2- loop Positive Control Block M9-25

Hydraulic Systems at Bosch Rexroth

Throttle-Control LUDV

Negative Control Positive Control

PST PST
A1 A1
PST
PST A1

+ + +

- - -
Open Center system

1. The pump flow in going to the

tank when the main spool is in
middle position.
2. With moving the main spool the
flow gets throttled until the
pressure raises to the consumer
level and the cylinder moves.
3. This system was originally
designed for constant pumps, but
is used today with variable
displacement pumps to run on a
constant power curve.
Load Sensing System

1. Here each axis has an individual

pressure compensator which is
located before the meter-in
orifice.
2. The highest consumer pressure
is called to the pump which
swivels out to the requested
flow.
3. In case of undersaturation the
consumer with the highest
pressure stops moving.
Load Sensing System

4. Different consumer
pressures are levelled by
the compensators.
5. The individual flow to each
cylinder is installed in the
meter-in orifice of the main
spool.
6. When the delta p of the
compenator spring is
saturated, the compensator
closes and there are no
losses to the tank.
Flow Sharing System

1. The difference to LS systems are

the compensators.
2. The delta p in LUDV is installed in
the pump regulator not in the
compensators.
3. The signal of the cylinder with the
highest load is send to all
compensators.
4. In case of undersaturation they
close and the remaining flow will
be proportional reduced in each
function. None of the consumer
stops.
Requirements for Control of Excavator

• Good fine control of consumers

• Simultaneous movements
• Controllability
• Low hydraulic losses
• Efficient use of power
• Compact design of components
• Space saving and service friendly installation
• Possibility of adding options
• Fast movements
Comparison of Excavator Control Principles
 Three Different Systems

Flow Sharing Systems, LUDV

• it can be realised a 1-loop system with a load independent control.
It is used in crawler excavators smaller 20ton and wheeled
excavators

Negative Control

1. It is a Open Centre system mainly used from Japanese and

Korean companies.
2. In neutral the pump always saturates the NC orifices.
3. When a main spool gets moves out of centre, the neutral closes
and the pressure at the NC orifice drops. This swivels out the
pump.
Three Different Systems

Positive control

1. This is also a Open Centre system, based on the NC systems.

2. There is a tendency of Japanese companies moving towards
this system.
3. The pilot pressure which moves the main spool is also used
to swivel out the pump
4. The advantage is an independent management of valve and
pump.
1-loop System in Flow Sharing for Wheel Excavator
1-loop System in Flow Sharing for Crawler
 Advantages of LUDV Systems in Excavators

1. Sensitive and load The operator does not have to think about
independent control of changing lever strokes, because the
Rexroth LUDV-system instantly, silently
different consumers and automatically send just the right
amount of oil to the actuators, at just the
right pressure to accommodate the change.
2. Constant fine control at
single and simultaneous The front end equipment works naturally
movements with the optimum combination of speed
and power.
3. Defined speed control for Priority for option on request possible
each consumer by
individual flow
adjustment
Advantages of LUDV Systems in Excavators

4. Flexibility for Options

• easy to adopt one or more optional consumers as
all functions are parallel
• Priority for Option on Request

5. 1-loop System possible

• only one variable displacement pump needed for
all functions
LUDV Control Block M7 - Applications
 New Rexroth 1-Loop Flow Sharing Block

New 1 loop LUDV Block M7- 400

• 6 section monoblock
• Spools on two levels for a very
compact design
• Section flow up to 420 lpm
due to spool dia. 32 mm for Boom and Arm
• Mainly focused on el. - hydraulic remote control
• Easy to attach options, also with priority (MFV)
• New arm- and boom regeneration system
for faster actuator speed without cavitation
• Anti drift valves on Boom piston side and Arm rod side
• Boom floating possible
 Comparison of Design
Comparison:

LUDV: System with high flexibility for options,

individual flow adjustment for consumer, load independent,
1-loop System possible

Negative Control: In 2-loop a good technical and proven system

Positive Control:
• Improved development based on Negative Control,
• Pump is no longer controlled by back pressure from NC orifice,
• Pump is swiveled out by pressure sensors in pilot lines and electronic,
• With this, independent and consumer adjusted flow controlled by the pump.
• Energy savings as no losses in neutral, and no control losses at swiveling out
the pump
Bosch Rexroth Controls for Excavator
New Rexroth 2-Loop Positive Control 6M9-25

Open Center

Positive Control

GFT+A10FD
(travel drive)
MX-25
GFB+A10FD
I (slew drive)
p

pilot
A1 pressure MC DRE pilot
pressure

I
p
MC
I
p
A8VO
(travel and implement
hydraulics)
TH6
(pilot control units)
 New Rexroth 2-Loop Positive Control 7M9-25

New Generation Hydraulic valve

for 20 to 40 ton Crawler Excavator System
1. Techn. key data :
• pump flow Q = 2 x 210...300 Ltr./min
( 2 loop system ),
• Pressure p = 400/420 bar
• hydr. or electr. hydr. Operated

2. Increased machine productivity and higher controllability through independent

valve / pump management ( pump is controlled by logic instead of valve signal )

3. Base for future Electro Hydraulic ( EH ) Controls

( electr. Logic replaces todays hydraulic logic )

4. Still simple, robust, dynamic, flexible and ready for the future ( EH )
( advantages of all current systems in one system )
 Description

To point 1:
Max flow 300l/min to cover a machine range up to around 38ton.
To point 2:
In NC the pump is controlled by valve signal
To point 3:
Eventually in 2 or 3 steps
1. total hydraulic management
2. hydraulic piloting - Pressure sensors for pump management
3. hydraulic piloting - Pressure sensors for all pilot signals
4. total el / hyd system
To point 4:
NC : Proportional pump management, Management of travel
compared to M8 (Combination of parallel and tandem circuits,
Mono-block)
Open Center Positive Control ( PC ) - 2 loop
New Control Valve‘s dimensions of 7M9-25 - block
ƒ 7 section monoblock design
ƒ Dimensions 650 X 420(280) X 235mm
ƒ Weight: ~180kg
ƒ 7 axis monoblock,

A
sub plate for straight travel at rear

rm
Sl
ew
Tr
ac
ƒ Spool diameter 32mm
k ƒ All spools on 1 layer,
Tr
ac

ƒ
Bo

Spoolbase 70mm
k
om

ƒ Ports:
O
pt

Implement Hydraulics in front -

io
n

P, T and Cooler on opposite side,

less piping - less bents - less p
ƒ Option slices easy to add on
ƒ Straight travel valve as flange on
housing
ƒ One Pump priority flow for option
on request
ƒ At EH DREs in pilot cover
 New Rexroth 2-Loop Positive Control 7M9-25

More benefits
•Integrated anti drift valves for Boom bottom
and Arm rod side - Ports SAE 1 ¼ - 6000
•Up to 2 Option can be flanged on
•Improved regeneration function for Arm in
•Flow summation for Option possible
•Regeneration for boom down
•At simultaneous movement straight travel and implement hydraulic
the travelling does not stop (at least 1 Pump for tracks)
•Improved sharing of flow with combined tandem and parallel ircuits
•Semi priority of Slew over Arm and Boom over Bucket with
combination tandem and restricted parallel circuit
•Better controllability of Option 1 with individual Neutral
Complete Excavator Schematic with a Positive Control system.
 Description of Hydraulic Schematic

We see a complete schematic of an excavator with a Positive

Control system.

-Variable displacement pump A8VO.. With integrated proportional pressure

relief valve for the load limiting control.
- Block 7M9-25
- Pilot pressure Control
- Logic for controlling the straight travel valve and realising a pump anagement
- Proportional pressure relief valves for the pump mangement
- Hydraulic valve for straight travel valve and solenoid valve to control the
primary two stage pressure relief valve.
-Slew Gear GFB
-- Travel Gear with motor and counterbalance valves
 Further considered

1. An electronic pump management is used to improve the performance

of the system.
Therefore we show pressure sensors on the logic block to transfer the
max. pilot pressure on each pump (P1 and P2on logic block) into an
electric signal which is send through a micro controller to the pump
and swivels out the pump to the requested performance.

2. In the logic block are also collected signals separately from the
implement hydraulics and traveling. With this signals the straight
travel valve is controlled.

3. The schematic shows two different versions of an arm regeneration

function. With the first prototype we want analysis which version
gives a better performance to the system and that will be realised in
the block.
Hydraulic Logic for 7M9-25
Dimension: 295 x 100 x 100mm (8 - Axis)
255 x 100 x 100mm (7 - Axis)

• The ports P1 and P2 to swivel out the pump,

• BB and AB to control the summation functions,
• SB for a pressure switch to release the electric brake in the slew gear,
• PI and PT to control the straight valve
• In a hydraulic system x can be used to change the pump flow.
Hydraulic Schematics
7M9-25
 Functions and locations in the block.
Main block:
•In the middle summation valves for boom and arm and cut valves
•Right and left travel, secondary pressure relief valves and
counter balance valves directly on travel motor.
•Right side slew, secondary valves on slew motor.
S-port for feeding in sub plate
•Arm with secondary pressure relief valve,
regeneration - meter out is controlled by pump pressure.
Anti-drift valves
•Boom with secondary pressure relief valve
regeneration in the spool & anti-drift valves
•Bucket with secondary relief valves
Sub plate:
•Ports for pump, tank and cooler
•Primary relief valves
•Straight travel valve
 New Rexroth 2-Loop Positive Control 7M9-25

Pump Management

-Hydraulic management for MCV and Pump

Shuttle valve block selects the highest signal and

pump swivels out accordingly.

With the proportional swivelling of the pump and the

individual designed spools, the single movements are
almost load independent when fine control is passed.

As there is no signal summation for pump flow in

simultaneous operation, the pump must deliver
relatively higher flow than actuator demands on one
actuator operation. In simultaneous operation pump
delivers the flow by highest pilot pressure
New Rexroth 2-Loop Positive Control 7M9-25

Merits of Positive Control

•Energy saving is a big advantage

- No losses like Dp in LUDV or from NC orifice
- reduced neutral flow Qmin
- location of ports (less bents)
- spool F32
-1 ¼“ flange on Boom up and Arm in
- better pump management:
reduced area of neutral notches ->
low torque- -> high flow control
•Easier modification of the controllability
- Separated management of Pump and MCV
New Rexroth 2-Loop Positive Control 7M9-25
 New Rexroth 2-Loop Positive Control 7M9-25

-Hydraulic management for MCV;

EH management for Pump

The hydraulic signal of the joystick is given directly to

the main control valve and the pump.

Pst sensors on pilot lines give the pilot pressure to

the micro controller which controls a DRE to
influence the swivelling of the pump.

Consumer load optimised swivelling of the pump. The

higher the load of a consumer, the more the DRE
influences the swivelling curve of the pump.
2-Kreis Positive Control Block 7M9-25 EH
7M9-25 Flushing in Neutral
7M9-25 Flushing in Neutral

•For a faster response of the pump there is installed a

Qmin flow .
•In stand by and start up this flow is used for flushing and
warming up the system.
•Due to the preload valves for Tank and Cooler there is
also always moved oil from the tank line over flushing
notches in the main spool into the pilot covers, going
trough the joysticks (when not moved) to the tank
•This keeps the pilot system on a constant temperature
and eliminates a viscosity dependence of the remote
control.
•In addition it eliminates an air bleeding of the pilot covers.
7M9-25 Straight Traveling
6MX-25 Straight Traveling

Here we see a straight traveling process.

•As we have a 2-loop system each single pump

serves one track.

•In the straight travel valve, which stays in neutral is

a bypass installed, which eliminates flow differences
in the two loops
 6MX-25 Straight Travel plus Bucket

When adding an additional function (for example bucket) to the traveling, the
straight travel shifts proportional up to 1pump serving the additional function over
the parallel gallery and the other pump serving both tracks.
 6MX-25 Slewing

Pump 1 serves slewing

Pump 2 does not get a signal to swivel out. It stays at Qmin and circulates the
minimum displacement flow.
6MX-25 Arm out

P1 goes directly over the Neutral gallery to the Arm.

P2 goes over the Neutral gallery to the summation spool and to the arm.
 6MX-25 Slewing and Arm out

When moving slew and arm, the flow from P1 goes to the slew and the Neutral
gallery is closed. Over a parallel bypass some flow still goes to the arm, a restriction
in that bypass prevents, that all oil goes to the arm and the slew might stop.
P2 goes over the summation valve to the arm
 6MX-25 Arm in

Also arm in as a single function is using both pump flows.

The arm in regeneration is controlled by the meter-in pressure.
In digging conditions the meter-in pressure opens the tank line and there are no power
losses.
6MX-25 Boom up
6MX-25 Boom up - Bucket in

Boom up with Bucket

As the Neutral gallery is closed, the boom gets flow over the
restricted bypass. We have the same semi priority like slew over
arm.
 6MX-25 Leveling: Boom up full - Arm in full

In start of leveling, boom and arm are working in 2 loops.

To achieve enough speed in the arm, there is installed a restricted bypass to increase the
speed of the arm.
Also the regeneration of the arm is working which can also increase the speed of the arm.
6MX-25 Leveling: Boom up fine - Arm in full

When leveling continues, the speed of boom up gets less and

the arm gets additional flow over the summation valve.
 6MX-25 Digging: Arm in - Bucket in - Boom up

In digging conditions, we have the semi priority boom over arm on pump 2.
Pump 1 goes to the Arm, the regeneration is stopped due to the high meter-in pressure.
 6MX-25 Loading: Boom up - Slew

When the digging is finished the excavator goes in a loading cycle.

In 2-loop boom up and slew are working. To have more flow for the boom
it is possible to send some oil over a restricted bypass in influence with this the 50/50 ratio
of the pump flow.
6MX-25 Loading: Boom up - Slew - Arm out Correction

In the same movement it will be necessary to make corrective movements with the arm out.
The arm gets oil through the bypass boom - arm and the restricted bypass slew over arm.
6MX-25
Loading: Boom up - Slew - Arm out and Bucket Correction

In addition there are also corrective movements of the bucket necessary.

The bucket gets oil over the restricted bypass that does not take priority from boom.
6MX-25 Options

Connection of Option Spools

• Standard Option parallel to Boom

• Option can be supplied with both

pump flows

• Option with priority of one pump

flow possible

• No Cut valve needed for Option

 New Rexroth 2-Loop Positive Control 6MX-25
Summery:
1. Compact design
2. Easier piping; all actuator port in front, pump and tank at the rear
3. No back to back design will result in less bents, less power losses
4. Anti drift valves on Boom piston side
5. Anti drift on Arm in
6. Option slices flange mounted
7. Improved Regeneration for Boom and Arm
8. Q1 and Q2 on Option possible
9. On request; Priority on one pump for Option
10. At simultaneously operation tracking and implement
one pump serves tracking the other serves implement
11. Improved flow sharing due to superimposed parallel bypasses
•Improved Semi - Priority Slew over Arm
•Improved Semi - Priority Boom over Bucket
12. Boom lowering without pump on request
 New Rexroth 2-Loop Positive Control 6MX-25
Merits of Positive Control

Merits of Positive Control

1. Energy saving is a big advantage
• due to reduced neutral flow
• better pump management
2. In reference to the pilot system different pump management principles possible
•Shuttle valve block selecting the highest signal
– No signal summation for pump flow in simultaneous operation, so pump must
deliver relatively higher flow than actuator demands on one actuator operation.
In simultaneous operation pump delivers the flow by highest pilot pressure
•Pilot pressure of each spool will be converted into an el. signal by pressure sensor.
– Micro Controller sums all electrical signals and prop. pressure reducing valve
will set pump
– Signal summation for just the right pump flow for all actuators even in
simultaneous operation.
 New Rexroth 2-Loop Positive Control 6MX-25

It is shown a hydraulic piloting with EL /HYD pump management, which can be the
first step if not realising a total hydraulic system.
Hydraulic pilot controller for excavator 4TH87
 4TH6NR and 6TH6NR

f Features
- Hydraulic control for travel
- Cushioning function integrated

f Advantages

SDPM 07 Page 58
- Smooth travel operation
- Safety function through arm
rest position
 New Rexroth 2-Loop Positive Control 6MX-25

Perspective for new generation electro-hydraulic systems

with PC control on crawler excavators ( long term plan )
- Logic for single and/or simultaneous movements

- Modes for different drivers specific behaviour of machine

- Working modes (Heavy duty to Light modes or any other )

-Curves of joystick and pedals can be programmed individually

- Less noise and no oil in the drivers cabin

- Programmable Attachments
 Schematic with Electronic Control

The proportional pressure reducing valves are installed in the pilot covers of the main block
Pressure reducing valve family DRE
 THE5 Electronic Joysticks

ƒ Available in 3 different ranges:

• 4THES5 Analog Signal range
• THEC5 CAN bus range New
• THE5 Power range PWM
ƒ Easily adapted on several handles:
• EC 2000/2000+
• EC 4000
• Customer handles
ƒ Technical performances :
• Tightness : IP65 on Upper part
• Lifetime : 3 millions cycles
ƒ Robust mechanical conception
ƒ Same ergonomic configuration than
4THES5 THE5 THEC5
hydraulic joysticks
4THES5 PWM for excavator

•Voltage supply : 8-32 VDC.

•Operating Temperature Range: - 40 C to +85 C
•Storage Temperature Range: -40 C to +85 C
•PWM Output is a 500 Hz nominal PWM signal.
•PWM Output have nominal range of 0.5 VDC to 5 VDC.
•The output is capable of sourcing 20 mA at 4.0 VDC and sinking 20
mA at 1.0 VDC.
•PWM output response time from lever/pedal is less than 5 msec.
•No breakdown when output stage or logic inputs are shorted to 32V or
ground.
•Generates precise PWM signal up to 100 V/m electromagnetic field.
•Protected against moisture, all electric parts meet IP 67 specification.
•Support vibrations test up to 5g from 20 to 2000 Hz.
 4THES5 PWM for excavator

Electronic components are potted to garantee

high protection against dust and water.
El pilot controller 4THE5 NR
4THES5 – 4THES5NR
4THES5NR PWM
Pedal base general description
THE5 : Tightness
Qualification Joystick base robustness
Qualification Joystick Endurance
Qualification Electronic components aging
Qualification Test in climatic chamber
Qualification Salt pray test
Qualification Vibrations Tests
Qualification EMI Tests
Open Center Positiv Control ( PC ) - 2 loop
New Control Valve MX-25 - basic hydraulic shematic
Open Center Positiv Control ( PC ) - 2 loop
New Control Valve MX-25 - features
ƒ Compact design ( 6 sections in monoblock housing )
ƒ New circuit arrangement through the neutral gallery
ƒ Easier piping; all actuator port in front, pump and tank at the rear
ƒ No back to back design will result in lesser bents, lesser power losses
ƒ Anti drift valves on Boom piston side and on Arm in
ƒ Option slices flange mounted easily
ƒ Improved Regeneration for Boom and Arm
ƒ Q1 and Q2 on Option possible
ƒ On request; Priority on one pump for Option
ƒ At simultaneously operation tracking and implement
one pump serves tracking the other serves implement
ƒ Improved flow sharing due to superimposed parallel bypasses
-Improved Semi - Priority Slew over Arm
-Improved Semi - Priority Boom over Bucket
ƒ Boom lowering without pump on request
ƒ Prepared for EH operation ( no shuttle valve block necessary in future )
 Open Center Positiv Control ( PC ) - 2 loop
New Control Valve MX-25 - advantages of PC
¾ Energy saving is the biggest advantage
-- due to reduce neutral flow (min flow:30/20l/min, delta P30/27bar)
-- better pump management
¾ In reference to the pilot system different pump management principles
possible
-Shuttle valve block selecting the highest signal
– No signal summation for pump flow in simultaneous operation, so
pump must deliver relatively higher flow than actuator demands
on one actuator operation. In simultaneous operation pump
delivers the flow by highest pilot pressure
-Pilot pressure of each spool will be converted into an el. signal by
pressure sensor.
– Micro Controller sums all electrical signals and prop. pressure
reducing valve will set pump
– Signal summation for just the right pump flow for all actuators
even in simultaneous operation.