Manufacturers from all sectors have recognized that electric drives are an important building block for future viable, sustainable mobile machines. To support and encourage the electrification of off-highway equipment, Bosch Rexroth is now presenting the eLION product portfolio.
The eLION family covers a wide range of components, including a full range of electric motor-generators, inverters and accessories as well as tailored gearboxes, hydraulics and software.
According to Matthias Kielbassa, vice president electrification, the three most important properties of the new product platform are scalability, robustness and functional safety. Thanks to a modular design, the electric 700 V eLION motor-generators from Bosch Rexroth cover a nominal power range from 20 to 200 kW (peak power up to 400 kW) and deliver nominal torques of up to 1,050 Nm and maximum torque of up to 2,400 Nm. They are available in four sizes with different lengths and winding configurations and, depending on the design, in a fast or standard-speed version. Over 80 configurations are possible, which means maximum design freedom for manufacturers when electrifying existing and new vehicle architectures.
To complement the range of motors, eLION also offers inverters in various power classes with up to 300 A continuous current and high overload capacity. The inverters support dc bus voltages from 400 to 850 V.
Gearboxes with high power density for hub and central drive configurations (eGFT and eGFZ) are also part of the eLION portfolio and allow compact drive units for a wide range of applications. Rexroth BODAS software modules are available for the entire eLION platform, along with matching hydraulic components such as axial-piston pumps. Other electrical components such as dc/dc converters, power distribution units, on-board chargers and high-voltage cables round out the range. As a result, manufacturers can rely on integrated solutions, irrespective of the energy source (for example, hybrid or battery).
The new components also stress a focus on operating conditions and functional safety. According to Kielbassa, eLION engineers relied on the company’s own experience with electrical industry systems and its comprehensive knowledge of the mobile working machine sector throughout the development process. On top of this, they took advantage of Bosch’s wealth of expertise when it comes to electric mobility. Because all components are newly developed, there is no need for compromises in light of the harsh off-highway operating conditions, he said. The eLION motor-generators and inverters are highly robust: both comply with the IP69K ingress protection requirements and can be used at a temperature range between -40°and 85° C. The maximum temperature for the motor-generators is as high as 100° C. Mechanical and structural resistance of the eLION components is up to 50 g for shock and 10 g for vibration.
A particular focus during product development was on functional and electrical safety. Manufacturers and users benefit from inverter safety functions in accordance with ISO 13849.
During pilot projects, OEMs such as Kalmar and Sennebogen have already gained positive experiences with eLION, said Kielbassa. “The aim is to use our technology to create a future with higher efficiency, lower noise emissions and less air pollution. We have the right products at the right time and we’re also helping our customers to strengthen their market position with future-viable mobile working machines,” he said. Market launch of the eLION platform is in 2022.