Dana reuses energy

A new line of integrated hydraulic-hybrid powertrain concepts for the off-highway market has been shown for the first time by Dana Holding Corporation at Bauma.

Alongside the Spicer PowerBoost System, Dana has also revealed the Spicer TE30 powershift transmission, and the R2 hydromechanical variable transmission (HVT) – the latest powersplit system resulting from the 50:50 joint venture between Dana and Bosch Rexroth.

Dana said that Spicer PowerBoost was deployed through series or parallel hybrid configurations that fitted into existing vehicle designs with minimal adaptation.

It captures kinetic energy otherwise wasted throughout the drivetrain and working hydraulics, and then uses this recuperated energy to help power the vehicle. Dana said this could reduce fuel consumption by 20 to 40% compared to conventional drivetrain concepts, depending on application and duty cycle.

Spicer PowerBoost can also reduce total owning and operating costs by increasing productivity, reducing maintenance, and allowing for the use of a downsized engine, said Dana.

Functional prototypes demonstrating the performance of the system will be available for field testing by OEMs in the second quarter of 2013.

Aziz Aghili, president of Dana Off-Highway Driveline Technologies, said, “In an era when equipment manufacturers are finding it difficult to identify incremental gains in efficiency, Spicer PowerBoost offers a tremendous leap forward in productivity and reduced costs that easily fits into existing design envelopes.”

Spicer PowerBoost uses an energy-management system to evaluate the levels of power needed in the entire vehicle system, predict operating demands, and determine the most efficient means of operation. Hydrostatic energy is captured in an accumulator from the powertrain during low-power operation of the engine and recuperated from braking and working.

When additional power is required, such as accelerating from a full stop, lifting a load, or driving into the pile, the advanced energy-management system uses the stored energy in the accumulator to provide an additional source of power for improving performance, increasing productivity, and reducing fuel consumption.

The Spicer PowerBoost system can also be configured to minimise idling by shutting off the diesel engine and accessing power captured in the accumulator for vehicle operations that consume low amounts of energy, such as inching, light working conditions, and low travel speeds.

TE30 powershift

Dana’s new Spicer TE30 powershift transmission is designed for reach stackers and heavy-duty forklift trucks with an optimised drivetrain system for greater fuel economy and lower cost of ownership.

The company said it was compatible with engines ranging from 225 to 300kW – including Tier 4 engines. The Spicer TE30 transmission has the same installation envelope as short-drop versions of the Spicer TE27 and Spicer TE32 transmissions, which it partially replaces.

It will be available in the first quarter of 2014.

Dana Rexroth Transmission Systems’ R2 hydromechanical variable transmission (HVT) is described as a modular platform that delivers a full suite of configuration options and software controls, such as direct or remote mounting, flexibility in shift control and drive strategy parameters, and the deployment of up to three PTOs.

Designed to maximise efficiency and reduce overall vehicle ownership and operating costs, the R2 is said to be ideal for front-end loaders, motor graders, industrial lift trucks, and other off-highway applications requiring 135 to 195kW of engine output power.

Initial tests on front end loaders with Dana Rexroth HVT powersplit systems demonstrate fuel savings in the drivetrain of up to 25% when compared with the same vehicle outfitted with a conventional torque converter transmission.

Jeroen Decleer, managing director of Dana Rexroth Transmission Systems, said, “The R2 is a truly innovative transmission platform that combines Dana’s and Bosch Rexroth’s deep knowledge of powertrains.”

He added that the R2 had the ability to integrate hydrostatic, mechanical and control systems through a modular approach that could accommodate the application requirements and customer preferences demanded by the off-highway market.

HVTs from Dana Rexroth are said to improve productivity by enabling sensitive, precise vehicle positioning and stepless drive with no interrupted acceleration. They occupy the same space within the design envelope as conventional torque converter transmissions while allowing for engine downsizing.

The HVT optimises the operating point of the diesel engine by decoupling engine speed from drive speed, and maintenance costs are said to be reduced by using hydrostatic braking and wear-free directional reversals.

The R2 extends the Dana Rexroth HVT portfolio toward smaller applications and complements the R3 series designed for machines up to 270kW that was revealed at Intermat last year.