Hydrostatic Regenerative Braking System Rexroth Ra98310 - 2010-08

Linear Motion and
Assembly Technologies Service Pneumatics Hydraulics

Electric Drives
and Controls
Hydraulic Hybrids from Rexroth:
Hydrostatic Regenerative
Braking System HRB
Recover Energy Reduce Emissions
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2
A Win-Win for Operators and the Environment
Dwindling resources, increasing environmental awareness, and above all, rising fuel prices are affecting business decisions as
never before. The HRB Hydrostatic Regenerative Braking System helps meet increasingly strict environmental regulations
and reduces operating costs by saving fuel. The HRB system will provide superior return on investment whether youre a fleet
operator of refuse trucks or shuttle buses, a construction firm, a municipal operation running school or public transit buses,
or a loading dock or port operator.
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Hybrid: Two Pulling Together
Hybrid has its origin in the Greek language and means: Mixture or combination
of two things. Hybrid vehicles use two types of energy to attain optimum propulsion.
Combustion engine demand is reduced by hybrid technology, giving the user two big
advantages: lower fuel consumption and a significant reduction in emissions. The most
common hybrid technologies are electric and hydraulic hybrids.
Hybrid Versions
High energy density and low power density: The battery can absorb
a great deal of energy, but the charge time is relatively long, so it is not
possible to fully recapture the braking energy.
Energy is stored in batteries.
Typically found in passenger cars.
More detailed information about electric hybrid technology can also be
found at the Bosch Web page www.bosch.de under Hybrid Technology.
Characteristics of an electric hybrid:
Hydraulic hybrids are ideal for vehicles with frequent,
short start-stop cycles, such as public transit buses,
refuse trucks, forklifts, pneumatic tire rollers, telehandlers,
swap body movers and much more.
Characteristics of a hydraulic hybrid:
Excess motor power is continuously accumulated in a battery over
a longer time period (blue) and accessed as needed (light blue).
The kinetic energy from braking is fed to a hydraulic accumulator
(blue) and immediately reused for starting (light blue).
High power density and low energy density: There are limits to the
amount of energy the system can accumulate. However, it takes less time
to collect and store this energy, which can be called upon as needed.
The full braking energy is then fed to a hydraulic accumulator and stored.
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4 Operating Principles
Innovation and Quality Complement Each Other
The Rexroth focus on high-end hydraulic solutions, and our unique product line, is the basis for the HRB combining
proven components with a new, innovative braking and drive concept. That means high production quality and a variety
of existing components allowing Rexroth to tailor a hydraulic hybrid system to your design requirements. We also have
extensive knowledge and experience in electronic control of complex systems. The end result is that we can offer a custom-
tailored hydraulic hybrid powertrain that fits the needs of your application.
The HRB stores a vehicles kinetic energy,
which would otherwise be lost during
mechanical braking operation. This energy
is then available for powering the vehicle
and reducing primary energy use. To ensure
that the Rexroth Hydrostatic Regenerative
Braking System reaches its full potential, the
following conditions need to be met:
High vehicle mass and strong, active de-
celeration for accumulating a large amount
of energy in a short time.
Frequent starting and braking.
Low rolling resistance to store the maximum
braking energy.
Weight matters
High
Low High Braking Frequency
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Cars
Trucks
Wheel Loaders
Telehandlers
Refuse Trucks
Forklifts
Swap Body Movers
Public Transit Buses
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Environment
Fewer harmful emissions, less pollution.
Help in meeting future emissions and environmental
requirements.
Reduced brake wear, lower braking noise, and less brake dust.
Advantages of the HRB
Function
High functional reliability and low risk of failure.
Simple maintenance and long service life.
Ideal solution for new systems or retrofits.
Costs
Significant reduction in operating costs.
Durable Rexroth components reduce maintenance needs.
More economical that other hybrid concepts.
Energy
Reduced fuel consumption to preserve energy.
Fuel-neutral system can be combined with diesel, gasoline,
or other types of motors.
Increased vehicle range.
For heavy vehicles with short, succeeding start-stop cycles,
Rexroth offers the Hydrostatic Regenerative Braking Systems
for capturing the braking energy.
The parallel HRB was developed especially for vehicles
with no hydrostatic drive. The HRB components are
installed in the vehicle as an ancillary system.
Optimal energy use with parallel HRB
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HRB parallel
for Vehicles with a Mechanical Drive Train
System and Advantages
The parallel HRB is a hydraulic hybrid for vehicles with no hydrostatic transmission: For example, vehicles used in refuse
collection and public transit buses. Use of an HRB system results in significant fuel savings of up to 25% and improved
acceleration depending on the focus of the application.
School Buses Shuttle Buses City Buses
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7

How the parallel HRB works
Storing braking energy
The hydraulic axial piston unit
is coupled to the mechanical drive train through

a gearbox
. When braking, the axial piston unit converts kinetic into hydraulic
energy and pumps hydraulic fluid into the pressure accumulator
, increasing
the pressure in the accumulator.
Reusing the stored energy to assist the vehicle drive
The pressurized hydraulic fluid in the accumulator drives the axial piston unit,
which now acts like a motor. Hydraulic energy is converted into kinetic energy.
The axial piston unit remains coupled to the mechanical drive train until the pres-
sure accumulator is discharged. The valve control block
controls the filling

and discharge cycle and protects the accumulator from excessive pressure.
The electronic controller
operates the HRB. In normal drive mode the

Hydrostatic Regenerative Braking System is decoupled.
Axial Piston Unit A4VSO + Gearbox, Hydraulic Pressure Accumulator, Pressure Relief Valve, Valve Control Block HIC, Electronic Contoller RC
Components of the parallel HRB
Simulated cost savings using the example of a refuse collection truck*
On a refuse truck (empty weight approximately 16 tons) the use of the parallel
HRB can result in saving of up to 2.25 liters (0.59 gallons) of fuel per hour.
The annual operating costs can thereby be reduced significantly without even
taking into account the additional savings potential of reduced brake wear.
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The higher the fuel prices, the sooner your HRB pays for itself.
* For the simulation Rexroth uses the AMESim simulation tool.
Calculated fuel savings for a refuse truck (empty weight 16 t)
during operation
Annual operating hours 1,300 1,820 2,340
Fuel savings (liters per year) 2,925 4,095 5,265
CO
2
reduction (kg per year) 7,750 10,850 13,950
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Printed in the United States
RA 98 310/08.10
Bosch Rexroth Corporation
Hydraulics
2730 Research Drive
Rochester Hills, MI 48309
Telephone: (248) 2674000
Facsimile: (248) 8442698
www.boschrexroth.com/hrb
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Linear Motion and

Assembly Technologies Service Pneumatics Hydraulics

is coupled to the mechanical drive train through

controls the filling

operates the HRB. In normal drive mode the

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