A New Medium Pressure

Pump MPR50

RT22/Dr. Rolf LasaarJuly 6th, 2012

06.06.2012 , RT22/Dr. Lasaar 2

A New Medium Pressure Pump MPR50 Contents

Q2Q1

Q

Unique Technical Features 4

MPR50 → 11 Customer Benefits

—Special Characteristics of the Pump (Benefit 1-6) 5-12

—Beneficial Options for the Vehicle System (Benefit 7-11) 13-20

Design Requirements from our Fork Lift Truck 3

MPR50 Versions 21

Nomenclature 22

06.06.2012 , RT22/Dr. Lasaar 3

Linde Fork Lift Truck 39X Design Requirements for the Working Hydraulics

Aim: Development of a New Variable Displacement Working Hydraulic Pump to

Reduce the Fuel Consumption

Installation Space

Pulsation/

Noise

Costs

Power Losses

Diesel Engine Starter Torque

Safety (Steering)

Maximum

Speed (Braking)

Pump

Control

Charge Oil

Supply

External

Customers

Technical Requirements from the Linde 39X

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MPR50 Innovations

MPR

New Medium

Pressure Pump

with Unique

Technical Features

Compact Installation Space

Maximum Rotational Speed

Pulsation Damper (Noise Emission)

Prop. Pump Control (with Direct Position Feedback)

Integrated Charge Oil/

Fan Drive Pump or PTO

Common Suction Port

Q2Q1

Q

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More Installation Options in Narrow

Environments

Compact Design

Figure Customer BenefitInnovation

Customer Benefit 1 Installation Space

Combustion

Engine

Driving

Pump

Working

Hydraulics

Charge

Pump

Overall Length

vs. Limited Vehicle Width

Often

Especially

the Length

is Critical

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Pump „A“

16 cm3/rev

Internal Gear Pump

45 cm3/rev

+16 cm3/rev

Compact Installation Space –Linde MPR50+16 and Pump “A”

(!) approx. 200 mm

Linde

MPR50+16 E1(P)

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More Flow, More Power and

Important for Retarder Braking

High Rotational

Speed

Figure Customer BenefitInnovation

Customer Benefit 2 Max. Speed / Max. Flow

RetarderECU

psuc=1.0 barpsuc=0.9 barpsuc=0.8 bar

psuc=pressure@suction port

max. speed for retarder braking2500

2700

2900

3100

3300

3500

3700

30 35 40 45 50V g [cm³]

nmax [U/min]

nmax[rpm]

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New Electric

Proportional Control

Integrated Charge

Pump

An Integrated Pulsation Damper

Reduces Noise Emission

Low Pulsation Level

High Suction Speed

Compact Design

Figure Customer BenefitInnovation

Customer Benefit 3Low Noise Emission

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Easy Charge Oil Supply on the

Vehicle / Simplified Piping

Integrated Charge

Pump

An Integrated Pulsation Damper

Reduces Noise Emission

Low Pulsation Level

Important Characteristic when a

Retarder Valve for Breaking is Used

High Suction Speed

More Installation Options in Narrow

Environments

Compact Design

Figure Customer BenefitInnovation

Customer Benefit 4Integrated Gear Pump

Common Suction Port

80 bar

Q2Q1

Q

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Precise Electric Control of

the Pump Flow

New Electro

Proportional Control

Integrated Charge

Pump

Low Pulsation Level

High Suction Speed

Compact Design

Figure Customer BenefitInnovation

Customer Benefit 5Pump Control Strategy

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0%

20%

40%

60%

80%

100%

0 200 400 600 800 1000 1200 1400

I mag [mA]

Vg/V

g,m

ax [%]

New Pump Control

High Dynamics

Charge Oil Supplied

(20 bar)

Retarder Function

Possible

Direct Response

Precise Flow Control

Switched off at Vmin

Fail Safe at Vmin

Adjustable Control

Beginning

Vg,max = 50 cc/rev

also Vmin>0

Measured Small Signal Behaviour (1mA Steps)

Pressure Cut-Off

Optional

84

85

86

87

0 25 50 75 100

Zeit t [s]

α/α m

ax [%

]

1000

1025

1050I M

ag [mA]

near αmaxn=1000 U/min, p<15bar

High Precision also in Difficult

Operating Points

Imag

α/αmax

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73%75%77%79%81%83%85%87%89%91%93%

500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000

Drehzahl n [U/min]

Gesamtwirkungsgrad ges [%]

Customer Benefit 6: EfficiencyOverall Efficiency of MPR50 vs. Well-Established Pumps

Pump “B” 49cc

MPR50

Pump “C” 45cc

Pressure p = 280 bar

Swash Plate Angle α=αmax

Linde

Pump “C”

Pump “B”

Linde MPR50 without Gear Pump

Measurement

Catalogue Data

Overall Efficiency ηtot[%

]

Rotational Speed n [rpm]

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Benefit 7: Fuel Consumption & CostsComparison IGP & MPR50 in Linde Truck Series 394

VDI Cycle 2198

Measured Relative Fuel Consumption

in Linde Truck Series 394 (H50D) in % Internal Gear

Pump IGP (fixed displ.)

Source: E/EV

MPR

-15%85%100%100%

-21%79%100%50%

∆∆∆∆MPRIGPLoad

Linde Measurement Data

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Benefit 7: Reduced Fuel Consumption in Practice Experiences of our Customer “Klingele“

Internal Gear

Pump IGP (fixed displ.)

MPR

Comparative Fuel Consumption

Measurement of New Model with

MPR50 vs. Previous Model with IGP

over 1,5 years.

=> 20% Fuel Saving in Practice

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0 €

200 €

400 €

600 €

800 €

1.000 €

1.200 €

1.400 €

1.600 €

500 1000 2000

0 €

2.000 €

4.000 €

6.000 €

8.000 €

10.000 €

12.000 €

14.000 €

16.000 €

10000 20000

Basic Fuel Consumption at 50% Load: approx. 5 l/h (Exemplary Assumption)

Diesel Price (without VAT): 1 €/l

Assumed Average Fuel Consumption Reduction with MPR: -15%

Customer Benefit 7: Fuel CostsSaving with MPR50 over Vehicle Lifetime

Fuel Cost Saving with MPR [€]

Vehicle Operation Time [h]

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Benefit 8: Modern System Designs Efficient and Dynamic Hydraulic Circuit

1 HPV-02 E1/E2

2 MPR50 E1(P) (Integrated

Fan-/Charge Pump

3 HMV-02i

E1(P)

Lifting, Tilting, …

n

1

23

E1/E2 Control

…Prio

Retarder

…

Directional Valve

1 2ECU

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—Driver Defines Set Values for End Effector

Speeds (Joystick Position)

—Electronic Calculates Instantaneous

Overall Flow Requirement

—Electric Signal to Pump Control

Defines Pump Flow

1 HPV-02

Benefit 8: Modern System Designs Control Strategy

2 MPR50 E1(P) (Integrated

Fan-/Charge Pump

3 HMV-02i

E1(P)

Lifting, Tilting, …

n

1

23

E1/E2 Control

…

Directional Valve

Prio

Retarder

…—Electric Signal to Directional Valve

Defines End Effector Speeds

—Spontaneous System Response

ECU

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Efficient

Displacement

Control

Customer Benefit 9 Displacement Control

0 Vmax

E1

Set Rotation Speed n2

Consumer, i.e.

Power Take-Off

MPR Drives without Directional Valves in the Hydraulic Power Line Possible

due to Sensitive Electro Proportional Pump Control (1 Consumer per Pump)

2 Modes:

Output Speed n2=f(n1)

Output Speed n2=const.

- No Throttle Losses in the

Hydraulic Power Line

- Both Rotational Directions with

Additional Switch Valve

n2n1

ECU

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Customer Benefit 10 Retarder Braking

Vmin Vmax

Retarder

Retarder Braking Requires Fast Generation of Shaft Torque

Pressure and Displacement must be Increased Dynamically

- Synchronous Activation of

MPR-Control and Retarder

Valve

- MPR Braking Torque

Adaptable and Adjustable

(Software)

- Online Control of MPR

Displacement Along Suction

Speed Characteristic During

Retarder Braking Possible

E1

MPR

ECU

Retarder Valve Optional

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Customer Benefit 11Influence of Pump Control on Engine Starter

Vmin Vmax

—High Pressure Pump Control

—Swivel Out Spring necessary

—Switch-Off Position at Vmax

—Cold Start Valve Necessary (?)

During Engine Start Initially the Full Flow

Circulates in the Line Until the Pressure

Demand for Swivel Back is Generated

� High Load on the Engine Starter on Cold

Winter’s Days

—Charge Oil Supplied

—Swivel Back Spring

—Switch-Off Position at Vmin

—No Cold Start Valve

During Engine Start the Pump is at Vmin

� Low Load on the Engine Starter

Vmin Vmax

Signal

MPR

Load Sensing Pump

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MPR Versions

Adaption of the MPR50 to Specific Customer Demands

Shafts & Flange SAE B-B

Adjustable Vmin Stop

Fork Lift Truck Version as a Basis

Pressure Cut-Off optional

2nd Leakage Port

CW & CCW Rotation

Gear Pump Size

PTO , w/o PTO

Further Sizes? (e.g. MPR100)

Steering Priority & Retarder optional

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Nomenclature

Q2Q1

Q

n [rpm]Rotational Speed

Vg, V [cm3/rev]Geometric Displacement

PTO [-]Power Take-OffQ [l/min]Maximum Theoretic Pump Flow

α [°]Swash Plate Angle

max/min[-]Maximum/Minimum

Index

Variable Description Unit

theo[-]Theoretic

tot[-]Total

η [%]Efficiency

ECU [-]Electronic Control Unit

EMC [-]Electronic Motor ControlIGP [-]Internal Gear Pump

CW/CCW [-]Clockwise / Counter Clockwise Rotation

psuc [bar]Inlet Pressure at Suction Port

IMag [mA]Electric Current at the Solenoid