174 Mobile 2003 Telehandlers Bosch Rexroth AG

Application Center Telehandlers

Head: Werner Ooster

Bosch Rexroth AG
Mobile Hydraulics
Zum Eisengießer 1
97816 Lohr, Germany
Telephone: +49 (0) 93 52 18 - 20 36
Facsimile: +49 (0) 93 52 18 - 21 59
E-Mail: werner.ooster@boschrexroth.de
Bosch Rexroth AG Telehandlers Mobile 2003 175

Drive and Control Systems for Telehandlers

1. Introduction
The term „telehandler“ suggests that
we speak of a versatile and universal
handling device with a variable reach.
The first telehandlers were developed
simultaneously in England and France
25 years ago. The basic idea behind
this development was to provide fork-
lift trucks additionally with a horizon-
tal reach in order to position loads at
places that cannot be approached di-
rectly.
It turned out soon that the concept
with the telescopic arm is suitable for Fig. 1.1: Application examples of telehandlers
a multitude of tasks, which go far be-
yond simple material handling. Efficient drive and control systems by
Telehandlers are used in the agricul- Rexroth which are characterized by
tural sector, the construction industry their reliability, efficiency and ease of
and in the warehouse management operation form an integral part of
where they act as forklift trucks, wheel these machines and create the precon-
loaders, mobile cranes or working dition for an optimal market success
platforms. Some of the telehandlers of this equipment.
are fitted with articulated steering sys- In the field of telehandlers, the cur-
tems, but most of them with axle piv- rent technological trends are the fol-
ot steering systems. lowing:
Today, about 30 companies worldwide • Single-circuit system for the com-
offer telehandlers for payloads rang- plete working hydraulics (steering
ing between 1 and 16 t and telescop- Fig. 1.2: 14-t telehandler system, brake, trailer brake, fan in-
ing heights of 3 to 21 m. cluded)
In 2001 about 30,000 telehandlers With its Telehandlers Application • LUDV system
were manufactured worldwide, about Center which consists of a team of • Higher handling capacity
two thirds in Europe alone. The specialists from the product units,
• Higher working pressure
strongest countries of production, Rexroth offers its customers compre-
France, Great Britain and Italy are at hensive help, from the selection of the • Higher velocity of the working
the same time the largest sales mar- optimum components through to en- cylinders
kets for this equipment. gineering of complete package solu- • Increased operational safety
tions. • Standardized components
• Reduced fuel consumption
• Reduction in exhaust gases and
Authors: noise emission
Werner Ooster BRM-MC/VTB3
Manfred Glöckler BRM-AK/VME3
Michael Schuler BRM-AK/VMH3
176 Mobile 2003 Telehandlers Bosch Rexroth AG

2. Travel drive
Efficiency, handling capacity and ease
of operation are the decisive factors I II A6VM
for the selection of a drive system for
travel drives. In the power class below
60 kW the hydrostatic travel drive has
been widely accepted due to its
known advantages. An axial piston
variable displacement motor drives
the front and rear axle of the vehicle
via a splitter gearbox (Fig. 2.1).
The use of hydrostatic gears offers the
A4VG
following advantages:
• Automotive driving with stepless
transmission of forces Fig. 2.1: Hydrostatic travel drive with variable displacement motor and splitter gearbox
• Sensitive positioning of the goods
(inching)
• High acceleration and deceleration
capacity
• Fast change of direction through re- A20VM
versing of the pump
• Wear-free braking
• Maximum traction even at low rev-
ving speed
• Simple load-limiting control via DA
cartridge
• Free arrangement of drive compo- A4VG
nents in the equipment
Fig. 2.2: Travel drive with double motor
To make these benefits available even
in higher power classes, drives with can be realized without mechanical 2.3). It is derived from the tried-and-
hydrostat and downstream mechani- gear stages, purely by hydraulic con- tested A4VG technology with signifi-
cal gear stages are used. The hydraulic version. Two swashplate-type rotary cant further developments in the de-
conversion is stepless; with mechani- groups arranged in series directly sign. The new sophisticated heavy-
cal shifting, the tractive force is inter- drive the front and rear axles via two duty rotary group allows high work-
rupted. output shafts (Fig. 2.2). ing pressures and speeds, which re-
markably increases the hydraulic con-
Latest developments aim at avoiding On the basis of decades of experience version range. The new modular sys-
these gear-change gearboxes through in the development and production of tem offers many advantages with re-
the use of large-capacity axial piston swashplate units, Rexroth has devel- gard to installation and service-
double motors. Maximum tractive oped the A20VM double motor spe- friendliness. The double motor is ei-
forces and high speeds up to 40 km/h cifically for this drive concept (Fig. ther directly fitted to the vehicle axle
Bosch Rexroth AG Telehandlers Mobile 2003 177

by means of an SAE mounting flange

or fitted to the frame by means of cus-
tom adapters.

For the equipment manufacturer, this

results in a significant technical
progress and, at the same time, in a
reduction in the number of compo-
nents used. The motor will be availa-
ble in sizes 210 (2x210ccm) and 140
(2x140ccm) with electro-proportional
or speed-related control.

Extended functions due

to electronic drive Fig. 2.3: A20VM double motor
management
Thanks to the electronic drive man-
agement (Fig. 2.4) known functions
Software
can be extended almost infinitely via BB-3 BODEM
software parameterization.
Travel Direction Working Inching Control unit
speed of hydraulics
Variable driving characteristics BB-3 travel
RS232

For variable driving characteristics, Diagnostics

Parameter setting
different characteristic curves are Process monitoring
saved in the driving software. For ex-
Nominal speed

ample, it is possible to change be-

Actual speed
CAN-Bus

tween soft and hard driving or work-

ing and transport mode. The selec-
tion can be made by the driver during
operation by means of a mode switch
or by the manufacturer or a service U
p

technician via a PC interface.

A4VG A20VM
Variable displacement Variable double
pump motor

Fig. 2.4: Travel drive with double motor and electronic control
178 Mobile 2003 Telehandlers Bosch Rexroth AG

Parameterization, monitoring and 3. Steering unit With type LAGZ, two rotor sets of the
diagnosis steering system are active in standard
The driver can operate the steering
It is possible to communicate with the operation. In case the oil supply fails,
wheel of the telehandler with his left
integrated driving software via the in- a rotor set is switched off in analogy
hand. Depending on the axle load, the
terface of the electronic control device to the LAGU.
steering wheel diameter and the di-
using the BB-3 service module or the Depending on the application, tele-
mensions of the steering cylinder,
BODEM software and a laptop. Apart handlers usually operate with up to
steering units of type LAGC (stand-
from driving software parameteriza- three types of steering „front axle
ard), LAGU or LAGZ (with reduced
tion, errors and their history can be steering“, „all-wheel steering“ or „crab
emergency steering forces) are used.
read out. The BODEM software al- steering“.
With type LAGU, chambers are
lows measured data to be recorded for To realize one of these types of steer-
switched off in the case of an oil sup-
parameters that can be processed by ing principles, so-called „steering type
ply failure. In this way, the torque re-
the electronic control device. During valves“ are used. These must be as
quired at the steering wheel is reduced
driving, these data can be viewed on a leak-free as possible in order that
so that the manual force is sufficient
display. For this purpose, Rexroth of- front and rear wheels are still in align-
to steer the telehandler and comply
fers the „DI“ display. The control de- ment after driving over a longer peri-
with the regulations for emergency
vice can be integrated into the com- od of time. Some telehandlers are fit-
steering, usually without the use of
plete electronic vehicle management ted with steering type valves with de-
additional components.
via the CAN bus interface. tent in order that the relevant type of
steering is maintained even in the
event of a potential failure of the
electrics.

Fig. 3.1: Steering unit type LAGC Fig. 3.2: Steering unit type LAGU

Fig. 3.3: Steering unit type LAGZ

Bosch Rexroth AG Telehandlers Mobile 2003 179

4. A10VO working pump Sizes 28, 45*, 63, 85*

Pressure 250 bar
The call for higher handling capacities
Controller DR, DFR(1), LR5...9, EP/EK, ED
on the one hand and greater efficiency * in development
on the other hand can only be com-
Features
plied with through the use of axial
piston pumps, considering the large • high precision
• compact size
oil volumes required for this. Apart • high system efficiency
from the known A10VO axial piston • electronic pressure and flow regulation
pumps of series 31 and 52 Rexroth • low noice level

now also offers series 53.

It is provided with an extended con-
troller program with a mechanical- Fig. 4.1: A10VO axial piston pump series 53
hydraulic power controller (LR5 ...9)
and the option of electrical-propor-
tional flow control (EP/EK) in con- EP: direct electro-proportional
displacement control
junction with a standard DFR (1) (I = Imax
Vgmax; I = Imin
Vgmin;
valve. With the electrical-proportional I = 0 mA
Vgmin)
EK: direct electro-proportional
EP control, the pump swivels out in displacement control,
proportion to a rising current value. with „fail save“ function
(I = Imax
Vgmax; I = Imin
Vgmin;
Version EK offers additionally a „fail I = 0 mA
Vgmax)
save“ function. When the electric cir-
cuit is interrupted, the pump swivels P
A10VO E F1
at maximum displacement. Only from K
a defined current intensity the pump
Fig. 4.2: EP/EK electro-proportional variable displacement pump
swivels back at minimum displace-
ment in order to swivel out propor- With telehandlers it is nothing unusu- A sensor checks the momentary speed
tionally according to its characteristic al that when the diesel engine is idling of the diesel engine (actual value) and
curve. while the travel drive (e.g. in rough passes this information on to a micro-
This type of control is ideal, if the terrain) and the working hydraulics controller (RC2-2). The microcon-
working pump does not only supply (lifting and telescopic arm) demand troller compares the actual value with
the working hydraulics, but also the high power, the diesel engine may the speed command value that is se-
brake and steering system with oil. In stall. lected by the driver via the position of
the event of an electrical defect, all A solution to this problem is the the accelerator pedal. In case that
safety-relevant components are never- speed sensing power control, which is more power is demanded than availa-
theless supplied with a sufficient superimposed to the traditional load ble, the pump is swiveled in accord-
amount of oil. sensing control. ingly. All functions can be driven at
Overloading of the diesel engine can reduced speed without stalling of
be avoided with the help of the elec- diesel engine.
tro-proportional control of the pump
by reducing the swivel angle of the
pump as required.
180 Mobile 2003 Telehandlers Bosch Rexroth AG

With the LUDV control, in this case,

the available oil volume is shared
among all controlled actuators in rela-
tion to their required speed. The indi-
vidual machine movements slow
down accordingly, but no function
comes to an unwanted standstill.
Further benefits of the LUDV control
are:
• Ease of operation, even for un-
trained operators, since even at dif-
ferent load pressures, the various
functions such as lifting, telescoping
and tilting do not have to be com-
pensated for by means of the hand
lever
• Load pressure-independent fine
control range
• Higher precision for movements,
Fig. 4.3: Speed sensing power control independently of pressure and oil
flow
5. Control Valves Their great advantage over directional • Higher handling capacity due to
Efficiency, handling capacity, reliabili- valves according to the 6-way throttle improved ease of operation even
ty and operator comfort are key as- principle or the pure LS principle lies with unchanged pump size.
pects also with regard to directional in the fact that in the case of a possi-
valve technology in telehandlers. ble oil shortage, no actuator comes to
Due to the wide valve product range, a standstill.
Rexroth is able to offer optimally
matched valves or valve combinations Weight (t) 2,0 4,0 16,0
according to the different demands
placed on the individual types of tele-
max.
handlers. actuator flow
On equipment that must simultane- [l/min]
ously carry out different functions,
which require a great amount of oil, LS
control valves with load pressure-in-
dependent flow distribution (LUDV)
Valve system

are now widely accepted. LUDV

Open
Center

Fig. 5.1: Directional valve assignment telehandler

Bosch Rexroth AG Telehandlers Mobile 2003 181

If the working functions are to be

controlled electrically - for example
within the framework of an electro-
hydraulic concept of the entire tele-
handler - one can also use proven di-
rectional valves according to the LS
principle.
Due to their technical data, direction-
al valves of series M4-15 have proven
Fig. 5.2: M4-15 load-sensing control block Fig. 5.3: SX14 LUDV control block
successful in these applications.
With the electro-hydraulic LUDV, the
characteristic curves for the direction- • integr. pilot oil supply with
al valve spools are saved in electronics. shut-off function
With the help of a central micro-
• possebility of output external supply
controller the data saved are com-
pared with further sensor values, • accumulator connection port
(for emergency lowering)
which are made available (e.g. via the
amount of oil momentarily available), • Flushing valve and OC module
and then evaluated. The functions as-
• Priotity flow divider, CC module
signed to the individual spools are
then controlled accordingly. In con-
nection with this, load compensation
is assumed by existing LS section Fig. 5.4: SX14 NGE LUDV control block
pressure compensators.
For a mechanical-hydraulic or partial- A variant of the SX14 is the new valve one side. However, like the standard
ly electrical control of the working series SX14NGE, which was designed SX14, the valve can also be operated
functions and maintenance of the for actuator flows of up to 160 L/min mechanically or hydraulically. With
LUDV function, directional valves of and can be adapted to electro-hydrau- electro-hydraulic operation, the
series SX14 are the perfect choice. lic operation. The max. inlet flow is control is as with the LS valve series
Manufacturers call for minimum cost 200 L/min at an operating pressure of M4-15 by means of proportional
and demand that the operator can ex- up to 270 bar. pressure reducing valves of type DRE2.
ecute all working functions with only In contrast to the standard valve series
one hand lever, if possible. Due to its SX14, the section housing was extend-
modular design, valve series SX14 can ed at the bottom for transporting pi-
be fitted and combined with different lot oil and in order to realize an elec-
operating elements. tro-hydraulic operation from only
182 Mobile 2003 Telehandlers Bosch Rexroth AG

6. Ancillary valves Due to the design of the main spool

of the stabilizing valve, the accumula-
Telehandlers comprise some functions
tor is protected from any pressure
that are technically less demanding
peaks occurring in the system. This
such as extending and retracting of
results in a considerably longer service
the stabilizing cylinders or orientation
life of the accumulators.
of the running gear.
To comply with the Pressure Equip-
These functions can be integrated in
ment Directive that is in force in Eu-
the main control block. However, due
rope, a type-tested pressure relief
to the relatively small amount of oil
valve is used additionally in the sup- Fig. 6: Stabilizing module type RSM2-16
required for these functions and due
ply line to the accumulator.
to the fact that most of the manufac-
turers design these functions accord-
ing to the on/off principle, separate,
compact control blocks are often
used. Here, various valve variations
are possible, with or without connec-
tion to the LS signaling chain.
Especially when telehandlers are used
in agriculture, the call for increased
comfort and higher handling capacity
leads to the use of valves that reduce
Fig. 7.1: EC4000 grip Fig. 7.2: 4THES5, THE5, THEC5 joysticks
so-called pitching oscillations.
Here, the second generation of the
stabilizing valve of type RSM2-16 7. Joysticks It can optionally be fitted with two to
three proportional rollers or two to
with its compact dimensions presents The joystick plays a decisive part for
three rocker switches. A maximum of
itself. the operation of the machine. The
nine switch buttons are possible.
According to applicable law, the use of driver should operate the steering
The new electronic THE5 joystick
safety valves on the cap side of the lift- wheel with his left hand and be able to
generation is available in three vari-
ing cylinder is compulsory. In order perform all working function with his
ants:
that the amount of oil required for os- right hand. To be able to meet this re-
• THE5 power encoder
cillation damping can flow between quirement, Rexroth developed the
the lifting cylinder and the hydraulic joystick „EC4000“. It can be attached • THES5 signal encoder and
accumulator, the safety valve must be on known hydraulic joysticks (e.g. • THEC5 CAN bus-capable encoder
opened. In practice, the activation of TH6) and on new electronic joysticks
the RSM2-16 is linked to a certain of type THE.
traveling speed (e.g. 5 km/h). The
load pressure available in the accumu-
lator opens the safety valve in the cyl-
inder cap via a shuttle valve.
Bosch Rexroth AG Telehandlers Mobile 2003 183

Apart from the known Rexroth

4TH5 4THES5, THEC5, THE5
EC2000 grip and the new EC4000, Hydraulic Joystick Electronic Joystick
other grips can also be attached. The
Same mechanical
THE5 joystick complies with protec-
parts
tion class IP67.
In terms of the lever length, deflection
angle and force situation, the elec-
tronic joysticks feature the same ergo-
nomic data as the hydraulic joysticks.
Also with regard to ruggedness, the
electronic joystick meets the same re- Same type of
fixation flange
quirements as the hydraulic joystick
thanks to the use of the same compo-
nents.

Fig. 7.3: 4THES5, THEC5, THE5: Robustness

8. Brake LT31
The trend towards higher driving
speeds and the more exacting regula-
tions to be fulfilled call for a higher
SP1 BR1
braking performance. This can be PBRAKE

achieved through the use of remotely T

Service brake
powered brakes of modular or com-
pact design. PINCH
M2 SP2
In this field, Rexroth offers a wide
range of matched components. The
inching/brake valve of type LT31 is
Inch-Brake pressure in bar

suitable for vehicles with hydrostatic

travel drive. According to regulations, PBREMS
the operating brake must consist of
PINCH
two independent circuits that brake
the vehicle operationally reliably.
Here, the closed hydrostatic drive as-
sumes the function of the first brak- Pedal operation angle in degree

ing circuit by swiveling back the travel

Fig. 8: LT31 inching/brake valve
hydraulic pump.
The second compulsory, independent is operated, first of all the pilot oil Only when the operator presses the
braking circuit can be implemented, flow of the travel hydraulic pump is brake pedal down even further is the
for example, in the form of a drum discharged at zero pressure to the operating brake pressurized with the
brake. With one pedal and one hous- tank. This causes the pump to swivel actual braking pressure.
ing, the inching/brake valve integrates back, and the driving speed of the ve-
both functions. When the brake pedal hicle is reduced without any wear.
184 Mobile 2003 Telehandlers Bosch Rexroth AG

Drive management CAN bus Implement management

• Direction-of-travel preselection • Diesel engine data exchange • Automatic parallel guidance of the
• Set speed • Communication with extern control units fork lift / shovel
• Set acceleration / deceleration • Load moment limitation, i.e. protec-
• Driving characteristic tion against overloading (LMB)
• Working mode: flat characteristic • Safety logick
• travel mode: steep characteristic • Weigher for shovel content / fork
• Load limiting control load
• Inching / brake functiuon • Speed sensing control for diesel
• Overspeed safety for diesel engine engine
• Hydraulic motor control • Joystick control of steering with
• electronic DA control safety switch
• Vg max- switching • Ramps for the limit stop
• Limitation of tractive effort • Limitation of the working area
• Speed limitation (telescopic arm)
• crawl gear • electronic pressure and volumetric
• Constant speed drive (CSD) flow control (LUDV)
• Fuel-efficient driving • Preselection of different modes
PC and BB3 (hard to soft drive)

• Diagnostic function
• Parameter setting
• Process motoring
• Output display

Fig. 9.1: Electronic driving and working management

9. Electronics
Electronics are increasingly finding Another possibility of improving Tilt cylinder
their way into telehandlers. Be it for functions with the help of electronics
Compensation
the realization of a relatively simple or making other components super- cylinder
auxilary function or for the engineer- fluous is the parallel guidance of the
ing of complete equipment with fork. For telehandlers, a so-called Lift cylinder
matching of travel and working hy- master cylinder (compensation cylin-
draulics - thanks to electronics, a der) is usually installed to hold the
whole series of useful functions can fork in parallel. This cylinder ensures
be realized. Rexroth has created the via its area ratio that, e.g. during rais- Fig. 9.2: Parallel guidance with compensati-
preconditions for this with the new ing of the boom, exactly the amount on cylinder
RC controller family. The smallest mi- of oil is displaced from the rod side as
crocontroller of this family, the RC2- is required by the tilting cylinder on
2, can be used to prevent the diesel the cap side to keep the fork in paral-
engine of a telehandler from stalling lel. This function can also be assumed
while idling and with high power re- by the RC2/2 with the help of two ro-
quirements for travel and working hy- tary angle encoders and proportional
draulics as described at the beginning valves (e.g. of type DRE).
of this article.
Fig. 9.3: MHVES75 angle sensor with plug
Bosch Rexroth AG Telehandlers Mobile 2003 185

10. Rexroth testing and

demonstration model
To be able to analyze and optimize the
possibilities and interrelationships as
described before and bring the results
to maturity for series products,
Rexroth decided to buy its own tele-
handler for testing purposes under the
leadership of the Telehandlers Appli- Fig. 10.3: Cabin with 4THE S5 joystick
cation Center.
Rexroth opted for one of the techni-
cally most demanding telehandlers. 11. Conclusion
Fig. 10.1: Rexroth testing and demonstration
The Rexroth testing and demonstra- model
Thanks to the wide variety of different
tion model is provided with a super- components and control options,
structure that can be rotated through Rexroth is able to meet the different
360° without stop and can therefore requirements and wishes of customers
be used as mobile crane, fork lift in the field of telehandlers.
truck, working platform and wheel Whether individual components are
loader. At present, the following com- to be used or complete systems engi-
ponents are installed and documented neered, Rexroth is your partner right
at Rexroth: from the start:
Implement hydraulic: The Drive & Control Company.

• SX14NGE control valve Fig. 10.2: SX14 NGE control valve

• 4THE 5C joystick
• LAGC steering unit
• A10VO 63EK working pump
• RC6-9 (MHVD18/6) controller Direction of Accelerator Inching Traction
Implement
Steering
P
Parallel
kinematics
Diesel
engine
V
Variable V
Variable
displacement
travel pedal pedal C motor

• 4WE6 G...T06 steering mode valve

Hydrostatic transmission:
• A4VG 90EO transmission pump valve
Software
• A20VM 210/210EP transmission displacement

double motor RC
+
S ft
Software
f a
ariables
alues)
a
Control unit

BB 3

CAN-Bus

Fig. 11: Electronic driving and working management