HRB Hydrostatic Regenerative Braking System The Hydraulic Hybrid Drive From Bosch Rexroth. And. Hydrostatic Fan Drive in Vehicles

| Vehicular hydraulic systems
HRB – Hydrostatic Regenerative Braking System

The Hydraulic Hybrid Drive from Bosch Rexroth
and
Hydrostatic Fan Drive in Vehicles

Mauro Silva – DCBR/Mobil Sales
Energy Environment
Eric Lindzus | 18.04.2011 | Abteilung | © Bosch Rexroth AG 2010. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung,
1 Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
| The Company
Within The Bosch Group

Bosch Group
Revenue: 38,2 Bill. euros
Associates on Jan. 1, 2010:
270,687
Automobile Industrial Consumer Goods and

Technology Technology Building Services Eng.
Bosch Rexroth Packaging

Solar Energy
Drive and Control Techn. Technology
Revenue: 4,146 Bill. Euros
Associates 2009: 34,225
| 5/12/2010 | © Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of
2 applications for industrial property rights.
| The Workshop
HRB and Fan Drive
| The Workshop
HRB and Fan Drive
| Comparison E-Hybrid vs. HRB
Fuel cell
Energie density [Wh/kg]

Battery
Battery / Ultracaps Ultracap Hydro. Accumulator

Hydr. Accumulator
Energy
Elkos
Power density [W/kg]

High energy density High specific power density
Power density
Energy density Battery: 10 - 300 W/kg
Battery: 10 - 100 Wh/kg Ultracaps: 200 - 4000 W/kg
Ultracaps: 1 - 10 Wh/kg Hydr. Accumulator: 2000 – 300 000 W/kg
Hydr. Accumulator: 0,2 - 5 Wh/kg (Depends on diameter of opening)
| Storage Loading Speed vs. Brake Energy
Refuse Truck Delivery Vehicle Passenger Car

25 to, 10 km/h, 1,5 m/s2 7 to, 30 km/h, 2,5 m/s2 1,5 to, 50 km/h, 2 m/s2
80 80
200
70 180 70
160
60
60
140
50
50
Energy [kJ]
Energy [kJ]
Energy [kJ]
120
40
100 40
Braking
30 80
time 30
20 60
20
40
10
10
20
0
0 0
0 1 2 3 4 5
0 1 2 3 4 5 0 1 2 3 4 5
Time [s]
Time [s] Time [s]
Only the hydraulic The hydraulic accumulator The Lithium Battery fits well,
accumulator is sufficient is suitable and the lithium however the lead battery is
fast to absorb the complete battery can largely recover never sufficient to recover a
breaking energy the braking energy part of the braking energy
Hydraulic Bladder Accumulator, Lithium Battery, Lead Battery and real Breaking Energy
| Parallel – HRB System
HCU
P/M
G V
SHP
System Components:
P/M Pump/Motor Unit G Gearbox
C Clutch V Valveblock
SHP High Pressure Accumulator HCU Hybrid Control Unit
| Parallel – HRB System
HCU
P/M
G V
SHP
APU (A4VSO) 210 ccm; Pmax: 250 kW; Tmax: 1100 Nm

HRB-Gearboxratio: 3.21; 2.2; 1.5
Accumulator: 2 x 32 l, pmax: 325 bar, ca. 550 kJ/0,15 kWh
Weight HRB: 500 kg
HRB operation range 0…50 km/h
| Braking with the HRB
Driver activates HRB

by button or lever
acceleration pedal is
released HRB engages
& disengages engine
Axial Piston Unit (APU)

charges accumulator
Braking torque is
controlled by APU’s
displacement
| Accelerating with the HRB
acceleration pedal
is pushed
accumulator discharges
via Axial Piston Unit (APU)
Drive torque is controlled

by APU’s displacment
and supplemented by
engine if neccessary
HRB disengages
when accumulator
is discharged
| Test Vehicles
Test vehicles in 2009 / 2010
MAN TGS
(Germany)
MAN TGM
(Germany)
Crane Carrier LET2

(USA)
Quelle Grafiken: media.daimler.com; MAN MediaCenter
17
| Benefits of HRB – confirmed in Practical Tests
 Actual test confirms fuel savings of up to 25 % and lower emissions from simulation and test course
 Reduction in brake wear app. 50 %
 High power density of the hydraulic accumulator
 Great cost advantage (Hydraulic vs. Electric) at
the same fuel efficiency
 Long lifetime, high level of ruggedness
(HRB-System lifetime = vehicle lifetime)
 Well known maintenance and servicing requirements
 The HRB-System consist of Million-fold tested components
 Simple, reliable operation means high driver acceptance
 No deceleration during shifting  Increased drive comfort
Quelle Grafik: MAN MediaCenter

HRB from Bosch Rexroth tested by the
Independent German Automobile Association
During the test runs, performed under daily refuse truck conditions, the hybrid
drive HRB from Bosch Rexroth shows an fuel savings between 13-28% and a
significant break wear reduction. The HRB system shows the highest
potential with short distances between stops and a slight uphill grade
because it is then possible to drive the vehicle via the hybrid drive.
Eric Lindzus | 18.04.2011 | SPP23 | © Bosch Rexroth AG 2010. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung,
| History
06 / 2008 started with the first prototype testings in Berlin and New York
09 / 2008 presentation on IAA commercial vehicle 2008
03 / 2009 availability of HRB for further prototype vehicles
08 / 2010 final TÜV (German technical inspection agency) certification
10 / 2010 over 15 vehicles in 4 countries on the streets
10 / 2010 start of series production
First customer feedback:

Carsten Mielke, Head of Department for Transport
in Kassel, Germany:
“Our refuse collection vehicles consume clearly less
diesel fuel than vehicles without HRB. Over an entire
route we are seeing savings from 15 to 18 percent.
This is enough to justify the acquisition of additional
vehicles with the hydraulic hybrid.“
| The Workshop
HRB and Fan Drive
Fan Drive Applications
Applications Mobil Cranes
Buses
Wheel Loader
Carrier Trucks
Dumper
Locomotives
Excavators
Harvester
Fan Drive control systems
Control systems
Hydrostatic fan
drives
hydro - electro -
mechanical hydraulic
control control
constant system variable displ. system constant system variable displ.

• External gear pump • Axial piston pump • External gear pump system
• External gear motor • External gear motor • Axial piston pump

• Axial piston motor
• Thermal relief valve • Electronics • Axial piston motor
• Thermal relief valve
• Priority valve • Temperature sensors • Electronics
• Temperatur sensors
• Direct linkage between fan • 3-step linkage between fan • Fan speed is independent
speed and engine speed speed and engine speed of the engine speed
• stepless variable fan speed
from minimum to maximum
• Limited fan power at lower • Limited fan power at lower • Additional power supplied
engine speed engine speed at lower engine speed
2500 Fan Speed Diagram 2500 Fan Speed Diagram 2500 Fan Speed Diagram
Fan speed
Fan speed
Fan speed
2000 2000 3 2000
[rpm]
[rpm]
[rpm]
1500 1500 1500
2
1000 1000 1000
500 1 500
500
0 0 0
500 750 1000 12501500 17502000 500 750 1000 1250150017502000 500 750 1000 12501500 17502000
Diesel Engine Speed [rpm] Diesel Engine Speed [rpm] Diesel Engine Speed [rpm]
Hydromechanical Control / Constant System
External gear pump External gear motor Priority valve LPS

AZPF AZMF Thermo relief valve MHDBDT
Size 4 … 28 cc Size 8 … 28 cc
Advantages of the system :

Thermo
relief
• radiator can be positioned valve
independently of the engine
• short overall length of the gear pump
Turbo charged air

External Gear
Pump
Water
Oil
• good price/performance ratio
• infinitely variable fan speed, from
External
gear motor
minimum to maximum, if permitted

by oil flow from the external gear pump
• low weight
Hydromechanical Control / Variable System
Var. Displ. Pump Var. Displ. Pump Fixed motor Thermal relief valve
A10VO...DRG/31 A10VO...DRG/52 A10FE / FM MHDBDT
size 18 ... 140 size 28 ... 85 size 10 ... 63

• radiator can be positioned
Thermo relief
independently of the engine valve
MHDBDT
• infinitely variable fan speed
from minimum to maximum
Turbo charged air

• drive power of the variable displacement
Water
pump corresponds with the required fan
Oil
power
• no throttling losses Axial piston
motor
• fan speed is largely independent A10FE
Axial –
of the engine speed piston pump
A10VO…DRG/31
• lower fuel consumption
Electroproportional Control / Fixed Displacement
External Gear Pump External Gear Motor BODAS Control Unit RC 2-2/2x
AZPF AZMF PTC - Temperature Sensor for
size 8 ... 28 cc size 8 ... 28 cc Air / Water
Advantages of the system : Retarder

Temperature Ambiente Air
Control Unit
PTC
RC 2-2/2x
• variable fan speed control
Temperature Oil
Turbo Charged air
• fan speed is largely independent Temperature Water
of the engine speed PTC
Turbo Charged Air

• direction and weighting
Water
OIl
of several operating parameters
• minimum throttling losses External Gear Motor
with integrated Prop.
Valve
• Fail - safe function PTC

External
Gear
• reduced power consumption

Pump
Electroproport. Control / Variable Displacement
Var. Displ. Pump Var. Displ. Pump Fixed Motor BODAS Control Unit RC 2-2/2x
A10VO...ED/31 A10VO...ED/52 A10FE / FM PTC - Temperature Sensor for
size 18 ... 140 size 28 ... 85 size 10 ... 63 Air / Water

• infinitely variable fan speed Speed Sensor DSM
Retarder
from minimum to maximum PTC Ambiente Temperature
Control Unit
RC 2-2/2x
Temperature OIl
• fan speed is largely independent Turbo Charged Air
of the engine speed Fluid Temperature Water
PTC
• direction and weighting
Turbo charged air

PTC
of several operating parameters
Water
Oil
• high control quality
• no throttling losses Axial Piston-
Motor A10FE
• Fail-safe function
Axial Piston
• lower fuel consumption Pump

A10VO...ED/52
Summary
Hydraulic control is used in Electronic control permits the configuration

configura- of complex systems, covering several gas /
tion simple systems, i.e. typically for fluid temperatures and switching signals.
measuring one or two temperatures
of fluids
hydraulic control electronic control
simple systems complex systems
• fixed pump system or • fixed pump system or

• Variable displacement system • Variable displacement system
Advantages
Advantages of a hydrostatic fan

drive with variable displacement
pump :
• steplessy variable fan control from minimum
to maximum speed
• drive power of variable displacement pump

corresponds to the fan capacity required
• no lost energy
• fan speed largely independent of internal
combustion engine speed
• position of radiator independent of engine

• compact design
• enhanced fuel economy
• reduction of noise level emission
Option : Fan Function Manifold (FFM)
Change of direction of rotation

Axial Piston-
Motor Speed Sensor DSM
A10FE Retarder
Steuergerät
RC 2-2/2x
Temperature for Oil
Temperature for Water
Temperature turbo charge air
Ambiente temperature
a b
Fan Function
Manifold HSH 06 / 10
Features:
• Bi - directional fan rotation
• No shock valves needed
• Option: fan standstill
• Variable oil heat-up function
(via controlling ED-pressure setting)
Axial Piston • No anti-cavitation valve
Pump
A10VO...ED/52 • No pump drain line
• Fail safe mode
Preview - Combined Systems
AC Compressor
Air Compressor
Alternator
Misc.
 - Fixed displacement system  - Variable displacement system  - Variable displacement system

 - Usage for fan drive  - Usage for fan drive  - Combined systems
 - Depending Cooling Power  - Independent Cooling Power  - Independent Cooling Power
 - One Parameter  - Multiple Parameters  - Multiple Parameters
 - Closed Loop Control
The Drive & Control Company
Thank you!

HRB Hydrostatic Regenerative Braking System The Hydraulic Hybrid Drive From Bosch Rexroth. And. Hydrostatic Fan Drive in Vehicles

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HRB Hydrostatic Regenerative Braking System The Hydraulic Hybrid Drive From Bosch Rexroth. And. Hydrostatic Fan Drive in Vehicles

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| Vehicular hydraulic systems

HRB – Hydrostatic Regenerative Braking System

Hydrostatic Fan Drive in Vehicles

Within The Bosch Group

Automobile Industrial Consumer Goods and

Bosch Rexroth Packaging

HRB and Fan Drive

HRB and Fan Drive

Energie density [Wh/kg]

Battery / Ultracaps Ultracap Hydro. Accumulator

Power density [W/kg]

Refuse Truck Delivery Vehicle Passenger Car

APU (A4VSO) 210 ccm; Pmax: 250 kW; Tmax: 1100 Nm

Driver activates HRB

Axial Piston Unit (APU)

Drive torque is controlled

Crane Carrier LET2

Quelle Grafiken: media.daimler.com; MAN MediaCenter

Quelle Grafik: MAN MediaCenter

First customer feedback:

HRB and Fan Drive

Applications Mobil Cranes

constant system variable displ. system constant system variable displ.

• External gear motor • External gear motor • Axial piston pump

External gear pump External gear motor Priority valve LPS

Advantages of the system :

Turbo charged air

minimum to maximum, if permitted

Advantages of the system :

Turbo charged air

• lower fuel consumption

Advantages of the system : Retarder

• fan speed is largely independent Temperature Water

of the engine speed PTC

Turbo Charged Air

• Fail - safe function PTC

• reduced power consumption

Advantages of the system :

from minimum to maximum PTC Ambiente Temperature

• fan speed is largely independent Turbo Charged Air

of the engine speed Fluid Temperature Water

• direction and weighting

Turbo charged air

• lower fuel consumption Pump

Hydraulic control is used in Electronic control permits the configuration

• fixed pump system or • fixed pump system or

Advantages of a hydrostatic fan

• drive power of variable displacement pump

• position of radiator independent of engine

Change of direction of rotation

 - Fixed displacement system  - Variable displacement system  - Variable displacement system

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