156 Mobile 2006 Backhoe Loaders Bosch Rexroth AG Bosch Rexroth AG
Energy
The call for optimization of the energy requirement to reduce environ-
mental pollution is becoming louder. With the A10VO dual torque and
speed sensing, Rexroth offers already today intelligent systems for
power management that meet this requirement in a cost-effective way.
Cost
Costs prove to be a continuous driver for the manufacturers of backhoe
loaders. With its flow-sharing-valves SX14, Rexroth has already brought
the backhoe hydraulics to the next technical level. The new S-section of
the SX14 valve enlarges the range of machines that can benefit from this
cost efficient solution.
Backhoe Loaders Mobile 2006 157
Specific Performance for
Backhoe Loaders
The environmental situation that is aggravating worldwide and rising oil
prices are two factors that call for new solutions for reducing exhaust gas
emissions and for saving energy. In the field of hydraulics, this means that
the power source in a vehicle must be monitored and that energy is to be
generated only when required and to the necessary extent. On backhoe
loaders, the energy source is in most of the cases a gear pump. Power man-
agement systems that are tailored to the requirements of backhoe loaders
and based on Rexroth variable displacement pumps of type A10VO (Fig. 1)
can efficiently meet the demand for a reduction in environmental stress and
optimization of energy requirements. Further saving potentials for the user
lie in the employment of modern valve technology with even more integrated
functionalities.
Philippe Fillon
Vnissieux (F)
Bernd Fassnacht
Horb (D)
158 Mobile 2006 Backhoe Loaders Bosch Rexroth AG

1 Design to Market
systems for backhoe loaders
Based on a tractor, backhoe loaders
combine two typical construction
machines in one vehicle. Both, the ex-
cavator and the loader, are rugged and
easy to operate. This versatile machine
concept has been accepted worldwide
for many years. The hydraulic system
is based on medium-pressure technol-
ogy, which is continuingly developed
further in line with the increasingly
strict requirements. Apart from the
demand for higher efficiency and
improved operator convenience, legal
stipulations with regard to reduced
fuel consumption and at the same
time optimized exhaust gas and noise
Fig. 2: Backhoe loader in action.
emission are becoming more and
more stringent. These objectives can
only be met with a modern hydraulic 2 Reduced cost and controls and extended functionalities
in other mobile applications, for ex-
system. The specialty that the backhoe energy for attachments
loader integrates two machines in one ample, the telescopic handler.
represents an additional challenge that 2.1 Integrated functionality
machine manufacturers have to face, If one reads mobile hydraulics bro-
but can be taken by means of intelli- chures issued since 1997, oil flow dis-
gent hydraulics. With todays hydrau- tribution by means of valve type SX14
lic systems tomorrows demands can (Fig. 3) has always been the favored
be satisfied over the complete band- system. It is therefore not surprising
width from the standard category that the SX14 is also a topic today
the system has, however, constantly Fig. 3: SX14 valve with hydraulic control.
through to the top class (Fig. 2).
been developed further to meet the
requirements of the market today and
in the future.
Despite its advance, for example due
to the possibility of controlling auxil-
iary functions by means of a joystick,
the electronics for controlling the
complete machine is not yet a stan-
dard. Rexroth has therefore developed
the SX14NGE (New Generation Elec-
Fig. 1: A10VO..EK variable displacement tronics, Fig. 4) for backhoe loaders,
pump. Fig. 4: SX14NGE valve (New Generation
which is comparable with electronic Electronics).
Bosch Rexroth AG
Based on the SX14 standard, this valve
allows the conversion to an electrohy-
draulically controlled machine. All of
the functions required for a backhoe
loader are already available in this new
development.
Controls can be built up by means of
MHDRE 2 (Fig. 5) pressure reduc-
ing valves around the PWM control
elements, or a CAN bus module in-
tegrated in all blocks (Fig. 6) can be
used. Suitable operating elements are
electronic joysticks of type 4THE5,
which can be fitted with the same
family of handles as todays hydraulic
joystick type 4TH5 (Fig. 7).
Fig. 5: SX14NGE valve with pressure reducing
valves of type MHDRE 2.
Fig. 6: SX14NGE valve with CAN bus module.
Fig. 7: Joysticks 4THE5 and 4TH5.
Backhoe Loaders Mobile 2006 159
One of the key features of the SX14 oil With regard to energy savings, all of
flow distribution system is its distinct the new SX14S sections will generate
possibility of individual adjustment. considerably lower pressure losses,
This refers not only to the flow con- which will contribute remarkably to
trol like speed or metering properties, energy savings.
but also to the valves capability of
Apart from cost and energy savings,
distorting its operating characteris-
particular importance was attached
tics and taking on another operating
to greater flexibility. The new SX14S
behavior. Thereby the function of the
sections are all suitable for block de-
valve exceeds by far the function of
signs and can be combined with both,
pure oil distribution and even reaches
available inlet and outlet elements and
parallel open-center characteristics.
existing sections of the SX14 standard.
At the same time, manufacturers gain
Consequently, all functionalities can
great flexibility in developing ma-
be implemented that are expected
chines that meet their own criteria.
from a control block in a backhoe
loader. Moreover, the identical valve
2.2 New sections offer savings
can be used in conjunction with fixed
potentials
or variable displacement pumps,
The continuing further development
which also contributes to cost cutting.
of the valve will lead to the produc-
tion of new SX14 sections with differ- NEW
ent objectives in the next two years:
To provide cost reductions, Rexroth
will, on the one hand, offer SX14SL
sections (Fig. 8) without the optional
combination with secondary pressure
relief valves. These sections will be
available with a pressure compensator Fig. 8: SX14SL valve.
or a simple load-holding valve and
can be used, for instance, for support- NEW
ing legs. On the other hand, SX14SC
sections (Fig. 9) will be offered with
cost-efficient secondary pressure re-
lief valves. These sections can also be
equipped with a pressure compensa-
tor or a simple load-holding valve.
Fig. 9: SX14SC valve.
160 Mobile 2006 Backhoe Loaders Bosch Rexroth AG

NEW EC2000+ EC4000

Abb. 10: Ventil SX14SD.

EC2000 EC1000
The leak-free models of the SX14S
(SX14SD, Fig. 10) offer freedom from
leakage in series SX14 due to the real
poppet-to-seat seal elements and
the very stable opening and closing
method. The minimal pressure drop
values occurring with this section are
Fig. 12: Overview of handles.
ideal for functions that must be drift-
free such as for supporting outriggers,
booms or arms. Electronics as means for controlling
the main valve is not yet very popu-
2.3 Joysticks simplify operation lar, but this could change soon for a
Hydraulic joysticks, which have been multitude of reasons so that backhoe
employed on excavators for decades, loaders, too, could benefit from this
have found their way into backhoe technology. In this case, the SX14NGE
loaders just recently. Offering more is already available manufactured in
comfort and new possibilities of ar- Europe and America. It offers various
chitecture, seat-mounting (Fig. 11) control options (PWM or CAN bus)
and improved ergonomics (switches and functionalities such as integrated Fig. 11: Cabin with joysticks mounted to the
and rollers in the handles), they have pilot oil supply, pilot control check seat.

already won a stable market share. valve, leak-free isolator valves in the
They facilitate operation and offer working ports, electrical valves for re-
more functionalities with numerous leasing the displacement mechanism
handle configurations. of the attachments and priority valves.
For controlling, the 4 or 8 THE5 de-
Rexroth is producing a great selection vice in various versions (signal, work-
of handles for various applications ing current or CAN bus) will be used.
from EC1000 through to EC4000 (Fig. Fig. 13: Handle of type EC3000+.
12). Soon a new handle will be avail-
able: the EC3000+ (Fig. 13). It will
allow the integration of even more
functionalities than the common
EC2000 and can be provided with
soft-touch material like the EC2000+.
Bosch Rexroth AG Backhoe Loaders Mobile 2006 161

3 Product range exten- (Fig. 14) includes solutions for boom 4 Power management
and arm cylinders, loader lifting arms
sion in compact hydraulics with A10VO
and steering systems as well as addi-
Over and above, Rexroth is extending When selecting the diesel engine for a
tional valves such as the very success-
the comprehensive product range for backhoe loader, two generally differ-
ful heavy-duty hammer valves which
backhoe loader applications by a new ent operational states have to be taken
control both, manually actuated ham-
product line of the former Oil Con- into account. In the loader mode, the
mers and also boom hammers. The
trol Group. This company was leading diesel engine simultaneously supplies
integration of the product series of
in manufacturing of compact hy- the working hydraulics and the travel
Rexroth and the Oil Control Group,
draulics, in particular for the mobile drivel with energy. In the excava-
development activities included, has
market and has supplied the backhoe tor mode, the full diesel power can
resulted in an expansion of both the
loader market for many years. With be used for the working hydraulics.
product range and also in the pos-
the acquisition of the Oil Control This problem is aggravated by the
sibility of developing special solutions
Group, Rexroths latest product line fact that a backhoe loader works on
rapidly and cost-effectively.
average 70 percent of the time in the
excavator mode and 30 percent in
Steering Pump System the loader mode. This means that the
Steering mode valves In-loader and double load of loading and travel-
Un-loader ing occurs during only 30 percent of
Outriggers Integrated manifolds the operating time. The diesel power
PO check valves
Counterbalance valves Loader Arms installed for powering the hydraulic
Directional valves Load control pump at maximum displacement and
Integrated manifolds Regenerative manifolds maximum pressure is sufficient in
only very rare cases. In order to meet
Boom and Dipper Load Sensing System
Boom lock valves Pressure control
these special backhoe loader require-
Flow control ments, controller variants for the
Pilot System In-line check / shuttle valves power management were developed
Pressure reducing valves for the A10VO medium-pressure
Integrated manifolds Side Shift
pump. In this way, optimum perfor-
Solenoid cartridge valves
Attachment / Qick Coupler Systems Integrated manifolds mance can be realized at low opera-
Diverter valves tional and installation cost while more
Integrated manifolds Ride Control stringent environmental requirements
In-line check valves Solenoid cartridge valves
are met.
Hammer valves Integrated manifolds
Fig. 14: Rexroth offers all the required valves from a single source.
162 Mobile 2006 Backhoe Loaders Bosch Rexroth AG

4.1 Dual torque limitation Function Pressure

The power controller of the A10VO Simple operation of the machine p
has been used on mobile machinery functions
for many years and allows optimum No stalling of the diesel engine Corner power
utilization of the diesel power in- Higher working speeds due to larger
stalled. For hydraulic pumps without oil flows
power controller, the diesel power
Greater forces due to higher pres-
must correspond to the rated pump
sures
power (power at maximum displace-
ment and maximum pressure) (Fig. Energy
15). This means that power reserves of
Less fuel consumption
the diesel engine are not utilized. Q (Vg)
Optimum utilization of the diesel Flow
On the basis of this standard power engine in the excavator mode Fig. 15: Rated pump power with displacement
controller, Rexroth developed a vari- Optimum utilization of the diesel control.
ant that is tailored to the needs on engine in the loader mode P high adjustment
a backhoe loader. The dual torque backhoe
power controller adjusts the torque, Environment
which is taken up, to the operational Lower noise generation
state. During loading operation, the No overloading of the diesel engine
power setting of the hydraulic pump
Better exhaust gas characteristics
is reduced, because a part of the diesel
engine capacity is required for travel- Cost low
adjustment
ing. In the excavator operating mode, Smaller diesel engine for the same loader
the entire diesel engine power can be handling capacity
fed to the hydraulic pump, since the Q
Longer service life
machine is at a standstill (Fig. 16 and Fig. 16: Dual horsepower A10VO control
17). Lower fuel cost allows adapted working behavior.

Excavator mode
Working hydraulics only high Torque
power setting of the hydraulic pump available
Engine characteristic torque
Loader mode high pump
setting
Working hydraulics plus travel drive
Transmission control range
low power setting of the hydraulic low pump
pump setting

This results directly in the following Pump pump

only
advantages for the user:

low idle high idle Engine

speed
Fig. 17: Power distribution with dual horsepower control.
Bosch Rexroth AG
Shifting of the horsepower
control
The shifting of the horsepower con-
troller is based on the pilot oil-related
characteristics of the power control
valve. If a greater amount of oil is fed
to the power control valve, the pres-
sure in the pilot oil line increases and
the power setting is raised. If less pilot
oil is supplied, the pressure falls and
the power setting is reduced. Gener-
ally, we have to distinguish between
the hydromechanical shifting and the
electrical shifting.
Hydromechanical shifting
With this solution, dual horsepower
control can be implemented easily
and cost-effectively (Fig. 18). On the
basis of the feedback of the LS pres-
sure signals due to different orifice
cross-sections, the amount of pilot oil
can be varied within certain limits.
Bagger
Backhoe
Lader
Loader
Fig. 18: Hydromechanical shifting with standard A10VO DFLR.
Backhoe Loaders Mobile 2006 163
Here, the following is valid: Irrespective of the type of shifting se-
lected, the following is valid:
Larger throttling cross-section
high setting excavator operation The horsepower setting can be varied
Smaller throttling cross-section within certain limits. This means that
low setting loader operation the A10VO variable displacement
pump takes up the power made avail-
In conjunction with flow-sharing
able to it according to the operational
(LUDV) control blocks, only electrical
state of the backhoe loader. The ad-
change over is possible.
vantages of the horsepower control
can be fully utilized in both operating
Electrical shifting
modes.
In the case of electrical shifting, the
entire shifting function is implement-
ed in the hydraulic pump and there-
fore forms a compact unit. The pilot
oil flow is influenced independently
of the operating mode via a 2/2 direc-
tional valve, which is screwed directly
into the port plate of the hydraulic
pump (Fig. 19 and 20). Apart from
the shifting depending on excavator
operation or loader operation, ad-
ditional parameters can be integrated
Fig. 20: A10VO71DFLR-SO128 with 2/2
in the shifting logic. The operator can, directional valve screwed in.
for example, also switch manually be-
tween the high and low setting.
X1
X
X2
DC
high adjustment
low adjustment
Fig. 19: Electrical shifting with A10VO DFLR-SO128.
164 Mobile 2006 Backhoe Loaders
4.2 Infinitely variable torque limi-
tation with speed sensing
Since the introduction of A10VO se-
ries 53, the EK control (electropropor-
tional displacement control, Fig. 21)
has represented a further cost-efficient
controller variant for limiting the
torque. Power management through
speed sensing is a further develop-
ment of the dual-torque limitation
feature. Here, the maximum torque
taken up by the hydraulic pump can
be infinitely varied via the electric
power. The electric current acts di-
rectly via the EK control cartridge on
the pump adjustment mechanism
(Fig. 22).
The decisive fact is that merely the
maximum displacement of the pump
is controlled via the current. Below
the maximum limit, the pump oper-
ates under pressure and flow control
(Fig. 23). In this way, the operator
comfort offered by a variable displace-
ment pump in conjunction with LS or
flow-sharing (LUDV) control blocks
is maintained without any restric-
tions. To close the control loop, the
following components are required
in addition to the A10VOEK/53:
speed-controlled diesel engine,
BODAS controller RC2-2, angle sen-
sor WS1 and speed transducer ID
(Fig. 24).
The speed sensing (Fig. 25) with
A10VOEK is based on a command
value/actual value comparison of the
diesel engine speed. The angle sensor
establishes the setpoint speed of the
diesel engine at the accelerator pedal
or at the injection pump. The speed
sensor measures the actual diesel
speed. The BODAS controller RC2-2
processes both values and converts
them into a corresponding signal for
the EK controller. If the speed drop
is excessively high, the torque taken
up by the pump must be reduced.
The coil current at the EK control-
ler is lowered so that the maximum
displacement is reduced. If the speed
drop is too small, the control device
Fig. 21: A10VOEK with electroproportional
flow control.
X
L L1
B
S Fig. 23: Pressure/flow controller overrides EK
L2
1
EK
a/amax
0 1
I/Imax
Fig. 22: Operating principle of the
A10VOEK.
Bosch Rexroth AG
increases the coil current and conse-
quently the maximum torque taken
up by the pump. In both cases, the
following is valid:
Excessive speed drop on the diesel
engine
The torque taken up by the pump is
too high:
The control device reduces the coil
current, which reduces the maximum
displacement of the pump.
Insufficient speed drop on the diesel
engine
The diesel engine power is not fully
utilized:
The control device increases the coil
current, which increases the maxi-
mum pump displacement.
controller at Vg Vgmax.
Fig. 24: BODAS controller RC2-2, angle
sensor WS1, speed transducer ID.
Bosch Rexroth AG Backhoe Loaders Mobile 2006 165

In this way, the power taken up by the

BODAS
working hydraulics is adjusted to the controller
torque made available by the diesel RC2-2
engine. This happens independently Control
block
of other influences on the diesel SX
torque (Fig. 26) such as travel drive,
air conditioner, AC generator, opera-
tion at high attitude, or tolerances.
This results directly in the following Angle sensor
advantages for the user: WS1

Speed sensor
Function ID
Simple operation of the machine
functions
Higher handling performance when
compared with a power-controlled
pump
Programmable machine operating
modes A10VO..EK.
Diesel engine Gearbox
Automatic compensation of weak
diesel engines Fig. 25: Speed sensing system.

Diagnostic options Torque

Energy Engine characteristic available

torque
Less fuel consumption high pump
setting
Diesel engines always runs in the Transmission
optimum operating range low pump
setting
Lower idling speed
Pump
Environment
Lower noise generation
No overloading of the diesel engine
low idle high idle Engine
Optimal exhaust gas characteristics speed

Cost Fig. 26: Power distribution with speed sensing.

Identical handling performance
with smaller pump The call for optimizing the energy
Lower fuel cost consumption to reduce environ-
mental stress is constantly becoming
louder. With intelligent hydraulics for
power management, Rexroth contrib-
utes to achieving this objective and
offers systems, which cost-effectively
solve functional tasks today and in
the future. Apart from the dual-
torque limitation, speed sensing with
A10VOEK will determine the back-
hoe loader of the next generation.
166 Mobile 2006 Backhoe Loaders Bosch Rexroth AG

5 Fast shifting with Travel Inching Diagnostics Gear Gear

direction pedal parameterization selection control
shift-on-fly process monitoring lamp
The gearbox is the section of the
backhoe loader, in which hydraulic
solutions can be found in smaller
numbers. For this important part RC2-2 +
of the machine, Rexroth presents a speed AS/AGSD

new concept: The fast shift-on-fly

(Fig. 27). In view of an increasingly
demanded maximum speed of 40 4/2-Valve
km/h and, at the same time, calls for
less fuel consumption and reductions
in cost and environmental loads, this
A6VM.EP
new concept is the ideal, cost-ef-
ficient solution. A gearbox that can
be shifted at standstill was modified
and provided with a feature that al- Diesel A4VG.DA
lows jerk-free gear-shifting during engine

traveling. With the shift-on-fly, the

tractive force is interrupted for only
0.6 seconds on average when gears are
shifted. Hydrostatic travel drive con-
cepts of backhoe loaders can basically
be compared with those of telescopic
handlers. Additional information on
shift-on-fly is available in the special-
ist article regarding Telehandlers.
This article also refers to further pos-
sible alternatives to todays common
classic solutions for the drive system.
Fig. 27: Electronic traveling control with shift-on-fly transmission management.
6 Conclusion
Rexroth offers already today solu-
tions and components that meet the
requirements of modern vehicles. The
increasing influence of electronics
in controls of backhoe loaders, the
improved control accuracy, the reduc-
tion of pressure losses across valves as
well as the constantly extended spec-
trum of intelligent hydraulic compo-
nents to implement a power manage-
ment reflect these trends. Also in the
years to come, the criteria of cost,
environment, energy and function of
the drive will play an important role
in the development of new compo-
nents and systems.
Bosch Rexroth AG Backhoe Loaders Mobile 2006 167