76 Mobile 2012 | Hydromechanical Variable Transmission Bosch Rexroth AG

Energy System Design

for Optimized Power Management
The focus of this topic is the description of modules that support the realization of a customized
control system for the distribution of power and energy in hydraulic systems.

In order to make efficient use of the energy supplied by the engine while optimizing the
performance of the system as a whole, there is a need for efficient components – and especially
for modules that support equipment manufacturers in the development of control systems that
distribute power and energy as required by the system.

The basis of this technology is an electronic control unit that communicates with the diesel engine
to regulate power consumption and influence the level of output power. In practice, this happens
by controlling the speed of the hydrostatic travel drive, for example, and reducing the speed of the
diesel engine.
Bosch Rexroth AG Hydromechanical Variable Transmission | Mobile 2012 77

From Components to Systems –

Hydromechanical Variable Transmission
Abstract
Dana and Bosch Rexroth have demonstrated a commitment to innovative fuel-saving technology by
establishing a 50 : 50 joint venture that specializes in the engineering, manufacturing and marketing
of advanced power-split drive transmission units for the off-highway market.
Operating under the name of Dana Rexroth Transmission Systems and based in Arco, Italy, the
joint venture produces Hydromechanical Variable Transmission (HVT) power-split systems. This
technology combines Dana’s experience as a TIER 1 supplier of off-highway drive trains and
expertise in off-highway transmission engineering and manufacturing with Bosch Rexroth’s vast
understanding of hydraulics, design, system integration, and control.

Diego Cornolti
Sales and Product Management
Hydromechanical Variable Transmission (HVT)
Dana Rexroth Transmission Systems S.r.l.
78 Mobile 2012 | Hydromechanical Variable Transmission Bosch Rexroth AG

HVT concept and benefits The three-range concept (Fig. 1) delivers a high ratio range
for drive and working strategies with optimized engine
Following the evaluation of numerous existing and theore- speed and torque. It also offers a robust design that balan-
tical transmission systems, the HVT concept was selected ces low speeds and circulating power.
as the ideal solution for meeting the latest functional
requirements of off-highway vehicles, including wheel Different hydrostatic units can be combined on the same
loaders, graders, heavy material handling equipment and mechanical transmission. This means that the hydrostatic
forestry machines such as skidders. unit can be arranged with a high degree of flexibility, and
the configuration optimized to achieve maximum efficien-
The particularity and peculiarity of HVT systems is that cy in the R2 and R3 HVT power ranges (Fig. 2).
they are the first fully hydrostatic range of drives – techno-
logy that facilitates efficient and precise traction control
while entering into the pile with a wheel loader, for examp- HVT HVT-R2 HVT-R3
le. During operation at standstill, it has been proven that
Engine Power 135 to 185 kW 200 to 270 kW
the power required by an HVT system to achieve maximum
Hydrostatic Units A4VG 85 to 110 cm3 A4VG 145 to 175 cm3
tractive effort is approximately 30 % less than a traditional A6VM 115 to 150 cm3 A6VM 170 cm3
torque converter such as might be used for the implement
hydraulics. Additionally, hydrostatic reversing facilitates
wear-free operation and saves fuel in comparison to clutch Fig. 2: HVT transmission configuration

reversing.
HVT optimizes the operating point of the diesel engine
The hydrostatic units on the HVT are based on proven by decoupling engine speed from drive speed. At the
solutions from Bosch Rexroth that combine flexibility with same time, maintenance costs are reduced by hydrostatic
robust performance. braking. Furthermore, in partial load conditions, HVT
provides the capability to optimize the engine operation
point by raising the load.
1st Range 2nd Range 3rd Range
Figure 3 presents an example of this potential compared
to a torque converter transmission. The input power of the
torque converter depends on the input speed. In contrast,
CVT technologies like HVT act independently of speed and
make it possible to use the entire map of diesel engines,
including engine brake torque during deceleration.
Efficiency

Hydrostatic Power

For the off-highway vehicles of the future, power-split

transmission systems must also meet certain functional
requirements in terms of tractive effort management, ratio
Ratio
management and power management if they are to be
integrated into the vehicle to improve fuel efficiency and
functionality.
Fig. 1: The three-range HVT concept
Bosch Rexroth AG Hydromechanical Variable Transmission | Mobile 2012 79

HVT development status The HVT-R3 is currently in the final stage of validation with
an extensive range of checks being carried out on test
The initial focus of the joint venture is the development of benches to prove the reliability of the concept in all con-
the HVT-R3 and R2. ditions. At the same time, vehicle testing is underway to
demonstrate the durability of the system in real working
The expertise of both parent companies is an essential conditions and to further enhance functionality in order
factor in bringing a high-performance and reliable soluti- to optimize performance and driver comfort.
on to market. HVT is a sophisticated solution that incor-
porates time-proven components from both Dana and
Rexroth. Furthermore, each individual component has
undergone extensive performance and durability testing
in order to optimize the HVT system as a whole.

The approach taken by the joint venture is to combine the

interaction between clutch control and hydrostatic con-
trol in a single, optimized system in which all the various
sub-components interact with a high level of precision.

120 230

225
CVT Operation
100 223.2

10% fuel 100

Engine Torque [%]

80 saving
Engine Torque

230
Power [%]

80
240
60
250
60
260
Torque 40
Converter 280
40
Operation

20 Fuel consumption
[g/kWh]
Engine Speed HVT
Torque converter
40 60 80 100
Engine Speed [%]

Fig. 3: Example of CVT/HVT potential compared to torque converter transmission

80 Mobile 2012 | Hydromechanical Variable Transmission Bosch Rexroth AG

Increased system potential with HVT
HVT power-split systems focus on meeting customer
demands for improved fuel economy and productivity,
lower emissions and greater vehicle maneuverability.
Tests on wheel loaders using the new HVT demonstrate
fuel savings in the drive train of more than 20 % compared
to operation of the same vehicle with a conventional
torque converter transmission.
However, even greater potential lies in the comprehensive
integration of the HVT into the system as a whole. Besides
HVT, OEMs stand to benefit from significant added value
with products from Bosch Rexroth and Dana: innovative
products and solutions that combine the potential of indi-
vidual components and maximize machine performance
can be provided.
The cornerstone of this approach is the integration of the
drive with the implements, which have to be adapted to
working and load conditions. Smart and electronically
controlled implement hydraulics, fan drive system and
Hydraulic Flywheel by Bosch Rexroth minimize the energy
requirements in combination with an engine management
system.

Implements Hydraulics Engine Management and

Fan Drive System
▶▶ Electro-hydraulics control valve
▶▶ A10VO pumps with ED function. ▶▶ Engine management
▶▶ Downsizing approach
possible

HVT
Energy Banking HFW Axle and Cardan Shafts

▶▶ Braking optimization ▶▶ New design to cost due to

▶▶ Diesel over speed the 1st hydrostatic range
protection ▶▶ Disconnectable front axle
▶▶ Boost function ▶▶ Cardan shaft angle
▶▶ Start-stop function

▶▶ The potential of the system is bigger that the sum of single components potential

Fig. 4: System Potential with HVT

Bosch Rexroth AG Hydromechanical Variable Transmission | Mobile 2012 81

On the axle side, in a wheel loader for example, a new de-

sign could be taken into consideration to lower the cost.
The hydrostatic first drive range, compared to a torque
converter, acts as a torque limiting device (fuse) when the
vehicle reaches maximum tractive effort entering the pile
and in stall condition.

In addition, a front axle that can be disconnected at

higher speeds could improve efficiency and reduce tire
wear. Without any doubt, then, the potential of a system
approach is much greater than the effect of optimizing
single components.

Fig. 5: System integration of HVT together with other components in a wheel loader
82 Mobile 2012 | Hydromechanical Variable Transmission
HVT and further potential
Power-split transmission shows considerable potential
for other applications such as articulated dumpers
and compact vehicles when it comes to meeting the
requirements of OEMs in terms of fuel economy, lower
emissions, increased comfort and productivity.
The best solution for articulated dumpers
In dumpers, the power-split transmission increases
vehicle performance and comfort when compared with
eight-gear transmission, but even greater potential lies in
the incorporation of other Rexroth technologies such as
Hydraulic Traction Assistant (HTA).
Fig. 6: HVT with HTA in a articulated dumper
Bosch Rexroth AG
At working vehicle speeds of 15 to 20 km/h, the HTA
supports vehicle acceleration by delivering the requested
traction to the front wheels. Given the fully hydrostatic
first range of the HVT, we aim to use the HVT pump to
carry out this function.
At operational travel speeds above the 15 to 20 km/h
range, the HTA is switched off, while the vehicle is moving,
and the power transferred to the rear axles only.
Additional benefits for the OEM are the reduction in
complexity of the front axle, a lower machine weight and
less wear to the front tires as a result of free-wheeling at
higher vehicle speeds.
Bosch Rexroth AG Hydromechanical Variable Transmission | Mobile 2012 83

The best solution for compact vehicles Summary

The TIER 4 final emission standards come into effect
HVT combines the mechanical and hydrostatic travel drive
in 2014. Vehicle manufacturers will be confronted with
to join the best features of both technologies.
new behavior patterns of diesel engines and will have
With HVT, Dana Rexroth Transmission Systems offers
to integrate more extensive cooling and exhaust gas
a convincing hydromechanical variable transmission
after-treatment systems. In some applications, the space
for mobile machines and, by integrating the travel and
requirements of these additional components will lead to
working hydraulics, provides even greater potential for
design constraints for OEM.
this advanced technology. Targeted for use on numerous
off-highway applications, the advanced HVT system
For vehicles with a power range near to 75 kW, HVT could
developed by Dana Rexroth is focused on meeting
play a central role in possible diesel downsizing – an
customer needs for improved fuel economy, productivity,
approach that essentially avoids the need for exhaust gas
emissions, and maneuverability.
after-treatment to comply with TIER 4 final standards.

Simulations have shown that the targets for driving per-

formance can be achieved. The first range of the hydro-
static system enables to achieve maximum tractive effort,
while the power-split ranges, due to their higher efficiency
compared to conventional mechanical transmission,
make it possible to reach maximum vehicle speed with a
lower engine speed.

If a power peak is requested for certain applications, for

example digging, the proven Rexroth Hydraulic Flywheel
(HFW) could provide a boost function using the energy
stored in the accumulator.

HFW provides additional system potential such as:

▶▶ A start-stop function

▶▶ A retarder for the hydrostatic power split function that

stores the energy

In this case, the HVT also shows high potential for impro-
vements to drivetrain efficiency, but it is first and foremost
the cornerstone for a new system approach that affects
the entire machine architecture.