ICPC 2005

Hydrostatic transmission for

mobile hydraulic applications

Dr. Markus G. Kliffken

Head of Engineering Machine Functions

Bosch Rexroth AG

Copyright © 2005 AVL List GmbH

3rd AVL International Commercial Powertrain Conference, April 20th & 21st, 2005, Graz, Austria SESSION II - 2.3 - Page 1
 ABSTRACT as well as electronics and sensors. But the emphasis of
the paper lies on the driving function using hydrostatic
Hydrostatic transmission systems have become state transmission. After a brief introduction to the basics, the
of the art for mobile applications like construction and following overview explains the wide range of possible
agricultural machinery, because they offer important solutions of pure hydrostatic transmission and the
customer benefits like: continuos driving without gear combination of hydrostatic and mechanical transmission
change, maximum traction effort with best starting in different applications. The use of simulation for the
efficiency, versatile power distribution, minimum wear of machine function and control development ensures
the mechanical bakes etc. More advanced approaches use high efficiency and best performance.
this in combination with classical mechanical transmission
to extend the field of applications for optimizing drivers
and machinery as well as working efficiency. Using BASICS OF HYDROSTATIC
simulation helps to find the right solution for the drive TRANSSMISSION SYSTEMS
train in a given application and has become an essential
technology for systems and controller development. In general, hydrostatic transmission systems of mobile
applications consist of the following main elements:
- a hydraulic pump for power generation that is in most
INTRODUCTION cases directly mounted to the combustion engine,
- a hydraulic motor for actuation that could be
Since the merger of Mannesmann Rexroth AG and connected to an axis, an additional gearbox or
Bosch Automation the Bosch ICPC Rexroth 2005
AG has- been
2.3 directly to the wheels of the vehicle,
offering a unique variety of products for mechanical, - hoses for the transport of oil and energy, respectively,
electric, pneumatic and hydraulic actuation. Like the and
Hydrostatic Transmission for
industrial automation, the market of mobile hydraulics - mechanical or electric control elements that allow

Mobile Hydraulic Applications

with the focus on construction, agricultural, material
handling and commercial machinery (Figure 1) is of
to change the displacement of the pump and the
motor - if possible.
major importance and spans a six to eigth billion Euro Figure 2 shows the four main Rexroth mechanical
market. With regard to this, Markus G.Application
the Rexroth Kliffken components for hydrostatic transmissions. Swashplate
Centers offer their customers experts who are focused
Bosch Rexroth AG axial piston pumps A4VG/A10VG are originally designed
on the application, in addition to the classic product to supply transmission systems, with a high nominal
support for sales and engineering experts. pressure of pnom = 350 - 450 bar and a wide range
The field of mobile hydraulics can roughly be divided of power Pmax = 80 - 400 kW. Radial piston motors
into two main areas: MCR with the typical high torque Tmax = 1 - 17.1 kNm
- implement hydraulics for working and at low speed nmax = 400 - 115 min-1 suit wheel drives
- transmission systems for driving. for light vehicles perfectly. Due to the better starting
efficiency, bent axis axial piston motors with constant
displacement A2VM and with variable displacement
A6VM (nmax = 5500 - 2900 min-1 ,Tmax = 0.18 - 1.27
ve become
kNm) are advantageous. Especially the integrated
ations like
y, because solutions with the gear boxes GFT13/17 are a perfect
nefits like: choice for wheel drives with high and very high torque
, maximum (Tmax = 7 - 330 kNm). In addition, Rexroth offers
cy, versatile electronic control units RC, sensors and the necessary
mechanical software for these applications.
use this in Figure 3 shows that the tractive effort F decreases
ransmission with the travel speed v according to the simple law
optimizing
F . v = constant .
g efficiency.
solution for
Starting at zero/minimum speed vmin and a maximum
has become possible tractive effort Fmax at point "1", the displacement of
d controller the hydraulic pump is proportional to the vehicle speed
v ~ α VGmax , with α = 0...100% .
This ends in point "2" with the maximum displacement
Figure 1: Application fields of mobile hydraulics of the hydraulic pump VGmax. To increase the total speed
Figure 1 Application fields of mobile hydraulics range of the vehicle 0...vmax, the displacement of the
Rexroth's main products for the implement hydraulics motor can also be reduced as long as there is sufficient
oth AG and are control valves
Rexroth’s main asproducts
mono blocks,
for slices
the or implement
cartridges power to reach point "3".
G has been
hydraulics are control valves as mono blocks, slices
mechanical,
or cartridges as well as electronics and sensors. But
on. Like the
the emphasis of the paper lies rdon the driving
of mobile Page 2 - 2.3 - SESSION II 3 AVLAfter
International
a briefCommercial Powertrain Conference, April 20 & 21 , 2005, Graz, Austria
th st
function using hydrostatic transmission.
onstruction,
introduction to the basics, the following overview
commercial
explains the wide range of possible solutions of pure
 The second curve in Figure 3 shows the corresponding - continuous variable transmission with a wide torque-
curve for the total efficiency of the hydrostatic to-speed range,
transmission system, which is composed of the individual - bi-directional operation without shifting,
ion that is in � = �Pump � �Motor .
efficienciesTotal
of both hydraulic pump and motor. - maximum tractive effort at minimum speed and high
combustion
ηTotal = ηPump . ηMotor . starting efficiency as well as
ation that is in �Total = �Pump � �Motor . - best total efficiency over the important operating/
at combustion
he could be working range
l gearbox or
Beside this, additional principle advantages are:
that could be - minimum abrasion of the mechanical brakes by using
andgearbox
nal energy,or hydrostatic breaking,
e, - versatile power distribution for optimal vehicle
and energy,
ements that traction and
of the pump Axial Piston Pump Radial Piston Motor - modular system with hoses instead of shafts giving
elements that maximum freedom of design
t of the pump Axial Piston Pump Radial Piston Motor
ain Rexroth
hydrostatic
APPLICATIONS WITH
main pumps
ston Rexroth HYDROSTATIC TRANSMITION
d tohydrostatic
supply
nal pressure
piston pumps
nge
ed of to power
supply Fork-lift trucks are a typical application that needs best
rs MCR
minal with
pressure maneuvering behavior of the laden as well as unladen
kNmofatpower
ange low vehicle at low speed and in both directions. Besides the
Planetary Gear Axial Piston Motor
tors MCR for
el drives with electric motor solutions for lower power and special
etter
1 kNm starting
at low
motors with Planetary Gear Axial Piston Motor indoor environments, hydrostatic transmission is the
heel drives for Figure 2 Rexroth pumps, motors and gearboxes
with variable
better -1starting favored solution for all kinds of combustion engine
for hydrostatic transmission systems
0motors
min ,Tmax with Figure 2: Rexroth pumps, motors and gearboxes for machinery. To achieve good traction, the hydrostatically
. with
Especially
variable Figure 2 Rexrothtransmission
hydrostatic pumps, motors and gearboxes
systems driven wheels are of cause in front, near the fork.
gear boxes
-1
900 min ,Tmax for hydrostatic transmission systems
Figure 4 shows the main approaches for industrial
el drives
us. with
Especially and off-road vehicles. While the first use mainly single
330 kNm).
gear In
boxes
rol wheel drives, the latter prefer axle driven systems
eel units
drivesRC,with
�
tractive effort F

e330 for kNm).

theseIn instead. For these applications, the preferred Rexroth
efficiency

ntrol units RC, hydraulic products are:

tractive effort F

are for these - the A4VG or A10VG pumps and

efficiency

ve effort F - the MCR or the A6VM(E) motors with a GFT type

ording to the gear box for the wheel drive solution.
TotalTotal

tive effort F
cording to the
torque converters. The above discussed technical Industrial
characteristics indicate the following benefits: Applications
a maximum
- continuous variable transmission with a wide
nt “1”, the A6VE+GFT/

nd a maximum torque-to-speed range, MCR

proportional A6VE+GFT/
oint “1”, the - bi-directional operation without shifting, MCR

s proportional A4VG/

- maximum tractive effort vehicle speed vspeed and

at minimum A10VG

.
high starting efficiency as well as
vehicle speed v
Figure 3: Traction effort and total efficiency versus
e% . maximum Figure - 3bestTraction
total effort
efficiency
and totalover the versus
efficiency important
vehicle speed for classic circuits
operating/working
VGmax. To vehicle speed range
for classic circuits Off-Road
he
hicle maximum
0...vmax, Figure 3 Traction effort and total efficiency versus Applications
p beVGmax . To Beside this, additional
vehicle speedprinciple
forthe
classicadvantages are:
reduced As the vehicle accelerates, totalcircuits
efficency ηTotal
ehicle
reach0...v max, As the vehicle accelerates, the total efficency �Total by A6VM
point - minimum
increases abrasion
and reaches of the
its peak mechanical
ηTotal,max with both brakes
pump
so be reduced increases and reaches its peak � with both
to reach point and theusing
As motor athydrostatic
vehiclemaximum breaking,
accelerates, the total
displacement. Total,max
efficency �Total
It thenIt drops
pump and motor at maximum displacement. then
shows the increases
again,- as the and
motor
versatile reaches its peak is�Total,max
displacement
power distribution reduced
for with both
towards
optimal vehicle
drops again, as the motor displacement is reduced
iency of the pump and motor at maximum displacement. It then A4VG/

3 shows the towardstraction

maximum maximum and
vehicle speed.
vehicle speed. A10VG

is composed drops again, as the motor displacement is reduced

iciency of the Hydrostatic
- modular
towards
transmissions
maximum system
vehicle
compete
with hoses on
speed.
the market
instead of shafts
draulic pump against giving
mechanical transmissions with or without
h is composed maximum freedom of design
ydraulic pump torque converters. The above discussed technical
characteristics indicate the following benefits: Figure
Figure4:1ForkFork
lifters withwith
lifters wheel andand
wheel axleaxle
drives
drives
APPLICATIONS WITH HYDROSTATIC
2 TRANSMITION
23rd AVL International Commercial Powertrain Conference, April 20th & 21st, 2005, Graz, Austria SESSION II - 2.3 - Page 3
Fork-lift trucks are a typical application that needs
best maneuvering behavior of the laden as well as
unladen vehicle at low speed and in both directions.
ing,
A4VG/

m speed and A10VG

e important
Off-Road
Applications
ges are:
Common approaches to addressA6VM
traction problems are
cal brakes by multiple pump systems or motors that are entirely or
partially connected in series.
ptimal vehicle The Rexroth integrated solution AP7 is specially
A4VG/

Drive Torque Drive Torque

designed for the A10VG
drive train of light and medium power

Continuous Interrupted
ad of shafts tractors (see Figure 5). It consist of:
- a constant displacement bent axis piston motor, a
variable displacement swashplate axial piston pump
2-spe
Figure
and 1 Fork lifters with wheel and axle drives
STATIC - a servo valve to mechanically control the vehicle speed.

n that needs
en as well as
oth directions. Figure 6: Hydrostatic and mechanical transmission for 60
lower power Figure 3 Hydrostatic and mechanical transmission
hydrostatic Municipal vehiclesvehicles
for Municipal Figure 4 H
r all kinds of s
achieve good In Europe, hydrostatic transmissions have been the
heels are of APPLICATIONS WITH ENHANCED
state-of-the-art for wheel loaders up to an installed
HYDROSTATIC which calls
of 60 kW forTRANSMISSION
4 shows the
power many years. For vehicles with chosen solu
oad vehicles.
el drives, the a power range of 120 - 250 kW the pure hydrostatic of a mechan
Municipal vehicles are often used by the operator for
d. For these approach has totasks.
very different be extended by summation
Cleaning the street gearboxes
posts for operating
th hydraulic (Figure 7). The use of two hydraulic motors
example requires best maneuverability at low speed allows transmission
truly
(Figurecontinuos variable transmission.
6). Therefore, a hydrostaticWith only one tractive effo
transmission
would be
motor thea drive
very suitable solution.
torque will other system.
But on theduring
be interrupted
shifting, which is done by a microcontroller. Figurefor
hand, these vehicles are also used 8
with a GFT transportation. This solution
requiresfor
good efficiency at high In Europ
shows the complete a transmission system
olution. Figure speed, the state-of
Figure5:2Hydrostatic geargear
Hydrostatic boxbox
for for
tractors
tractors with an enhanced summation gear box using two
ion problems hydraulic motors incl. the electronic products. Herein,
ors that are
From
From the the functional point of
functional point of view,
view, this
this system
system isis the electronic control unit is connected directly or via
identical to the above mentioned solutions and offers CAN-Bus to the sensors, the control elements Gear Direction Drive In
and the
identical to above mentioned solutions and offers
selection of travel pedal
continuous variable
7 is specially continuous variable transmission to
to increase the
increase the combustion engine and is responsible for the gearbox
operating efficiency. However, the main
and medium operating efficiency. However, the main advantages advantagesof managementDiagnostics,
incl. some special features like load limiting
t of: of this approach are control and parameterization,
automotive driving. The driver can express
this approach are
process
piston motor, -- the the
veryvery compact
compact design
design that minimizes
that minimizes the
the weight his wish with using panels for gear selection, driving
monitoring
e axial piston andweight and direction, speed and inching. Through digital speed
-- thethespace envelope
space as an
envelope as integrated
an integratedmechanical part
mechanical sensors at the hydraulic pump, the hydraulic motors
ol the vehicle of the complete drive train of the vehicle.
part of the complete drive train of the vehicle. and gearbox the state can be clearly determined. The
Rp

APPLICATIONS WITH ENHANCED

HYDROSTATIC TRANSMISSION
Drive Torque Drive Torque

1 Municipal vehicles are often used by the operator for

Continuous Interrupted

very different tasks. Cleaning the street posts for

example requires best maneuverability at low speed i1, i2 i1, i2, i3
(Figure 6). Therefore, a hydrostatic transmission 2-speed mech. trans. 3-speed mech. transm.
would be a very suitable solution. But on the other
hand, these vehicles are also used for transportation.
This requires good efficiency at high speed, which calls Engine with electronic
for a mechanical transmission. The chosen solution injection pump i1, i2, i3

combines both principles by the use of a mechanical summation enhanced summation

gear box for switching between two operating modes: 60 120 Drive power in kW 250
Figure 3 andHydrostatic
hydrostatic mechanicaland mechanical transmission
transmission. Figure 6 Figure 8 Wheel loaders with enhanced summation
for Municipal
shows the diagram vehicles effort versus the
of the tractive Figure7:4Hydrostatic
Figure Hydrostatic transmission
transmission concepts
concepts withwith
vehicle speed for this system. summation
summation gearboxes
gearboxes for wheel
for wheel loaders
loaders
APPLICATIONS WITH ENHANCED 2
HYDROSTATIC TRANSMISSION which calls for a mechanical transmission. The
chosen solution combines both principles by the use
Municipal vehicles are often used by the operator for of a Powertrain
Page 4 - 2.3 - SESSION II 3rd AVL International Commercial mechanical gear box
Conference, for20switching
April between
& 21st, 2005, two
Graz, Austria
th

very different tasks. Cleaning the street posts for operating modes: hydrostatic and mechanical
example requires best maneuverability at low speed transmission. Figure 6 shows the diagram of the
example requires best maneuverability at low speed transmission. Figure 6 shows the diagram of the
(Figure 6). Therefore, a hydrostatic transmission tractive effort versus the vehicle speed for this
would be a very suitable solution. But on the other system.
hand, these vehicles are also used for
transportation. This requires good efficiency at high In Europe, hydrostatic transmissions have been
speed, the state-of-the-art for wheel loaders up to an in-

Gear Direction Drive Inching � Load limiting control

selection of travel pedal pedal � Automotive driving
Diagnostics, � Gearbox management
parameterization, � Inching function
process
� Diagnostics
monitoring
Electronic control
unit + Software

Rpm speed

Engine with electronic

injection pump

Figure 8 Wheel loaders with enhanced summation gearbox incl. electronic control
Figure 8: Wheel loaders with enhanced summation gearbox incl. electronic control

actuators for controlling the pump and the motors2 as

well as the electric valves for the clutches are analogue
driven. In addition, there is the possibility to connect
with external programming and diagnosis control
units.
In the last decades the number of speeds for agricultural
tractor gear boxes has increased up to 20 or more.
This makes the gearboxes more and more complex
and partly distracts the driver from his actual job. Thus,
the introduction of transmission systems with stepless
speed selection and speed capabilities up to the vehicle
top speed vmax = 50 km/h in the past decade have lead
to better comfort for the driver and increased the
working efficiency. Figure 9 shows in a principal sketch
the function of those gear boxes. With a spur gear the
power output from the combustion engine is divided into
two branches: one mechanical and one hydrostatic. The
variable speed of the hydrostatic branch in combination Figure 9: CVT by hydrostatic transmission
with a planetary gear stage allows to control the output
speed of the gear box without varying the rotational
speed of the combustion engine. For the driver this FOUR WHEEL DRIVE AND ANTI-SLIP
yields an infinite gear box that combines the advantage CONTROL
oft continuos variable transmission (CVT) over the
hole range and a good mechanical efficiency at high Since the ninetieth electronic stabilizing systems like
travelling speed. Rexroth offers for these systems the ESP have become state-of-the-art in the automotive
hydrostatic gearbox A40CT, the electronic control unit industry. The main advantages of the widely introduced
RC incl. software for the gear management as well as anti-slip control in cars are: increased passenger safety
valves and sensors (Figure 9). by improved vehicle stability and reduced tire wear.

3rd AVL International Commercial Powertrain Conference, April 20th & 21st, 2005, Graz, Austria SESSION II - 2.3 - Page 5
However, for mobile applications and especially for
agricultural and forestry machines anti-slip control
is important to prevent damage to the susceptible
environment. Standard hydrostatic solutions work as
a differential lock and use series connection of the
motors, supplied by multiple pumps or flow dividers.
The new Rexroth approach uses electrohydraulic
control and achieves in comparison to the before
mentioned solutions:
- best tractive effort,
- best vehicle performance,
- minimal wear of the components and
- maximum efficiency.
As Figure 10 shows, it consist of: a swashplate axial Figure 11: A real driving cycle in simulation
piston pump A4VG and four bent axis axial piston
motors A6VM in combination with the new drive gear CONCLUSION
GFT 13/17. The latter allows wear-free dynamic braking
via the internal disc brake and enables high traveling Hydrostatic transmission systems have been the state-
speed of the vehicle up to v = 40 km/h. To control the of-the-art in mobile applications for many years because
rotational speed of the wheels each motor is equipped of their substantial technical and economic advantages
with a speed sensor DF11i. The electronic control unit for the customers like continuous variable transmission,
RC manages the displacement of the pump and the wide torque-to-speed-ratio, bi-directional operation ,
motor corresponding to the driver command and the maximum tractive effort at low speed, high efficiency
maximum possible traction. in the relevant operating modes. In particular, the
combination of hydrostatic and mechanical transmission
expand the range of solutions. As the discussed
examples show, Rexroth is able to provide products
and systems for nearly every field of application. In the
development of new solutions, simulation has become
a very important and improved technology for precise
predictions.

REFERENCES

[1] Robert Bosch GmbH (Hsg.): Fahrsicherheits-

systeme. 2. Aufl., Vieweg, Braunschweig, 1998.
[2] Programmübersicht Mobilhydraulik, Mobil-
elektronik, Getriebe, RD 90 112/08.02. Bosch
Figure 10: Four wheel drive with anti-slip control Rexroth AG, Elchingen.
[3] Mobile 2000 International Mobile Hydraulics
In this fundamental project, system simulation was Conference, Ulm, 12-13 Oct. 2000, RE 00 207/10.00.
intensively used in the development of the enhanced Bosch Rexroth AG, Elchingen.
control algorithm. Hereby, it was very important to find [4] Mobile 2003, International Mobile Hydraulics
a good compromise between the effort of modeling and Conference, Ulm, 16-17 Oct. 2003, RE 00 207/10.03.
parameterization, and the really necessary accuracy. The Bosch Rexroth AG, Elchingen.
comparison between the measured and the simulated [5] Murrenhof, H.; Wallentowitz, H.: Fluidtechnik für
motor speeds for a real driving cycle in Figure 11 gives mobile Anwendungen. Umdruck zur Vorlesung an
an impression, how reliable the predictions based on der RWTH Aachen, 2. Aufl. 1995.
simulation could be. With this, the control strategies [6] Kliffken, M.G.; Geerling, G.: Neue Entwicklungen
could be considerably improved and the number of und Trends in der Mobilhydraulik. O+P Ölhydraulik
tests in total reduced. und Pneumatik 47 (2003) Nr. 7, S. 478-483.
[7] Kliffken, M.G.; Behm, M.: Antriebsschlupfregelung
für hydrostatische Fahrantriebe. 4th International
Fluid Power Conference IFK, Dresden, 25.-
26.03.2004.

Page 6 - 2.3 - SESSION II 3rd AVL International Commercial Powertrain Conference, April 20th & 21st, 2005, Graz, Austria
[8] Matthias, H.J.; Renius, K.Theo.: Einführung in die
Ölhydraulik. B.G. Teubner, Stuttgart, 4. Aufl., 2003.
[9] Pütz, C: The John Deer AutoPowrTM Transmission.
VDI Tagung Landtechnik, Hannover, 7.-9. Nov.
2003

ABBREVIATIONS

α Swivel angle
η Efficiency
F Tractive effort
n Rot. Speed
p Pressure
P Power
T Torque
v Vehicle speed
VG Displacement of pump/motor
max Maximum
min Minimum
nom Nominal
CVT Continuous Variable Transmission
ESP Electronic Stability Program.
A4VG Swash plate axial piston pump
A2VM Bent axis axial piston motor
A6VM(E) Bent axis axial piston motor
A10VG Swash plate axial piston pump
AP7 Integrated hydrostatic gearbox
GFT 13/17 Planetary gearbox
MCR Radial piston motor
RC Electronic control unit
DF11i Rotational speed sensor

3rd AVL International Commercial Powertrain Conference, April 20th & 21st, 2005, Graz, Austria SESSION II - 2.3 - Page 7