Hydraulics and Electronics

in Civil Engineering
1

Bosch Rexroth, with production facilities, Systems & Engineering

and sales and service companies in more
than 80 countries, is a part of Robert Your Solution Partner in
Bosch GmbH. Bosch Rexroth has approxi-
mately 26,000 employees worldwide with Civil Engineering
annual sales of $3.8 billion. In the
Americas, Bosch Rexroth has over 3,000
employees with annual sales of over $700 Why a hydraulic drive? Lower costs of installation and
million. Like no other drive technology, construction

In all aspects of Drives & Controls, Rexroth hydraulics offers outstanding Excellent controllability
is a strong partner and a comprehensive benefits:
To best serve our customers, Bosch
supplier with a broad spectrum of products High reliability Rexroth has organized industry
and systems. Our core competency of specific teams. Application
Great power density
Drive & Controls is the result of expertise in engineers specialize in a given
hydraulics, electronic drives and Compact dimensions market such as Civil Engineering.
pneumatics and the ability to integrate the Flexibility in layout With our experience in technical,
disciplines. and commercial aspects of a given
Enormous robustness
The Systems and Engineering group of industry, the Civil Engineering
Bosch Rexroth supports the most techni- Low maintenance requirements group can assist you to successfully
cally demanding applications that typically Flexibility in design and future complete each stage of a project.
include: innovative and customized upgrades
designs, long-term contracts, and a high
degree of project and contract manage-
ment. The Systems and Engineering group
is a worldwide organization with local sales
and production offices strategically
located. Application specialists concen-
trate on a given field such as Marine and
Offshore, Power Generation, Test
Machinery, Entertainment, Materials
Handling, Civil Engineering etc. Individuals
trained in each discipline interact with their
colleagues across the globe to share
experiences and technologies. Value is
created for the customers with the groups
ability to develop innovative designs and
then oversee all phases of a project from
manufacturing through commissioning. As
a result, the entire offerings of Bosch
Rexroth can be transferred directly to serve
our customers diverse needs through the
Systems and Engineering Group.
 2

Water Power

Cushman No. 1 - Hydraulic drive and controls for

The scope of our support is deter-
mined by customers needs. This
can range from highly specialized
individual components through to
the planning and commissioning
of complete systems. We have the
engineering expertise to transform
our vast product line to best suit
an applications needs. Our
capabilities include:
Complete Product Offerings
Application / Engineering
Assistance
Computer Simulation
Animation
Engineering Calculations tainter gates - Tacoma, Washington
such as FEA
Navigation
Electronic Controls
Field Service
Training
As a full service provider, the
Industrial Hydraulics Division
operates exceptionally efficiently.
Highest product quality, long
service life, fast and worldwide
local presence and the utilization
of synergies within the Bosch Olmsted Locks, Illinois
Rexroth Group generate measur-
able cost benefits for the customer. Water Management

Sidi Yacoub, Algeria

Transportation

North American Center for

Industrial Hydraulics,
Bethlehem, Pennsylvania Tower bridge, London
 3

Weirs and Dams

- Gaining Energy by Water Power

Sir Dam, Turkey

The field of waterpower offers a nized. In the case of turbine con-

diverse variety of challenges for
the drive system. Tainter gates
require large slender cylinders.
Although the cylinders move slow-
ly they must be closely synchro-
trols, high position accuracy,
short response times as well as
high dynamics are of paramount
importance. In every project, safe-
ty and reliability must be integral
to the design.

Hydraulic Drives for:

Turbine Intake Gates
Vertical Lift Gates
Tainter Gates
Blade on Runner Control
Integrated shop testing at Bosch Rexroth, Bethlehem,
PA - Hydraulic cylinders, power units and electronic
controls for Braddock Dam tainter gates.
 4

Emsworth Locks and Dam - Pittsburgh, PA

Hydraulic drive and electronic controls for
double trunnion cylinder (indexing system
that minimizes stroke length). The above
illustrates cylinders in the uppermost posi-
tion needed for flood condition.
Winfield Locks and Dam
Hydraulic drive and electronic controls for tainter gate
(synchronization of cylinders with CIMS) and hydraulic
drive for miter gate - Kanawha River, West Virginia

Hydraulic cylinders for

Harry S. Truman
(5 stage telescopic cylinder,
total stroke = 40 feet)
5

The Delta-Plan-Project for protecting the

Dutch coast at Nieuwe Waterweg, Netherlands

Ship Locks, Boat Lifts and Flood Barrages

Direct connected hydraulic cylin-
ders have become the industry
standard for the drive system for
miter gates. Hydraulic drives with
electronic controls are the ideal
choice for remote and automated
operation of locks. Conversion of drives for the
double-hook gates in the
upper head of the ship lock
Ybbs Persenbeug, Austria
Open gearing and wire ropes
to be replaced by hydraulic
power unit and cylinders.

Panama Canal - general overview

Hydraulic Drives for:

Miter Gates
Culvert Gates
Boat Lifts
Flood Barrages
 6

Layout of a display showing the current situation of the

drive system of a miter gate at the Panama Canal.

Central control system for Panama Canal

Culvert gate - display for showing the

situation of the drive system

Hydraulic power unit and

manifolds for Olmstead
Lock - Olmstead, IL

Circuit diagram of the drive unit of

a miter gate - visualized

Alarm, error and operation list

7

Movable Bridges and

Transfer Spans (Ro-Ro Bridges)
Hydraulic drive is the ideal choice
for the operation of movable
bridges due to the inherent torque
sharing capabilities and flexibility
of layout. In either refurbishments
or new designs, a hydraulic drive
offers lower initial construction
costs, high reliability, and lower
operating and maintenance costs.
The use of hydraulic cylinders for
vehicular transfer spans (Ro Ro
bridges) has become the industry
standard primarily due to redun-
dancy, safety and low maintenance
requirements.
Ro-Ro Bridge and passenger walkway in the port of Hull - Hull, Great Britain

Hydraulic power unit

and cylinders for
Donald Ross Road
Bridge - Jupiter, FL

Hydraulic Drives for:

Movable Bridges
Ro-Ro Bridges

Hydraulics for Brickell Ave. bridge -

Miami, FL
 8

520 Bridge - Evergreen Point

Bosch Rexroth supplied power
units, cylinders and electronic
controls

Piping for AIW bridge replacement

(Piping assemblies pre-fabricated at
our facility in Bethlehem, PA

Ro-safe Brake - self contained safety system

for vehicular transfer spans (ro-ro bridge)
provides redundancy to primary drive system
9

Irrigation Systems -
Creating New Living Spaces
This application group includes
storage and distribution of water
for either flood control, irrigation, Hydraulic Drives for:
potable supply, and waste. Typical
of these projects are gates under a Storage of water
large head (400 ft +). Consequently, Management of water
hydraulic cylinders are the ideal
choice to reliably exert the large Distribution of water
force required.

Bottom Outlet Gates

Irrigation systems make a contribution to convert deserts into fertile oasis.

 10

Cylinder for bottom outlet gates,

Seven Oaks Dam, California

Mud Mountain Dam Flow Control

Enumclaw, Washington - Hydraulic
drive for tainter gates and bottom
outlet gates Sidi Yacoub, Algeria
11
Cylinders for
Civil Engineering Applications
The team of engineers for Civil
Engineering applications includes
a group of cylinder designers who
have developed standards to suit
the type of project. Materials, rod
coatings, sealing technologies,
bearings, and other attributes are
optimized with our years of expe-
rience on similar applications.
Ceramax Engineered Coatings
Piston rods of hydraulic cylinders
are often exposed to extremely
aggressive environmental condi-
tions that lead to corrosion,
scratching and wear. Rexroth
Hydraudyne developed Ceramax
in the 1970s and introduced the
product to the market in 1989. To
date, over 13,000 cylinders have
been produced with this coating.
Ceramax consists of specially
selected ceramic materials and is
applied to a piston rod by a spray-
ing process. This coating is superi-
or to the traditional chrome plat-
ing in regards to its resistance
against corrosion, scratches and
other mechanical damage.
p = 10 mm
0,25 p
N N
Z Z
Output 1 Output 2
Ceramax is virtually insensitive to
dust, sand, or chemical con-
stituents coming into contact with
the piston rod. Furthermore,
sparks and particles from welding
do not adhere to Ceramax.
To meet even more challenging
demands, Ceramics Engineered
Coatings (CEC) is the next genera-
tion of piston rod protection. The
resulting properties of the coating
can be customized specifically for
an application. For example, in an
offshore oil platform, resistance
against corrosion is the driving
criteria. Whereas, in a mining
application, the environment may
be less corrosive, but a high resist-
ance to impact is required. The
properties of the coating are
achieved with both the plasma
process and the new HVOF (High
Velocity Oxygen Fuel) spraying
technology.
Ceramax Integrated Measuring
System (CIMS)
The carbon steel piston rod used
with the Ceramax coating enabled
Input Coating procedure HVOF
(High Velocity Oxygen Fuel)
Redundant CIMS MKll solution
the development of the CIMS
positioning system that offers
many advantages over the tradi-
tional linear transducers or other
external devices.
Operation of CIMS MKII
A magnetic field is created and
shaped between a permanent mag-
net and a grooved piston rod cov-
ered with Ceramax. Two half
bridged magneto-resistive ele-
ments, located in the magnet field
produce sine and cosine signals
that are the input for a tracking
phase resolver. The outputs of this
resolver are quadrature incremen-
tal counting pulses. For long dis-
tance transmission these pulses are
converted to RS422A differential
output pulses. With appropriate
cabling, shielding, impedance and
counting equipment, the result is a
simple, high quality, accurate and
reliable displacement measuring
system.
 12

Computerized Simulation Optimizes Hydraulic

Drive System Design & Performance
On critical or unique applications,
Bosch Rexroth recommends the use
of a computerized simulation to best
predict the behavior of the hydraulic
drive and moving structure. The
analysis provides an opportunity to
optimize the design before construc-
tion and alleviates potential difficul-
ties at commissioning.

The simulation may include techni-

cal calculations, such as a finite ele-
ment analysis, a geometrical model
that includes the characteristics of
the drive system and the structure,
an animated model, or any combi-
Model and FEM-investigation for a pressurized nation of these. In all cases, the
cylinder bottom segment with cylinder tube.
simulation must balance the theo-
retical results with practical realities
of real life systems as observed
through our years of experience.
Given the proper input data to
describe the structure, the predicted
results will be within 95% of the
actual performance. Furthermore,
simulation analysis is an excellent
tool to diagnose under performing
existing systems.

Numerical fluid mechanics: distribution of pres- FEM-calculation for the distribution of stress in
sure and velocity at a valve seat. the trunnion of a hydraulic cylinder.
13
Training
We offer a series of courses for the
training needs of our customers at
five different locations, as well as
custom on-site instruction.
Service
Bosch Rexroth has service centers
across the country for repair /
refurbishment of all your equip-
ment. Furthermore, a staff of field
service technicians trained in both
Course work includes tra-
ditional lectures as well as
hands-on laboratory
exercises.
Locations
Pennsylvania (BAVTS)
Bethlehem Area
Vocational Technical School
Bethlehem, Pennsylvania
Michigan (HFCC) Canada (ON)
Henry Ford Community College Bosch Rexroth Canada
Dearborn, Michigan Burlington, Ontario
Washington (SCC) Canada (BC)
Spokane Community College Bosch Rexroth Canada
Spokane, Washington Burnaby, British Columbia
hydraulic systems and electronic We have a 24 hour emergency
controls are available for installa- service hotline, 1-800-REXROTH.
tion assistance, commissioning,
routine maintenance and trou-
bleshooting.
 Location Name of Project Customer Project Type Year
Alabama Demopolis Lock U.S. Army Corps of Engineers Navigation 1992
Argentina Yacyreta Voith Hydro Inc. Water Power 1992
Arizona Roosevelt Dam Bureau of Reclamation Water Power 1993
Arkansas Arkansas Dam II Arkansas Electric . Water Power 1997
Arkansas Montgomery Point U.S. Army Corps of Engineers Navigation 2001
California Devils Canyon Voith Hydro Inc. Water Power 1990
California Grizzley Powerhouse Pacific Gas & Electric Co. Water Power 1992
California Seven Oaks Dam U.S. Army Corps of Engineers Irrigation 1998
Belize City of Belize Bridge City of Belize Movable Bridges 1991
China Shisanling Voith Hydro Inc. Water Power 1994
China Yang Zhuo Young Voith Hydro Inc. Water Power 1994
China Guang Zhou Project Voith Hydro Inc. Water Power 1997
Colorado Minidoka U.S. Bureau of Reclamation Water Power 1992
Connecticut Stamford Hurricane Barrier U.S. Army Corps of Engineers Navigation 1996
Connecticut Niantic River Bridge Connecticut DOT Movable Bridges 1989
Florida Queens Harbor Queens Harbor Navigation Lock 1990

Major Civil Florida

Florida
Florida
27th Avenue Bridge
San Pablo Creek Bridges
Sisters Creek
Florida Dept. of Transportation
Florida Dept. of Transportation
Florida Dept. of Transportation
Movable Bridges
Movable Bridges
Movable Bridges
1992
1993
1993
Florida S.W. 1st Street Bridge Florida Dept. of Transportation Movable Bridges 1993

Engineering Florida
Florida
Atlantic Avenue Bridge
Brickell Avenue Bridge
Florida Dept. of Transportation
Florida Dept. of Transportation
Movable Bridges
Movable Bridges
1993
1994
Florida SR 666 Welch Causeway Florida Dept. of Transportation Movable Bridges 1995

Projects by Florida
Florida
Florida
SR 693 Corey Causeway
SR 684 Cortez Bride
SR 688 Indiana Rocks
Florida Dept. of Transportation
Florida Dept. of Transportation
Florida Dept. of Transportation
Movable Bridges
Movable Bridges
Movable Bridges
1995
1995
1995
Florida SR 758 Siesta Key Florida Dept. of Transportation Movable Bridges 1996

Bosch Rexroth- Florida

Florida
Florida
SR 80 Southern Blvd.
SR 706 Bridge
SR 816 - Oakland Park Blvd.
Florida Dept. of Transportation
Florida Dept. of Transportation
Florida Dept. of Transportation
Movable Bridges
Movable Bridges
Movable Bridges
1995
1996
1996
Florida A1A / 17th Street Causeway Florida Dept. of Transportation Movable Bridges 1997
USA Florida
Florida
Donald Ross Road Bridge
Structures 355A & 355B
Palm Beach County
U.S. Army Corps of Engineers
Movable Bridges
Irrigation
1998
1997
Florida Venetian Causeway Florida Dept. of Transportation Movable Bridges 1998
Florida Ulmerton Road SR688 Florida Dept. of Transportation Movable Bridges 1998
Florida SW 2nd Avenue Bridge, Miami Florida Dept. of Transportation Movable Bridges 2002
Georgia Rocky Mountain Voest Alpine Water Power 1992
Hawaii Wailuku Voith Hydro Inc. Water Power 1992
Idaho Lucky Peak Reservoir IMPSA International Water Power 1985
Idaho Horseshoe Bend Voith Hydro Inc. Water Power 1994
Illinois Olmsted Locks & Dam U.S. Army Corps of Engineers Navigation 1999
Illinois Calumet Tunnel System Chicago - MWRD Irrigation 2000
Indiana ARAMCO Bachman Industries Water Power 1991
Iowa Keokuk Voith Hydro Inc. Water Power 1991
Italy Rocky Reach Project Chelean County, WA. Water Power 1997
Illinois Olmsted Lock & Dam U.S. Army Corps of Engineers Navigation 1994
Maine Brassau Dam Voith Hydro, Inc. Water Power 1989
Maine Central Maine Power Central Maine Power Water Power 1997
Massachusetts Deerfield # 5 New England Power Service Co. Navigation 1992
Massachusetts Route 6 New Bedford Mass. Highway Dept. Movable Bridges 1995
Mexico Chilapan Project Voith Hydro Inc. Water Power 1994
Michigan St. Marys Falls U.S. Army Corps of Engineers Water Power 1998
Michigan Benton Harbor Bridge Michigan Dept. of Transportation Movable Bridges 2000
Mississippi Popps Ferry Bridge Harrison County Board, Mississippi Movable Bridges 1996
Missouri Harry Truman Dam U.S. Army Corps of Engineers Water Power 1992
Missouri Osage Voith Hydro Inc. Water Power 1991
Missouri Lock # 27 U.S. Army Corps of Engineers Navigation 1997
Nevada Lahonton Dam Voith Hydro Inc. Water Power 1989
New Jersey Victory Bridge NJ Dept of Transportation Movable Bridges 1988
New Mexico Aibquiu Dam U.S. Army Corps of Engineers Water Power 1998
New York West Delaware Tunnel Voith Hydro Inc. Water Power 1988
New York Shinnecock Locks Suffolk County NY Navigation 2002
Ohio Belleville Lock U.S. Army Corps of Engineers Navigation 2000
Oklahoma Kaw Dam IMPSA International Water Power 1988
Oregon Bonneville Headgate Cylinders U.S. Army Corps of Engineers Water Power 2002
Oregon Bonneville Project Voith Hydro Inc. Water Power 1998
Pennsylvania Allegheny Lock & Dam # 5 U.S. Army Corps of Engineers Navigation 1991
Pennsylvania (Braddock) Dam No. 2 U.S. Army Corps of Engineers Navigation 2001
Pennsylvania Emsworth Vertical Lift Gate U.S. Army Corps of Engineers Navigation 2001
Panama Miter Gate Panama Canal Commission Navigation 1995
Panama Cylindrical Valve Panama Canal Commission Navigation 1995
Panama Windless System Panama Canal Commission Navigation 1995
Panama Rising Stem Valve Panama Canal Commission Navigation 1999
Rhode Island Roosevelt Hydro Dam Voith Hydro Inc. Water Power 1992
South Carolina Dearborn Project Voith Hydro Inc. Water Power 1995
South Carolina Santee Cooper South Carolina Public Service Navigation 1998
South Carolina Wapoo Creek South Carolina D.O.T. Movable Bridges 2000
South Dakota Gavins Point Dam U.S. Army Corps of Engineers Water Power 1982
Taiwan Mingtan Pumped Storage Project Voith Hydro Inc. Water Power 1981
Tennessee Large Cavitation Channel Voith Hydro Inc. Water Power 1989
Tennessee Raccoon Mountain Tennessee Valley Authority Water Power 2000
Texas Austin Hydro Voith Hydro Inc. Water Power 1992
Texas Inks Project Voith Hydro Inc. / LCRA Water Power 1997
Texas Buchanan Project Voith Hydro Inc / LCRA Water Power 1998
Virginia AIW Bridge Replacement Project U.S. Army Corps of Engineers Movable Bridges 2002
Washington Cushman No. 1 City of Tacoma Water Power 1990
Washington South Fork Tolt River Voith Hydro Inc. Water Power 1994
Washington Mud Mountain Dam U.S. Army Corps of Engineers Irrigation 1993
Washington South Fork Tolt River Voith Hydro Inc. Water Power 1994
Washington Ice Harbor Dam U.S. Army Corps of Engineers Water Power 1994
Projects coordinated by Bosch Washington Bonneville Project U.S. Army Corps of Engineers Water Power 1998
Rexroth organizations based in other Washington Lake Washington Ship Canal U.S. Army Corps of Engineers Navigation 2001
Washington SR-520 Bridge Evergreen Point Wash DOT Movable Bridges 1994
countries are not included. Washington Cedar River Bridge Boeing Movable Bridges 1998
West Virginia New Martinsville Dam City of New Martinsville Navigation 1988
West Virginia Winfield Locks & Dam U.S. Army Corps of Engineers Navigation 1995
Bosch Rexroth Corporation
Industrial Hydraulics
2315 City Line Road
Bethlehem, PA 18017-2131
Telephone (610) 694-8300
Facsimile (610) 694-8467
www.boschrexroth-us.com

Bosch Rexroth Corporation

Corporate Headquarters
5150 Prairie Stone Parkway
Hoffman Estates, IL 60192-3707
Telephone (847) 645-3600
Facsimile (847) 645-6201

Bosch Rexroth Corporation

Electric Drives and Controls
5150 Prairie Stone Parkway
Hoffman Estates, IL 60192-3707
Telephone (847) 645-3600
Facsimile (847) 645-6201

Bosch Rexroth Corporation

Linear Motion and
Assembly Technologies
816 E. Third Street
Buchanan, MI 49107
Telephone (616) 695-0151
Facsimile (616) 695-5363

Bosch Rexroth Corporation

Pneumatics
1953 Mercer Road
Lexington, KY 40511-1021
Telephone (859) 254-8031
Facsimile (859) 281-3491

Bosch Rexroth Corporation

Mobile Hydraulics
1700 Old Mansfield Road
Wooster, OH 44691-0394
Telephone (330) 263-3300
Facsimile (330) 263-3333

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