Drive and Control Systems for Excavators

Drive and control systems for crawler and wheeled excavators

There are differing drive and control hydraulic demands for excavators, these are dependent on the machine size and area of application. This leads to the use of differing systems. The Mannesmann Rexroth group of companies with its business sectors of Rexroth Hydraulics, Brueninghaus Hydromatik and Lohmann + Stolterfoht are in the position of being able to provide all systems from one supplier. When defining drive and control concepts, our aim is to select the most economic and optimum technical solutions. We are able to select in close collaboration with the machine manufacturer optimum solutions. Our project engineers have extensive experience in the design of differing machines and systems: k Systems for crawler and wheeled excavators for machines ranging from 1.5 to 800 tons k High and medium pressure range systems k Implement hydraulics with load sensing or open center controls k Travel and slew drives in open and closed circuits k Electronic systems for all of the control management and monitoring functions k Hydraulic steering and braking systems for wheeled excavators k Auxiliary drives, e.g. winch drives and cooling fans Drive and control systems for mini excavators see data sheet RE 98064.

Excavator types

Spider excavator

Drag-line excavator

Crawler excavator

Wheeled excavator

Mining excavator

Telescopic excavator

Open center control

2 circuit system (example: 20 ton crawler excavator)

GFB + A2FE (slew drive)

GFT + A6VE (travel drive)

8M8 (control)

A8VO (travel and implement hydraulics)

TH6 (pilot control units)

Preferred system for machines that have to operate under adverse conditions
k A system that has been proven over many years in numerous applications k A simple and robust design k Easy system matching k Good fine controllability k Direct control relationship k Good torque control with load feedback k Particularly efficient work under full load k A very service friendly system k Compact monoblock without many connections Flow summation within the valve block saves additional pipe work A motion control spools for crawler drives can be integrated if required Tandem drive of actuators for fast working movements is possible

k Particularly robust and proven double pump 1 housing with a common suction port A short build length provides good installation conditions Cast on SAE diesel motor flange for compact installation Integrated pilot oil pump and pressure valve Pumps for additional options can be builton without the need for a splitter gearbox

Applications are
k Compact and standard excavators k Drag-line excavators k Excavators as base carriers Swing gear box GFB with fixed displacement motor A2FE

LUDV control
1 circuit system (example: 13 ton wheeled excavator)

GFB + A2FE (slew drive)

1M7 + 5M7 + 1M7 (control)

A6VM + MHB (travel drive)

A11VO (travel and implement hydraulics)

TH6 (pilot control unit)

Preferred system for compact and standard excavators with limited installation space
k Sensitive and load independent actuation of differing actuator functions k Only one variable displacement pump for all functions k Easy installation and assembly k Very good fine controllability also with parallel operation k Defined speed allocation due to optimum flow distribution k Particularly economic operation when under partial load, e.g. grading k Additional optional actuators can be easily rectro fitted by adding additional valves k Priority supply of the slew drive k Loss-free slew drive acceleration k Torque control for the slew drive k Pump with an SAE diesel motor flange for compact installation

Applications are
k Compact and standard excavators k Drag line excavators k Spider excavators

Wheeled excavator travel drive with an A6VM variable displacement motor and a MHB motion control valve

LUDV control
1.5 circuit system - an open circuit slew drive (example: 15 ton wheeled excavator)

GFB + A2FE (slew drive)

2SX + 3M7 + 1M8 (control)

A6VM + MHB (travel drive)

A11VO + A10VO (travel and implement hydraulics) TH6 (pilot control units)

Particularly advantageous system for excavators that are used as material loading machines or those that perform lifting functions
The implement hydraulics are identical to the 1 circuit LUDV system, however the separate open circuit slew drive pump provides the following features: k Independent slew drive function with absolute priority k Favourable boosting, system cooling and filtration via the slew drive pump k Higher pressures are permitted on the slew drive than the main circuit, therefore, it is possible to utilise a smaller slew drive motor k Defined power allocation to the slew drive k Additional auxiliary actuators can be supplied by the slew drive pump via open center control valves

Applications are
k Compact and standard excavators k Telescopic excavators k Excavators for material loading operations

A11VO implement pump with an A10VO slew drive pump

LUDV control
1.5 circuit system - closed circuit slew drive (example: 20 ton wheeled excavator)

GFB + A2FE (slew drive)

1M7 + 5M7 (control)

A6VM + MHB (travel drive)

A11VO + A4VG (travel and implement hydraulics) TH6 (pilot control unit)

k Loss-free acceleration and deceleration of Used in machines where particular the slew drive results in lower cooling importance is placed on effective slew requirements drive functions The implement hydraulics are identical to the 1 circuit LUDV system, however the separate closed circuit slew drive pump provides the following features: k Independent slew drive function with absolute priority k Good utilisation of the permissible pressure level in the slew drive k Particularly effective slew drive due to the direct connection between the pump and slew drive motor without any restriction points k Higher pressures are permitted in the slew drive than the main circuit, therefore, it is possible to utilise a smaller slew drive motor k Defined power allocation to the slew drive and limitation by the sensitive DWD slew drive control k Energy reclamation when decelerating the slew drive due to the closed circuit k Adjustable basic decelerating torque

Applications are
k Standard excavators k Excavators for material loading operations k Telescopic excavators

Mining excavators
Multi-circuit 6/3-way open center system (example: 100 to 800 ton crawler excavator)

GFB + A2FE (slew drive)

GFT + A4VSE (travel drive)

3MO (control)

3MO (control))

3MO (control)

PVG + A4VSO + A4VG (travel and implement hydraulics)

TH6 (pilot control units)

Multi-circuit open center control systems for machines up to 800 tons in operating weight k Open or closed circuit slew drives k Single pumps with a displacement volume of up to 1000 cm3 per revolution k Electronic load limit control for the entire power limitation control system k Valve blocks for flows up to 1600 l/min per valve section k Simple design, easy system matching and direct control relationships k Good torque control with load feedback k Easy assembly and logic linking via the electro-hydraulic control of the directional valves k Comfortable control without noise and temperature transmission into the operators cab k Hydraulic fan drives with electronic control

k Travel and slew gearboxes matched to the long service life requirements k Proven components with a long service life k Experience gained over many years

Applications are
k Mining excavators

Fan drive
Drive with a fixed displacement pump
Thermo-pressure valve type MHDBDT

External gear pump with integrated priority flow divider and maximum pressure limitation Data sheet RE 10046 External gear motor for fan drives, fan is mounted separately

LS B A

Thermo-pressure valve MHDBDT 06 Data sheet RE 64309 Cooling power is also electronically controllable via the MHVDL proportional valve and fan electronics Data sheet RE 29878

S Fan motor MF2G2

Fan wheel drive power 3...10 kW

Thermo-pressure valve MHDBDT 06

Drive with variable displacement pump, electronic control

Supply voltage U=24V / 12V Temperature option Ambient air temperature Super charger air temperature Retarder Variable displacement pump

Control electronics MHVDL

Variable displacement pump A10VO...DRG (ED) Data sheet RE 92701 Internal gear motor MGF2 or axial piston motor A10FSM Data sheet RE 91180 Fan electronics Data sheet RE 29878 Cooling power is also hydraulically controllable with the MHDBDT 06 thermo-pressure valve Data sheet RE 64309

Oil cooler
U

Cooling medium

S A10VO Fan wheel Fan motor

L1

Fan wheel drive power 6...30 kW Fan electronics MHVDL

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Electronics
Electronic speed sensing control with additional functions
BB-3 Software Bodem Pre-set diesel Mode 1 2 3 RPM Hoist load increase Work Temperature Brake light Travel pedal with lock

BB-3

RS 232

Diagnostics Parameter setting Process monitoring

MC7 + Software GLB

Position actual value

Position command value

Actual RPM

Diagnostics display Hoist load increase

STM

Variable displacement pump A11VO + A4VG

Mechanical injection pump Electrical actuator

k Optimum conversion of the drive power with changing operating conditions k Programmable power modes k Safety monitoring

Microcontroller MC7 + Software GLB

for RPM dependent control of hydraulic pumps Data sheets RE 95050, RE 95072

Encapsulated potentiometer GP
for the acquisition of the accelerator pedal position Data sheet RE 95037

Adjustment motor STM

for adjusting the diesel injection pump Data sheet RE 95035

Impulse detector ID/HD

for the inductive acquisition of speeds, e.g. diesel motor RPM ID see RE 95038 HD see RE 95042

Pressure reducing valve DRE

for the proportional conversion of the GLB signal into a pilot pressure Data sheet RE 29181

Control box BB-3

for diagnostics and parameterisation in conjunction with the MC microcontroller Data sheets RE 98080, RE 29798

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Electronics
Electronic control of directional valves

k The pilot control components can be located wherever required k Low installation requirements k The machine operator is not subjected to heat or noise k Simple operation, low forces required k Easy storage and reproduction of characteristic values k Easy matching of the unit characteristics

Digital amplifier MHVDO 6

with 6 switched outputs Data sheet RE 29871

Microcontroller MHVD 4
with 4 proportional outputs and up to 4 switched outputs Data sheet RE 29872

Microcontroller MHVO 18
for up to 18 proportional outputs and up to 16 switched outputs Data sheet RE 29884

Electronic remote control THE 6

Data sheet RE 29771

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Brakes
Hydraulic remotely powered braking system for wheeled excavators Compact design
k Piping reduced to a minimum k Parking brake electrically actuated k Possibility of directly mounting the accumulator
Brake pedal 2 circuit brake valve Accumulator pressure warning switch Accumulator loading valve
Additional (optional) actuators

Brake light switch

k Sensitive metering

Parking brake valve

Diesel
Diesel

Spring loaded accumulator

Compact brake block LT13, Data sheet RE 66220 Accumulator loading valve LT06, Data sheet RE 66191

Compact brake block LT17, (for mounting in the drivers cab) Data sheet RE 66222

Modular design
k Components have a low space requirement
Brake pedal

k Components can be located wherever required k Sensitive metering

2 circuit brake valve Brake light switch

k Quickly ready for operation

Accumulator pressure warning

Additional (optional) actuators

Parking brake valve

Accumulator loading valve

Diesel
Spring loaded accumulator

1 circuit remotely powered brake valve LT05, Data sheet RE 66144

Inching brake valve LT31, Data sheet RE 66226

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Steering
Hydrostatic steering for wheeled excavators Steering unit type LAGC
Nominal sizes 50 to 630 Series 1X Nominal pressure 175 bar Maximum flow 63 l/min Data sheet RE 14365

k Integration of all of the valves required for the hydrostatic steering circuit that are needed to protect the steering unit, pump and steering axle k Easy steering during servo operation k Emergency steering facility provided k Low noise k More flexibility for the designer k Extremely good power to weight ratio

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Installation examples

Drag-line excavator drive with a tandem pump A4VG and a fixed displacement pump A2FO

Slew drive with a plug-in fixed displacement motor A2FE and slew gear box GFB

Compact excavator drive with a variable displacement pump A8VO and gear pump G2

Axle drive with a variable displacement motor A6VM and motion control valve MHB

Mining excavator drive with variable displacement pumps A4VSO 750 built onto a pump splitter gear box GFC Track drive with plug-in variable displacement motor A6VE and turas gear box GFT
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Components

Variable displacement double pump A8VO with a large auxiliary drive which is fitted with a variable displacement pump A10VO for open center control systems Data sheets A8VO: RE 93010, A10VO: RE 92701, G2: RE 10030

Variable displacement pump A11VO with a diesel motor mounting flange and built-on slew drive pump A4VG...DWD for load sensing systems Data sheets A11VO: RE 92500, A4VG: RE 92005

Control block 7M8 for open center control systems Data sheet RE 64294

Control block M7 for LUDV load-sensing systems Data sheet RE 64287

Plug-in variable displacement motor A6VE with integrated motion control valve for crawler excavator turas drives Data sheet RE 91606

Variable displacement motor A6VM with built-on motion control valve MHB for wheeled excavator axial drives Data sheets A6VM: RE 91604; MHB: RE 64317

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Components
Turas drive GFT with plug-in variable displacement motor A6VE optionally with plug-in fixed displacement motor A2FE For further information see data sheet RE 77110 Plug-in switching motor A10VEC motion control valve and pressure safety integrated into the connection plate For further information see data sheet RE 91710

Slew drive GFB with plug-in fixed displacement motor A2FE For further information see data sheet RE 77201

Variable displacement double pump A2OVO open circuit For further information see data sheet RE 93100

Variable displacement pump A4VSO open circuit For further information see data sheet RE 92050

Pipe burst safety valve MHRB For further information see data sheet RE 64623

Pilot control units TH6 and TH7 for hydraulic control For further information see data sheets RE 64551, RE 64552, RE 64555, RE 64558

Remotely powered brake LT 13 For further information see data sheet RE 66220

Drive and Control

RE 98055/04.98

Brueninghaus Hydromatik GmbH Glockeraustrae 2 D89275 Elchingen, Germany Tel +49 (0) 7308 820 Fax +49 (0) 7308 7274

Mannesmann Rexroth AG Rexroth Hydraulics Jahnstrae 3-5 D97816 Lohr am Main, Germany Tel +49 (0) 9352 180 Fax +49 (0) 9352 181040

Lohmann + Stolterfoht GmbH Mannesmannstrae D58455 Witten, Germany Tel +49 (0) 2302 877360 Fax +49 (0) 2302 877404