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Mobile 2012 | Hydraulic Traction Assistant for Trucks

Bosch Rexroth AG

Efficient and Innovative Components

for Better Use of Installed Energy
Energy efficiency implies an increase in the productivity of mobile working machines. The basic
requirements here are the reduction of power loss and the optimization of components in the
hydraulic system in terms of their efficiency.
By introducing new components and working with existing components in an innovative way, it is
possible to meet market requirements and customer demands that center on the improved use of
installed energy, a reduction in fuel consumption, and greater overall vehicle functionality.
In the context of this topic, Bosch Rexroth presents innovative solutions with new model series
while continuing to develop its existing product range in all respects.

Bosch Rexroth AG

Hydraulic Traction Assistant for Trucks | Mobile 2012

59

A New Dimension in Four-Wheel Driving

Hydraulic Traction Assistant for Trucks
Abstract

As a rule, trucks with a conventional mechanical four-wheel-drive system are mainly limited to the
segment of high-terrain vehicles and dump trucks. For commercial vehicles that are predominantly
active on the road and only infrequently enter construction sites to carry out deliveries, or that
occasionally travel on soft, waterlogged surfaces or steep slopes and mountain passes in the
winter, the hydrostatic auxiliary drive is a good alternative to a conventional mechanical four-wheeldrive system. In terms of distance, these commercial vehicles spend very little time traveling off
road however, it is in these moments that traction problems are often the greatest.

Harald Ludescher

Sales and Industry Sector Management

On-Highway and Commercial Vehicles

Andreas Wolf

Sales and Industry Sector Management

On-Highway and Commercial Vehicles

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Mobile 2012 | Hydraulic Traction Assistant for Trucks

Hydrostatic auxiliary drive for

commercial vehicles greater
off-road traction
Nowadays, practically every manufacturer of commercial
vehicles offers permanent or part-time four-wheel-drive
technology in their portfolio. However, all-wheel drive
technology does not bring advantages only, since there is
no such thing as free traction. Bosch Rexroth presents the
Hydraulic Traction Assistant (HTA), a hydrostatic auxiliary
drive that offers a number of benefits when compared to
the conventional mechanical alternatives available to date.

Bosch Rexroth AG

Hydraulic Traction Assistant (HTA)

increases efficiency
In comparison to conventional mechanical all-wheel-drive
systems, HTA reduces overall vehicle weight by around
400kg. This in turn has a positive effect on cost-efficiency,
improving fuel consumption and permitting a greater cargo load. The HTA hydrostatic auxiliary drive is capable of
mastering challenging driving situations and deployment
conditions, resulting in improved schedule reliability and
greater efficiency. HTA is available for a wide range of
vehicle types with two to four axles. Its modern hydraulic
technology is extremely flexible as regards its integration

Fig. 1: Hydraulic Traction Assistant (HTA) offers additional traction while reducing vehicle weight and saving fuel

Bosch Rexroth AG

into the vehicle: the HTA makes it possible to dispense

with heavy drive axles, splitter gearboxes and axle gearing. The axle driven by HTA can be positioned anywhere
in the vehicle, for example on a leading axle, pusher axle
or trailing axle. For this reason, the HTA system requires
no alterations to the basic chassis design (overall height,
drivers cab, center of gravity), and neither does it compromise the vehicles maneuverability or turning circle.
By incorporating a hydrostat such as HTA, Bosch Rexroth
is making use of technology for individual components
thatHydraulic
has proven valuable
for manyAssistant
years in the plant
Traction
(HTA)
construction industry.

Hydraulic Traction Assistant for Trucks | Mobile 2012

HTA: components and system design

The key components of the Hydraulic Traction Assistant
(HTA) are the MCR10-R radial piston motors, which are
seamlessly integrated into the axle and reliably provide
additional traction in difficult driving situations (snow
and ice, mud, loose ground, dirt tracks and construction
sites). Other main components include an axial piston variable pump, a valve block with pressure and temperature
sensors, oil coolers with fan drive, a filter and hydraulic
reservoir and an electronic controller.

Status: Confidential

HTA C
Components
t

Radial Piston
Radial
Piston
Motor MCR10-R
Motor
MCR10R

BODAS

Rexroth
Controller RC
Control Unit RC

Manifold
Manifold

Axial Piston
Axial Piston
Pump A4VG

Pump A4VG

Reservoir TMP
Reservoir
TMP

Fig. 2:| Harald

Layout
of the |main
components
in a| commercial
Ludescher
16.07.2012
| DC-MA/SMV2
Bosch Rexrothvehicle
AG 2012. Alle Rechte vorbehalten, auch bzgl. jeder Verfgung, Verwertung, Reproduktion,
Bearbeitung, Weitergabe sowie fr den Fall von Schutzrechtsanmeldungen.

61

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Mobile 2012 | Hydraulic Traction Assistant for Trucks

The controller in the driver cab consists of switches to

activate the HTA and hydraulic drive mode, as well as
indicator lights.
The hydraulic system of the hydrostatic auxiliary drive is
a closed circuit coupled to the mechanical drive train of
the commercial vehicle. The hydraulic system also works
when the vehicle is in reverse, in which case the suction
and pressure pipes of the high-pressure circuit switch
functions.

Bosch Rexroth AG

HTA: functionality
The axle driven by HTA receives its drive torque of up to
6000Nm per wheel via the MCR10-R radial piston motors. The level of torque builds up very quickly once HTA
has been activated, which takes less than one second.
The operating pressure required for activation of around
400bar is supplied by an A4VG axial piston variable pump
with electric proportional control (EP) and an integrated
boost pump, which is driven by a cardan shaft at the PTO
of the diesel engine. The HTA is actuated by the BODAS
Rexroth controller RC12-10/30.

Neutral Valve (2)

(5/2-Valve pilot operated)

Flushing and Relief Valve

(for Traction Mode)

Clutch Valve (1)

(Hydraulic A-B Bypass 2/2-Valve)

T1

T2

Fa

PS

X1

X2

MA A

MH

MB

HTA Engage Valve (3)

(Activating the motor from
neutral mode into standby)

Fig. 3: Hydraulic schematic HTA (traction mode)

Bosch Rexroth AG

A distinction is made between two operating modes for

the HTA:

HTA neutral mode (inactive)

Additional traction is normally not required during
on-road driving. The standard setting for HTA is neutral
mode. For this, the A4VG axial piston variable pump is set
to zero delivery and a small level of flow from the integrated boost pump is used for its own lubrication and that
of the MCR10-R radial piston motors. The pistons of the
motors are extended without contacting the cam track. It
follows that there is no relative movement in the cylinder.
To ensure thermal balance in the wheel motor particularly when the driving brake is engaged it has integrated
flushing valves with check valves. This arrangement
reduces the amount of piping needed for the radial piston
motors to three lines.

Fig. 4: Radial piston motor MCR10-R

Hydraulic Traction Assistant for Trucks | Mobile 2012

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Thanks to minimal drag losses on the leading axle, a

system of this type consumes considerably less fuel compared to a mechanical part-time all-wheel-drive system.

HTA traction mode (active)

HTA is turned on by a rocker switch on the instrument
panel. This can be done even when the vehicle is loaded
and in transit. To activate HTA, a current is sent to the
magnetic actuators in the valve block, controlling the
hydraulic pressures in the MCR10-R radial piston motors
so that their pistons engage and make contact with the
cam track. This can happen when the vehicle is stationary
or traveling at speeds of up to around 30km/h. At the
same time, the A4VG axial piston pump varies its flow by
moving the cradle bearing so that the necessary flow for
the MCR10-R radial piston motors is reached.

Mobile 2012 | Hydraulic Traction Assistant for Trucks

Bosch Rexroth AG

Once the displacement has been synchronized, the

coupling valve closes the hydraulic coupling on the valve
block and the HTA hydrostatic auxiliary drive can build up
pressure, transmitting power from the diesel engine to
the leading wheels.

Bosch Rexroth as an engineering partner

64

While traction mode is active, the HTA system transmits

power from the diesel engine to the leading wheels of
around 50kW and torque of up to 6000 Nm per wheel, as
desired by the driver. The simplest method of determining
the drivers intention is performed by the BODAS Rexroth
controller RC12-10/30, which gauges the position of the
gas pedal. However, it is also possible to integrate the
HTA controls into the control strategy for the vehicle as a
whole, including moment management between the front
and rear axle.
Traction mode is available in the speed range from
0to30km/h. If the driving speed increases to above
30km/h, neutral mode is automatically activated. If the
driving speed then falls below 20km/h, traction mode is
automatically reactivated.

HTA hydraulic driving: creep mode

And that is not all HTA can do. A hydraulic driving creep
mode function has been implemented in HTA. For this,
the transmission is set to neutral. By toggling a rocking
switch on the instrument panel, the driver can select
creep mode either to move forward or to reverse. An
indicator light on the driver panel shows that creep mode
is active. The vehicle speed can be controlled using the
gas pedal or joystick. Creep mode can be used at speeds
of 0 to 10km/h, improving ease of use for all operations
that are carried out at slow, steady speeds, such as
maneuvering.

Any OEM that wishes to offer HTA on their vehicles can

rely on the benefits of our system expertise. The level
of competence we are able to provide as an engineering
partner makes us the market leader. As part of the Bosch
Group, we understand and meet the requirements of
businesses in the engineering and automotive sector,
especially as regards functional safety as per ISO26262.
The new requirements in terms of functional safety in
accordance with ISO26262 have led to important changes in development processes in the automotive industry.
Today, the automotive functional safety standard is already one of the most important pieces of legislation in the
industry, even though it has not yet come into effect.
There is a trend toward more extensive use of electronic equipment in commercial vehicles, which in turn
increases requirements concerning quality and quality
assurance and ultimately automotive functional safety,
too. As a result of such exacting demands in automotive
functional safety, it is more important than ever before
to have the right partner at your side, protecting your
interests in this matter.
For vehicle manufacturers, Bosch Rexroth is thus a reliable expert partner that also serves as a one-stop shop for
all core components, providing items of reliable quality on
time, all the time.
A collaboration with Bosch Rexroth also provides manufacturers with advantages in form of a long-term replacement parts service: OEM-quality parts, preassembled
components and kits, a well-developed global logistics
service, and the availability of replacement parts for many
years are key features of the expert services provided by
Bosch Rexroth.

Bosch Rexroth AG

Hydraulic Traction Assistant for Trucks | Mobile 2012

65

Summary
Unlike conventional all-wheel-drive systems, the Hydraulic
Traction Assistant (HTA) hydrostatic auxiliary drive from
Bosch Rexroth is ideally suited for commercial vehicles
that are mainly active on asphalt surfaces and only occasionally go off road. This means that HTA can be deployed in
almost every segment of the market, for example in traditional dump trucks, fire trucks, concrete mixers, concrete
pumps, skip trucks, roll-off dump trucks, tankers, silo
trucks and lumber trucks.
A creep speed has been integrated into HTA, which facilitates use for all operations that are carried out at slow,
steady driving speeds.
Compared to standard vehicles, HTA offers:
Greater traction resulting from auxiliary drive on the
leading axle in both directions
The possibility to have the axle that receives additional
power anywhere on the vehicle, e.g. on a leading,
pushing or trailing axle
Greater vehicle versatility
Improved driving safety and better stability on loose
ground, even when traveling uphill
Hydraulic driving (creep mode)

Compared to mechanical all-wheel drive, HTA offers:

Greater efficiency thanks to fuel savings and improved
load capacity
Reduced net load of around 400kg thanks to vehicle
weight reduction
Superior maneuverability/agility
Automatic activation of traction mode at speeds of
30km/h and toggling of the mode based on driving
movements
Compatibility with existing vehicle height, drivers cab,
wheel base and axle position
With the development phase successfully completed,
the HTA system from Bosch Rexroth is now ready to be
implemented in the vehicles of interested OEMs.