truck
as well. Fig. 7: Garbage truck cycle.
30
Lift trucks 20 normal traction drive
10 reg. traction drive
Garbage trucks 0
0 3 6 9 12 15
Commercial vehicles used in re-
30
gional and distribution traffic
km/h
Velocity
trucks Y-cycle km /h
Loading up 5 t load
The basis of the simulation was a ten- 5t
5t 15
Velocity [km/h]
10
-5
stalled in the hydraulic circuit.
-10
0 10 20 30 40 s 60
Time
HRB. 40
20
The results show that fuel savings of 0
0 5 10 15 20 25 30 35 40 45 50 55
up to 25 percent are achieved by an
HRB integrated in the hydraulic cir- 30
cuit. km/h
Velocity
10
0
7 Conclusion
The hydrostatic regenerative brake
system (HRB) is an economically
significant solution for the recovery
of brake energy and makes the savings Diesel price [EUR]
potentials of hybrid drives available Fig. 11: Fork lift truck cost savings.
to commercial vehicles and mobile
working machines. Through the com-
bination of components which are The fuel savings achieved through the HRB drops fuel consumption by up to
serial or modified serial components, use of an HRB must be compared to 35 percent. These savings are realized
Rexroth is able to configure highly the additional costs associated with constantly, the low additional costs for
reliable, customized system solutions adding such a system. Depending on adding the system must be paid only
for specific vehicle types. The integra- the vehicle type, system and driving once.
tion of HRB is achieved with only mi- cycle, these costs may be amortized
nor modifications to the drive train, at various rates. For extremely short
thereby opening the door to afford- work cycles, as are common with gar-
able retrofitting. bage trucks and lift trucks, the use of
Bosch Rexroth AG Hydrostatic Regenerative Brake System (HRB) Mobile 2006 59
Literature
[1] John M. Miller, Miller J-N-J,
Design Services, Comparative Assess-
ment of Hybrid Vehicle Power Split
Transmission, 4th VI Winter Work-
shop Series, 2005.
[2] Regenerative Braking for Buses
Gives Big Fuel Saving, D. Scott, J.
Yamaguchi, pp. 95-99, Automotive
Engineering, vol. 92, No. 10, Oct.
1984.
[3] F. Korkmaz, H.-P. Willumeit, B.
Benneter, Th. Thier: Stadtlinienbus
mit hydrostatischer Bremsener-
gierckgewinnung (HYDROBUS);
(City Line Bus with Hydrostatic Re-
covery of Braking Energy). Hydraulik
und Pneumatik, 23 (1979). No. 7, pp.
520- 522, Kraussko pf-Verlag, Mainz.