106 Mobile 2003 Road Pavers and Road Rollers Bosch Rexroth AG

Application Center Road Construction Machines

Head: Klaus Renz

Bosch Rexroth AG
Mobile Hydraulics
Glockeraustrasse 2
89275 Elchingen, Germany
Telephone: +49 (0) 73 08 82 - 20 11
Facsimile: +49 (0) 73 08 - 53 38
E-Mail: klaus.renz@boschrexroth.de
Bosch Rexroth AG Road Pavers and Road Rollers Mobile 2003 107

Technical Innovations in Drive Systems for Road

Rollers and Road Pavers

1. Introduction
Technical innovations in drive systems
for road rollers and pavers - what’s the
story behind the title? Based on the
example of a roller, we look at travel
drives and vibration drives.
Rexroth has come up with several in-
novations in this area which, though
not revolutionary, nevertheless greatly
simply and improve the operation of
road rollers and pavers (Figure 1).

2. Drive systems for

tandem rollers with split
drum Figure 1: Example application of tandem rollers and pavers
Working in partnership with gear and
axial piston manufacturers, Rexroth
has developed a new travel drive con- BB-3

cept for a tandem roller with split

drum.
Until now, radial piston motors with a
through drive were virtually the only
type of motor used for this applicati-
on. An anti-slip control system was
realized with an appropriate configu-
ration of the hydraulic motors or in
conjunction with a flow divider.
To open up this area of application,
with all the advantages of the axial pi-
ston unit combined with gears, it was
necessary to develop a gear that allo- 3
wed the travel and vibration drives to 1 2 1 Vibration Motor
be installed separately for each side. 4 2 Drive Motor
For a detailed description of this gear,
see 2.3. 3 Speed measurement

4 Proportional Valve

Figure 2: Travel drive with Rexroth RC control unit

Authors:
Stefan Ley BRM-AK/VME2
Michael Natrop BRM-GT/VTG
108 Mobile 2003 Road Pavers and Road Rollers Bosch Rexroth AG

With this component arrangement, 2.1 Electronic system for a tan-

the anti-slip control system is realized
in the following way.
A speed detector reports the drum
speeds to the Rexroth control unit and
the speeds are compared. If a slipping
drum is detected, the Rexroth control
unit activates proportional valves
which operate the dynamic multiple
disk brake in the gearbox (Figure 2).
The benefits for the customer of this
gearbox / hydraulic motor system:
dem roller with split drum
The newly developed Rexroth RC6-9
or RC12-18 control unit with stan-
dard software is used to control the
pumps for the travel drive and vibra-
tion. All other functions, such as fan
drive, air conditioning or cabin con-
trol can be programmed either by the
customer using Bodas, or by Rexroth
according to the specification
(Figure 3).

Water control system

- Better efficiency Diagnostics

Speed of Motors
Display

Parameter adjustment

Climate control
- Longer service life Process monitoring
Drive-Joystick

Immobilizer
ASR on/off
- Anti-slip control

Working /
Vibrations

Transport
Steering

- Higher tractive forces compared

DI2

ESC F1 F2 F3 F4

with conventional radial piston ar-

F5

BB-3
BODEM

RC+
rangements, because no summation
BB-3

SW
forces act on the hydraulic motors.
- Far less tubing than a radial piston Air conditioning
Cabin control
Water Pump

Drive Pump

with flow divider

Vibration

Steering
Pump

Brake

- No need for a flow divider

Figure 3: Electronic control system for tandem rollers with Rexroth RC control unit
Bosch Rexroth AG Road Pavers and Road Rollers Mobile 2003 109

2.2 Modified vibration pump

mounted to the diesel engine po-
wer take-off BB-3

In the case of tandem rollers, no mat-

ter whether two or four drums are
used, the principal assumption is that
the diesel engine, across the drive di-
rection, and the mounted pumps
must not exceed the maximum per-
mitted machine width.
For this reason it was not possible to 3

use two independently controllable 1

vibration pumps with half the displa- 1 Drive Pump

cement volume, instead of one vibra- 2
2 Vibration Pump 1
tion pump with a vibration valve. 3 Vibration Pump 2
5 4

A modification to the housing of the 4 Vibration Motor

A10VG variable displacement pump
series with a nominal volume of 18 or
28 cm3 now makes it possible for these
pumps to be mounted direct to the
power take-off of a diesel engine.
As a result, the travel pump and vibra-
tion pump can be used in the tried
and tested compact configuration (Fi-
gure 4), with a vibration pump at the
power take-off.
(Figure 5/6).
5 Drive Motor
Figure 5: Travel and vibration drive for tandem roller with split tire
The advantages of this arrangement
are obvious:
- There is no need for a vibration
valve
- Vibration motors with half the dis-
placement
- Higher compaction performance
thanks to identical or independently
controllable frequencies
- To prevent unwanted beat frequen-
Figure 6: Mounted to the diesel engine
cies due to vibration power take-off

A4VG 56, 71, 90 A10VG 28, 45

Bild 4: Compact Pump A4VG + A10VG

110 Mobile 2003 Road Pavers and Road Rollers Bosch Rexroth AG

2.3 Gear units for tandem rollers
with split drum
Tandem rollers with a split drum
make particular demands on the tra-
vel gearbox. With these drive systems,
the travel and vibration drive must be
arranged on the same side. The pre-
vious solution was to have a radial pi-
ston motor with a hollow shaft as the
through drive for the vibration drive.
Rexroth’s gearbox manufacturer de-
veloped a planetary gear unit especial-
ly for this application, which also al-
lows the possibility of a through drive
for the vibration.
This new travel gearbox basically con-
sists of a planet stage on the output
side and a spur gear stage on the drive
side. In this way the travel motor can
be coaxially offset and the vibration
motor can be coaxially installed.
A hole is made in the drive-side spur
gear and the sun wheel of the planet
stage, through which the shaft leading
to the vibration apparatus passes.
brake are incorporated into this gear-
box as part of the anti-slip control sy-
stem. The brake, which is designed for
dynamic operation, can also be used
as a parking brake.
The GFT 7G gearbox shown in Figure
7 with a transmission ratio of i= 25.06
and an A2FM32 offers an output tor-
que of 5000 Nm at the maximum
pressure of 400 bar. This is equivalent
to a radial piston motor with 802 cm3, Technical Data
which is used for tandem rollers bet- Hydrostatic Motor A2FM 32 32 ccm
ween seven and nine tons. Other gear- Ratio i = 25,06
box sizes are planned for road rollers Max. Output torque 5000 Nm
in higher weight categories. Output Speed 60 rpm
Vibration Motor A2FM 23/28 ccm
A4FM 22/28 ccm
A10FM 23/28 ccm
Speed sensor HDD direct mounted
Figure 7: GFT 7G drum drive with A2FM32
motor

The travel gearbox has a robust taper

roller bearing which supports the
weight of the machine like a wheel
bearing.
The drive unit is designed to be atta-
ched directly to the drum, and is joi-
ned to the machine frame via rubber
elements.
In the development of this travel gear-
box, the main priority was to keep the
overall drive system as short as possi-
ble. Rexroth A2FM axial piston mo-
tors are used as travel and vibration
motors, but A10FM or A4FM hydrau-
lic motors can also be installed for vi-
bration, depending on the customer’s
requirements.
A speed detector and a multiple disk
Bosch Rexroth AG Road Pavers and Road Rollers Mobile 2003 111

3. Efficient anti-slip sy- A30VG 28 – Split Flow Pump

stem for tandem rollers
A new development from Rexroth, the
A30VG28 (Figure 8), now also makes
– Closed Loop Pump
it possible to offer anti-slip control for
– Swash Plate Design
tandem rollers in the weight category
between three and eight tons. – Split Flow in the Rotary Group
Basically, the volumetric flow of an – One common Suction Port
axial piston rotary group is divided in – Four Pressure Ports
half, so that the same number of pi- – Standard Control Range for A4VG
stons is used for each high pressure – Size 28 (2 x 28)
flow.
– Max. Pressure 450 bar
The pump is controlled via one con-
trol unit which ensures that the oil
flows are almost identical and therefo-
re ideal for driving two synchronously
running drums. The slippage of a Figure 8: Split Flow Pump
drum is prevented by the equal volu-
metric flows if, for example, the roller
has to drive up a ramp on to a truck
for transportation (Figure 9).

Figure 9: Travel and vibration drive for tandem roller with split flow pump
112 Mobile 2003 Road Pavers and Road Rollers
4. Sprocket and wheel
drives for pavers
4.1 Extremely compact sprocket
drives for tracked pavers
In the design of tracked pavers, the
aim is to accommodate the widest
possible conveyor within the machine,
but at the same time the permitted
transport width of the machine must
not be exceeded. Consequently only a
limited installation width is available
for the track travel gear.
For this purpose, Rexroth has desi-
gned two further gearbox sizes with a
very short overall length. The new ge-
arbox types GFT 24 T3 and GFT 36
T3, used in conjunction with A6VE
plug-in motors, make the use of speci-
al gearboxes with spur gear primary
stages unnecessary in the case of com-
pact tracked pavers with a transport
width of 2.5 meters (Figure 10).
This is an economical drive solution
for tracked pavers, which is based on
GFT 17 T2 / A6VE 55 HA 419 mm
GFT 24 T3 / A6VE 55 HA 456 mm
GFT 36 T3 / A6VE 80 HA 490 mm
Figure 10: Compact tumbler drives for
pavers
standard components and optimizes
the overall design of the machine (see
table).
Bosch Rexroth AG
Total swept volume
Planetary gear units Reduction ratio Hydraulic motor cm3 • i
Typ i Typ cm3
GFT 9 T2 47,6 A10VT 45 2142
55,3 A10VT 45 2489
GFT 17 T2 54,0 A6VE 55 2959
GFT 24 T3 137,2 A6VE 55 7546
GFT 36 T3 138,8 A6VE 80 11104
GFT 50 T3 125,7 A6VE 107 13450
Table: Sprocket drives for tracked pavers
4.2 Two-speed gearbox for pa-
vers with a high traveling speed
Rexroth has developed a two-speed
gearbox for wheeled and tracked pa-
vers with rubber tracks which are de-
signed to reach high traveling speeds.
This drive unit, used in conjunction
with the A6VE axial piston displace-
ment motor, allows a very slow wor-
king speed with good true-running
properties and a high traveling speed
– Hydrostatic motors A6VE 55 or
in fast mode.
A6VE 80
It involves a three-stage planetary
– Ratio 1. Gear 40,5
gear, whereby it is possible to change
2. Gear 279,5
down a gear for fast operation. The
– Park brake
gear-changing process uses two inte-
– Switching Pressure 23 - 40 bar
gral multi-plate clutches which engage
– Taper roller bearings for high
or disengage the input planet stage. radial forces
The gear-changing process is always – very short overall length
smooth, regardless of the position of
the gearwheels. If the multi-plate clut- Figure 11: HYDROTRAC GFT 25 T2/3
ches are depressurized, they act as a two-speed gearbox
parking brake (Figure 11). even at working speeds of
Thanks to the high variation range 1 m/min.
with reduction ratios of 40.5 and When used as a travel gearbox in rub-
279.5, when used in conjunction with ber track machines, heavy taper roller
A6VE55 or A6VE80 variable displace- bearings are used because of the high
ment motors, it is possible to achieve radial forces encountered in the field.
traveling speeds of 20 km/h with Last but not least, with this drive unit
wheel-mounted pavers, and good too, the shortest possible overall
true-running properties of the hy- length was aimed for.
draulic motor during installation,
Bosch Rexroth AG Road Pavers and Road Rollers Mobile 2003 113

5. Prospects
To go on achieving simpler operation,
higher efficiency and cheaper produc-
tion for road rollers and pavers in the
future, it will be essential to explore
new avenues.
For Rexroth it is a question of mee-
ting the needs of the market. On the
one hand this means offering flexible
customer support and providing the
best possible individual components
for their applications; on the other
hand it means developing complete
drive units ourselves and offering
them as a system supplier to machine
manufacturers.
Clearly it is necessary to be able to of-
fer a whole system, particularly where
electronics are involved. It is especially
important to have a precise know-
ledge of all the components and how
they interact with one another. Also, if
problems arise in the prototype stage
or in series production, it makes mat-
ters easier if one is able to deal with a
single contact person.
Rexroth aims to keep up to date and
be a reliable partner for manufactur-
ers of road construction machines. In
the future it will remain the leading
supplier of hydrostatic drive systems -
the one which sets the trend.