134 Mobile 2006 Telehandlers Bosch Rexroth AG Bosch Rexroth AG Telehandlers Mobile 2006 135

Costs Reaching higher with

Continuous acceleration up to 40 km/h while maintaining the full startup
tractive force is demanded by the market. The economical solution from Telehandlers Drive and Control
Rexroth in cooperation with leading gearbox and axle manufacturers is
the robust shift on fly shifting concept, which can be adapted to various Solutions from Rexroth
sizes of telehandlers, tractive efforts and axles. This, with the accustomed
small installation space and a variety of transmission ratios.
Important progress is currently being made in the further development of te-
lehandlers. Rexroth largely contributes to this development. New travel drive
Function concepts for the affordable replacement of standstill gearboxes; new, exten-
sive electronic control concepts for the entire vehicle together with specially
The core function of a telehandler is the precise and fast maneuvering of
matched pumps, motors, valves and sensors support the manufacturers in
the jib and, thus, the load. The optimal matching of and between joystick,
their push forwards.
variable pump and valve block is the key to this functionality. For this rea-
son, the coordinated development of new joysticks with their yet-again
expanded ergonomic grip variants, new valve blocks and variable pumps
is of high priority for Rexroth. This has now been further extended by tele- Carsten Vogt
Elchingen (D)
handler-specific software solutions which offer new functions or realize
familiar functions more easily. Co-authors

Philippe Fillon
Vnnissieux (F)

Thierry Dumont
Schwieberdingen (D)

Thomas Krumrey
Horb (D)
136 Mobile 2006 Telehandlers
1 Faster: New drive con-
cept for speeds up to 40
km/h
Today, most telehandlers with hydro-
static travel drive are equipped with a
standstill gearbox. At the same time,
however, demands are growing for
the ability to drive through the entire
tractive effort range and speed range
of up to 40 km/h without restrictions.
Working together with renowned
gearbox manufacturers, Rexroth now
offers affordable shifting concepts
which facilitate comfortable shifting
during travel. This, while maintaining
the flexibility in the selection of the
starting tractive effort and still keep-
ing the installation space small.
Presented here as an example is a
functional solution equipped with
the Dana 367 gearbox (Fig. 1). The
mechanical basis is the Dana 357
standstill gearbox, which is widely
used in telehandlers. This gearbox has
a number of possible ratios, compact
design and can be combined with
many axles.
Fig. 2: Shift on fly hardly changes the vehicle
concept: same DA pump, motor only with a
different control, gearbox dimension nearly
identical.
Travel Inching Diagnostics,
direction pedal parameterization
process monitoring
Diesel engine A4VG.DA
Gearbox management
Hydro motor management
Diagnostics
Fig. 1: Dana 367 shift on fly gearbox with mounted A6VM hydraulic motor: as compact and flexible
as the well-known 357 gearbox.
The basic conceptional additions
for shifting which can be performed
either by the driver or triggered auto-
matically are:
Integration of speed sensor and
synchro rings in the gearbox for
fast synchronization of the different
gear velocities during the shifting
operation.
Electronically controlled A6VM
motor with the ability to swivel to
zero displacement for brief hydrau-
lic decoupling and active gear
acceleration (speed shifting) in
order to accelerate the shifting op-
eration to well under one second.
Fully automatic control of the shift-
ing operation by means of a small
Bosch Rexroth AG
Gear Gear
selection control
lamp
RC2-2
+ AS/AGSD
speed
4/2-Valve
A6VM.EP
and inexpensive electronic Rexroth
BODAS RC2-2 controller which, in
addition to jolt-free shifting, also
ensures that the shifting operation
is initiated only while the gearbox is
in its safe shifting window.
1.1 Simple: Vehicle layout is
nearly the same
The changes to the travel drive are
limited to the gearbox and the motor
(Fig. 2). A purely hydro-mechani-
cally controlled A4VG.DA or A10VG.
DA may still be used as a drive pump.
Above all, the installation space re-
mains just as compact as before when
using the Dana 367 gearbox.
Bosch Rexroth AG
1.2 Comfortable: Fast, soft
shifting
Extensive testing on Rexroths own
development vehicles and roller test
stands (Fig. 3) and during a series of
commissioning operations onsite with
customers confirm the shifting com-
fort. In all relevant load states (uphill,
downhill, both loaded and unloaded),
the solution provides the driver with
jolt-free operation with the same level
of quality experienced with power
shifts. The average shifting speed is
only 0.6 seconds.
Due to the minor additions, this so-
lution, which is known by the name
shift on fly, is an affordable im-
provement in comfort in travel drives
of modern telehandlers. All necessary
components, including the software,
are available on short notice from
Rexroth and Dana as complete solu-
tion packets.
1.3 Upgradable: Increase in
comfort with a fully electronic
solution
This semi-electronic travel drive so-
lution can also be easily upgraded to
a fully electronic travel drive. For this
purpose, Rexroth offers a variety of
tested solutions based on the BODAS
RC4-4 and RC6-9 controllers and
the AS/DRCD (Application Software
DRive Control, Version D) travel drive
software.
Having integrated pump, motor and
diesel engine control means a con-
siderable increase in the use of tele-
handlers. The ability to intervene in
the acceleration behavior, maximum
speeds and safety functions made pos-
sible through electronics, facilitates
the optimal and safe adaptation of the
Telehandlers Mobile 2006 137
Fig. 3: Extensive testing of the shift on fly gearbox in Rexroths own experimental vehicles on the
Rexroth roller test-bench.
travel behavior to various work tasks. (for all sizes) considerably improves
The corresponding Rexroth BODAS the freedom of design.
software modules have already been
Matching the new selection of sizes
successfully used in various vehicles.
45, 65, 85, 110, 145, 175, 210, 280 cm3/
In telehandlers with rotating upper
revolution for the A4VG, correspond-
structures for instance, the targeted
ing new A6VM motors of series 71
control of the travel drive as a func-
are now available. These motors dem-
tion of hook-load management and
onstrate the same high pressure level
jib management leads to a consider-
over all the sizes 60, 85, 115, 150, 170,
able increase in performance with
215 and 280 cm3/revolution.
nearly the same steel construction.
Rexroth has improved the efficiency
of both the A4VG as well as the
2 More compact: The new A6VM in order to better transfer the
pumps and motors primary drive power and minimize
the amount of cooling required. This
Always faster and smaller is a de-
drops fuel consumption in two ways.
mand constantly made by vehicle
Performance of both the pump as well
manufacturers with regard to drives.
as the motor are also improved with
The energy density of the drive units
regards to speed endurance strength
plays an important role, particularly
and noise.
in the small installation spaces found
on telehandlers. The A4VG high-pres-
sure pump of the new series 40 with
its nominal and peak pressures now
increased by 50 bar to 450/500 bar
138 Mobile 2006 Telehandlers
3 Far reaching: Rexroth
working hydraulics for
telehandlers
In addition to the solutions for travel
drives, Rexroth also offers an exten-
sive program of products for working
hydraulics. The most important new
developments in this area include the
SX14NGE flow sharing (LUDV) valve
for various electronic control con-
cepts, the matching 4THE5 electronic
joystick and the A10VO.EK working
pump for electronic load limiting
control.
3.1 Flexible and clever: The
SX14NGE flow sharing (LUDV)
valve with 4THE5 joystick
In addition to load-independent flow
sharing (LUDV), the new SX14NGE
(Fig. 4) offers full freedom of control:
Either directly from the joystick via
PWM signals or via CAN bus (Fig. 5).
Together with the just as flexible,
new 4THE5 joystick either a central
control concept (with BODAS RC
controllers) can be implemented or
a decentral control concept between
input device and valve.
The load-independent flow sharing of
the SX14 ensures that the movements
of the telehandler are performed
Fig. 4: New SX14NGE electronic pilot spool
with flow sharing (LUDV) technology.
Bosch Rexroth AG
with the same precision at all loads,
i.e. independent of various pressure
and flow conditions. The simpler and
more reliable control behavior associ-
ated with this approach increases the
operators productivity and reduces
fatigue.
Practical technical details, in addition
to the good control characteristic of
the SX14 pilot spool, are
an integrated priority valve in the
input section for simple supply of
Fig. 5: SX14NGE facilitates control via both
the steering system, PWM current signal (top) and CAN bus
(bottom) directly by the joystick as well as via
an integrated pilot oil supply both the BODAS controllers.
for the valves own pilot spool as
well as for external consumers such
the variety of switches, buttons, rock-
as the joystick,
ers and rollers possible in the handles.
an integrated pressure override In this way it is possible to operate
valve for safety functions which all of a telehandlers functions, such
centrally switch off the above men- as telescoping, fork movements and
tioned pilot oil supply, gripper, comfortably and ergonomi-
compact dimensions, with all con- cally with one hand. The other hand
nections on the same side. remains on the steering wheel.
Although the SX14NGE was devel- This broad range of variants with
oped with focus on electronic control, optimal ergonomics is based on the
it is also available with mechanical modular 4THE5 joystick base module
and hydraulic control elements. The and the EC2000 and EC4000 handle
SX14 is manufactured both in USA as series. The selection of handles will
well as in Europe in order to keep the
supply distances to the primary areas
of telehandler production short.
3.2 Precise: The new BODAS
4THE5 joystick
For controlling the control block,
(above all the SX14NGE), Rexroth
offers a full range of joystick variants
based on precise and redundant Hall-
effect sensors. Three different signal
variants are available: Pulse-width-
modulated (PWM), power signal or Fig. 6: BODAS 4THE5 electronic joystick
CAN bus. In addition to the normal with EC4000 ergonomic handle for direct or
indirect control of the SX14NGE pilot spool.
axes of the joystick, this also applies to
Bosch Rexroth AG Telehandlers Mobile 2006 139

again be expanded in the next future EC 2000 EC 3000

with the new EC3000 handle series
(Fig. 6 and 7).

3.3 Solid: The SX14 mechani-

cal-hydraulic control variant with
4TH5
For telehandlers which do not yet
need the increased functionality avail- EC2000+ EC4000
able through electronics, Rexroth
continues to offer the proven SX14
control block with mechanical and
hydraulic control as a cost-effective
base solution. For hydraulic control,
the 4TH5 joystick valve is available.
Development continues here as well: Fig. 7: The EC2000 and EC4000 ergonomic handle series offer a variety of combinations with
Rexroth engineers are focused on cost integrated switches and rollers. The new EC3000 handle series extends the selection.

optimization and further improve-

ment of the basic functions. The re-
engineered SX14 control block, which
will be available early 2008, will have
lower fluid resistance and simplified
pressure-relief valves. Through full
compatibility with existing inlet and
outlet sections as well as previous
SX14 valve slices, extension or re-
placement is possible at any time.
valves and counterbalance valves as
complete control blocks and also as
cartridge valves. The high pilot ratio
of 4:1 allows low working pressures
and, thus, low energy losses. The high
flexibility of the control block solu-
tions enables simple integration of
a wide array of additional functions
such as, for instance, drive stability
controls. Developments up to now
have focused on systems for level con-
trol, telescope control and steering,
all with compact design and low costs
and high power density.

3.4 Diverse: Rexroth compact

valves Attachement Systems:
Diverter valves Pump System:
With the take over of the Oil Control Integrated manifolds In-loader & un-loader
Group, Rexroth can now, with its ex- In-line check valves Integrated manifolds

tensive programm of compact valves,

Boom Lift & Extension: Axle Lock:
generate complete hydraulic solutions Load controls Integrated manifolds
for telehandlers from a single source Regenerative manifolds
(Fig. 8). The specialist for compact Ride Control:
Load Sensing System:
hydraulics has accompanied telehan- Fork Tilt: Solenoid cartridge valve
Pressure controls
Load controls Integrated manifolds
dlers since their invention with a vari- Flow controls
ety of valve solutions. Thus, Rexroth is In-line check valves and
Outriggers & Levelling: shuttles Steering & Braking:
backed by extensive experience in this PO check valves Pressure reducing valv.
area as well. Counterbalance valves Pilot System: Solenoid cartridge valv.
Directional valves Pressure reducing valv. Priority flow control
The core of the offerings available for Integrated manifolds Integrated manifolds Integrated manifolds
telehandlers consists of load holding
Fig. 8: Rexroth offers a variety of telehandler-specific valve solutions.
140 Mobile 2006 Telehandlers Bosch Rexroth AG

3.5 Maximum diesel power:

A10VO axial piston pump with
electronic load limiting control
The load limiting control has been
a standard part of the travel drive
for quite some time. Either through
the integrated, continuous power
monitoring within the DA-controlled
A4VG and A10VG pumps or through
the integrated load limiting controller A10VO.EK RC 2-2
in the AS/DRCD travel drive software
with electronic systems. Fig. 9: New A10VO.EK with electronic load limiting control by the BODAS RC2-2 controller.

With working hydraulics, this is also

possible in the new series 53: A10VO A10VO is again available. The optimal reduced fuel consumption, low idle
with EK control. This is a further use of the diesel engine power occurs speed, programmable machine oper-
development of series 52, which is independent of the other influences, ating modes and simple diagnostic fa-
already well known in the telehandler such as travel drive, air-conditioning cilities. The general structure is shown
market. It is available in sizes 28, 45, system, tolerances, or operation at in Figure 10.
63 and 85 cm/revolution (see Fig. 9). high attitudes. In addition to optimal
power management, the user benefits
The load limiting control constantly from additional advantages such as
adjusts the consumed power of the
A10VO.EK to the available power of
the combustion engine. It thereby Controller
prevents overloading of the combus- RC2-2
tion engine while the hydraulic pump Angle of
Control block
transfers the maximum available rotation sensor
SX
power at a given time. This is per- WS
formed as follows: The actual engine
speed value is constantly compared
with the set speed (both analog or via
CAN bus) in the BODAS RC2-2 con-
Speed sensor
troller with the aid of the AS/LLCA ID
(Application Software Load Limiting
Control, Version A) standard soft-
ware. This operational software can
be easily modified through the use
of parameter sets. If the speed of the
combustion engine drops too strongly
(actual speed value << set speed), the
swivel angle of the A10VO is reduced
by the overlying EK electro-propor- Variable pump
Diesel engine Gearbox A10VO
tional swivel angle control. As soon as
the engine is no longer in speed drop, Fig. 10: Structure of the A10VO.EK electronic load limiting control with variable pump and BODAS
the maximum swivel angle of the RC2-2 controller.
Bosch Rexroth AG Telehandlers Mobile 2006 141

3.6 Versatile: Rexroth software

Standard software packages
from a standard module to indi-
vidual solutions DRC AGS LLC VAC AFC ASR ...
The range of available BODAS con-
trollers makes possible not only the
electronic control of the travel drive, Combination and extension of standard modules
but also of the working hydraulics.
DRC + AGS + LLC VAC + AFC ASR + ...
With SX14NGE valves and THE joy-
sticks, the complete solution can be
implemented according to customer Rexroth programs according to individual specification
requirements. On the software side,
this occurs on the basis of complete Specification
application software packages, base
modules or with individual program-
ming by Rexroth or the vehicle man- Vehicle manufacturer programs himself on the basis of the BODAS-de-
sign development tool or BODAS C-API
ufacturers own software engineers
(Fig. 11). Specification

With the BODAS RC6-9 controller

Fig. 11: Rexroth offers various levels of cooperation in matters related to software from application
and the AS/VAC (Application Soft- packages ready-to-use to individual solutions which can be programmed by Rexroth or the vehicle
ware VAlve Control) standard soft- manufacturer. Software developments can be implemented according to IEC 61131 with the
ware for valve control system, a work- BODAS-design development tool or in C on the basis of the BODAS C-API C programming library.

ing hydraulics system can quickly be

put into operation. Previously used The range of available solutions and
systems for jib load control, which the ability to combine them should be
take back the movement release via discussed in an individual meeting in
relay contacts in critical cases, remain order to find the optimum and most
usable. cost efficient solution for the respec-
In addition, electronics can be used to tive vehicle.
implement new functions which were
developed and have already been test-
ed by Rexroth. These functions con-
tribute to the comfort and safety of
machine operation: Safe shutdown of
the working hydraulics during travel
as well as the electronic parallel guid-
ance (replacement of the compensat-
ing cylinder) with extended function,
such as the vertical movement along
a wall, positioning memory of the
bucket/fork with return-to-position
function or electronic end-position
switch for softly reaching the me-
chanical end positions.
142 Mobile 2006 Telehandlers Bosch Rexroth AG

Consequence Frequency and Possibility for Probability of the Result of the risk
exposure time avoidance unwanted occurence analysis

C F P W

3 2 1
a = no safety requirements
1
a = no special safety
1 1 a requirements
1
2 1 1 a 1 - 4 = safety requirements
2 according to SIL
1 2 1 1
2 + = not covered by the
2 3 2 1 standard
1 3 3 2 Example (red line):
3 C2, F2, P2, W1
2 4 3 3
results in SIL1
4 + 4 3

1 = minor injury 1 = rare to more often 1 = possible 1 = very low

2 = serious injury or death 2 = frequent to permanent 2 = almost impossible 2 = low
3 = death of several people 3 = relatively high
4 = death of many people

Fig. 12: System for risk analysis and classification in SIL classes according to IEC/EN 61508-5.

4 Safe: Tested safety

concepts from Rexroth
Together with the vehicle manufac-
turers, Rexroth intensively tests the
selected solutions using risk analyses
according to IEC/EN 61508-5 and
the associated classification according
to SIL (Fig. 12). An extensive pool of
base documentation facilitates fast
execution. Moreover, these procedures
provide the manufacturer with a high
level of safety not only in the Rexroth-
related software and hardware solu-
tions, but also provide solid docu-
mentation for certification authorities
(Fig. 13). Because telehandlers with
mounted aerial working platforms are
Fig. 13: Example of the Rexroth documentation for risk analysis, risk evaluation and safety concept.
subject to special safety requirements,
it may be necessary to use and take
into consideration relevant standards
such as EN 280 and the corresponding
safety classification according to EN
954-1.
Bosch Rexroth AG Telehandlers Mobile 2006 143

5 Conclusion
The variety of innovations presented
from the Telehandlers Application
Center shows the importance which
Rexroth gives to this group of vehicles.
All products and function extensions
make a considerable contribution to
extending and improving the func-
tionality of telehandlers:
The shift on fly concept facilitates
an economical and compact form
of shifting on the fly. As a result,
it is possible to shift while driving
at speeds of up to 40 km/h while
maintaining the accustomed trac-
tive effort and installation space.
The electronic BODAS controllers,
sensors and joysticks together with
the hydraulics which have been
adapted for this purpose, such as
A10VO.EK and SX14NGE, allows
new functions as well as extending
the operational limits of machines
while reducing fuel consumption.
A well-designed safety concept for
hardware and software on the basis
of IEC/EN 61508-5 reduces risk and
permits faster certification of the
telehandlers with authorities.
Valve technology with load-inde-
pendent flow sharing as with the
SX14 considerably improves opera-
tion of the telehandler through the
precise control of the functions
and the elimination of unexpected
movements.