sistemas hidrostaticos para maquinas concreteras
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Brueninghaus Hydromatik
R E 98050/04.95
H ydrostatic D rive S ystems for M obile C oncrete M ixers
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Hydros tatic Drive S ystem s for Drum Drives
on Mobile Co ncrete Mixers
2
Hydrostatic transmissions from Brueninghaus
Hydromatik fulfill these requireme nts by offering
the following advantages :
stepless and sensitive setting of drum
speed
sm ooth reversal of drum direction for
mixing and emptying
High dem ands are placed today on modern
technology when designing drum drives for
mobile concrete mixers.
Hig h operat ional s afe ty
Easy handling
Hig h leve l o f e ffic ien cy
Environmental acceptability
Lo ng serv ice life
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Drives , Control, Movem ent.
A com plete trans m is s ion
sys tem from a single
supplier.
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The quality of the Brueninghaus Hydromatik
produc ts is along with the high level of
technologies the reason for content customers
worldwide.
The certification as to DIN ISO 9001 therefore
is the log ical result of our extensive quality
assurance strategy.
The Mannesm ann Rexroth group of companies
is able to offer a com plete solution for any
drive application.
Why not talk to our mob ile concrete mixer
sales department?
simplification of mob ile mixer design
mounting of internal combustion engine
independ ent of position of drum drive
simple operation of transmission from a
number of positions
reduction in noise
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Standard Mod elconventional des ign
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Our A4V variable pum ps are equiped with
hydraulic servo control. Actuation is distanc e
depen dent by m eans of a control lever. This
permits both the flow and thus the drum s peed
to be infinitely set between Q0and Qma xfor
mixing and emptying.
1,0 0,8 0,6 0,4 0,2 0,2 0,4 0,6 0,8 1,0
I in mA
VgVg max
VgVg max
I in mA
80 0
60 0
40 0
20 0
20 0
40 0
60 0
80 0
40
30
20
10
10
20
30
40
1,0 0,8 0,6 0,4 0,2 0,2 0,4 0,6 0,8 1,0
in
VgVg max
VgVg max
in
Strong end stops of the lever in the pump
eliminate the need for further end s tops in the
cable line for maximum drum s peeds . The cable
support is mounted on the pump u sing the
special bores provided.
Electrical control is also p oss ible if required
e.g. for a particular mixing prog ramme or for
remote control.
For this an amplifier card (a 12 or 24 V PVR,
see data s heet RE 95 02 2) is required together
with one or more potentiometers.
Hydraul ic co ntrol , m ec hanical s erv o, HW
Electrical con trol with proportional so lenoid, EP
Pump speeds down to 500 rpm are permit ted
with all un its.
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Standard Mod elconventional des ign
6
All A4V variable displacem ent pu mp sizes are
available with S AE-A or SAE-B throu gh drives
or with a moun ted gear pum p (for operation of
a con veyor belt, chute or an au xiliary axle on
the vehicle).
Axial piston pumps may also be mou nted onto
the through drive for operating the distributor
mast on combination mixers/concrete pumps.
Axial piston p ump s s izes 71 and 90 are fitted
with drive flange s for the steering s haft (stand ard
flange 100 mm d ia.).
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Components
8
Series A2F fixed displacemen t motors in ben t
axis design are the best cho ice for the hydraulic
motor.
These motors are characterised by a high
starting torque and long s ervice life.
Dimensions co rrespond to standards for mixers.
All motors are e quipped with a flushing valve
for chang ing the oil in the main circuit.
For further information s ee data s heet
RE 91 00 1.
Any comb ination of the following pum ps and m otors m ay be us ed.
Pump
Shaften
dMo
unting
centeri
ngdia .
Suction
connec
tionfr
forboo
stpum
p
High p
ressure
ports
Weight
ofpum
p
(appro
x.)
Motor
Shaften
dMo
unting
centeri
ngdia.
Weigh
tof
motor
(appro
x.)
A2FM45 16/32 p itch , 21 s p lines 127 mm 13,5 kg
A2FM56 16/32 p itch , 21 s p lines 127 mm 18 kg
A2FM63 16/32 p itch , 21 s p lines 127 mm 18 kg
A2FM80 16/32 p itch , 21 s p lines 127 mm 23 kg
A2FM90 16/32 p itch , 21 s p lines 127 mm 23kg
A4V40 16/32 p itch, 21 s plines 127 mm M36x2 external thread 3/4" 30 kg
A4V56 16/32 p itch, 21 s plines 127 mm M36x2 external thread 3/4" 37 kg
A4VTG71 16/32 p itch, 21 s plineswith drive flange for 127 mm M42x2 internal thread 1" 48 kg
cardan shaft
A4VTG90 16/32 p itch, 23 s plines
with drive flange for 127 mm M42x2 internal thread 1" 50 kg
cardan shaft
A4VG125 SAE 1 3 /4", 13 s p lines 152 mm M48x2 internal thread 1 1/4" 80 kg
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S tand ard Drum Drives
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Either the vehicle engine (secon dary power
take-off) or a sep arate drive motor is used to
drive the variable pump .
In order to reduce n oise d uring filling, m ixing
and em ptying of the drum the vehicle engine
is normally run only at low speed (nma x= 1600
rpm), whereas with a se parate drive mo tor
speeds of up to 2500 rpm are poss ible.
To achieve the maximum d rum s peed, the
appropriate pump size must be selected.
4 m 3 14 18 rpm
6 m 3 13 16 rpm
7 m 3 12 15 rpm
8 m 3 11 14 rpm
9 m 3 10 12 rpm
10 m 3 9 12 rpm
12 m 3 8 12 rpm
Ag it at io n 1 5 r pm
The selection of the mixer drive depends
mainly on the required torque of the m ixer
drum.
Given a s tandard drum d iameter of 2200 -
2300 mm we can assu me a standard
value of
6000 Nm per m 3concrete.
This represents the m aximum value taking into
consideration peaks occuring when starting
up the d rum after a long journey (setting ofconcrete).
Furthermore the g ear ratio of the mixer drive
used is also decisive. The gear ratio of the
mixer transm ission varies co nsiderably from
one m anufacturer to an other, but lies within
the range of approx. i = 100 - 1 60.
From the maximum drum speeds the following
mixer sizes can b e ass umed:
S tandard transm ission for mobile concrete
mixer
Trans m ission with 2-s tage planetary gear with
axially mounted hydraulic motor.
Optional secondary power take-off for water
pu m p and spee d s en s ing dev ice .
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Selection of hydraulic motor
Example:
Mixer drum capacity 6 m3
Drum speed 14 rpm
Mixer trans m is s ion i = 141
Drive s peed (pump) 1500 rpm
Selection of hydraulic pump
To obtain a drum spe ed of 14 rpm a
pump d rive speed of 1725 rpm is
required.
A pum p drive speed o f 1500 rpm gives
a drum speed of 1716 rpm /141 = 12.2
rpm.
On request we can supply exact
dimensioning using CAD, stipulating the
most sui table hydraul ic com ponents.
nmotor= n drum. itransmission =
14 rp m . 141 = 1974 rpm
As a general rule the d rive of a mo bile
concrete mixer can be selected inaccordance with these diagrams.
40000 50000 60000 7000030000
= 255 Nm
10000
10
8
6
4
2Capacityofmixerdrum
(m3)
20000
100 200150 300 400350 500450
s e l e c t e d h y d r a u l i c m o t o r S iz e 5 6
600550
Size 80Size 63Size 56Size 45 Size 90450
400
300
200
100
Operatingpressureathydraulicmotor(bar)
250
Determination of hydraulic motor (mh=0,95)
Required drive torque atmixer drum
Hydraulic motor drive torque (Nm)
Drum drive torque (Nm)
Nm
Nm
20 40 60 80 100 120 140 160 180 200 220 240
4000
3000
2000
1000
v=0,95
1725
1500
20 40 60 80 100 120 140 160 180 200 220 240
4000
3000
2000
1000
Size 80Size 90
Motor displacement (l/min)
v=0,95
Size 125
Size 90
Size 40
116,3
Size 56Size 71
Size 32
Size 63
Size 56Size 45
Pump flow (l/min)
selec ted hydraulic pump Size 71
Determination of Qreq
Determination of hydraulic pump
19741716
Outputsp
eedhydraulicmotor(rpm)
Drivespeed
hydraulicpump(rpm)
36000 Nm
141 (itransmission)
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Cams haft drivenot s witchable, on ly part load transferable, Mdma xapprox. 600 Nm, short time 720 Nm
i = rev 1:1 motor speed, torque limitation necessary when using pumps > 90 cm3/ rev.
Separate motor
Pum p mo unted directly by means of elastic coupling, no torque limitation required
Front e ng ine p owe r take- off (FEPTO)
Md ma xdepending on design characteristics, i = 1:1
Drives for Low-no ise M ob ile Co nc rete Mixers
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HA1 HA2
HA1 HA2
Hydraulic pum ps
It is pos sible to reduce no ise with minimaleffect o n o perating efficiency.
Good resu lts were achieved at a drive speed
reduction of up to min. 800 rpm.
Naturally larger pumps are then necessary
which require higher drive torques a lthough
this can lead to overloading of the camsh aft
drive.
To prevent this the pum p m ust b e fitted with a
torque control (applies to pum ps > 90 cm3/r ev).
Our A4VG 125 pu mp is particularly suitable
and is available with the following control
characteristics:
On entering the speed reduction field the d rum
speed is automatically reduced in accordance
with the diagram .
Press ure relief valves 450 bar
Press ure cut-off 420 bar
S tart of of speed reduction ~ 300 b ar = 600 Nm
500
400
300
200
100
0,25 qv max
0,5 qv max
0,75 qv max
qv max
Flow qv
O
peratingpressurep(bar)
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"Low no ise" mob ile m ixer transm ission On request we can sup ply exact dimension ing
for devices with thes e drives us ing CAD.
Hydraulic motors
In these d ays of environmen tal awarenes s large
volume radial piston motors are com monly
used owing to their reduced noise. They are
either an integral part of the mixer trans miss ion
or are mounted such that the transm ission and
the motor build a s ingle unit. At the same time
a cooler and pump suction filter are mounted,
the housing also b eing used as an oil reservoir
for the hydraulic fluid.
The result is an extremely compact un it.
Such transmissions demonstrate an i of approx.
7:1 (planetary stage)
The highest sp eed of all rotating pa rts is less
than 100 rpm, making them quieter than
conventional mixer transmissions.
These transmissions could well be introduced
in the long term in standard devices.
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The New WayModel with EL constant speed drive (CSD)
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The electrical constant s peed d rive was
developed es pecially for use in m obile concrete
mixers.
The drive cons ists bas ically of the sam e
hydraulic components as with the standard
drive, but with the control via a control flow
(see c haracteristic EP, pag e 5).
Proportional so lenoids mou nted onto the d rive
(EP co ntrol) are used to co ntrol pump flow as
required.
The constant sp eed function effects a co nstant
drum s peed, even with varying sp eed of the
drive motor.
This function is b rough t about by determination
of the required pump swivel angle dependent
on the pre-selected drum and pump speeds .
From these two parame ters the electronics
calculate continuou sly the required control flow
and chang es the pum p swivel angle so that the
pump flow remains co nstant, corresponding to
the given value.
Even m ixing of the conc rete during travel, with
correct metering o f the water sup ply, eliminates
the need for additional fuel and wear-intensive
mixing at high drum speeds on site before
unloading.
Even for "kerbstone concreting" the con stant
drum s peed allows e ven flow of the con crete.
The electric CSD also permits com plete mixing
programm es to be c arried ou t with the aid of
additional devices i.e. by setting the no. o f
drum revolut ions and rpm a programme can
be produ ced to include s pecific intervals during
mixing.
As a general rule the ELCSD can be eas ily
operated by remote co ntrol, as only electrical
signals are required to operate the pump.
The drum s peed can be set by ramps, this
method o f operation being kinder to the
materials.
1
2
3
6
7
5
4
This drive offers the following advantages for
use in mixers:
The drum m ay be s et to agitate during travel
at a constant drum speed.
This has only a minimal effect on the
performance of the vehicle. The co ntinuous
acceleration and deceleration of the drum with
changing vehicle speeds is eliminated.
This means less wear of all rotating p arts
(transm ission, h ydraulics, d rum), longer s ervice
life and lower fuel cons ump tion.
When accelerating the vehicle no add itionalpower is necessary for simultaneous
acceleration of the mixer drum. The power
reserve of the prime m over is available for
acceleration o f the vehicle. This is of particular
advantage in vehicles with low engine po wer
and when travelling up hill.
300020001000
18
12
6
Diesel engine speed (rpm)
Potentiometersetting
Drivespeed(rpm)
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M = 1,59 x Vg maxx p
100
Function
See also data sh eet RE 95 075
Selection of drum speed can be m ade from on e
of two pos itions .
a) By potentiometer (3) in the driver's cab . This
is a potentiometer without housing and is
mounted on the dashboard.
b) By potentiometer (4), which is mou nted near
the chu te at the rear of the vehicle. This is built
into a water-resistant rubber hous ing (type SP,
see data sheet RE 95 040).
Speed feedback, which has to bear a fixed
relationship to the pump drive speed, can beeither by means of terminal W (5) on the
generator or, if not pos sible, via the speed
sens or on the starting g ear ring (6) or elsewhere.
If using terminal W as sp eed feedback an
electronic device with a frequency rang e of
100 - 1000 Hz must be used.
If a VDO is used for speed feedback at the
starter gearing, electronics with a frequen cy
range of 2000 - 8000 Hz must be used.
Torque limitation
If overloading of the camshaft drive or of the
drive motor is to be avoided, then mo del CSDwith torque limitation should be used (see data
shee t RE 95 075).
The relevant high pressure is measured by a
pressure sens or 7 and the torque l imited in
accordance with the following formula:
i.e. when the p re-set torque is exceede d the
control flow for the pum p is reduc ed, the pu mp
will swivel back and the torque m easu red is
reduced to prevent overloading.
The drum s peed will automatically be reduced
accordingly.
With vehicles in comm on us e today the current
max. Md at the cam sh aft drive is 60 0 Nm for
cont inuous operation and 72 0 Nm for short
periods.
Torque limitation of these vehicles h as been
shown to be only necessary when using pum ps
of over 90 cm 3/ re v (predomin an tly with lo w-
noise concrete mixers).
Both potentiometers are of the same design (1x
with ho using , 1x without ho using ). They are
fitted with strong mech anical end stop s to
prevent overspeed ing. Only one potentiometer
may be us ed at any one time. Switchover is by
means of switch 2, installed in the driver's cab.
After switchover the potentiom eter switched on
mus t first be set to the zero position to prevent
malfunctioning and accidents.
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Hydraulic fluids
Note: Environmen tally accep table fluids are
also subject to the relevant regulations regarding
disposal .k
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Plant Elchingen
Glockeraus trae 2
D89275 Elchingen
Telephone (0 73 08 ) 8 20
Telefax (0 73 08) 72 74
Plant Horb
An d en Kelterwiesen 14
D72160 Horb
Telephon e (0 74 51 ) 9 20
Telefax (0 74 51) 82 21
Brueningh aus Hydroma tik GmbH
D97813 Lohr am Main
Telephon e (0 93 52 ) 18 0
Telefax (0 9 3 52 ) 18 21 59
Telex 689 418 -12
Mannesm ann Rexroth GmbH
Our units are e qually suitable for use with
mineral oil based hydraulic fluids and
ecologically acceptable fluids.
When us ing fire resistant hydraulic fluids pleas e
consul t us.
Please also refer to our recommendations for
oils.
Mineral oil based hydraulic fluids
see data sheet RE 90 220
Ecologically acceptable fluids
HETG, HEPG, HEE
see data sheet RE 90 221
Axial piston u nits for us e with HF hydraulic
fluids
see data sheet RE 90 223
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