HRB Hydrostatic Regenerative Braking System The Hydraulic ... · Quelle Grafik: MAN MediaCenter ....

1 Eric Lindzus | 18.04.2011 | Abteilung | © Bosch Rexroth AG 2010. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung,

Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.

| Vehicular hydraulic systems

Environment Energy

HRB – Hydrostatic Regenerative Braking System

The Hydraulic Hybrid Drive from Bosch Rexroth

and

Hydrostatic Fan Drive in Vehicles

Mauro Silva – DCBR/Mobil Sales

2 | 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

applications for industrial property rights.

Within The Bosch Group

Industrial

Technology

Bosch Group Revenue: 38,2 Bill. euros

Associates on Jan. 1, 2010:

270,687

Automobile

Technology

Consumer Goods and

Building Services Eng.

Packaging

Technology Solar Energy Bosch Rexroth

Drive and Control Techn. Revenue: 4,146 Bill. Euros

Associates 2009: 34,225

| The Company



| The Workshop

HRB and Fan Drive



| Comparison E-Hybrid vs. HRB

Fuel cell

Ultracap

Battery

Elkos

Power density [W/kg]

En

erg

ie d

en

sity

[Wh

/kg

]Hydr. Accumulator

Fuel cell

Ultracap

Battery

Elkos

Power density [W/kg]

En

erg

ie d

en

sity

[Wh

/kg

]Hydr. Accumulator

High energy density

Battery / Ultracaps

Energy density

Battery: 10 - 100 Wh/kg

Ultracaps: 1 - 10 Wh/kg

Hydr. Accumulator: 0,2 - 5 Wh/kg

High specific power density

Hydro. Accumulator

Power density

Battery: 10 - 300 W/kg

Ultracaps: 200 - 4000 W/kg

Hydr. Accumulator: 2000 – 300 000 W/kg

(Depends on diameter of opening)

Energ

y



| Storage Loading Speed vs. Brake Energy

Passenger Car

1,5 to, 50 km/h, 2 m/s2

0

10

20

30

40

50

60

70

80

0 1 2 3 4 5

Time [s]

Energ

y [

kJ]

Hydraulic Bladder Accumulator, Lithium Battery, Lead Battery and real Breaking Energy

The Lithium Battery fits well,

however the lead battery is

never sufficient to recover a

part of the braking energy

Delivery Vehicle

7 to, 30 km/h, 2,5 m/s2

0

20

40

60

80

100

120

140

160

180

200

0 1 2 3 4 5

Time [s]

Energ

y [

kJ]

The hydraulic accumulator

is suitable and the lithium

battery can largely recover

the braking energy

Refuse Truck

25 to, 10 km/h, 1,5 m/s2

Only the hydraulic

accumulator is sufficient

fast to absorb the complete

breaking energy

0

10

20

30

40

50

60

70

80

0 1 2 3 4 5

Time [s]

En

erg

y [kJ]

Braking

time

Passenger Car

1,5 to, 50 km/h, 2 m/s2

0

10

20

30

40

50

60

70

80

0 1 2 3 4 5

Time [s]

Energ

y [

kJ]

Hydraulic Bladder Accumulator, Lithium Battery, Lead Battery and real Breaking Energy

The Lithium Battery fits well,

however the lead battery is

never sufficient to recover a

part of the braking energy

Delivery Vehicle

7 to, 30 km/h, 2,5 m/s2

0

20

40

60

80

100

120

140

160

180

200

0 1 2 3 4 5

Time [s]

Energ

y [

kJ]

The hydraulic accumulator

is suitable and the lithium

battery can largely recover

the braking energy

Refuse Truck

25 to, 10 km/h, 1,5 m/s2

Only the hydraulic



breaking energy

0

10

20

30

40

50

60

70

80

0 1 2 3 4 5

Time [s]

En

erg

y [kJ]

Refuse Truck

25 to, 10 km/h, 1,5 m/s2

Only the hydraulic



breaking energy

0

10

20

30

40

50

60

70

80

0 1 2 3 4 5

Time [s]

En

erg

y [kJ]

Braking

time



| Parallel – HRB System

System Components:

P/M Pump/Motor Unit G Gearbox

C Clutch V Valveblock

SHP High Pressure Accumulator HCU Hybrid Control Unit

P/M

V

C

G

HCU

SHP

8

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

Eric Lindzus | 18.04.2011 | Abteilung | © Bosch Rexroth AG 2010. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung,


| Parallel – HRB System

P/M

V

C

G

HCU

SHP



| Braking with the HRB

Driver activates HRB

by button or lever

10

acceleration pedal is

released HRB engages

& disengages engine




11

Axial Piston Unit (APU)

charges accumulator




12

Braking torque is

controlled by APU’s

displacement






| Accelerating with the HRB

acceleration pedal

is pushed

14

accumulator discharges

via Axial Piston Unit (APU)







Drive torque is controlled

by APU’s displacment

and supplemented by

engine if neccessary

16

HRB disengages

when accumulator

is discharged




17

Test vehicles in 2009 / 2010

| Test Vehicles

Crane Carrier LET2

(USA)

MAN TGM

(Germany)

MAN TGS

(Germany)

Quelle Grafiken: media.daimler.com; MAN MediaCenter

18

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

Eric Lindzus | 18.04.2011 | SPP23 | © Bosch Rexroth AG 2010. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung,


| Benefits of HRB – confirmed in Practical Tests

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.

HRB from Bosch Rexroth tested by the

Independent German Automobile Association

Quelle Grafik: MAN MediaCenter

19

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.“



| 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:



| The Workshop

HRB and Fan Drive



Fan Drive Applications

Mobil Cranes

Buses

Wheel Loader

Carrier Trucks

Dumper

Locomotives

Excavators

Harvester

Applications



Fan Drive control systems

Control systems

hydro -

mechanical

control

electro -

hydraulic

control

constant system

• External gear pump

• External gear motor

• Thermal relief valve

• Priority valve

variable displ. system

• Axial piston pump

• Axial piston motor

• Thermal relief valve

Hydrostatic fan

drives

constant system

• External gear pump

• External gear motor

• Electronics

• Temperature sensors

variable displ.

system

• Axial piston pump

• Axial piston motor

• Electronics

• Temperatur sensors




Diesel Engine Speed [rpm]

Fan

sp

ee

d

[rp

m]

Fan Speed Diagram

0

500

1000

1500

2000

2500

500 750 1000 1250 1500 1750 2000

• Fan speed is independent

of the engine speed

• stepless variable fan speed

from minimum to maximum


Fan

sp

ee

d

[rp

m]

Fan Speed Diagram

0

500

1000

1500

2000

2500

500 750 1000 1250 1500 1750 2000

• Direct linkage between fan

speed and engine speed


Fan

sp

ee

d

[rp

m]

Fan Speed Diagram

0

500

1000

1500

2000

2500

500 750 1000 1250 1500 1750 2000

• 3-step linkage between fan

speed and engine speed

1

2

3

• Additional power supplied

at lower engine speed

• Limited fan power at lower

engine speed

• Limited fan power at lower

engine speed



Hydromechanical Control / Constant System

Advantages of the system :

• radiator can be positioned independently of the engine

• short overall length of the gear pump

• good price/performance ratio

• infinitely variable fan speed, from minimum to maximum, if permitted by oil flow from the external gear pump

• low weight

Wate

r

Oil

Tu

rbo

ch

arg

ed

air

External

gear motor

External Gear

Pump

Thermo

relief

valve

External gear pump

AZPF

Size 4 … 28 cc

External gear motor

AZMF

Size 8 … 28 cc

Priority valve LPS

Thermo relief valve MHDBDT



Hydromechanical Control / Variable System


• radiator can be positioned

independently of the engine

• infinitely variable fan speed

from minimum to maximum

• drive power of the variable displacement

pump corresponds with the required fan

power

• no throttling losses

• fan speed is largely independent

of the engine speed

• lower fuel consumption

Var. Displ. Pump

A10VO...DRG/31

size 18 ... 140

Var. Displ. Pump

A10VO...DRG/52

size 28 ... 85

Fixed motor

A10FE / FM

size 10 ... 63

Thermal relief valve

MHDBDT

Axial piston

motor

A10FE

Thermo relief

valve

MHDBDT

Axial –

piston pump

A10VO…DRG/31

Wate

r

Oil

Tu

rbo

ch

arg

ed

air



Electroproportional Control / Fixed Displacement


• variable fan speed control

• fan speed is largely independent of the engine speed

• direction and weighting of several operating parameters

• minimum throttling losses

• Fail - safe function

• reduced power consumption

External Gear Pump

AZPF

size 8 ... 28 cc

External Gear Motor

AZMF

size 8 ... 28 cc

BODAS Control Unit RC 2-2/2x

PTC - Temperature Sensor for

Air / Water

External

Gear

Pump

External Gear Motor

with integrated Prop.

Valve

Wate

r

OIl

Tu

rbo

Ch

arg

ed

Air

PTC

PTC

Temperature Water

Temperature Ambiente Air

Co

ntr

ol U

nit

RC

2-2

/2x

Retarder

Turbo Charged air

PTC

Temperature Oil



Electroproport. Control / Variable Displacement


• infinitely variable fan speed from minimum to maximum

• fan speed is largely independent of the engine speed

• direction and weighting of several operating parameters

• high control quality

• no throttling losses

• Fail-safe function

• lower fuel consumption

Var. Displ. Pump

A10VO...ED/31

size 18 ... 140

Var. Displ. Pump

A10VO...ED/52

size 28 ... 85

Fixed Motor

A10FE / FM

size 10 ... 63

BODAS Control Unit RC 2-2/2x

PTC - Temperature Sensor for

Air / Water

Co

ntr

ol U

nit

RC

2-2

/2x

Axial Piston-

Motor A10FE

Axial Piston

Pump

A10VO...ED/52

PTC

PTC

Fluid Temperature Water

Ambiente Temperature

Retarder

Speed Sensor DSM

Temperature OIl

Turbo Charged Air

PTC

Wate

r

Oil

Tu

rbo

ch

arg

ed

air



Summary

hydraulic control

simple systems

electronic control

complex systems

Hydraulic control is used in

configura-

tion simple systems, i.e. typically for

measuring one or two temperatures

of fluids

• fixed pump system or

• Variable displacement system

• fixed pump system or

• Variable displacement system

Electronic control permits the configuration

of complex systems, covering several gas /

fluid temperatures and switching signals.



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)

Speed Sensor DSM

Temperature for Oil

Temperature for Water

Temperature turbo charge air

Ambiente temperature a b

Ste

ue

rge

rät

RC

2-2

/2x

Change of direction of rotation Axial Piston-

Motor

A10FE

Fan Function

Manifold HSH 06 / 10

Retarder

Features: • Bi - directional fan rotation

• No shock valves needed

• Option: fan standstill

• Variable oil heat-up function

(via controlling ED-pressure setting)

• No anti-cavitation valve

• No pump drain line

• Fail safe mode

Axial Piston

Pump

A10VO...ED/52



Preview - Combined Systems

AC Compressor

Air Compressor

Alternator

Misc.

- Fixed displacement system

- Usage for fan drive

- Depending Cooling Power

- One Parameter

- Variable displacement system

- Usage for fan drive

- Independent Cooling Power

- Multiple Parameters

- Variable displacement system

- Combined systems

- Independent Cooling Power

- Multiple Parameters

- Closed Loop Control



The Drive & Control Company

Thank you!

HRB Hydrostatic Regenerative Braking System The Hydraulic ... · Quelle Grafik: MAN MediaCenter ....

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Transcript of HRB Hydrostatic Regenerative Braking System The Hydraulic ... · Quelle Grafik: MAN MediaCenter ....