Machinedesign 3353 Mechanical Drives Hydrostatic Drives

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Hydrostatic Drives
Machine Design
Fri, 2002-11-15 12:30
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Hydrostatic drives are widely recognized as an excellent means of power transmission when variable
output speed is required. Typically outperforming mechanical and electrical variable-speed drives and
gear-type transmissions, they offer fast response, maintain precise speed under varying loads, and allow
infinitely variable speed control from zero to maximum.
Unlike gear transmissions, hydrostatics have a continuous power curve without peaks and valleys, and
they can increase available torque without shifting gears. But despite the superior performance of
hydrostatics, a major drawback has been higher cost compared to their mechanical counterparts.
Manufacturers, however, continue to boost performance levels, produce smaller and lighter packages,
and offer advanced electronic controls. These factors now make hydrostatics an economical choice for
many applications.
A basic hydrostatic transmission is an entire hydraulic system. It contains pump, motor, and all required
controls in one simple package. Such a system provides all the noted advantages of a conventional
hydraulic system -- such as stepless adjustment of speed, torque, and power; plus smooth and
controllable acceleration; ability to be stalled without damage; and easy controllability -- with the
convenience of single-package procurement installation.
Early hydrostatic transmissions were intended primarily for low-cost applications such as farm
equipment and garden tractors. But improved designs -- particularly in controls -- have made these
transmissions suitable for a broad range of applications.
As a result, light-duty units (less than 20 hp) are being used on equipment such as lawn tractors, golf-
course maintenance equipment, and small machine tools; medium-duty units (25 to 50 hp) on skid-steer
loaders, trenchers, harvesters, and other such vehicles; and heavy-duty transmissions (approximately 60
hp and higher) on agricultural and large construction equipment.
http://machinedesign.com/print/mechanical-drives/hydrostatic-drives 2/3/2016
Part of the reason for the increasing attractiveness of hydrostatic transmissions is improved design of
pumps and motors -- particularly higher flow and pressure ratings in a more compact package. For
example, several years ago, most pumps could be expected to deliver about 0.125-gpm flow per pound of
pump. Currently available pumps deliver about 0.5 gpm/lb, a 400% increase. Similarly, older motors
provided about 0.5 hp/lb of motor; new motors provide about 2.5 hp/lb.
Performance: Hydrostatic transmissions are commonly available with at least three standards of
output performance:
• Variable-power, variable-torque transmissions are based on a variable-displacement pump

supplying a variable-displacement motor. They can provide a combination of constant torque and
constant power. These units are adjustable, flexible, and expensive.
• Constant-torque, variable-power transmissions are based on a variable-displacement pump
supplying fluid to a fixed-displacement motor under constant load. Speed is controlled by varying
pump delivery. This is considered the best general-purpose drive, with wide speed ranges, up to
42:1, and simple controls.
• Constant-power, variable-torque transmissions are based on a variable-displacement pump with a
power limiter, driving a fixed-displacement motor. The forte of this unit is efficiency, but speed
range is usually limited to 4:1.
Drive configurations: Hydrostatic transmissions usually take one of two general configurations, split
or close coupled. A split transmission consists of a power unit with the hydraulic pump, heat exchanger,
filters, valves, and controls mounted on a reservoir. The hydraulic motor is remotely mounted and
connected to the power unit through hose or tubing. Split transmissions are typically used in heavy-duty
applications because they offer wide flexibility in configuring a system for the most efficient use of space
or best weight distribution.
Integrated, or close-coupled, transmissions have a hydraulic pump and motor that share a common
valving surface. This arrangement provides an extremely short oil-flow path, eliminating high-pressure
oil leaks either to the reservoir or to the environment. A cast casing or housing provides a self-contained
oil reservoir, structural support for the rotating elements, and heat dissipation. They are usually bolted
directly to a mechanical differential axle to form a hydrostatic transaxle. Close-coupled transmissions are
typically found in light-duty applications, where tight space constraints require compact units, while
high-volume production mandates easy assembly.
Transmission sizing: Hydrostatic transmission size normally is based on the corner horsepower of
the work function. Corner horsepower is the product of the maximum force and maximum speed
required by the function, even though these two conditions rarely occur simultaneously. Corner
horsepower for vehicle propulsion is
Hc = ( Ft * V ) / 3,600n
where Hc = corner horsepower, kW; Ft = maximum vehicle tractive force, N; V = maximum vehicle
speed, km/h; and n = final drive efficiency, %.
Transmission corner horsepower, Ht, is the product of maximum output torque (generally at a specified
maximum pressure) and maximum output speed:
Ht = ( Tt * N ) / 9,550
:where T = theoretical torque at maximum system pressure, N-m; t = torque efficiency, %; and N =
maximum transmission speed, rpm.
Initial transmission selection is made by comparing the results of these calculations. Selection is refined
by considering the effects of duty cycle, final-drive ratio, rolling radius, primer-mover speed, and design
life.
Electronic controls: Control capabilities for hydrostatic transmissions have advanced from simple
remote electrical actuators to packages that offer complete optimization of machine performance. For
example, electronics on paving equipment not only controls the transmission, including speed and rate
of acceleration and deceleration, but also steering, paving height, rate of material flow, road crown, slope
on curves, and so on.
While not currently economical for every application, proportional controls offer a reasonable payback in
most traction drives and propel systems through fuel savings and increased productivity. Acceptance will
quicken when the added benefits in addition to primary control are recognized. One such feature is
performance monitoring, another is system diagnostics -- relating when servicing is needed, when failure
is imminent, or where a failure has occurred. Such features are relatively easy to add into software
because many of the variables needed are already measured for control.
Source URL: http://machinedesign.com/mechanical-drives/hydrostatic-drives

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Hydrostatic Drives Page 1 of 3

High-density motor - maxon precision motors inc.

Induction motor comes in three efficiency levels - SEW-Eurodrive Inc.

Bearing protection ring - Baldor Electric Co.

• Variable-power, variable-torque transmissions are based on a variable-displacement pump

Source URL: http://machinedesign.com/mechanical-drives/hydrostatic-drives

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