94 Mobile 2003 Track Vehicles Bosch Rexroth AG

Application Center Track Vehicles

Head: Günter Girschikofsky

Bosch Rexroth AG
Mobile Hydraulics
Glockeraustrasse 2
89275 Elchingen, Germany
Telephone: +49 (0) 73 08 82 - 24 21
Facsimile: +49 (0) 73 08 - 53 38
E-Mail: guenter.girschikofsky@boschrexroth.de
Bosch Rexroth AG Track Vehicles Mobile 2003 95

Track drives of the future:

compact, strong, reliable and safe

1. Hydrostatic track
drives for closed loop
with high power density
1.1 Characteristic features of the
working machines and propel
concepts
Turning, changing direction and acce-
lerating, or the constant transmission
of high motive forces: the Rexroth
drive concepts will make your equip-
ment dynamic and mobile, too. The
tougher the requirements facing your
track drive, the more likely it is that
Rexroth will find the ideal solution for
you in one of its modular systems. Figure 1: Track vehicles
The applications vary widely, and ran-
ge from large-scale earth-moving to
the inexorable advance of a cutting Focus on driving functions: – High output speed in order to meet
tool through hard rock, or even the
The requirements facing the hydrosta- the requirement for an even higher
painstaking preparation of a ski-run.
tic travel drive, in the form of con- final speed and shorter transfer
Common feature of these applications
stantly increasing performance requi- times.
are extended running times and seve-
rements by the end customer and a – Long service life even under severe
re operating conditions.
continually growing demand for more operating conditions
economical travel drives, are very exa-
– High efficiency, as travelling is the
cting.
main function
– Compact dimensions to give the ve-
hicle manufacturer the greatest pos- – Take-up of ever-increasing external
sible design. Small diameters at the forces through increased machine
output also allows a greater tractive dynamics
force for the same installed torque – Optimum conversion of diesel po-
through the use of a smaller sprok- wer using interfaces between the
ket. electronic management of the diesel
– Low weight: The market is always engine and the hydrostatics.
expecting more dynamic and more
efficient machines. Hence the
demand for compact, powerful yet
lightweight drive systems.

Authors:
Carsten Ricken BRM-GT/VTG
Klaus Renz BRM-AK/VME2
96 Mobile 2003 Track Vehicles Bosch Rexroth AG

Special modules for extraordina- Weight Power Traction V max

class to to Hydrostatic travel drive
ry requirements:
[to] [kW] [kN] [km/h] 2x Gears 2x Motor 2x Pump
In the track vehicle Application Cen-
ter, Rexroth has matched up the A2FE 56
50 25 GFT 13 T2 4000 A4VG 71
pumps, engines and gears and by to 5 130 A2FE 63
doing so has consistently directed 50 25 GFT 13 T2 4000 A6VE 55 A4VG 71
them towards the requirements of the
GFT 24 S2 9000 A2FM 107 A4VG 125
customers and the market. The mo- 5 to 8 240 85 24
GFT 24 T2 7000 A2FM 107 A4VG 125
dular system allows that these com-
ponents can be combined in such a GFT 24 S2 9000 A2FM 107 A4VG 140
8 to 10 320 100 20
way that they are capable of meeting GFT 24 T2 7000 A2FM 107 A4VG 140
even extraordinary specifications. The
Table 1: Hydrostatic travel drives for snow groomers - The critical parameters here are high
drive concepts for track vehicles in a
travel dynamics, weight and final speed
closed loop can be subdivided as fol-
lows, depending on the equipment Weight Power Traction V max Hydrostatic travel drive
class to to
specifications for the driving function.
[to] [kW] [kN] [km/h] 2x Gears 2x Motor 2x Pump
1) Snow groomer with high travel dy-
to 3,5 40 42 12 GFT 7 T2 4000 A10VT 28 / HZ A10VG 28
namics
3,5 to 5 50 60 12 GFT 9 T2 2000 A10VT 45 / HZ A10VG 45
2) Crawler dozers and crawler loaders
with high tractive force 70 12 GFT 13 T2 4000 A6VE 55 A4VG 56
5 to 6,5 60
3) Trenchers with uniform tractive 90 12 GFT 17 T2 4000 A6VE 55 A4VG 56

power 6,5 to 9 70 140 12 GFT 26 T2 1000 A6VE 80 A4VG 71

Tables 1 to 3 summarize common 160 10 GFT 40 T2 9000 A6VE 107 A4VG 90 / 105
9 to 12 90
combinations used in individual ap- 180 12 GFT 40 T2 9000 A6VE 160 A4VG 90 / 105
plications.
11 to 16 150 250 12 GFT 65 T2 1000 A6VE 160 A4VG 125 / 140

Depending on requirements, indivi- Table 2: Hydrostatic travel drives for crawler dozers and crawler loaders - tractive force, com-
dual layouts can vary from the sugge- pactness of the drive and transfer speed are critical here
sted ones shown here. Other products
Weight Power Traction V max Hydrostatic travel drive
and combinations can be obtained class to to
upon request. [to] [kW] [kN] [km/h] 2x Gears 2x Motor 2x Pump
10 to 15 150 180 5 GFT 24 T3 1000 A6VE 55 A4VG 40 / 56

15 to 25 200 250 5 GFT 36 T3 3000 A6VE 55 A4VG 40 / 56

25 to 35 250 340 5 GFT 50 T3 1000 A6VE 80 A4VG 71

35 to 45 280 370 4 GFT 60 T3 3000 A6VE 107 A4VG 90

45 to 55 300 430 4 GFT 80 T3 1000 A6VE 107 A4VG 125

55 to 70 380 550 4 GFT 110 T3 1000 A6VE 160 A4VG 125

70 to 90 450 750 4 GFT 160 T3 1000 A6VE 160 A4VG 140

90 to 110 600 920 3 GFT 220 T3 1000 A6VE 160 A4VG 180

Table 3: Hydrostatic travel drives for trench-cutting machines - The most important features
here are large uniform feed power and an extraordinarily robust drive. Similar designs apply
to drainage machines.
Bosch Rexroth AG Track Vehicles Mobile 2003 97

1.2 Planetary gears for track

drives with high power density
Stability even for the most demanding
uses, low weight and compact dimen-
sions are the core requirements for a
planetary gear these days. To meet this
set of requirements successfully with
innovative products, Rexroth combi-
nes in its productline geartechnology
high-specification materials with the
most modern computation programs
and thoroughly tried and tested ma-
nufacturing processes (Figure 2).

Forged ring gears to reduce the

diameter: Figure 2: GFT 40 T2 with A6VE 160
In line with our philosophy of not
yielding a millimeter, the ring gears
are forged, highly tempered and sur-
face-hardened. Compared with the
ther with a good tooth contact pat- High-quality connection with the
widespread version of a „cast ring ge-
tern. working machine:
ars with a hard metal ring insert“, our
The use of cageless planetary bearings The load-bearing axles create the flow
design permits appreciably lower di-
(the planetary gear is also hardened of force to the machine frame. The
mensions to be used for the same tor-
and ground inside and assumes the entire weight of the machine is often
que capacity or, for the same dimensi-
function of the outer ring of the bea- supported here. For this reason, the
ons, markedly higher torque capacity
ring) permits higher load ratings for load-bearing axles of the gear box are
and longer service life.
the given diameter. exclusively forged components. This
greater strength also has a beneficial
High manufacturing accuracy for
Reduction of installed length: influence on dimensions where con-
optimum load distribution:
The planet carriers of the planetary nection to the frame is concerned.
The smallest possible tolerances and
gears are made exclusively from for- Due to the specially adapted contours
proven processes guarantee that the
ged parts, as these are considerably for the integrated A10VT motors and
high torques and forces in the output
stronger than cast planet carriers and the A6VE / A2FE plug-in motors Rex-
stage are evenly distributed over 4 to 5
use the same amount of material. roth has the shortest drives on the
planetary gears (we have already made
Rexroth has achieved a further reduc- market.
7 planetary gears at a customer’s re-
tion in dimensions with the cantilever
quest). Compared with the standard
design of the planetary gears. When Reliable even in winter:
option of 3 planetary gears, this achie-
compared with the standard two- A welcome „side effect“ of the low-
ves a considerable reduction in the
cheeked web, this version is consi- temperature strength of the material
diameter of the ring gears.
derably shorter when assembled and used is its considerably greater reliabi-
The planetary gears and sun wheels
thus achieves advantages in installed lity in wintry temperatures, provided
are case-hardened and ground in or-
length. that the recommended lubrication is
der to guarantee the best possible soli-
adhered to.
dity and dimensional stability toge-
98 Mobile 2003 Track Vehicles
Robust output bearing for stabili-
ty with increased travel dynamics:
In order to be able to meet the more
stringent requirements of users, the
Rexroth productline geartechnology
only employs robust tapered roller
bearings for closed-loop track drives.
The high pre-tension of the bearing
assembly provides it with the required
robustness to resist external forces.
The entire weight of the vehicle is of-
ten supported on the sprocket and
therefore on the ring gears. The high
travel dynamics during steering with
oppositely directed tracks, for examp-
le introduces additionally considera-
ble axial forces into the bearing as-
sembly. The solution, often favored by
our competitors, of using angular ball
bearings (originally designed for
„soft“ use in the chassis of an excava-
tor, drill, stonebreaker etc.) can suffer
premature bearing play under severe
use. This then results in leaks between
the ring gears and the bearing axle or
even damaged teeth, owing to the ske-
wed position of the ring gears.
Reliable mechanical seal:
For the principal seal between the
bearing axle (connection with the fra-
me) and the output, Rexroth uses only
high-performance mechanical seals
for track drives in the hydraulic cir-
cuit. Even under extremely severe
conditions of use these guarantee a re-
liable seal between the oil sump and
the outside. Increasing awareness with
regard to possible pollution of the en-
vironment does not allow any other
solution for demanding applications.
Frame
Sprocket
Track
Figure 3: Crawler installation situation
For some working machines (e.g. do-
zers) there is the option of very nar-
row chains. Understandably, the pla-
netary gears are required to remain
within the width of the chains in or-
der to avoid extra projecting edges.
For the chassis too, the option of very
narrow drive chains limits the space
available (Fig. 3).
Equipped for the future:
By using high-specification forged
components for the parts transmitting
the force and power, the cantilever
design of the planetary gears and the
optimized bearing axles for the
company’s own motors, Rexroth is in
the ideal position, according to its
philosophy:
Bosch Rexroth AG
Tapered roller
bearings
Ring gear,
(forged)
Planetary gear rod
(forged)
Bearing axle
(forged)
„ .... to supply the strongest and most
robust planetary gears for a given set
of mounting dimensions, or alterna-
tively to manufacture the most com-
pact drive for a given set of perfor-
mance data“
to satisfy the requirements of custo-
mers and the market for an extremely
compact drive.
In order to provide users with even
more freedom in future when desi-
gning their machines, we at Rexroth
will continue to pursue this basic
principle and minimize the mounting
space required whilst maintaining or
even increasing performance.
Bosch Rexroth AG Track Vehicles Mobile 2003 99

2. Modern systems for 2.1 System architecture of the

new technology
the control and propel Rexroth recognized this requirement
systems of tomorrow’s in good time and has made the appro-
priate strategic preparations. The awa-
generation of machines reness of applications and the market
Pressure on the manufacturer is gro- needed for the careful selection of
wing because of the ever-decreasing components and successful system
intervals between changes of vehicle project planning have been brought
generation - and this includes the together for this purpose in what are
construction machinery sector. The known as Application Centers. This
market demands ever shorter product bundled skill and knowledge provides
development times and higher inno- technically optimized and economical
vation cycles. The necessary innovati- support for machine design. With its
ve output can only be achieved within wide range of products, Rexroth is
this narrower timeframe with tailor- now in a position to offer virtually all
made systems and all-embracing solu- the significant components for the
tions. principal functions of mobile con-
struction vehicles „from a single sour-
ce“ (Fig. 4).

Service- Emergency Travel drive controls

Controls Display tool stop
DI2
RC-
ESC F1 F2 F3 F4 F5
ECU
BB-3

Data
collection
CAN-Bus

Fan drive

ECU-
engine
Working
functions

Figure 4: Overall solution for track drive vehicles

100 Mobile 2003 Track Vehicles
A summary of the main compon-
ents:
– Axial piston pumps
a) for travel drives
b) for working hydraulics
c) for closed-loop-controlled fan
drives or other secondary drives
– Axial piston motors
a) with adapted planetary gears for
travel drives
b) without secondary transmissions
for fan drives or other secondary
power take-off drives, e.g. milling
or mulching drives (Fig. 5)
– The latest generation of electronic
ECU‘s from the „RC family“ to au-
tomobile production quality for
many and varied tasks such as:
a) pilot operated or closed-loop-
controlled travel drives
b) closed-loop-controlled fan drives
c) steer-by-wire integrations
d) power management and
diesel control
e) Monitoring and protection
systems
– Open-loop and closed-loop control
software created for specific machi-
nes or customers with facilities for
setting parameters as desired by the
user
– Manual control transducers as
a) hydraulic or
b) electronic actuation elements
– Servicing and diagnostic tools to as-
sist with monitoring and fault ana-
lysis
– Graphic displays for status, error
and operator displays
Bosch Rexroth AG
– Sensors for picking up relevant ac- – Optimized application-specific ma-
tual machine data and for real-time chine software enables an unusually
adjustment and monitoring of ma- high degree of economy and ex-
chine behavior ploitation of the vehicles plus a mi-
– Control blocks for supplying all the nimum of the emissions.
hydraulic work functions - Development and application times
are shortened by sending the soft-
ware updates by email and trans-
mitting them with Laptop and
flashtool on the ECU in the vehicle
on site
In spite of all these efforts to standar-
dize components and make them
compatible, Rexroth still has sufficient
freedom for individual, technically
specific requirements and adjust-
ments, owing to our longtime experi-
Figure 5: Hydrostatic mulch drive
ence and good knowledge of the mar-
ket. The customers often desire these
A few illustrative highlights:
adjustments for strategic reasons as
– Rexroth axial piston pumps Rexroth
well as from the standpoint of marke-
axial piston pumps have got the ca-
ting and brand politics. These factors
pability of full through-drive and
open to the vehicle manufacturer a
are therefore available for both open
high degree of individuality and pos-
and closed loops as tandem units
sible variants at nearly unchanged
and also as three-pump combinati-
product costs. The result is a clear
ons.
higher potential for a high market pe-
– Our transmission-gearboxes for tra- netration.
vel drives with hydrostatic plug-in
motors are shorter and more com-
pact then all comparable products
with the same performance
– The intervals chosen for the new ge-
neration of RC-controllers cover a
good range. Beginning with RC2-2/
20 via RC4-4/20 and RC6-9/20 up
to RC12-18/20 there are controllers
with minimum two PWM and two
switch outputs and maximum 12
PWM and 18 switch outputs availa-
ble. Thus, there is a useful and eco-
nomical solution available for al-
most all requirements.
Bosch Rexroth AG
2.2 Rexroth closed-loop control
systems for the safety require-
ments of tomorrow
These days, there are many subjects
centered on electronics which are the
main focus of vehicle manufacturers’
interests. In the construction ma-
chinery sector, in particular, the as-
pects of economy and the environ-
ment, protection of natural resources,
the many ways that machines can be
used and increasing requirements for
comfortable operation are becoming
more and more important.
In parallel with this market develop-
ment, the presence of an automotive
industry with extensive experience
and the continually progressing tech-
nical development of electronic ele-
ments for mobile use justify the grea-
ter confidence placed in the perfor-
mance and reliability of this technolo-
gy.
Robust technology for safer solu-
tions
Below are a few examples of new pro-
ducts and systems in the field of mo-
bile electronics.
– Plug design from „Deutsch“
In order to improve the degree of
protection of two position and pro-
portional solenoids, Rexroth uses
the integrally molded plug connec-
tors manufactured by Deutsch as
standard. In this way, these assem-
blies meet the requirements of pro-
tection IP67 (plugs) and IP69K
(connection to the solenoid), which
are demanded by the common
practice nowadays of cleaning ve-
hicles with a steam jet. The soleno-
ids are also able to withstand the
Service Tool +
diagnostics collection
Controls
Display
Engine
ECU
Figure 6: Focus on electronics, main systems in for track vehicles
severe conditions of use of the ma-
chines and their components.
- Proven ECU technology from the
automotive sector:
For the RC family of ECU‘s, Rex-
roth uses robust aluminum die-cast
housings and the manufacturing
technology of the Bosch automotive
division. Our ECU‘s are therefore:
– vibration resistant up to 10 g
(to IEC 60086-2-6)
– bump-resistant up to 25 g
(to IEC 60086-2-29)
– thermostable from -40°C to
+85°C
– EMC-resistant up to 100 V/m
(to KFZ-RL (Automotive
Directive 95/54/EG), and
– meet degree of protection IP65
under operating conditions
Track Vehicles Mobile 2003 101
Data other
Systems
RC -
ECU
Fan Travel
control drive
– Redundant signal technology for
safety-related functions:
In new projects, wherever feasible,
signal generators and sensors with
redundant signal outputs are used.
In this way, machine availability is
retained - wherever sensible and
safe - whilst possible malfunctions
are detected.
However, the continually growing de-
mand in the mobile electronics sector
is also based on the further tightening
of safety requirements, set to become
even tighter in the future.
102 Mobile 2003 Track Vehicles Bosch Rexroth AG

2.3 Current rules and regulations nes and safety components“. – More concrete and much more spe-
for earth-moving machinery It makes no reference, however, to cific to earth-moving-machinery
The safety engineering required in special machines, assemblies or are:
mobile construction machines is also working conditions, even though it – DIN EN 474-2 3)
strongly influenced by the validated is here that the principles of general „Safety of earth-moving ma
standards. The most important bin- safety requirements are manifested. chinery, Requirements for
ding guidelines at present are (Fig. 7): dozers“, and
– DIN EN 61508 2) „Functional safety
– The EC Directive 98/37/EC 1)
of safety-related electrical / electro- – DIN EN 474-3 3)
known as the „Machine Directive“.
nic / programmable electronic sy- „Safety of earth-moving ma
As a European regulation it defines,
stems“, with the relevant parts 1 - 5 chinery, Requirements for
in Appendix I, the general „basic he-
& 7. This contains the generally ap- loaders“.
alth and safety requirements for the
plicable requirements for electronic These standards include, above all, de-
design and construction of machi-
systems. tailed normative references to the in-
dividual assemblies and functions of
the machines.

Machine Directive
98/37/EG

DIN EN 474, Parts 1 - 12 IEC 61508

Earth-moving machinery - safety, Functional safety of safety-related
requirements electrical/electronic/programmable
electronic systems

IEC 61508-2 /-3

DIN EN 474
Part 1, 4...12
ISO/DIS 15998
Earth moving machinery-
IEC 61508-1 /-4 /-5 /-7
Machine-control systems (MCS)
DIN EN 474
using electronic components
Part 2:
Requirements for dozers
DIN EN 954
Risk assessment
Control systems
Fault prevention
DIN EN 474
Fault containment
Part 3:
Requirements for loaders
...

= refers to

Figures 7: Standards for earth-moving machinery

1 2
) Source: Official Journal of the European community, L 207, 41. Class, 23 July 1998 ) German version: 2001
3
) State of March 1996
Bosch Rexroth AG Track Vehicles Mobile 2003 103

2.4 A look into the future
Many of these national and European
regulations and standards are current-
ly being revised and will be subject in
part to certain clear amendments and
harmonization. In this connection
further standards and regulations will
also be drafted, requiring a closer look
at machine safety and accommodate
to the increased product liability.
One of the central documents of the
future for the open-loop and closed-
loop control units of devices in the
field of earth-moving machinery is
the current draft standard
ISO/DIS 15998 „Earth-moving ma-
chinery - Machine-control systems
(MCS) using electronic components -
Performance criteria and test“.
In many areas this draws on the Euro-
pean standard already referred to,
DIN EN 61508, to which it contains
corresponding references.
The committees concerned intend
that Parts 1 to 12 of DIN EN 474, in
their amended form, will contain,
among other things, a normative refe-
rence to the version of ISO 15998 in
force at the time. The introduction of
these technical guidelines is expected
to take place in 2004.
The requirement for risk assessment
of machines and an „assessment of
the degree of safety integrity“, called
the „SIL rating“, to ISO/DIS 15998
(corresponding to DIN EN 61508-5)
therefore has a statutory basis. And
the „SIL-ratings“ also have, indissolu-
bly linked to them, corresponding
technical safety requirements for the
machines.
2.5 Rexroth’s ECU safety concept:
In order to meet the requirements of
SIL2 for track vehicle drives, Rexroth
has developed a safety concept that
satisfies ISO/DIS 15998.
This new design redefines the „state of
the art“ for this type of machine con-
trol system (Fig. 8).

Safety switch Solenoid valve

Joystick + Emergency stop
CAN
analog Central
analog switch
Input 1 analog redund . Dual circuit drive
analog Drive program Functional Pump left forward
Input 2 analog redund . control PWM Pump left backward
with fault monitoring
analog unit F Motor left
Input 3 analog redund . Soll Pump right forwards
Ist Pump right backwards
Motor right
Operating system
Safety-related
electrical with fault monitoring
controls Speed/direction
Motor left
Speed/direction
Motor right

Pressure sensor
Safety program Parking brake
Safety
control
unit S Solenoid valve
Operating system
with fault monitoring Diesel protection

Figure 8: Control unit safety concept, block diagram

104 Mobile 2003 Track Vehicles
The salient features of this safety con-
cept are:
- Two mutually independent micro-
processors
- Independent electrical connection
of safety-related setpoint generators
and sensors to the two microproces-
sors. In this way, each microproces-
sor reads the original data from the
signals itself
- Redundant input signals from safe-
ty-related setpoint generators
- Redundant input signals from safe-
ty-related sensors
- Continuous comparison of the re-
sults of computations by both con-
trollers via the CAN bus
- Continuous monitoring of all safe-
ty-related output signals
- Central switch-off of all output
functions of the functional ECU by
the monitoring ECU in the event of
a recognized fault.
- Central switch-off of the hydrostatic
travel drive by the monitoring ECU
in the event of a recognized fault.
With this ECU safety concept, Rex-
roth makes another considerable con-
tribution to ensuring that in the fu-
ture, too, our machines will be able to
satisfy in full all relevant safety requi-
rements, and to enabling machines in
the earth-moving sector to achieve the
CE mark to 98/37/EC
Bosch Rexroth AG
3. Greater success with
safety
For the manufacturers concerned the
development and construction of the
machines does not hold any obligati-
on to use the standards mentioned,
and for the legislator there is therefore
no duty to ensure that they are met.
At first glance this could be an invita-
tion not to make the required effort.
However, no manufacturer will mar-
ket machines with known and avoida-
ble accident risks and thus expose
himself to the tighter guidelines and
laws of product liability.
There is also another aspect that
should not be entirely disregarded:
every operating requirement always
carries a residual risk with which the
risk of machine liability is associated.
It therefore seems logical, and only a
matter of time, before insurance com-
panies require proof of risk as-
sessment in order to undertake a cor-
responding rating of the machines.
If we take all the arguments for „grea-
ter safety“ on machines together and
use them effectively, this can be tho-
roughly beneficial for the sale of ma-
chines and increase the success of the
company through increased market
penetration. Rexroth is happy to sup-
port and accompany you on this path!
Bosch Rexroth AG Track Vehicles Mobile 2003 105