60 Mobile 2006 Hydrostatic Fan Concepts
Environment
To comply with the increasingly strict legal requirements for pollutant
emissions from diesel vehicles, vehicle and engine manufacturers are
making use of various measures that require an additional temperature
control system.
Electrohydraulically controlled fan systems from Rexroth pick up the re-
sulting signals and process them such that all controlled media are within
their optimum temperature window. Thus the combustion engine com-
plies with emissions requirements at all times.
Energy
When fuel prices increase, energy-saving technologies gain importance.
Among these technologies are hydrostatic fan drives from Rexroth.
Thanks to the fan speed which can be adjusted independently of the
speed of the combustion engine an energy savings of up to ten per-
cent is possible using a hydraulic fixed pump system instead of an un-
controlled fan drive. In addition, the energy-optimized control system with
axial piston pump can reduce operating costs by another five percent.
Bosch Rexroth AG Bosch Rexroth AG Hydrostatic Fan Concepts Mobile 2006 61
Low Emissions, low Costs
Hydrostatic Fan Concepts from
Rexroth
The worldwide trend towards increasingly strict legal requirements regarding
noise and exhaust gas standards has made hydrostatic fan drives a subject
of increasing interest to vehicle and construction machinery manufacturers.
The stricter the environmental laws become, the more economic sense it
makes to use these systems. In both Europe and the USA, new emissi-
ons laws took effect in 2006. By 2010, they will be made significantly more
stringent and the major emerging countries, such as China, have already
announced their intention to follow suit. (Fig. 1). For fans with 7 kW or more
of power, controlled hydrostatic fan drives already provide significant advan-
tages over V-belt fan drives or direct drives via crankshaft. Large potential
savings exist, primarily in the ability to arrange the components in the vehi-
cle in any way desired, and in the reduction in fuel consumption attained by
controlling the fan drive. The Fan Drives Application Center, in which Rex-
roth combines comprehensive skills and knowledge in engineering, state-of-
the-art simulation tools and powerful trial systems, plays an important role
when implementing tailor-made solutions. Working in close cooperation with
customers and partners, the engineers create complete, ready-to-operate
system solutions with matched components and interfaces.
Harald Ludescher
Horb (D)
62 Mobile 2006 Hydrostatic Fan Concepts Bosch Rexroth AG

1 New drive concepts

for increased cooling de-
mands
To comply with exhaust gas emis-
sions laws, vehicle and construction
machine manufacturers are offering
advanced drive concepts based on
diesel and alternative fuels. Todays
exhaust-optimized diesel engines
use particulate filters, EGR (Exhaust
Gas Recirculation) or SCR (Selective
Catalytic Reduction) and multistage
turbocharging. Hybrid drives with
electric or hydraulic brake energy re- Existing (more stringent) directives of industrialized countries
generation, also powered by Rexroth, More stringent directives expected in the next 5 years
expand these approaches. Further-
More stringent directives expected in the next 10 years
more, manufacturers are working on
Fig. 1: Emissions laws around the world.
engines with alternative fuels such as
natural gas, liquid gas and ethanol. An
additional realm of development is Demand-oriented, infinitely vari-
the hydrogen drive, both in the form able control of the fan from mini-
of a combustion engine and with a mum to maximum speed.
fuel cell (Fig. 2). Activation of the fan only when
All drive concepts require powerful necessary (fan standstill option).
cooling systems that operate with The fan speed is largely independent
optimized consumption. Todays of the engine speed.
controlled hydrostatic fan drives with Measuring and weighting of mul-
variable pumps fulfill both require- tiple operating parameters (such as
ments efficiently and economically. water, oil, charge air and exhaust gas
temperature).
Automatic speed increase of the fan
2 A comparison of fan sys- wheel when cooler output decreases,
tems for example due to contamination
Controlled hydrostatic fan drives are of the cooling fins or use at extreme
superior to conventional mechanical altitudes.
Fig. 2: Bus with fuel cell and hydrostatic fan
and/or electrical systems in the fol- Fuel costs are lowered by up to five (Citaro, roof cooling system).
lowing respects: percent by using a variable pump.
High flexibility with regard to the
arrangement of the entire fan sys-
tem. This allows the components
(such as the cooler) in the vehicle to
be arranged in any way desired; as a
result, less space is required.
Bosch Rexroth AG Hydrostatic Fan Concepts Mobile 2006 63

3 Hydrostatic fan drives
Hydrostatic fan drives from Rexroth
can be divided into four different cat-
egories: hydromechanically and elec-
trohydraulically controlled fan drives
as well as fixed pump and variable
pump systems.
3.1 Control types
Depending on the requirement, hy-
drostatic fan drives in vehicles can be
operated either hydromechanically or
electrohydraulically (Fig. 3).
Until the most recent increase in stan-
dards for exhaust gas values, simple,
hydromechanically controlled fan
drives were sufficient. These systems
were very suitable for controlling one
or two fluid temperatures, such as the
water and oil temperature. The sys-
tem advantages of hydraulics proved
convincing to many manufacturers, as
this solution gave the designers a new
degree of freedom in the placement
of the coolers. By separating the com-
bustion engine and the cooler, they
could optimize the necessary installa-
tion space and take advantage of pre-
viously unused spaces in the vehicle.
These first-generation hydrostatic fan
drives already made it possible to, for
the first time, decouple the combus-
tion engine speed from the fan speed
from a control technology standpoint.
However, in todays vehicle technol-
ogy, the cooling system is required to
monitor an increasing number of me-
dia and temperatures, such as charge
air for diesel engines or exhaust gases
when using EGR. The complex evalu-
ation and weighting of the different
operating temperatures requires an
electrohydraulically controlled fan
drive in order to generate demand-
oriented cooling output. Digital con-
trol electronics process the various
signals more quickly and efficiently
while, at the same time, providing
higher-quality control largely inde-
pendent of the engine output.

Hydrostatic fan drives

Hydromechanically controlled Electrohydraulically controlled

Fixed System Variable System Fixed System Variable System

External gear pump Axial piston pump External gear pump Axial piston pump
External gear motor External gear motor Axial piston motor
Axial piston motor
Thermo pressure valve Electronic/Sensors Electronic
Priority valve Thermo pressure valve Electric pressure relief valve Temperature sensor

Applicable independent (Diesel Applicable independent (Diesel Applicable independent (Diesel Applicable independent (Diesel
engine, gas drive, fuel cell etc.) engine, gas drive, fuel cell etc.) engine, gas drive, fuel cell etc.) engine, gas drive, fuel cell etc.)
Free assembly of the cooler Free assembly of the cooler Free assembly of the cooler Free assembly of the cooler

Infinitely variable control of the fan
speed independent of the speed
of the combustion engine
Low mass of pump and motor
Short overall length of the pump
Noise-optimized gear pump Si-
lence
Low prime costs
Infinitely variable control of the
fan speed independent of the
speed of the combustion engine
Long service life
Power of the pump is adapting
to the fan power (up to 5 percent
Kfuel saving compared to the
fixed pump system)
Reduction of the cooler size by
approx. 50 to 70 percent (com-
pared to the fixed pump system)
Infinitely variable control of the fan
speed independent of the speed
of the combustion engine
Low mass of pump and motor
Short overall length of the pump
Noise-optimized gear pump Si-
lence
Low prime costs
Record and assessment of
several operation parameters
(compliance with the waste gas
emission figures)
CAN bus connection
Infinitely variable control of the
fan speed independent of the
speed of the combustion engine
Long service life
Power of the pump is adapting
to the fan power (in combination
with the fand standstill option up
to 5 percent Kfuel saving compa-
red to the fixed pump system)
Reduction of the cooler size by
approx. 50 to70 percent (compa-
red to the fixed pump system)
Record and assessment of
several operation parameters
(compliance with the waste gas
emission figures)
CAN bus connection

Fig. 3: Control types of hydrostatic fan systems.

64 Mobile 2006 Hydrostatic Fan Concepts
BODAS, the digital controller fam-
ily from Rexroth, has been specially
designed for robust applications in
mobile equipment and commercial
vehicles. The electronics are resistant
to vibration and shock up to 25g and
operate in an ambient temperature
range from -40C to +85C with no
reduction in performance. A particu-
larly important feature for vehicle
applications is their high electromag-
netic compatibility of 100V/m in ac-
cordance with Directive 2004/104/EC,
which allows them to communicate
with other systems via CAN bus.
Developed by Rexroth the AFC (Au-
tomatic Fan Control) application
software for the fan drive evaluates
the various parameters of up to eight
input signals, weights them according
to the stored program map and uses
this to generate a control signal for the
bypass valve of the constant system or
the control valve of the variable pump
system.
3.2 Fixed pump system
Rexroth offers fixed pump systems
in a simple design with a noise-op-
timized Silence gear fixed pump and
a corresponding external gear mo-
tor located directly on the fan. The
pressure pulsation of the Silence gear
pump, which is decreased by up to
75 percent, lowers the vibrational ex-
citement of downstream parts of the
hydraulic system and the body. The
particularly quiet gear pump emits
very little airborne noise. Both effects
considerably reduce noise emission
into the vehicles interior and the sur-
rounding area.
A valve arranged in bypass allows the
hydraulic motor speed to be increased
continuously in fixed pump systems.
Here, the control can be implemented
either hydromechanically or electro-
hydraulically.
If the control is hydromechanical, a
priority valve is used that can be inte-
grated into the port plate of the gear
pump and is controlled in the cir-
cuit by a thermo pressure valve. The
thermo pressure valve used is a pres-
sure-relief valve that provides tem-
perature-proportional control within
its working range.
If the control is electrohydraulic, an
electroproportional pressure-relief
valve with digital control electronics
is used. The pressure-relief valve can
be integrated into the port plate of the
external gear motor. In the fan system,
control of the electrical valve current
of the control electronics takes place
based on the temperatures measured
by the temperature sensors.
Whether hydromechanically or elec-
trohydraulically controlled, fixed
pump systems have one thing in com-
mon: the gear pump supplies more oil
than is required to drive the fan motor
at the desired pressure and the desired
speed. The excess quantity, the unnec-
essary hydraulic energy, can be used
for other hydraulic consumers.
The following are the primary advan-
tages of a fixed pump system:
They can be used independently of
the drive concept (such as diesel en-
gine, gas drive, fuel cell).
The cooler can be arranged inde-
pendently of the combustion en-
gine.
The short overall length of the gear
pump.
Bosch Rexroth AG
Noise-optimized Silence gear pump.
Low mass of Silence gear pump and
motor.
Infinitely variable control of the fan
speed from minimum to maximum
speed.
Consideration of the charge air
temperature and exhaust gas tem-
perature for compliance with ex-
haust gas emission values (electro-
hydraulic control).
Reasonable purchase price.
3.3 Variable pump system
A more up-to-date and, from an
energy standpoint, more attractive
option is variable pump systems with
an axial piston pump. Regardless of
the control type hydromechanical
or electrohydraulic the control valve
is located directly on the axial piston
variable pump.
For the hydromechanically controlled
variable pump system with variable
pump and remote-controlled pressure
controller DRG, the thermo pressure
valve controls the operating pressure
of the pump depending on the tem-
peratures of the media to be cooled.
In doing so, the flow of the pump
adjusts in a demand-oriented manner
to the required quantity and thus to
the required fan speed. This variable
pump system avoids the power dissi-
pation associated with the fixed pump
system.
The electrohydraulically controlled
variable pump system (Fig. 4) uses
the ED electroproportional pressure
controller, which was specially devel-
oped by Rexroth for the controlled
fan drive with Rexroth A10 variable
pumps. The method of operation is as
Bosch Rexroth AG
follows: The ED electroproportional
pressure-relief valve of the variable
pump controls the system pressure
independently of the electric valve
current. The system pressure is in-
versely proportional to the valve cur-
rent. Within the adjustable range, the
variable pump maintains fixed system
pressure regardless of the delivery
flow taken in by the system. Thus it
pumps only as much fluid as is taken
in by the consumers. The system pres-
sure can be continuously adjusted as
specified by the electric valve current.
The controller controls the electrical
valve current of the fan system based
on the temperatures measured by the
temperature sensors. If the speed of
the combustion engine changes, the
flow of the variable pump adapts in
a demand-oriented manner to the
required delivery rate and thus to the
necessary fan speed. If the fan control
system fails, for example if the valve
current fails because of a cable break,
the pump generates the maximum fan
power (fail-safe behavior). The de-
mand-oriented control, together with
the optional fan standstill function,
lowers the fuel consumption of the
engine by up to five percent compared
to a fixed pump.
The standstill option, which is avail-
able for the variable pump, stops
fan operation until the combustion
engine reaches the desired tempera-
ture. This energy-optimized function
provides enormous advantages, par-
ticularly at low ambient temperatures.
The engine reaches the optimum
combustion temperature, and thus
the lowest exhaust gas emission, more
quickly.
Hydrostatic Fan Concepts Mobile 2006 65
Coolant temperature-oil
TSF
CAN-Bus
Temperature
Water
Charge air
BODAS
ECU
Charge air
Controller
Water
Combustion engine
Fluid
Sensors
AZMF
Fixed
motor
A10VO..ED/52
Variable pump
Fig. 4: Circuit diagram of electrohydraulically controlled hydrostatic fan drive.
The following are the primary advan- sion values (electrohydraulic con-
tages of a variable pump system: trol).
They can be used independently of Fuel savings of up to five percent at-
the drive concept (such as diesel en- tained by using an axial piston vari-
gine, gas drive, fuel cell). able pump, in combination with the
The cooler can be arranged inde- optional fan standstill function.
pendently of the combustion en-
gine.
Infinitely variable control of the fan
speed from minimum to maximum
speed.
The fan speed is largely independent
of the combustion engine speed.
The service life of the axial piston
variable pump is up to two-and-
one-half times that of gear compo-
nents.
Reduction of the size of the oil cool-
er by up to 70 percent (compared to
a fixed pump system).
Consideration of other parameters,
such as the charge air temperature
and exhaust gas temperature, for
compliance with exhaust gas emis-
66 Mobile 2006 Hydrostatic Fan Concepts
3.4 Ensuring a clean cooler: Re-
versing function
For fan systems which, because of
heavy contamination from the out-
side, require a reversing mode of the
fan wheel to clean the cooling vents,
the optional Reversing function
module is available. Reversing is par-
ticularly useful for mobile machines
that operate in a very rough environ-
ment. Particularly in wheel loaders,
forestry machines and combine har-
vesters, the fan sucks in not only air,
but also dust and dirt that accumulate
on the vents of the cooler, reducing
cooling capacity and increasing the
energy consumption of the fan drive.
For this reason, the Reversing func-
tion module is integrated into the
hydraulic fan system, and also stored
in the electronic controller.
4 Costs over the entire
lifecycle
4.1 Influencing factors
The decision as to whether a variable
pump system makes more economic
sense than a fixed pump system de-
pends mostly on three influencing
factors:
first, the maximum required fan
output;
second, the combustion engine
speed beginning at which the maxi-
mum fan output is needed;
third, the required size of the oil
cooler.
In todays engine concepts, the com-
bustion engine speed beginning at
which the maximum fan output is
required (fan design point) is adjusted
Bosch Rexroth AG
3500
System fixed pump: 3
The excess flow has to be
3000
by-passed into the tank by
means of a bypass valve
2500
Speed fan [U/rpm] 2000 1 2
Operating area
1500 of the fan
1000
500
0
0 250 500 750 1000 1250 1500 1750 2000 2250
Speed diesel [U/rpm]
Fig. 5: Speed diagram of combustion engine fan speed.
in an increasingly low speed range. In The variable pump system, on the
the speed diagram (Fig. 5), the design other hand, is demand-oriented: If
point is indicated by index 1. Fan de- the speed of the combustion engine
sign point 1 determines the size of the changes, the flow of the variable
pump. pump adapts without throttling losses
to the required delivery rate and thus
4.2 Dimensioning the oil cooler to the necessary fan speed. This avoids
the power dissipation associated with
When dimensioning the oil cooler,
the designers consider the maximum the fixed pump system (Fig.5, speed
speed of the fan and the maximum diagram, index 2). Depending on fan
speed of the combustion engine. In design point 1, this allows the size of
a fixed pump system, the fixed gear the oil cooler to be reduced by up to
pump generates an excess flow if the 70 percent.
speed of the combustion engine ex-
ceeds the speed of fan design point 1.
Usually, this excess quantity must be
routed directly into the tank as dissi-
pation power. Therefore, the required
cooling capacity of the oil cooler is
calculated from two components: the
efficiency of the fixed pump system
plus the dissipation power from the
excess quantity generated (Fig. 5,
speed diagram, index 3).
Bosch Rexroth AG Hydrostatic Fan Concepts Mobile 2006 67

4.3 Fuel savings depending on

the load collective
Considering the load collective of the
fan for applications in construction
machinery, commercial vehicles and
buses, the variable pump system takes
full advantage of its demand-oriented
fan control. Depending on the load
collective, fuel savings of up to five
percent are realistic.

4.4 System costs

The variable pump system reduces
the purchase price of the oil cooler. In
this way, it compensates fully or par-
tially for the added cost of a variable
pump. At the same time, the variable
pump system provides added value
over the entire lifecycle thanks to the
great reduction in fuel costs (up to
five percent) and the service life of the
variable pump, which is two-and-a-
half times lower than that of the gear
pump.
Fig. 6: Ability to arrange the coolers as desired, using a dump truck as an example.
5. Conclusion
Because it can be used independently
of the drive train, the hydrostatic fan
drive will become increasingly im-
portant for construction machinery
and vehicle manufacturers. Important
advantages such as flexible position-
ing of the cooler, demand-oriented
control of the fan speed between the
minimum and maximum, conformity
with worldwide emissions standards
for exhaust gas and noise, and fuel
savings of up to five percent by using
an axial piston pump contribute to
the trend towards electrohydraulically
controlled hydrostatic fan systems
with variable pumps.
Worthy of future attention is the
opportunity to work with electrohyd-
raulically controlled hydrostatic fan
drives and combined systems. This in-
cludes the combination of hydrostatic
fan drives with auxiliary drives such
as air-conditioning compressors, air
compressors and loading of accumu-
lators and alternators.
In the Fan Drives Application Cen-
ter, Rexroth makes available compre-
hensive services and supports manu-
facturers of combustion engines,
coolers, construction machinery and
vehicles in the configuration, param-
eter setting and commissioning of the
fan drives. Working in close coopera-
tion with customers and partners,
Rexroth creates complete, ready-to-
operate system solutions for fan drives
with matched components and a
minimum number of interfaces.