Bosch Rexroth AG The future starts now Electronification enables new hydraulic solutions | MOBILE 2017 151

Chapter 3: Automation

The future starts now

Electronification enables new hydraulic solutions

Abstract
For the electronification of the open circuit, Bosch Rexroth pursues a concept that
uses the hydraulic characteristics of pumps supported by electronics and software.
This reduces the hardware variation of hydraulic pumps and the number of sensors
needed. The straightforward software structure enables robust results and faster
optimization of customer machines. This concept significantly reduces system costs
and engineering expenses.

Edwin Heemskerk
Senior Engineer New Technologies

Michael Brand
Project Electronification

Karlheinz Vogl
Sales and Industry Sector Management Construction Machines

Automation
152 MOBILE 2017 | The future starts now Electronification enables new hydraulic solutions Bosch Rexroth AG

Electronification of construction machinery

In order to reduce exhaust emissions and increase productivity, manufacturers have con-
tinuously increased the electronification of their mobile machinery. In the process, most of
the times hydraulic components were enhanced with solenoid valves and sensors in order
to improve the function.

Adaption of dynamics
Power modes
Energy saving
Flexibility
Time ramps
Priority
Flexible characteristics
Mode detection

Fig. 1: Added functions through electronification

Electrohydraulic pump control

The controller axes of the open circuit pumps have historically been influenced strongly
from two directions:

From the standard excavator with complex flow and pressure controls with power
overrides on high pressure units.
From the tractor with robust load-sensing and pressure control functions for medium
pressure units.

For the dynamics and stability of the function, different orifices were used in hydraulic con-
trollers or a large enough hysteresis was created depending on the application so that the
behavior was controllable under consideration of all production tolerances (Fig.2).

a
X qV

b
c
L L1

t
d
Target flow
Actual flow dynamic
S
Actual flow smooth
L2

Fig. 2: Modification of the dynamic of an EPDS pump by means of orifices and spring values (a through d)
Bosch Rexroth AG The future starts now Electronification enables new hydraulic solutions | MOBILE 2017 153

This design approach increased the hardware variation of the pump. A subsequent modifi-
cation of the pumps characteristics through software was only possible in part. As stability
under all conditions was the focus, these solutions only achieved a limited dynamic.

The variable displacement pumps used in open circuit for working hydraulics up to now
have various controllers depending on the application and architecture, for example for
flow control, pressure control or torque limitation. These controllers are generally imple-
mented hydraulically and are electronically overridden in part. They are hydromechanically
complex and interactions between the controller axes exist when they work in parallel.

Novel approach: Electronified open circuit

The continued electronification of mobile working machines from diesel engines to the
hydraulic pump and valves to safety functions opens up the opportunity for a completely
novel approach, electronified open circuit, EOC. When electronifying the open circuit pump,
Bosch Rexroth chose the approach of using a specially designed, uniaxial, electronically
controllable hydraulic actuator. A pressure sensor and a swivel angle sensor detect the
pump state. All controlling and regulating tasks are handled exclusively by software in an
electronic control system (Fig.3). Adjustments are made through software parameters.

The swivel times of modern displacement pumps today, depending on the size, are less
than 50milliseconds and thus provide a strong dynamic. Two signal conversions are a
result from the electronification. On the one hand in the area of the sensor system, on the
other hand in the area of the actuator. The processing time and adjusted cycle time in the
electronic control unit act as variable dead time in the dynamic chain. The electronic con-
troller concept achieves a strong dynamic due to optimized reaction times through every
single link in the process chain and through the software. Thus the EOC approach follows
the principle of the greatest possible simplicity with the strongest possible dynamic.
At the same time, the software implemented on the provided controller encapsulates the
complexity. Communication with the vehicle control system takes place over the standard
CAN-Bus interface.

Automation
a
qV

Up A P
Vg min
t

Vg max Target flow

U Actual flow dynamic

S M T1 T2 T3 Actual flow smooth

Fig. 3: Modification of the dynamics of an EOC pump with the help of software parameters (a)
154 MOBILE 2017 | The future starts now Electronification enables new hydraulic solutions
A B
p p
Vg Vg
Pressure-independent Flow-independent
flow control pressure control or
pressure limitation
Fig. 4: Typical control pattern for a variable pump
Some working hydraulics architectures require a hydraulic
interface to the pump, such as the LS control, especially
in combination with mechanically or hydraulically actuated
valves. This interface can also be electronified (see article
e-Load-Sensing Adaptive working hydraulics for tractors).
EOC offers all of the functions that were previously avail-
able hydraulically and that were electronically overridden in
part.
EOC can be used in the vehicle architecture without major
adjustments in the applications that already use the elec-
tronic overriding. This was apparent when the demonstra-
tor for future technologies was upgraded to an A10VO EOC
together with the Tampere University of Technology for
MOBILE 2017. The electronification of the pump not only
reduces the complexity and variation of the controller and
thus the hardware but, through software, also brings along
with it functional benefits and an additional degree of free-
dom in the system design.
Bosch Rexroth AG
C D
p Cmd
Vg t
Power or Time based
torque limitation dynamic parameters
Variable power control
The available power for the hydraulic system depends on
the supplied power of a combustion engine in the form of
the engine speed, which is influenced by different variable
operating conditions, the power requirements of other
loads and sometimes additional power from hybrid sources
(see article Electric drivetrains The right solution for
every power level). The EOC software can modify the
maximum power limit in a highly dynamic way, proactively
avoiding an overloading of the diesel engine. This also in-
cludes the stalling protection, which previously had to be
realized as a drift compensation with dynamic disadvantag-
es. Moreover, EOC allows for a more precise utilization of
the power limit compared to a non-hyperbolic spring type
power controller and thus a higher degree of productivity.
Energy efficiency
Hydraulic systems work with pressure differences between
the pump and loads that produce power losses. They are
required in order to maintain or stabilize the functions in
the undersupply, power or oil flow, but produce power
losses on the other hand. EOC reduces these differences in
pressure. Along with the significantly smaller losses in the
controller itself and through the elimination of the linkage
of the hydraulic controller axes, the efficiency of the overall
function during power operation increases by 20%.
Bosch Rexroth AG The future starts now Electronification enables new hydraulic solutions | MOBILE 2017
Load feeling
The controller dynamics of the EOC allows for very dynamic
limitation of the pump pressure. As a result, function-
dependent pressure modulation in operation is possible
based on operator commands or time. By limiting the rate
of the pressure increase and the resulting defined energy
buildup, the machines behavior becomes significantly
more comfortable with the same performance. In total, a
combination of flow control and variable pressure limita-
tion facilitates intuitive operability which has proven itself
on the market in the Rexroth solutions Virtual Bleed Off
(VBO) (see article Prepared for the excavator market of
tomorrow VBO 2nd generation), pQ-Control and Electro-
hydraulic Flow Matching (EFM) with load feeling. Through
this for instance, the open center control proven in excava-
tors can be adapted using a closed center solution without
the losses in the neutral gallery. It furthermore eliminates
the energy losses during the acceleration of the swing
drive. Manufacturers thereby improve the efficiency of their
machines.
Simplified logistics
Manufacturers previously needed different pump controller
hardware and settings for different machine types. As the
controller behavior of the EOC is produced in the software,
significantly fewer pump variants cover the same number
of machine variants in series production. This streamlines
OEM warehousing and logistics.
Simplified machine design and assembly
Electric wires are easier and faster to install than hydraulic
hoses with the required flanges. As a result, installation
processes on the machine are much easier and consequent-
ly less expensive.
155
Variable dynamics /modes
The electronified solution with an EOC controller offers the
same high dynamics as hydraulic solutions with significantly
higher flexibility. Using parameters, the dynamics can be
customized to the individual function, work task or opera-
tors preference. Software variably controls the pumps
performance depending on the function performed or the
diesel engine speed.
Safety
With previous hydraulic realization, working functions could
attain functional safety of up to performance level PLc
according to ISO13849. Higher performance levels require
an electronic feedback as a testing channel. Without further
change in technology, EOC is also suited for higher perfor-
mance levels.
Improved disturbance response
EOC includes additional influencing variables such as
oil temperature and adjusts the dynamics of the system
accordingly. Manufacturers thereby avoid oscillation and
expand the design limits.
Regulation in two quadrants
Mooring-capable pumps, in other words pumps in an open
circuit having the capability for proportional flow rate rever-
sal, still are not too common in the mobile sector. In order
Automation
to control these hydraulically, high efforts are required
which are only justified for larger numbers of machines.
With the electronic solution, pump control in two quad-
rants without additional hardware is possible with only an
expansion of the software. This means that, in the future,
hybrid systems can be built as plug and play solutions.
156 MOBILE 2017 | The future starts now Electronification enables new hydraulic solutions Bosch Rexroth AG

Summary
With the EOC, Rexroth is currently demonstrating how to
master the dynamics of pumps, by using the hydraulic prop-
erties in a positive way and support it with electronics and
software. The concept cuts down on sensors and reduces
the hardware variation for the hydraulic pump. Together
with software the functionalities and dynamic requirements
of modern robust working hydraulics are achieved.
EOC reduces system costs and the time required for opti-
mization. Along with the results on the pump test stand,
the first tests of an EOC pump on the Tampere University
of Technology test vehicle demonstrate the advantages
described above.

This approach also allows for more flexible development

strategies for the OEM. The robust plug and play solutions
can be integrated into the machine without a great deal of
effort. The hydraulic control functions are encapsulated in
the software and are driven by the vehicle control system
via the CAN Bus. Manufacturers can incorporate them into
their own electronics infrastructure and consequently
adjust machine behavior themselves.