Hydraulics and Electronicsin Civil Engineering

1

Systems & Engineering– Your Solution Partner inCivil Engineering

Why a hydraulic drive?

Like no other drive technology,hydraulics offers outstandingbenefits:

• High reliability

• Great power density

• Compact dimensions

• Flexibility in layout

• Enormous robustness

• Low maintenance requirements

• Flexibility in design and future upgrades

• Lower costs of installation and construction

• Excellent controllability

To best serve our customers, BoschRexroth has organized industryspecific teams. Applicationengineers specialize in a givenmarket such as Civil Engineering.With our experience in technical,and commercial aspects of a givenindustry, the Civil Engineeringgroup can assist you to successfullycomplete each stage of a project.

Bosch Rexroth, with production facilities,and sales and service companies in morethan 80 countries, is a part of RobertBosch GmbH. Bosch Rexroth has approxi-mately 26,000 employees worldwide withannual sales of $3.8 billion. In theAmericas, Bosch Rexroth has over 3,000employees with annual sales of over $700million.

In all aspects of Drives & Controls, Rexrothis a strong partner and a comprehensivesupplier with a broad spectrum of productsand systems. Our core competency ofDrive & Controls is the result of expertise inhydraulics, electronic drives andpneumatics and the ability to integrate thedisciplines.

The Systems and Engineering group ofBosch Rexroth supports the most techni-cally demanding applications that typicallyinclude: innovative and customizeddesigns, long-term contracts, and a highdegree of project and contract manage-ment. The Systems and Engineering groupis a worldwide organization with local salesand production offices strategicallylocated. Application specialists concen-trate on a given field such as Marine andOffshore, Power Generation, TestMachinery, Entertainment, MaterialsHandling, Civil Engineering etc. Individualstrained in each discipline interact with theircolleagues across the globe to shareexperiences and technologies. Value iscreated for the customers with the group’sability to develop innovative designs andthen oversee all phases of a project frommanufacturing through commissioning. Asa result, the entire offerings of BoschRexroth can be transferred directly to serveour customers diverse needs through theSystems and Engineering Group.

2

The scope of our support is deter-mined by customers’ needs. Thiscan range from highly specializedindividual components through tothe planning and commissioningof complete systems. We have theengineering expertise to transformour vast product line to best suitan application’s needs. Ourcapabilities include:

• Complete Product Offerings

• Application / Engineering Assistance

• Computer Simulation

• Animation

• Engineering Calculations such as FEA

• Electronic Controls

• Field Service

• Training

As a full service provider, theIndustrial Hydraulics Divisionoperates exceptionally efficiently.Highest product quality, longservice life, fast and worldwidelocal presence and the utilizationof synergies within the BoschRexroth Group generate measur-able cost benefits for the customer.

Olmsted Locks, Illinois

Tower bridge, London

Cushman No. 1 - Hydraulic drive and controls fortainter gates - Tacoma, Washington

Sidi Yacoub, Algeria

Water Power

Navigation

Water Management

Transportation

North American Center forIndustrial Hydraulics,Bethlehem, Pennsylvania

3

Weirs and Dams - Gaining Energy by Water Power

The field of waterpower offers adiverse variety of challenges forthe drive system. Tainter gatesrequire large slender cylinders.Although the cylinders move slow-ly they must be closely synchro-

Sir Dam, Turkey

nized. In the case of turbine con-trols, high position accuracy,short response times as well ashigh dynamics are of paramountimportance. In every project, safe-ty and reliability must be integralto the design.

Hydraulic Drives for:

• Turbine Intake Gates

• Vertical Lift Gates

• Tainter Gates

• Blade on Runner ControlIntegrated shop testing at Bosch Rexroth, Bethlehem,PA - Hydraulic cylinders, power units and electroniccontrols for Braddock Dam tainter gates.

4

Winfield Locks and DamHydraulic drive and electronic controls for tainter gate(synchronization of cylinders with CIMS) and hydraulicdrive for miter gate - Kanawha River, West Virginia

Hydraulic cylinders for Harry S. Truman

(5 stage telescopic cylinder, total stroke = 40 feet)

Emsworth Locks and Dam - Pittsburgh, PAHydraulic drive and electronic controls for“double trunnion” cylinder (indexing systemthat minimizes stroke length). The aboveillustrates cylinders in the uppermost posi-tion needed for flood condition.

5

Ship Locks, Boat Lifts and Flood Barrages

Direct connected hydraulic cylin-ders have become the industrystandard for the drive system formiter gates. Hydraulic drives withelectronic controls are the idealchoice for remote and automatedoperation of locks.

Panama Canal - general overview

The Delta-Plan-Project for protecting the Dutch coast at Nieuwe Waterweg, Netherlands

Hydraulic Drives for:

• Miter Gates

• Culvert Gates

• Boat Lifts

• Flood Barrages

Conversion of drives for thedouble-hook gates in theupper head of the ship lockYbbs Persenbeug, AustriaOpen gearing and wire ropesto be replaced by hydraulicpower unit and cylinders.

6

Central control system for Panama Canal

Layout of a display showing the current situation of thedrive system of a miter gate at the Panama Canal.

Culvert gate - display for showing thesituation of the drive system

Circuit diagram of the drive unit of a miter gate - visualized

Alarm, error and operation list

Hydraulic power unit andmanifolds for OlmsteadLock - Olmstead, IL

7

Movable Bridges andTransfer Spans (Ro-Ro Bridges)

Hydraulic drive is the ideal choicefor the operation of movablebridges due to the inherent torquesharing capabilities and flexibilityof layout. In either refurbishmentsor new designs, a hydraulic driveoffers lower initial constructioncosts, high reliability, and loweroperating and maintenance costs.The use of hydraulic cylinders forvehicular transfer spans (Ro Robridges) has become the industrystandard primarily due to redun-dancy, safety and low maintenancerequirements.

Ro-Ro Bridge and passenger walkway in the port of Hull - Hull, Great Britain

Hydraulic power unitand cylinders forDonald Ross RoadBridge - Jupiter, FL

Hydraulics for Brickell Ave. bridge -Miami, FL

Hydraulic Drives for:

• Movable Bridges

• Ro-Ro Bridges

8

Piping for AIW bridge replacement(Piping assemblies pre-fabricated atour facility in Bethlehem, PA

520 Bridge - Evergreen PointBosch Rexroth supplied powerunits, cylinders and electroniccontrols

“Ro-safe Brake” - self contained safety systemfor vehicular transfer spans (ro-ro bridge) provides redundancy to primary drive system

9

Irrigation Systems - Creating New Living Spaces

This application group includesstorage and distribution of waterfor either flood control, irrigation,potable supply, and waste. Typicalof these projects are gates under alarge head (400 ft +). Consequently,hydraulic cylinders are the idealchoice to reliably exert the largeforce required.

Irrigation systems make a contribution to convert deserts into fertile oasis.

Bottom Outlet Gates

Hydraulic Drives for:

• Storage of water

• Management of water

• Distribution of water

10

Mud Mountain Dam Flow ControlEnumclaw, Washington - Hydraulicdrive for tainter gates and bottom outlet gates

Cylinder for bottom outlet gates,Seven Oaks Dam, California

Sidi Yacoub, Algeria

11

Cylinders for Civil Engineering Applications

The team of engineers for CivilEngineering applications includesa group of cylinder designers whohave developed standards to suitthe type of project. Materials, rodcoatings, sealing technologies,bearings, and other attributes areoptimized with our years of expe-rience on similar applications.

Ceramax Engineered CoatingsPiston rods of hydraulic cylindersare often exposed to extremelyaggressive environmental condi-tions that lead to corrosion,scratching and wear. RexrothHydraudyne developed Ceramaxin the 1970’s and introduced theproduct to the market in 1989. Todate, over 13,000 cylinders havebeen produced with this coating.

Ceramax consists of speciallyselected ceramic materials and isapplied to a piston rod by a spray-ing process. This coating is superi-or to the traditional chrome plat-ing in regards to its resistanceagainst corrosion, scratches andother mechanical damage.

Ceramax is virtually insensitive todust, sand, or chemical con-stituents coming into contact withthe piston rod. Furthermore,sparks and particles from weldingdo not adhere to Ceramax.

To meet even more challengingdemands, Ceramics EngineeredCoatings (CEC) is the next genera-tion of piston rod protection. Theresulting properties of the coatingcan be customized specifically foran application. For example, in anoffshore oil platform, resistanceagainst corrosion is the drivingcriteria. Whereas, in a miningapplication, the environment maybe less corrosive, but a high resist-ance to impact is required. Theproperties of the coating areachieved with both the plasmaprocess and the new HVOF (HighVelocity Oxygen Fuel) sprayingtechnology.

Ceramax Integrated MeasuringSystem (CIMS) The carbon steel piston rod usedwith the Ceramax coating enabled

Redundant CIMS MKll solution

Coating procedure HVOF(High Velocity Oxygen Fuel)

N

X

Output 1 Output 2

Input

Z

N

p = 10 mm

0,25 · p

Z

the development of the CIMSpositioning system that offersmany advantages over the tradi-tional linear transducers or otherexternal devices.

Operation of CIMS MKIIA magnetic field is created andshaped between a permanent mag-net and a grooved piston rod cov-ered with Ceramax. Two halfbridged magneto-resistive ele-ments, located in the magnet fieldproduce sine and cosine signalsthat are the input for a trackingphase resolver. The outputs of thisresolver are quadrature incremen-tal counting pulses. For long dis-tance transmission these pulses areconverted to RS422A differentialoutput pulses. With appropriatecabling, shielding, impedance andcounting equipment, the result is asimple, high quality, accurate andreliable displacement measuringsystem.

12

Computerized Simulation Optimizes HydraulicDrive System Design & Performance

On critical or unique applications,Bosch Rexroth recommends the useof a computerized simulation to bestpredict the behavior of the hydraulicdrive and moving structure. Theanalysis provides an opportunity tooptimize the design before construc-tion and alleviates potential difficul-ties at commissioning.

The simulation may include techni-cal calculations, such as a finite ele-ment analysis, a geometrical modelthat includes the characteristics ofthe drive system and the structure,an animated model, or any combi-nation of these. In all cases, thesimulation must balance the theo-retical results with practical realitiesof real life systems as observedthrough our years of experience.Given the proper input data todescribe the structure, the predictedresults will be within 95% of theactual performance. Furthermore,simulation analysis is an excellenttool to diagnose under performingexisting systems.

Model and FEM-investigation for a pressurizedcylinder bottom segment with cylinder tube.

Numerical fluid mechanics: distribution of pres-sure and velocity at a valve seat.

FEM-calculation for the distribution of stress in the trunnion of a hydraulic cylinder.

Course work includes tra-ditional lectures as well as“hands-on” laboratoryexercises.

Locations

Pennsylvania (BAVTS)Bethlehem AreaVocational Technical SchoolBethlehem, Pennsylvania

Michigan (HFCC)Henry Ford Community College Dearborn, Michigan

Washington (SCC)Spokane Community CollegeSpokane, Washington

13

Training

Service

We offer a series of courses for thetraining needs of our customers atfive different locations, as well ascustom on-site instruction.

Bosch Rexroth has service centersacross the country for repair /refurbishment of all your equip-ment. Furthermore, a staff of fieldservice technicians trained in both

Canada (ON)Bosch Rexroth CanadaBurlington, Ontario

Canada (BC)Bosch Rexroth CanadaBurnaby, British Columbia

hydraulic systems and electroniccontrols are available for installa-tion assistance, commissioning,routine maintenance and trou-bleshooting.

We have a 24 hour emergencyservice hotline, 1-800-REXROTH.

Major CivilEngineeringProjects byBosch Rexroth-USA

Location Name of Project Customer Project Type YearAlabama Demopolis Lock U.S. Army Corps of Engineers Navigation 1992Argentina Yacyreta Voith Hydro Inc. Water Power 1992Arizona Roosevelt Dam Bureau of Reclamation Water Power 1993Arkansas Arkansas Dam II Arkansas Electric . Water Power 1997Arkansas Montgomery Point U.S. Army Corps of Engineers Navigation 2001California Devils Canyon Voith Hydro Inc. Water Power 1990California Grizzley Powerhouse Pacific Gas & Electric Co. Water Power 1992California Seven Oaks Dam U.S. Army Corps of Engineers Irrigation 1998Belize City of Belize Bridge City of Belize Movable Bridges 1991China Shisanling Voith Hydro Inc. Water Power 1994China Yang Zhuo Young Voith Hydro Inc. Water Power 1994China Guang Zhou Project Voith Hydro Inc. Water Power 1997Colorado Minidoka U.S. Bureau of Reclamation Water Power 1992Connecticut Stamford Hurricane Barrier U.S. Army Corps of Engineers Navigation 1996Connecticut Niantic River Bridge Connecticut DOT Movable Bridges 1989Florida Queens Harbor Queens Harbor Navigation Lock 1990Florida 27th Avenue Bridge Florida Dept. of Transportation Movable Bridges 1992Florida San Pablo Creek Bridges Florida Dept. of Transportation Movable Bridges 1993Florida Sisters Creek Florida Dept. of Transportation Movable Bridges 1993Florida S.W. 1st Street Bridge Florida Dept. of Transportation Movable Bridges 1993Florida Atlantic Avenue Bridge Florida Dept. of Transportation Movable Bridges 1993Florida Brickell Avenue Bridge Florida Dept. of Transportation Movable Bridges 1994Florida SR 666– Welch Causeway Florida Dept. of Transportation Movable Bridges 1995Florida SR 693 – Corey Causeway Florida Dept. of Transportation Movable Bridges 1995Florida SR 684 – Cortez Bride Florida Dept. of Transportation Movable Bridges 1995Florida SR 688 – Indiana Rocks Florida Dept. of Transportation Movable Bridges 1995Florida SR 758 – Siesta Key Florida Dept. of Transportation Movable Bridges 1996Florida SR 80 – Southern Blvd. Florida Dept. of Transportation Movable Bridges 1995Florida SR 706 Bridge Florida Dept. of Transportation Movable Bridges 1996Florida SR 816 - Oakland Park Blvd. Florida Dept. of Transportation Movable Bridges 1996Florida A1A / 17th Street Causeway Florida Dept. of Transportation Movable Bridges 1997Florida Donald Ross Road Bridge Palm Beach County Movable Bridges 1998Florida Structures 355A & 355B U.S. Army Corps of Engineers Irrigation 1997Florida Venetian Causeway Florida Dept. of Transportation Movable Bridges 1998Florida Ulmerton Road – SR688 Florida Dept. of Transportation Movable Bridges 1998Florida SW 2nd Avenue Bridge, Miami Florida Dept. of Transportation Movable Bridges 2002Georgia Rocky Mountain Voest Alpine Water Power 1992Hawaii Wailuku Voith Hydro Inc. Water Power 1992Idaho Lucky Peak Reservoir IMPSA International Water Power 1985Idaho Horseshoe Bend Voith Hydro Inc. Water Power 1994Illinois Olmsted Locks & Dam U.S. Army Corps of Engineers Navigation 1999Illinois Calumet Tunnel System Chicago - MWRD Irrigation 2000Indiana ARAMCO Bachman Industries Water Power 1991Iowa Keokuk Voith Hydro Inc. Water Power 1991Italy Rocky Reach Project Chelean County, WA. Water Power 1997Illinois Olmsted Lock & Dam U.S. Army Corps of Engineers Navigation 1994Maine Brassau Dam Voith Hydro, Inc. Water Power 1989Maine Central Maine Power Central Maine Power Water Power 1997Massachusetts Deerfield # 5 New England Power Service Co. Navigation 1992Massachusetts Route 6 – New Bedford Mass. Highway Dept. Movable Bridges 1995Mexico Chilapan Project Voith Hydro Inc. Water Power 1994Michigan St. Mary’s Falls U.S. Army Corps of Engineers Water Power 1998Michigan Benton Harbor Bridge Michigan Dept. of Transportation Movable Bridges 2000Mississippi Popps Ferry Bridge Harrison County Board, Mississippi Movable Bridges 1996Missouri Harry Truman Dam U.S. Army Corps of Engineers Water Power 1992Missouri Osage Voith Hydro Inc. Water Power 1991Missouri Lock # 27 U.S. Army Corps of Engineers Navigation 1997Nevada Lahonton Dam Voith Hydro Inc. Water Power 1989New Jersey Victory Bridge NJ Dept of Transportation Movable Bridges 1988New Mexico Aibquiu Dam U.S. Army Corps of Engineers Water Power 1998New York West Delaware Tunnel Voith Hydro Inc. Water Power 1988New York Shinnecock Locks Suffolk County NY Navigation 2002Ohio Belleville Lock U.S. Army Corps of Engineers Navigation 2000Oklahoma Kaw Dam IMPSA International Water Power 1988Oregon Bonneville Headgate Cylinders U.S. Army Corps of Engineers Water Power 2002Oregon Bonneville Project Voith Hydro Inc. Water Power 1998Pennsylvania Allegheny Lock & Dam # 5 U.S. Army Corps of Engineers Navigation 1991Pennsylvania (Braddock) Dam No. 2 U.S. Army Corps of Engineers Navigation 2001Pennsylvania Emsworth Vertical Lift Gate U.S. Army Corps of Engineers Navigation 2001Panama Miter Gate Panama Canal Commission Navigation 1995Panama Cylindrical Valve Panama Canal Commission Navigation 1995Panama Windless System Panama Canal Commission Navigation 1995Panama Rising Stem Valve Panama Canal Commission Navigation 1999Rhode Island Roosevelt Hydro Dam Voith Hydro Inc. Water Power 1992South Carolina Dearborn Project Voith Hydro Inc. Water Power 1995South Carolina Santee Cooper South Carolina Public Service Navigation 1998South Carolina Wapoo Creek South Carolina D.O.T. Movable Bridges 2000South Dakota Gavins Point Dam U.S. Army Corps of Engineers Water Power 1982Taiwan Mingtan Pumped Storage Project Voith Hydro Inc. Water Power 1981Tennessee Large Cavitation Channel Voith Hydro Inc. Water Power 1989Tennessee Raccoon Mountain Tennessee Valley Authority Water Power 2000Texas Austin Hydro Voith Hydro Inc. Water Power 1992Texas Inks Project Voith Hydro Inc. / LCRA Water Power 1997Texas Buchanan Project Voith Hydro Inc / LCRA Water Power 1998Virginia AIW Bridge Replacement Project U.S. Army Corps of Engineers Movable Bridges 2002Washington Cushman No. 1 City of Tacoma Water Power 1990Washington South Fork – Tolt River Voith Hydro Inc. Water Power 1994Washington Mud Mountain Dam U.S. Army Corps of Engineers Irrigation 1993Washington South Fork – Tolt River Voith Hydro Inc. Water Power 1994Washington Ice Harbor Dam U.S. Army Corps of Engineers Water Power 1994Washington Bonneville Project U.S. Army Corps of Engineers Water Power 1998Washington Lake Washington Ship Canal U.S. Army Corps of Engineers Navigation 2001Washington SR-520 Bridge – Evergreen Point Wash DOT Movable Bridges 1994Washington Cedar River Bridge Boeing Movable Bridges 1998West Virginia New Martinsville Dam City of New Martinsville Navigation 1988West Virginia Winfield Locks & Dam U.S. Army Corps of Engineers Navigation 1995

Projects coordinated by BoschRexroth organizations based in othercountries are not included.

Bosch Rexroth CorporationIndustrial Hydraulics2315 City Line RoadBethlehem, PA 18017-2131Telephone (610) 694-8300Facsimile (610) 694-8467www.boschrexroth-us.com

RA 00 059/04.03

Printed in the United States

Bosch Rexroth CorporationCorporate Headquarters5150 Prairie Stone ParkwayHoffman Estates, IL 60192-3707Telephone (847) 645-3600Facsimile (847) 645-6201

Bosch Rexroth CorporationElectric Drives and Controls5150 Prairie Stone ParkwayHoffman Estates, IL 60192-3707Telephone (847) 645-3600Facsimile (847) 645-6201

Bosch Rexroth CorporationLinear Motion andAssembly Technologies816 E. Third StreetBuchanan, MI 49107Telephone (616) 695-0151Facsimile (616) 695-5363

Bosch Rexroth CorporationPneumatics1953 Mercer RoadLexington, KY 40511-1021Telephone (859) 254-8031Facsimile (859) 281-3491

Bosch Rexroth CorporationMobile Hydraulics1700 Old Mansfield RoadWooster, OH 44691-0394Telephone (330) 263-3300Facsimile (330) 263-3333