92 Mobile 2006 Forklift Trucks Bosch Rexroth AG Bosch Rexroth AG Forklift Truck Mobile 2006 93

Energy Forklift Truck Technology for

Load-sensing systems are being used more and more in industrial forklifts
with combustion engines. In a system like this, a variable-displacement axial
piston pump assumes the responsibility for providing an on-demand supply
to consumers. The flow is regulated independently of the load pressure.
The improved energy balance associated with this technology is mainly
attributable to the use of smaller combustion engines with lower fuel con-
sumption.
Function
The electrohydraulic pilot control and the load-independent flow control of
the electrically operated valve SB15-EH guarantee high performance and
perfect ease of operation. Integrated functions reduce piping complexity
and keep costs under control.
high Performance
Rapid, safe and good maneuverability, low fuel consumption, easy to control
and ergonomic this would be the optimum profile of a forklift truck. High
performance for minimum costs is the aim. With this very target in its sights,
Rexroth is developing new products for working hydraulics, drive transmis-
sion and steering and also offers users application-ready total solutions.
From a technical perspective, electronically actuated valves, quiet pumps
and highly functional control elements are very much at the fore. On this ba-
sis, integrated load-sensing systems pay off, thanks in no small part to their
energy savings and functionality.
Frank Rieckhof
Schwieberdingen (D)
94 Mobile 2006 Forklift Trucks Bosch Rexroth AG

1 Successful internal 2 AFM the future-proof

logistics
Transport loads safely and in as short
a time as possible: the tasks of a fork-
lift truck are clearly defined. To fulfill
these tasks on a technical level, the
forklift manufacturer may be rather
laboriously combining individual
products from different manufactur-
ers. It would be less time- and cost-in-
tensive, however, if he were to simply
select his user-specific system from
optimally matched components or a
total solution in line with his require-
ments.
With decades of experience and solid
know-how in forklift engineering,
Rexroth offers every relevant product
and system required to put together
a cost-effective solution. With costs
energy function environment
in mind, application-ready systems
are available for working hydraulics,
drive transmission and steering. They
make it possible for the forklift manu-
facturer to plan reliably for todays
and tomorrows expansions while at
the same time making the work of the
forklift truck operator easier.
total solution
The Advanced Forklift Truck Man-
agement (AFM) contains both main
components of the forklift hydraulics
(Fig. 2):
Working hydraulics for all mast
functions such as lifting, lowering,
tilting and additional functions
such as hydrostatic steering.
Fig. 1: Thanks to decades of experience and Hydrostatic drive transmission for
competence in forklift hydraulics, Rexroth is
able to supply outstanding components for rapid travel, easy maneuvering and
forklift trucks. precision positioning of the lift
truck.
motors for axle or wheel drive, the
Silence external gear pump series,
valves of the SB15-EH and SB12 LS
series, the LAGC steering unit and
electronic joysticks. The most recent
developments in the individual series
can also be seen in the AFM concept
(Advanced Forklift Truck Manage-
ment): Rexroths total solution for
modern forklifts.

From the components to the

management
The user-oriented concept of Rexroth
forklift engineering is built around
several product pillars: from compact
units, pumps and hydraulic motors,
valve technology, drive transmissions
and steering units to electronics and
software (Fig. 1). All components are
matched for compatibility and can
be easily combined to satisfy require-
ments. The most important parts of
Fig. 2: Ranging from the pump to the electronics, Rexroths product spectrum offers unique
this equipment package are the A4VG components and tailor-made total solutions for forklift hydraulics.
and A10VO pump series, hydraulic
Bosch Rexroth AG Forklift Trucks Mobile 2006 95

The modular AFM concept is fully Zusatz

Auxiliary functions
Neigen
Tilting
Heben / Senken
Lifting / Lowering
comprised of Rexroth components
that have been matched specifically
for use in forklift trucks. The user
therefore receives a total solution
including electronics, software and
control elements from a single source
Lenkung
that, when put together, satisfy his Steering
(LAG)
requirements completely (Fig. 3). Steuerblock
Control block
SB15EH
Development times are therefore re-
duced thanks to ready-prepared soft- Lenkzylinder
ware modules and high-performance Steering cylinder

development tools. The customized

solution is created with increased time Radialkolbenmotoren
Radial piston motor
and cost efficiency using the BODAS Software Inchpedal Fahrpedal Sensor Sensor
(MCR05)

electronics concept, which, in addi- BODEM Inch pedal Drive pedal DSM PR2 Verstellpumpe
Variable pump
(A4VG...)
tion to the software, contains all the Zahnradpumpen
Gear pumps
necessary electronic components such

Motor management
Motormanagement
(AZP-N+F)

as sensors, control units, joysticks and Diagnose

Parametrierung Joystick Display
RC 6-9 RCE 12-4
displays. Prozessgren
Diagnostics
+ DI2

Software
parameterization ESC F1 F2 F3 F4

process monitoring
F5

Forklift trucks with the AFM concept

are well equipped to meet the high CAN-Bus

demands in logistics: high flow rates

and hydrostatic braking with retarder Fig. 3: The CAN bus and the synergies between components make system configuration and the
integration of the combustion engine as easy as it could be.
support allow the lift truck to achieve
high working speeds. Together with
Hydrostatic drive transmission The reliable drive transmission is
faster reversing, this contributes to
with variable pump adaptable and has a range of inte-
an increase in performance. Fuel
The type of drive transmission grated functions. It makes pulling
consumption is optimized by both
wheel drive for industrial forklifts and away smooth and supports powerful
a reduction in engine speed and the
axle drive for rough terrain lift trucks acceleration, hard braking, the abil-
power management for the drive
depends on the scope of application ity to reverse direction and sensitive
transmission and working hydraulics.
of the forklift. The hydrostatic drive positioning. Two different concepts
The improvement in the lift trucks
transmission of the new AFM concept are available as drive controls: the
ergonomics is mainly attributable to
consists of a variable-displacement proven hydraulic solution and the
low noise levels and optimized han-
axial piston pump (A4VG) and two new electronic drive control, which
dling. Important information is dis-
radial piston motors (MCR) for the can be easily integrated into the gen-
played clearly, the driver retains one
closed circuit. The pumps offer fea- eral management of the lift truck.
hand control of all functions thanks
tures such as high power densities, Application-ready software packages
to new joystick technology and is
integrated safety functions and high- are therefore now a feature of drive
able to issue sensitive commands for
precision truck positioning capability. transmission. In addition to control of
arduous tasks. All this serves to make
the pump and combustion engine, the
working with the forklift truck easier
user is able to freely select acceleration
and hassle-free.
characteristics and speed limits. Fur-
thermore, the electronics provide
96 Mobile 2006 Forklift Trucks
protection against overload and over-
speed to diesel engines and hydraulic
motors.
Fig. 4: Variable pump A4VG series 40, with
electrical-proportional control. Due to an
updating of the well-established series 32 an
even higher reliability and life expectancy, at the
same time an increased pressure range (450 /
500 bar).
Bosch Rexroth AG
3 Energy and cost-saving
working hydraulics
The general question associated with
working hydraulics is which type of
pump should be used, a fixed pump
or variable pump? From purely an
investment cost point of view, the
manufacturer would often opt for the
fixed pump. However, the optimiza-
tion of system solutions now means
that the variable pump is an interest- Fig. 5: The A10VO compact variable pump
ing economic proposition despite the stands out for its improved controllability and
reduced energy consumption. The reduced
higher acquisition costs if lifecycle heating of the oil in the system increases the
costs and all the positive aspects the interval between oil changes and requires less
cooling output.
pump has to offer are taken into ac-
count.
4 Low-noise fixed pump
While the fixed pump normally pro- Fixed pumps from the external gear
duces power at all times, even when pump series are also the subject of
this is unnecessary and which the con- ongoing development. They convince
nected motor must also help to deliv- with their high power density and
er, the variable pump is able to regu- simple design, guaranteeing reliable
late back down to zero. As a result, the operation even under tough condi-
power is only delivered in response to tions. Conventional external gear
direct operation of a function, with pump series are, however, disadvanta-
the effect that the oil flow produced is geous in terms of noise development.
sufficient to satisfy actual demand and This is due to the fact that the pump
there is no wastage of energy. causes a pulsation as the pressure me-
These positive features of a variable- dium is pumped. This flow pulsation
displacement axial piston pump such agitates into vibration not only the
as the A10VO (Fig. 5) particularly pump but also the entire hydraulic
come to the fore within a load-sensing system, the sound waves from which
system. Controlled by a mechanically result in clearly audible noise emis-
operated SB12 LS valve, it supplies sions.
the consumers on-demand with the
flow of oil regulated independently
of the load pressure. The reduction in
costs associated with this technology
is mainly attributable to the use of
smaller combustion engines and lower
fuel consumption. Moreover, the oil
in the system is not heated as much,
which results in a significant increase
in the interval between oil changes.
Bosch Rexroth AG Forklift Trucks Mobile 2006 97

With the Silence design (Fig. 6), this up to 75% less pressure pulsation
flow pulsation is reduced by up to up to 5% lower sound level dB(A)
75 percent. This is achieved by the
two-flanked seal with ground tooth
flanks, which reduces the vibration
agitation of the pump and of the
entire hydraulic system to which it is
connected. With this new design, the
Silence pump now differs consider-
ably from previous positive-displace-
ment pumps. The quiet-running fixed
pump therefore makes a positive con-
tribution to improving ergonomics in Displacement 4 - 28 cm/U 20 - 36 cm/U 22.5 - 63 cm/U
the forklift drivers workplace. Pressure max. 280 - 200 bar 280 - 210 bar 280 - 200 bar
Speed max. 4000 - 3000 U/rpm 3000 - 2600 U/rpm 3000 - 2300 U/rpm

Fig. 6: The low-noise operation of the SILENCE version of the external gear pump distinguishes it
from conventional fixed pumps. It is available in three sizes with flow rates of 4.0 28 cm (S), 20
5 Compact units ready 36 cm (T) and 22 63 cm (U).
for installation and tailor-
made
The main focus of power packs is on
a reduction in installation effort (Fig.
7). The compact and robust hydraulic
units are ready for installation. Build-
ing on certain basic variants, they can,
as a modular system, be adapted in no
time to the installation space available
in the forklift truck. All the necessary
valves can be fully integrated into
the power unit. For this reason, not
only do the compact units require
less space but they also reduce the
effort and costs associated with ad-
ditional piping that would otherwise
be needed. In addition, the special
components operate at low noise
levels, meaning that the compact
units enhance the ergonomics of the Fig. 7: The new Power packs are rapidly and flexibly adaptable thanks to their modular system.

entire system. The power packs can

be equipped with proportional valves,
which, even at low loads, permit rapid
and sensitive lowering with pin-point
positioning.
98 Mobile 2006 Forklift Trucks
6 Task-oriented valve tech-
nology
Higher performance is the declared
objective of the already proven SB12
LS load-sensing control block (Fig. 8).
It has now been enhanced by a func-
tion to comply with the requirements
of the new ISO 3691. For safety rea-
sons, therefore, no hydraulic func-
tions, such as lowering of the mast,
are operable unless the forklift driver
is seated.
In addition to these mechanically op-
erated valves, the trend on the forklift
truck is moving towards electrically
operated valves. The SBE control
block developed specifically for the
forklift truck with its integrated,
forklift-specific functions stands out
for its high-precision control, small
space requirements and simpler pip-
ing and wiring thanks to optimally
accessible interfaces. The technology
of the SB15-EH (Fig. 9) goes one
step further. This new generation of
electrohydraulically pilot-controlled
Fig. 8: Where high performance is demanded,
the SB12LS mechanically operated load-
sensing control block convinces thanks to its
support of parallel operation, precision control
and pin-point positioning accuracy. With its
new, integrated safety function, the SB12 LS
meets the requirements of the new ISO 3691:
mast functions can only be operated if the
driver is seated on the lift trucks seat.
directional valves (SB15-EH) supports
parallel operation of functions, pre-
vents overly rapid lowering by means
of integrated load lowering valves and
offers highly sensitive control at high
loads. It is because of these techni-
cal features that the SB15-EH valve is
also used in Rexroths AFM concept,
where, among others, it takes over the
function of internal retarder regula-
tion, rendering a separate valve super-
fluous.
Fig. 9: The electrohydraulic pilot control and
the load-independent flow control of the
SB15-EH guarantee high performance and
perfect ease of operation. Integrated functions
reduce piping complexity and keep costs under
control.
Bosch Rexroth AG
7 New steering and joy-
sticks improve ergonomics
Independent and unforeseeable move-
ments of steered wheels used to be a
typical problem of forklift trucks with
open-center-based steering. The new
LAGC steering unit (Fig. 10), prevents
kick back and rebounding of the
steered wheels. While the relief of me-
chanical and hydraulic energy during
certain steering processes would cause
problems, this effect is now effectively
prevented by a new, patented oil duct
inside the LAGC steering unit. For the
forklift driver, this means increased
safety when picking up and setting
down loads, when steering, and when
the forklift truck subsequently backs
away. The jolt-free steering therefore
improves handling characteristics and
ergonomics and significantly reduces
the risk of an accident.
Fig. 10: The LAGC-OC steering unit effectively
prevents a jolting back of the steered wheels.
It solves the so far typical problem affecting
forklift trucks with open-center-based steering
(independent and unforeseeable movements).
Bosch Rexroth AG Forklift Trucks Mobile 2006 99

Hydraulic and electronic joysticks
are provided for controlling all func-
tions as well as the working hydraulics
and the drive transmission. In the
development of the new BODAS EJ
electronic joystick (Fig. 11), particular
emphasis was placed on improving er-
gonomics. The driver can use it to op-
erate all functions comfortably with-
out taking the hand off the joystick.
Furthermore, the new generation is
programmable, so specific customer
requirements can be easily accom-
modated. The new electronic joystick
meets the high demands of the AFM
concept and, in combination with
electrically operated valves, ensures
precision positioning.
8 Conclusion: demand-ori-
ented and future arrival of
ever more electronics
Cost-intensive labor times and in-
creasing energy prices are already
determining the nature of the fork-
lift engineering and technologies of
today. Integrated functions, more
electronics for improved controllabil-
ity and reductions in wasted output,
and software for quick and easy cus-
tomer-specific system configurations
will shape future developments. Even
ergonomics in the workplace are play-
ing a meaningful role as far as forklift
trucks are concerned, with the aim of
enabling the driver to carry out his
work activities in the most productive
fashion.
Rapid and safe driving and maneuver-
ing as well as the sensitive and preci-
sion control of loads are prerequisites
for high performance. The engineer-
ing required for this is becoming
increasingly complex and the advan-
tages it will bring will only become
apparent as part of a complete system.
Competency in product development
and, in particular, system know-how
will therefore play an even greater role
in future and be tested in the Applica-
tion Center Lift Trucks under real
conditions (Fig. 12) so as to be able to
fully meet the demands of the forklift
truck manufacturer and operator.

Fig. 11: The BODAS EJ electronic joystick can

be easily connected via CAN bus. The impro-
vements in ergonomics soon become apparent
to the driver, who is now able to control all
functions easily without having to take his hand
off the joystick.
Fig. 12: All components and systems for the working hydraulics and the drive transmission are
tested in the Application Center under real conditions.