186 Mobile 2003 Fork-Lift Trucks Bosch Rexroth AG

Application Center Fork-Lift Trucks

Head: Frank Rieckhof

Bosch Rexroth AG
Mobile Hydraulics
Robert-Bosch-Str. 2
71701 Schwieberdingen
Telephone: +49 (0) 711 811 - 19 53
Facsimile: +49 (0) 711 811 - 26 69 27
E-Mail: frank.rieckhof@boschrexroth.de
Bosch Rexroth AG Fork-Lift Trucks Mobile 2003 187

Drive and Control Systems for Fork-Lift Trucks

Driving, Steering, Working

In the field of mobile hydraulics and

electronics, Rexroth supplies a unique
variety of components and systems
for use in customers’ drive and con-
trol systems for fork lifts, allowing
them to create specifically-tailored so-
lutions. For internal combustion
or battery-powered fork lifts, for reach
trucks or hand-guided fork lifts, Rex-
roth has the perfect system for each
machine’s particular requirements.
Our broad range allows us to cover
the complete spectrum of applications
for material handling equipment.

At the fork lift application center,

where specialists from the various
Business Units work closely together, Figure 1
we can offer our customers extensive
support, from selecting the ideal com-
ponents through to planning comple- Economical solutions, whatever For the working hydraulics of fork
te systems. the working conditions lifts, we distinguish between open
The majority of vehicles for material center systems with gear pumps and
transport in the company are fork-lift load sensing systems with constant or
trucks with combustion engines. variable displacement pumps.
Systems for driving and working hy-
draulics are as varied as the lift trucks
themselves. Efficient load sensing con-
trol systems for the lifting functions
and the steering system are becoming
increasingly popular in modern indu-
strial lift trucks. These systems satisfy
today’s more exacting requirements
with regard to ergonomics and energy
consumption, and are capable of
achieving the greater levels of perfor-
mance now required in modern logi-
stics systems. This is typified by the
systems and components from the
Rexroth range.
Figure 2

Authors:
Frank Rieckhof BRM-MC/VTS2
Manfred Glöckler BRM-AK/VME3
188 Mobile 2003 Fork-Lift Trucks Bosch Rexroth AG

Open center system

Open center working hydraulics con-
stitute a tough system that has been
tried and tested over many years. Re-
liability and compact design are its
principle advantages. The directional
control valves may be mechanically,
hydraulically or electrohydraulically
actuated, and can also be combined in
many different ways.

Figure 3: Control Block SM12,

mechanically operated,
nominal flow 70 l/min,
operating pressure 250 bar

Figure 5: Hydrostatic drive with hydraulic control and working hydraulics in the open centre
system.

Figure 4: External gear pump,

constant displacement pumps
in standard and silence version,
operating pressure 280 bar
Bosch Rexroth AG Fork-Lift Trucks Mobile 2003 189

Load sensing system

Load sensing systems for working hy-
draulics naturally achieve the main
development goals for modern lift-
truck concepts – such as lowering the
energy consumption whilst simulta-
neously increasing performance and
improving user-friendliness.
The demand-oriented supply to the
steering and mast hydraulics ensures
that the energy required by the wor-
king hydraulics is consistently lowe-
red.
Since functions such as lifting and til-
ting can be operated in parallel, high
performance levels are achieved. The
load-independent actuating forces of
the directional control valve functions
ensure high-precision, fatigue-free
working.

Figure 6: Hydrostatic drive with electronic control and working hydraulics in the load
sensing system.

Figure 7: Hydrostatic steering unit Figure 8: Axial piston pump A10VO Figure 9: Control block SB12LS
LAGC/LAGU/LAGZ for open circuits, mechanically operated,
for steering nominal pressure 250 bar, nominal flow 80 l/min,
maximum pressure 315 bar operating pressure 250 bar
190 Mobile 2003 Fork-Lift Trucks Bosch Rexroth AG

Hydrostatic travel drive

For the travel drive, there are different
drive systems to suit the individual si-
tuation. These are tailored to specific
requirements.
The wheel drive, in which a variable
displacement pump drives two wheel
motors fixed directly to the vehicle
frame, is primarily used in industrial
fork-lift trucks (Fig. 10). The modular
construction allows the design engi-
neer maximum freedom. The MCR
radial piston motor or A6VE axial pi-
ston motor with planetary gearing is
used as the drive motor. Figure 10: Wheel drive as standard for industrial fork-lift trucks
For vehicles that are often used on
rough ground or on variable surfaces,
a differential lock is absolutely essenti-
al for tractive force transmission. The
axle drive with mechanical differential
lock is therefore used in fork lifts for
outdoor applications. In this case, a
constant or variable displacement
motor attached to the fork lift’s axle is
supplied by a variable displacement
pump (Fig. 11).

Figure 11: Axle drive as standard for fork lifts for use on rough ground

Figure 12: Axial piston pump Figure 13: Figure 14: Figure 15:
A4VG (A10VG), Radial piston motor MCR, Drive GFT Axial piston motor A6VM,
nominal pressure 400 (300) bar, nominal pressure up to 250 bar with axial piston motor A6VE nominal pressure up to 400 bar,
maximal pressure 450 (350) bar maxmimal pressure up to 450 bar
Bosch Rexroth AG Fork-Lift Trucks Mobile 2003 191

The Rexroth anti-slip system is an ef-

fective hydraulic differential lock that
may be used as an alternative to the
flow divider or mechanical differenti-
al. The pump circuits to the drive mo-
tors are divided to create a hydraulic
dual-circuit system, with one circuit
supporting the other, which thus
forces the corresponding driving MCR
wheels to run synchronously (Fig. 16).
Rexroth has developed the A30VG MCR
double pump, based on the proven A30VG
A4VG swash plate pump, especially
for this application. With this pump, a
driving mechanism pumps in two se-
parate hydraulic circuits via a com-
mon connecting plate. Alternatively, a
tandem pump may be used.

These solutions highlight the benefits Figure 16: Rexroth Anti-Slip-System for wheel drive systems
of the hydrostatic travel drive:
- Automotive travel with infinitely
variable power transmission
- Sensitive positioning of the unit
load (inching)
- Excellent acceleration and
deceleration
- Rapid change of direction of travel
by reversing the pump
- Non-wearing brakes
- Maximum pulling power, even at
low speed

• Common driving mechanism for two separate

Size hydraulic circuits
28 (2 x 28 cm3)
• Proven swash plate technology
Pressure range • Standard displacement range for the A10VG/A4VG
400 / 450 bar
• With through drive for attaching the working pump

Figure 17: Axial piston double pump A30VG

192 Mobile 2003 Fork-Lift Trucks Bosch Rexroth AG

Extended functions provided by diesel engine. This means that, at ma- Parameter assignment, monito-
electronic fork-lift management ximum power and reduced speed, a ring and diagnostics
With the electronic fork-lift manage- drive mode can be set that is optimi- Communication with the integral
ment system (Fig. 18), these existing zed in terms of both consumption drive software is possible via the con-
functions can be extended with little and noise, according to the characteri- trol unit’s interface (Fig. 18), either
time or expenditure by setting the stic curve of the diesel engine. With using the BB-3 service module or
software parameters. eco-drive, the system automatically using the BODEM software on a lap-
detects the „Transport mode“ opera- top. This can be used to read any er-
Variable driving characteristics ting point at high speed and low load, rors that have occurred and their hi-
With the variable driving characteri- and switches the diesel engine to a story, as well as to set the drive soft-
stic system, different characteristic mode that is optimized in terms of ware parameters. The BODEM soft-
curves are stored in the driving soft- both consumption and noise. This ware is also used to record test data
ware. It is thus possible to switch bet- changeover is compensated by adjust- for the values processed by the control
ween soft and hard driving or bet- ment of the hydraulic components, unit. In drive mode, the data can also
ween work and transport mode. The which ensures that the desired drive be read on a display, particularly the
choice is made either by the driver operating point is retained. This is DI display from Rexroth. The control
while the vehicle is in use or by the particularly useful for vehicles that are unit can be incorporated into the
manufacturer or service engineer via a often operated at high transport overall electronic vehicle management
PC interface. It can be adapted for a speeds. system via the CAN bus interface.
particular driver or specific applicati-
on.

Constant speed drive with lift Lifting Tilting Addit. Travel Drive
direction pedal
speed function Control
unit
The constant speed drive combined +
with the lift speed function allows the Software
RS 232

Parameterization,
Diagnostics FGR
power to be increased automatically via PC, BB-3
when the working hydraulic system is
actuated at a constant driving speed.
CAN-BUS

The power required for the work

function is signaled to the driving
software via an electronic signal. This
compensates for the rise in the diesel
speed due to varying the pump dis-
placement, and thus keeps the driving
speed constant at the value determi- MCR
Radial piston
ned by the accelerator pedal. motors

Environmentally-friendly drive
mode and eco-drive A4VG
Variable pump
As described above, the drive charac- for the drive
teristic can be selected as required,
which allows the operating point to be
defined for any power point of the Figure 18: Electronic drive management system (lifting, tilting, additional function)
Bosch Rexroth AG Fork-Lift Trucks Mobile 2003 193

Precise and energy-

saving systems for
electric lift trucks
Due to their limited battery capacity,
electric lift trucks have to rely upon
low energy con- sumption despite
high performance requirements. For
this reason, modern electric lift trucks
employ pulse control systems for the
lifting and steering hydraulics. Among
other things, these ensure energy-sa-
ving, low-noise operation.
Factory-set, non-contact sensors si-

Figure 19 Figure 20: Working hydraulics with pulse control

tuated on the directional control valve

block and steering column ensure a
demand-oriented flow of volumetric
flow for the steering and mast hydrau-
lic functions. The flow is provided by
one or two variable-speed, Silence
gear pumps. The important factor is
the conversion of the mechanical
spool stroke and the steering move-
ment into a proportional electrical si-
Figure 21: Steering columm LAB with sensor, Figure 22: Control block SB1-OC,
gnal for the pulse control system. for digital and analog signal integrated induktive position sensors
The pulse control system ensures en- transmission for measuring the spool travel,
nominal flow 30 l/min,
lifting/lowering 70 l/min,
operating pressure 250 bar
194 Mobile 2003 Fork-Lift Trucks Bosch Rexroth AG

ergy-saving, low-noise operation by our compact units since the Rexroth

means of demand-oriented flow con- solution is preassembled, robust and
trol. This technology means that the versatile.
mast and steering hydraulics can be They use hydraulic units consisting of
operated with maximum sensitivity. an electric motor, gear pump, oil tank
Electrical signal transmission takes and valve blocks of various configura-
place by means of factory-calibrated, tions. These units can be supplemen-
non-wearing sensors, without the ted with manufacturer-specific opti-
need for additional drive and adjust- ons, right through to the electronic
ment elements. Moreover, we offer an valve circuits.
extensive array of possibilities for One particularly striking feature is the
further optimising your system. lowering function that is controlled Figure 24: Compact power unit EP9,
with proportional technology
Ancillary functions, such as secondary by an electrical proportional signal preassembled hydraulic unit,
valves and mutually tuned compon- from the draw-bar. This allows preci- nominal pressure 210 bar,
ents, can also be integrated. sion lowering and pin-point posi- displacement up to 4,6 cm3
tioning.
Systems for pallet trucks
Pallet trucks and stackers are essential The low flow resistance permits a par-
aids in production and commercial ticularly high lowering speed, even
facilities. The decisive factors for the with small loads, which greatly increa-
manufacturer are to optimize the ses the working efficiency of a pallet
function/cost ratio of the system and stacker.
to take account of increasing demand Rexroth supplies compact units that
from operators for ergonomic design, are ready for installation, and require
combined with reliability and robust- no preassembly by the manufacturer.
ness. The robust and reliable technology
These requirements are wholly met by with its modular system can be com- Figure 25: Electrohydraulic pump EHP,
drive unit for automotive and
bined as required for many different
materials-handling technology,
devices and carrying power classes. nominal capacity up to 11,5 kW,
The compact units are also very versa- displacement up to 19 cm3
tile with respect to system optimizati-
on. For example, functions such as ad-
ditional valves, manufacturer-specific
tank shapes and assembly elements
may be integrated without problem.

Figure 23
Bosch Rexroth AG Fork-Lift Trucks Mobile 2003 195

Prospects for additional

functions • Load-torque limitation
• Variable tilting speed
Systems such as electronically control-
• Vibration damping
led hydrostatic drives and electrically
• Cornering stability
actuated valves are currently state of
• Automatic work sequences
the art in a wide range of applications.
The fork lifts of the future will also be
greatly influenced by systems to
increase both customer benefits and
functional reliability.
The development of future systems
will be determined by topics such as
variable tilt speed, oscillation dam-
ping and load torque limitation. Rex-
roth is meeting these challenges, and
is already working on ideas to extend
the range of functions of drive and
control systems for tomorrow’s fork-
lift trucks.
The control elements between the
driver and the load will play a central
role in this development. Rexroth is
aware of this, and is working intensi-
vely on the next generation of control
devices, electrically actuated valves
and electronic control units. Figure 26
The examples revealing the future of
the fork-lift truck show that the bund-
ling of technical knowledge will be of
particular importance in the imple-
mentation of future solutions.
Experience shows that harmonization
with the individual components plays
a central role in optimizing the overall
function. Rexroth has recognized this,
and has been cooperating intensively
with the fork lift manufacturers for
many years, with the aim of de-
veloping systems to increase customer
benefits and functional reliability.

Figure 27: Joystick Figure 28: Electrically actuated valve