Drive Solutions for Hydrostatic Wheeled Loaders.

Transcription

1 Drive Solutions for Hydrostatic Wheeled Loaders.

2 02 linde hydraulics portfolio Linde Hydraulics. Turning Power into Motion. At Linde Hydraulics we have always had a passion for converting power into motion. This passion is driven by customer care, a thirst for knowledge and a love of innovation. We power ideas, machines and markets, both today and in the future. We combine components to a system and create efficient overall solutions thanks to our intelligent blend of hydraulics, electronics and mechanics. Our aspiration can be summed up by one simple concept: Adding customer value through application expertise and the pursuit of system perfection. Linde Hydraulics makes all of this possible due to a combination of partnership, responsibility and the highest level of commitment. For us, partnership is an important, indispensable part of product development and quality assurance. Therefore, we add our knowledge, experience and international market expertise to help you exceed your customers expectation. We strive to be your best partner from initial contact to project engineering and product development, all the way through prototype commissioning, serial production and training your teams. Our interpretation of the term customer orientation is superior service and availability: worldwide, at any place. With companies in Europe, USA and China along with a great international network distributors we guarantee you the best possible customer service. Portfolio. By the logic combination of individual products that perfectly complement each other we offer solutions for almost every class of machines. Due to these capabilities we can always offer the best possible system to our customers. see application example on page 6 Pump HPV 55 HPV 75 HPV 105 HPV 135 CVT Motor HMV 75 HMV 105 HMV 135 HMV HMV CVT Valve VW 12 ECU Linde ECU Implement Pump IGP / EGP MPR 50 2x MPR 50 HPR 105D 0t 5t 10t 15t 20t 25t

3 Benefits of Hydrostatic Drive Systems 03 Benefits of hydrostatic drive systems. When compared with torque converters. Wheel loaders benefit from the use of a modern hydrostatic drive system most notably in terms of a very high productivity and low fuel consumption. In addition to that the hydrostat demands less service since a shifting gearbox can be omitted and the mechanical brake is not needed for deceleration. The amount of oil to be changed is lower and the wear of the fluid itself is less. But the best of that all these benefits remain valid over the whole lifetime of the machine without readjusting or the complete exchange of the hydrostatic components. The hydrostatic drive system offers more higher efficiency faster reversing better general controllability superior fine control easier to maintain Hydrostatic drive systems have proven to be superior over hydrodynamic drives systems in various types of machines. Beyond the general advantages of the hydrostatic drive, Linde drive systems offer an unbeatable driving experience in terms of precision, dynamics and reliability. Linde drive units offer load independent, direct unit control various types of controls reliable and robust yet most compact design high power density through drive capability for pumps and motors smooth and sensitive operation even at low speeds low noise The hydrostatic drive system takes less less losses and therefore less fuel consumption and less emissions no unintentional movement of machine like rolling back less components in the drivetrain, therefore no wear and tear of brakes and gearbox less service needed, less amount of oil to be changed 2 1,8 1,6 1,4 1,2 Speed ratio 1 0,8 0,6 0,4 0,2 0 LinDrive = Precision x Dynamics x Reliability = Benefit n Engine Pump Motor Low speed direct Low speed integration Gearbox Differential Planetary gear Wheel Low speed High speed

4 04 Seeing the bigger picture Seeing the bigger picture. Improving the details. Our goal is to increase the driving comfort and the economic efficiency of your machine. The individual goals of increased precision, dynamics and reliability are not only achieved by optimum design and adjustment of the driving system. We already focus on this goal during the development of individual propel drive components. This ensures that the HPV-02 CA offers all typical LinDrive advantages. Precision >> Continuously variable selection of driving and operating speed via the accelerator pedal through the integrated charge pump for hydrostatic speed sensing temperature independent pressure compensated performance optimised low noise level >> The same driving signal always triggers the same machine reaction through position feed-back control independent of traction forces and loads reproducible foreseeable precise low in hysteresis Dynamics >> Fast, powerful machine reaction and optimum traction at the wheel through high, load-independent actuating forces (system pressure) maximum actuation torque prompt swashing of pump >> Hydrostatic braking through maximum swashing torque load independent pump control not influenced by braking pressure >> Optimum reversing through co-ordinated swashing behaviour of pump and hydraulic motor gentle transition from braking to acceleration braking phase can be defined for each application The high swash forces of the pump control lead to the prompt swashing of the pump, independent of tractive effort and load. They also guarantee the direct conversion of the driving signals maintaining driving dynamics at a constantly high level. The maximum swash force of the pump control ensures the precise conversion of the driving signals, independent of the step stroke. Absolutely foreseeable and reproducible. Dynamics [%] Linde Hydraulics : HPV-02 CA Linde Hydraulics : HPV-02 CA Competitor: Variable pump with swash force feedback control Competitor: Variable pump with swash force feedback control Set point deviation [%] Swash force [%] Reliability >> High safety standard for defined starting and stopping through reliable neutral pump position at low idle and through activation and deactivation of the control signal at a defined diesel speed. Step stroke [%] >> Exact control at any point of operation through high setting forces in the pump control. >> High availability and long service life through proven design features and robust quality of the Series 02.

5 Best results with every solution 05 Best results with every solution. A) The pump control Linde pumps for the closed hydraulic circuit provide a superior handling performance. The reasons for that is that their servo-control mechanism with position feedback. It is designed to be precise and load-independent. This means that an identical driver command always leads to the same machine reaction independent of the load of the machine. No corrective action is required. Furthermore they offer a very dynamic response characteristic. This is true no matter what type of piloting is used. Being it mechanical, hydraulic, electric or engine-speed dependant piloting - Linde Hydraulics pumps can be integrated into any kind of vehicle management control system and can thus replace any less-performing system. The most common controller types for wheel loaders are: The CA control The E2 control speed related hydraulic mechanical control with torque-/power limiter intuitive operation direct control of speed and tractive effort speed-optimized inching function different types of motor control possible electro-hydraulic with switch-off function ("watchdog", active drive enable), suitable for road traffic use Defined and fast swiveling back: with HMF-02: for controlled deceleration in case of system fault with HMV-02: diesel overspeed protection best to use with a powerful ECU and electric actuation of the other components to gain the best overall system efficiency (see example on the next pages) B) The motor concept Standard > High engine power > High hydraulic motor speed > Low driving speed > With mechanical gearbox PTO single-motor > Reduced engine power > Reduced hydraulic motor speed > Higher driving speed: + 50% > Without mechanical gearbox PTO double-motor > Reduced engine power > Middle hydraulic motor speed > Double driving speed: + 100% > Without mechanical gearbox C) The type of motor used Type HMF-02 HMV-02 E2 HMR-02 HMV-02 EH1P CA HMV D-02 fixed flip-flop load dependently variable continuously variable and load dependently variable continuously variable and load dependently variable Driving speed Conversion ranges Mechanical gear steps Start-up resolution

6 06 application example wheeled loader Application example. Wheeled loader, 6.5 t. Equipment 1x HPV E2 (travel pump) + 1x MPR 50 (working hydraulic pump) 1x HMV E6 (travel motor) 1x VW12M3 (working hydraulic valves) 1x Pedal 1x Electronic control unit Advantages maximum energy efficiency thanks to optimized components with intelligent system coordination high machine availability owing to minimum, planable service times thanks to heavy duty units with a long service life low tyre and brake wear due to hydrostatic drive Options function on the MPR hydraulic start-stop function with auxiliary hydraulic accumulator and MPR as starter motor larger wheel loaders without hydrostatic drive unit benefit from Linde HPR self-regulating pumps and LSC valve technology in the working group and a hydrostatic fan drive The entire truck is controlled by a new-generation electronic control unit. All components are precisely set to the respective load situation in order to achieve the best possible performance with minimum fuel consumption. The use of a variable displacement pump rather than a fixed displacement pump for the working hydraulic is pivotal here. The MPR 50 is a medium-pressure pump that boasts the service life properties of Linde high-pressure pumps. Designed for heavy use, it ensures high machine availability thanks to precise, load-independent electrical control with position feedback and a compact build that means minimum service times. Compared to medium-pressure load-sensing pumps, it has greater overall efficiency, better cold start behaviour and integrated pulsation damping. The integrated feed pump uses the suction connection of the medium-pressure pump, which saves having to use a separate suction line. It is pressure-proof and suitable for fan operation. As such, the pump assembly consisting of HPV, MPR and gear pump is extremely short. The monoblock VW12M3 in layer-technology offers further optimisations in the working hydraulics. This allows optimised channel clearance with no dead areas or turbulence, while allowing larger internal cross-sections with less loss than a standard valve block with the same dimensions. Optimised components are often not enough to help realise ambitious targets when it comes to fuel savings. Real savings potential can only be achieved if the system components are perfectly coordinated with each other and work as one overall system. The sample configuration of a wheel loader demonstrates this. Measurements with a comparable truck (5 t forklift truck) based on VDI cycle 2198 show a fuel saving between the standard version and the optimised version of up to 21% in the partial load range and 15% in the full load range. A saving of 20% in the long-term field trial shows that it is already possible to achieve ambitious targets today.

7 application example wheeled loader 07 Fuel Consumption [l/h] Load Capability Source Load t Measurement 100% t Measurement 50% t 3.5 t 2.5 t 2.5 t Measurement Simulation Measurement Measurement 100% 100% 100% 50% Series Vehicle Test Vehicle with MPR

8 08 Start-Stop-System Start-Stop-System. Power Range kw Components Medium pressure pump MPR 50 Hydraulic retarder Hydraulic accumulator Valve block Check valve Advantages Works without the need for a separate hydrostatic unit and with few additional components Almost unchanged axial installation space Fast starting procedure Diesel speed [rpm] 0.34 s 1.4 s Electric starter Linde Start Stop Thanks to the use of an MPR50 medium-pressure pump instead of a gear pump, Linde has already been able to achieve fuel savings of around 20% in relevant comparable vehicles. The hydraulic start/ stop system for restarting the machine at operating temperature builds on this and opens up further saving potential. The working hydraulics pump charges an accumulator during operation via the retarder and works as a starter motor when charged with the accumulator pressure on the suction side. The criteria for shutting off and restarting the diesel engine are stored in the electronic control unit. These criteria can be adapted to the individual demands of the specific machine and manufacturer in order to achieve the acceptance of machine operator for the system. The size of the accumulator also varies from machine to machine and is determined by the intended speed to which the diesel is started. No wear of components will endanger the availability of this feature. Exemplary calculations (using a 50-kW machine, a fuel consumption of 1.5 l/h, 30% idling and 1000 operating hours per year) show that one active accumulator charging procedure i.e. without using energy from the deceleration for example already pays for itself after 2.5 seconds engine shut off time, and that the system can thus save around 450 litres of diesel per year. The system features a modular design. If an MPR is already used as the implement pump alongside a retarder, only a check valve and two additional components are needed for the start/stop functions: a valve block and a hydraulic accumulator. These weigh very little and can also be positioned anywhere in the machine. As a result, the manufacturer can simply build the start/stop option into the production process without the need for much additional work or storage Time [s]

9 Shift in Motion 09 Shift in Motion. Power Range kw Components HPV-02 variable displacement pump HMV-02 variable motor Electro-hydraulic control of the hydrostatic units Electro-hydraulic actuator at the gearbox Linde electronic control unit Advantages Shifting procedures possible while driving Simple, mechanically unsynchronized gearboxes Little installation space High transmission efficiency High overall efficiency Tractive effort [kn] Ground speed [kph] 1. Gear 2. Gear Shifting area Linde combines the comfort of CVT drives with the compact dimensions of machines featuring manual transmissions that can be shifted at standstill, at prices below those of powershift transmissions. "Shift in Motion" enables shifting procedures in a moving machine, equipped with a manual transmission that is intended to be shifted at standstill by electro-hydraulically synchronising the drivetrain. "Shift in Motion" is particularly suitable for vehicles that often change between transport and operation, i.e. vehicles that require both high tractive effort and a high top speed above 25 kilometres per hour. The shifting procedure is load-free thanks to electro-hydraulically synchronised gears and the ability to adjust the drive component s speed and torque. Thus there is no need for multi-disc clutches and mechanical synchronisation using synchronizer rings and moreover there s less pinion engagement. This makes the shifting procedures wear-free and also increases the transmission s efficiency. "Shift in Motion" is used with a manual transmission that can be shifted at standstill and that features a selectable neutral position. Having Linde drive components and control units already installed, it may only be necessary to adjust the control software in order for "Shift in Motion" to function. Thanks to a CAN bus connection, the Linde ECU can also be used in conjunction with the customer's controllers for the rest of the overall vehicle. It then only takes care of the synchronisation and gear shifting itself. The shifting procedure can be triggered on demand by the driver or automatically, based on the customer-specific acceptance criteria for the respective vehicle and situation. The drivetrain is brought to no load by adjusting the pump and motor, and the transmission is disengaged into the neutral position. The hydraulic transmission is then adjusted to the new ratio of the selected gear. Finally, the required gear is selected and the normal drive programme continues. The whole process only takes about half a second. The quick and easy gear changes mean that it is worth configuring the transport gear to a higher top speed than the target speed. Doing so enables the actual maximum speed of the vehicle to be achieved using a lower speed of the hydrostats and diesel. Operating the drive components in more favourable operating points (overdrive) lowers both fuel consumption and noise emissions.

10 10 technical data summary Find the right product for your application Variable pumps for closed circuit operation HPV Max. displacement cc/rev Permissible speed rpm Max. speed (intermittent) rpm Nominal pressure bar Peak pressure (intermittent) bar Continuous input torque Nm Max. input torque Nm Continuous power kw Max. power kw Weight w/m1r control kg Product advantages HPV-02 compact design high power density dynamic response high reliability long service life noise-optimized precise and load-independent Self-regulating pumps for open circuit operation HPR D D 165D Max. displacement cc/rev Continuous rated speed ( * 1) rpm Continuous rated speed ( * 2) rpm Max. oil flow l/min , Nominal pressure bar Peak pressure (intermittent) bar Continuous input torque Nm Max. input torque Nm Continuous power kw Max. power kw Weight kg Product advantages HPR-02 optimum interaction with Linde LSC control valves energy saving operation by flow on demand -control dynamic response excellent suction up to rated speed noise optimization over the whole range of operation compact design high power density high reliability long working life (*1) w/o pressurizing, 1,0 bar abs / (*2) w/o pressurizing, 1,2 bar abs Open circuit MPR IGP Max. displacement cc/rev Max. speed (at 1 bar abs.) rpm Max. speed (at <35 cc) rpm Nominal pressure bar Peak pressure bar Max. power (at rated pressure and max. speed) kw Weight incl. IGP kg Product advantages MPR 50 very short design particularly in combination with HPV low pulsation and low noise integrated charge pump pump position at standstill: V = V min suitable for rough application conditions same service intervals as high pressure pumps Variable displacement motors for closed and open circuits HMV Max. displacement cc/rev Max. operating speed at V max rpm Max. speed (intermittent) at V min rpm Nominal pressure bar Peak pressure (intermittent) bar Continuous output torque Nm Max. output torque Nm Continuous power kw Max. power kw Weight kg Product advantages HMV-02 jerk-free low speed high starting torque large conversion range zero angle possible dynamic response PTO through-drive motor compact design high power density high reliability long service life

11 technical data summary Well-informed 11 Self-regulating motors for open and closed circuit operation HMR Max. displacement cc/rev Max. operating speed at V max rpm Max. speed (intermittent) at V min rpm Nominal pressure bar Peak pressure (intermittent) bar Continuous output torque Nm Max. output torque Nm Continuous power kw Max. power kw Weight kg Product advantages HMR-02 steady low speed behaviour high starting torque large conversion range PTO Through-Drive Motor compact design high power density high reliability long service life dynamic response Fixed displacement motors for open and closed circuit operation HMF Max. displacement cc/rev Max. operating speed rpm Max. speed (intermittent) rpm Nominal pressure bar Peak pressure (intermittent) bar Continuous output torque Nm Max. output torque Nm Continuous power kw Max. power kw Weight kg Product advantages HMF-02 steady low speed high starting torque compact design high power density high reliability long service life available with integrated directional control valve for direct swing drive control Well-informed. Our current media at a glance. Product Catalogue Turning Power into Motion. Product catalogue. Brochures Drive Systems for Construction Machines. Drive Systems for Agricultural Machines. Drive Solutions for selected applications such as... Cranes, Dozers, Excavators, Rollers and Wheeled Loaders. LSC. Directional control valves. Data Sheets HPV-02. Variable pumps for closed loop operation. HPR-02. Self-regulating pumps for open loop operation. HMF/A/V/R-02. Hydraulic motors for open and closed loop. icon. Electronic drive controller. VT modular. Modular system for LSC manifold valve plates. Ask your local dealer for a printed copy or visit to find most up-to-date information

12 How to reach us. Post Linde Hydraulics GmbH & Co. KG Grossostheimer Str Aschaffenburg, Germany LHY.AWBw.04/16.M Phone Fax Internet switchboard Linde Hydraulics Worldwide. (E) (F) (GB) (I) (USA) (BR) (VRC) Linde Hydraulics Iberica Avda. Prat de la Riba, 181, Palleja (Barcelona), Phone , Linde Hydraulics France 1, rue du Maréchal de Lattre de Tassigny, Elancourt, Phone , info.fr@linde-hydraulics.com Linde Hydraulics UK Eyston Way, Abingdon Oxfordshire OX14 1TR, Phone , enquiries@lindehydraulics.co.uk Linde Hydraulics Italia Viale dell'unione Europea, 33, Gallarate (VA), Phone , info.it@linde-hydraulics.com Linde Hydraulics USA 5089 Western Reserve Road, Canfield Ohio , Phone , info.us@linde-hydraulics.com Linde Hydraulics do Brasil Rua Victorino, 134 Jardim Mutinga SP, Brazil, Phone , info.br@linde-hydraulics.com Linde Hydraulics China No. 197 Fushou East Road, Weifang, Phone , info@linde-hydraulics.com.cn No. 89 Jinshang Road, Xiamen, Phone , info@linde-hydraulics.com.cn Visit to find a dealer close to you. Turning Power into Motion. Linde Hydraulics GmbH & Co. KG, Grossostheimer Str. 198, Aschaffenburg Phone , Fax , Linde Hydraulics