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Bosch Rexroth around the world
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March 2014
Wind force 8. The ship is pitching and wallowing, its bow and stern lifting and dropping back into the waves. However, work on the crane does not come to a halt. In spite of the rough seas, it continues to lower heavy loads to the seabed, both accurately and smoothly. This is made possible by Rexroth’s proactive wave compensation system that can offset up to 95 percent of wave action.
Highly dynamic, secondary control drives from Rexroth are the foundation for this amazing performance. Rexroth’s unique drive concept is distinguished by its great rotation speed, torque and positioning accuracy – features also in demand for test beds and mechanical engineering as well as in conveyance and transportation technology. It is unbeatable in terms of eco-friendliness and efficiency. Secondary control makes it possible to recover up to 75 percent of the energy required for drive power.
Secondary-control drives are operated in high-pressure networks. They consist of at least one hydraulic pump (the primary unit), a hydraulic accumulator, and a using unit (the secondary unit).
The purpose of the hydraulic accumulator is to store the energy fed to the hydraulic network by the secondary unit whenever it is reversed, e.g. in the pumping mode. When operating under load, this accumulated energy is used to compensate for consumption peaks. The charge status of the hydraulic accumulator – in conjunction with the pressure-controlled primary unit and the operational status of the secondary unit – determines system pressure.
While conventional drives work with an interface via volumetric flow, secondary-control drives are linked to the specified operating pressure. Volumetric displacement is, therefore, not related to a precisely defined rotation speed but rather to a certain torque.
If an automated process, or the operator, prescribes the rotation speed required for a certain action, the using unit automatically determines – within milliseconds – the torque required to ensure that this rotation speed is maintained at the operating pressure currently available.
The high consistency of the rotation speed and the excellent performance of the secondary-control drives as used in the wave compensation system neutralize up to 95 percent of wave energy.
With its lifting power of 3,200 tons and a radius of 120 meters, the Giant Crane 120 made by Sarens is the largest crane in the world. Its six compact secondary-control winches can be operated at constant velocity and are capable of positioning loads with an accuracy of millimeters.
Individual pumps are examined, together with their ancillary components, at the universal test stand at the International Hydraulics Academy of Dresden (IHA). Secondary control hydraulic drives ensure an energy recovery rate of up to 70 percent.
Photo: IHA GmbH
Test beds for engines, gears, drive shafts, rotor blades; test benches for flat guides, wheeled guides, tension, and crash tests.
Drives for winches, cranes, and wave compensation systems.
Drives for hoisting gear, rotating mechanisms and traction drives
Rim compression tools, grinding machines, UPS backups; drives for saws, pinch rolls and centrifuges as well as presses.
The secondary-control drive in a crane works alternately as pump and motor.
1 Hoisting: A winch reels in the rope to hoist a load. The drive unit functions as a motor and consumes energy.
2 Lowering: The winch uncoils rope to lower a load. The drive unit operates in the pumping mode and feeds energy back into the hydraulic system.