PI 023-18 Lohr am Main, 2018-09-18

Reducing diesel consumption

Modular system for complete cooling systems: Rexroth provides variable speed drive solutions with very fine and wide adjustment range.

Manufacturers of rail vehicles require efficient and easily configurable cooling systems to reduce energy consumption and comply with new and complex emission guidelines. Fan drives that provide very fine speed adjustment are required to fulfill the important role of proper temperature control. Exacting design requirements, such that diesel engine cooling circuits in power conversion generators can maintain tight temperature windows irrespective of load and environmental conditions, all while reducing fuel consumption, are our hallmark.

State of the art designs require a more intelligent cooling system. Bosch Rexroth has therefore developed a modular drive system with specially engineered control units. Together with the control system for the diesel engine, the cooling system control unit delivers optimum fan speed. Variable displacement axial piston pumps generate the necessary flow to drive the fans via compact hydraulic motors. The cooling system control unit is part of the Rexroth BODAS family of modular mobile control systems. The electronic hydraulic system control allows rail vehicle OEMs to tailor drives to various climatic zones and update profiles via software – with no changes to the hardware.

The system solutions from Rexroth decouple the diesel engine speed from the cooling fan speed. The electronic control system monitors various sensor feedback data such as the temperatures of engine coolant, turbo charge air, generator coolant and hydraulic oil. Using these sensor values, it calculates the necessary cooling power independent of engine speed. As a result, it shifts the technical challenge from cooling mechanics to intelligent drive control. For many operating conditions, achieving maximum cooling is not the main goal; it is instead to keep the charge air flow within a narrow temperature window in order to ensure optimum exhaust gas combustion.

Recent developments in electro-hydraulic in high performance solutions use hydrostatic circuits and secondary control systems with variable displacement motors. With these control system enhancements, efficiency gains increase while the fuel consumption of the diesel engine is further reduced. Rexroth can also utilize variable speed electric fan drives to cool power conversion.

Rexroth has been a reliable drive and control specialist for decades and a development partner to manufacturers of rail vehicles of all types. Rexroth has been heavily involved with the simulation, construction and design of cooling systems, covering everything from the selection of components to the software for control and including connectivity with the overall system.

As one of the world’s leading suppliers of drive and control technologies, Bosch Rexroth ensures efficient, powerful and safe movement in machines and systems of any size. The company bundles global application experience in the market segments of Mobile Applications, Machinery Applications and Engineering, and Factory Automation. With its intelligent components, customized system solutions and services, Bosch Rexroth is creating the necessary environment for fully connected applications. Bosch Rexroth offers its customers hydraulics, electric drive and control technology, gear technology and linear motion and assembly technology, including software and interfaces to the Internet of Things. With locations in over 80 countries, more than 30,500 associates generated sales revenue of 5.5 billion euros in 2017.

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The Bosch Group is a leading global supplier of technology and services. It employs roughly 402,000 associates worldwide (as of December 31, 2017). The company generated sales of 78.1 billion euros in 2017. Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. As a leading IoT company, Bosch offers innovative solutions for smart homes, smart cities, connected mobility, and connected manufacturing. It uses its expertise in sensor technology, software, and services, as well as its own IoT cloud, to offer its customers connected, cross-domain solutions from a single source. The Bosch Group’s strategic objective is to deliver innovations for a connected life. Bosch improves quality of life worldwide with products and services that are innovative and spark enthusiasm. In short, Bosch creates technology that is “Invented for life.” The Bosch Group comprises Robert Bosch GmbH and its roughly 440 subsidiary and regional companies in 60 countries. Including sales and service partners, Bosch’s global manufacturing, engineering, and sales network covers nearly every country in the world. The basis for the company’s future growth is its innovative strength. At 125 locations across the globe, Bosch employs some 64,500 associates in research and development.

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Manuela Kessler
Maria-Theresien-Straße 23
97816 Lohr am Main
Phone: +49 9352 18-4145

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