216 Mobile 2003 Fan Drive Systems Bosch Rexroth AG

Application Center Fan Drive Systems

Head: Dirk Herber

Bosch Rexroth AG
Mobile Hydraulics
An den Kelterwiesen 14
72160 Horb, Germany
Telephone: +49 (0) 74 51 92 - 15 33
Facsimile: +49 (0) 74 51 - 82 21
E-Mail: dirk.herber@boschrexroth.de
Bosch Rexroth AG Fan Drive Systems Mobile 2003 217

An up to date alternative –
hydrostatic fan drive concept from Rexroth

Introduction
A framework with specific legislation center is making use of the synergies
and ever more stringent directives ai- arising out of the vast array of diffe-
med at protection of the environment rent business technologies within the
lead to a close examination of fan Bosch Rexroth AG.
drives. Drive specialists regard the hy-
draulic fan drive, also for vehicles with
lower fan power requirements, an ex-
tremely suitable alternative. Tempera-
ture controlled hydrostatic fan drives
offer substantial advantages over con-
ventional designs with V-belts or di- system advice
rect drives through the crankshaft,
and are feasible already for relatively application center Horb system knowledge system research
small drives from 7 kW and up. Espe-
cially the control side offers a tre-
mendous potential for savings. More
stringent directives for the protection
of our world’s atmosphere make it
more feasible and economical to deci-
de for such a new system. The Euro 3
commissioning at
norm for diesel driven vehicles has in- system training customer´s vehicle
tensified the competition for the best
fan drive technology. The next step Figure 1: System knowledge
will follow in 2005 with the introduc-
tion of Euro 4. For the variable pump
fan drive systems from Rexroth with Hydrostatic fan drives – accurate control of temperature in
their up to date control technology up to four different cooling circuits
Controlled hydrostatic fan drives are
no unsurmountable hurdle. superior to conventional mechanical – low hysteresis
and electrical systems in the following – low loss of hydraulic energy
The Rexroth application center „Hy- points: – high reliability through the use of
drostatic fan drives“ has the responsi- – flexible arrangement of the overall tough motors and pumps.
bility to analyze today’s and future fan drive system in the vehicle. This
customer requirements and come up enables an optional placement of A simple system for a hydrostatic fan
with effective solutions. In close co- the drive components, and space sa- drive consists of a fixed gear pump
operation with customers and part- ving installation and a gear motor coupled directly
ners the group works on optimum – fan runs only when needed onto the fan. A bypass-proportional
system solutions with matching com-
– complete control of maximum fan relief valve enables a steady control of
ponents. In addition, the application
speed, independent of diesel engine motor speed. The spare flow is going
speed back to the oil reservoir.
Authors:
Dirk Herber BRM-AK/VIH5 – in systems with variable pumps
Aras Tscharkhoscht BRM-AK/VIH5 control of fan speed (more or less)
independent of engine speed
218 Mobile 2003 Fan Drive Systems
For medium fan powers between 7
and 15 KW these fixed displacement
systems with bypass control form a
cost effective solution.
ED (fail-safe)
Hysterese
Figure 2: Example of a low hysteresis
fan drive
Newer and more energy efficient are
fan drives, using variable displace-
ments piston pumps. Today’s and fu-
ture design criteria are asking for cost
and energy efficient systems, in com-
pact and flexible layout. In drives,
with power levels above 15 KW these
goals can be best met with hydro-
statics, using variable pumps.
Depending on the requirements, hy-
draulic fan drives can be controlled
either hydro mechanically or electro
hydraulically.
engine speed
water
Figure 3: Connections in fan drive systems
Hydro mechanically controlled fan
drives are suitable for simple systems
with up to two temperature inputs.
More complex systems with multiple
input signals need the use of digital
control electronics.
The Rexroth variable displacement
pump A10VO with ED-control is ex-
tremely suitable for fan drives with
more complex requirements. During
operation the input power to the
pump is in correspondence with the
actual required fan power at all times.
This feature is based on the pump’s
electronic pressure control. The
pump’s output pressure depends on
the current signal to the ED-control’s
solenoid valve. The control behaves in
such a manner, that the system pres-
sure is inversely proportional to the
strength of the current signal. Fan
speed of course depends on the
Bosch Rexroth AG
fan speed
air oil
motor’s output torque, which again is
proportional to pressure. This accura-
te control of fan speed enables a pre-
cise control of engine temperature
within close limits. Changing engine
speed (pump drive speed) will result
in changing pump displacement, the-
reby keeping the output flow equiva-
lent to the required motor flow. Sys-
tem pressure is inversely proportional
to current signal; that means of course
that with zero current (cable break)
the system will go to max. pressure. In
this case the fan will go to max. speed,
and the engine might get too much
cooling, but overheating will be pre-
vented.
This feature (fail safe behaviour) was
developed especially for fan drives.
Bosch Rexroth AG Fan Drive Systems Mobile 2003 219

Fixed displacement pumps Construction Agricultural- Vehicles Rail vehicles

• Reasonable price machines Equipment
• Compact dimensions Excavators Tractors Buses Locomotives
Dozers Combines Trucks Diesel driven
Loaders Forestry machines Heavy loads trucks locomotives
Variable displacement pumps
Backhoe loaders Special vehicles
• Extreme energy efficient: steady ad-
Mobile cranes
aption of pump input power to re-
Rough terrain
quired fan power
Fork lifts
• High efficiency Telehandlers
• Low fuel consumption Road pavers
• Favourably emmisions other mobile
applications
In case of a bus, the additional cost for
a fan drive with variable pump can Figure 4: Examples for hydrostatic fan drive systems
pay for itself after 100.000 km already
through lower fuel consumption.
With an average lifetime of around a
million km it is obvious, that in the
long run the cost will be much lower.
The application center for fan drives
however is considering the hydrostatic
drive for vehicles with smaller fan po-
wer also a viable alternative.
The more severe the directives for en-
vironmental protection, the more eco-
nomical it becomes to decide for such
a system.

Reversible fan drive

Rexroth offers also reversible drives
for systems which are prone to severe
contamination of the radiator grid.
Depending on the required power,
systems in closed or open circuit can
be used. Without any further expenses Figure 5: Components for fan drive systems
for the customer, the fan reverses the
direction of rotation and cleans the
radiator automatically.
220 Mobile 2003 Fan Drive Systems
Prospects
Hydrostatic fan drives are subject to
steady development. A few new con-
cepts as well as current trends (increa-
se of service life, reduction of required
input power, intelligent electronics) to
optimize the control end are leading
to a continuous development of the
individual components. Considerable
attention should also be paid to the
possibility of providing drive power to
different systems with one variable
pump unit. Rexroth is carrying out
research and development already to
combine the hydrostatic fan drive
Fixed pump system
only fan drive
Fan Air conditioning
Figure 6: Combined systems, one pump, multiple drives
Bosch Rexroth AG
with accessory drives like compressor applications like these will lay the
for air conditioning, turbo charger, foundation for future success and are
generator, etc. E.g. in buses these type made possible through intensive co-
of solutions would offer the advantage operation and continuous dialogue
of an optimized weight distribution with customers and partners.
and use of mounting space. The
customer’s end product and the envi-
ronment will both benefit from an
improved fuel efficiency. Innovative
Air conditioning
Compressor
Generator
others
Variable pump system Combined systems
only fan drive (one pump, multiple drives)
Compressor Generator etc.
Variable displ.
piston pump
Diesel engine