The demand for increased productivity and performance in the mobile/off-highway industry is on the rise, and along with it is the need for reduced operational costs, enhanced efficiency, and lowered exhaust and noise emissions. The push for sustainability and social responsibility increases demand for local emission-free applications. To provide solutions to these challenges is the Bosch Rexroth eLION portfolio for mobile electrification complemented by our application, system, and technological expertise in motion control and electrification. eLION high voltage electrification solutions include a 700 V electric product portfolio that realizes electric vehicle architectures. These new topologies enable highly efficient systems, operations with zero local emissions, and significant noise reduction.
The high-voltage class is designed for heavier-duty mobile/off-highway applications but is especially suited for intermittent-duty applications such as stump grinders, drill rigs, and forklifts. This application class is typically equipped with diesel engines to power its drive trains and hydraulics, but these machines are now rapidly being electrified. Whether driving, working, hydraulic, hybrid, or fully electric, we offer highly efficient, low-noise, and powerful electric motors, generators, inverters, and hydraulics combined with modular software applications for high-voltage mobile applications.
eLION Electrification Solutions
The eLION portfolio features durable and robust products that ensure longevity and resilience in electric applications. With easy and flexible integration, eLION products are seamlessly adaptable to various electrification needs, making them the best-fit choice for mobile OEMs who seek reliability and sustainability in their applications.
Motors, Generators, and Inverters
The Rexroth eLION 700 V portfolio offers motors, generators, and inverters that cover a broad performance power range from 8 to 200 kW and deliver nominal torques of up to 1050 Nm and a maximum torque of up to 2400 Nm. These permanent magnet synchronous components provide unparalleled power density and efficiency. Both standard and high-speed variants offer the flexibility to tailor the optimal solutions for your traction and implement function needs.
Motors
- Permanent magnet synchronous motors with reluctance
- Durable and robust design
- Modular and scalable variants
- Easy integration using standardized mechanical interfaces
Inverters
- Three power classes up to 300 A continuous current
- DC bus voltages from 400 to 850 V
- CAN J1939 communication
- High overload capabilities
- Safety functions according to ISO 13849 and 25119
Gear Units and Pumps
The high-speed electric eLION portfolio is seamlessly harmonized with the ROTATRAC eGFT hub drives line and new developments in single- and multi-speed central drive gear units, offering compact and robust drivetrain solutions. As a leader in fluid power, we’re positioned to merge electric motors and hydraulic pumps to deliver advanced solutions for implement functions. Leveraging our years of experience and expertise in variable speed drives for factory automation, we provide advanced electrohydraulic functionalities to boost efficiency and implement control.
Gearboxes
- One and 2-speed gear drives
- Designed for wheel and axle-driven mobile solutions
- Plug and drive system
- Compact and robust design for limited installation space
- Smooth shifting
Application Software and Safety
The eLION high-voltage electrification portfolio includes modular software for traction and implement control tailored for mobile machines across various electric topologies, featuring power management and application-specific functions. With the Rexroth “Safety on Board” approach, mobile/off-highway OEMs benefit from integrated functional safety in accordance with ISO13849.
Functional Safety
- Safe torque off
- Local I/O
- Safety levels up to Category 3, PL d, and AgPL
Application Engineering
With extensive experience in the mobile market and electrification of mobile/off-highway applications, we’re well-equipped to assist OEMs in designing machinery, identifying the best solution, and bringing it to life. Our comprehensive portfolio of functionalities helps to develop the desired vehicle architectures and performances.
Benefits of the eLION Electrification Portfolio
Core Components
As the market rapidly shifts towards electrification, Rexroth has expanded to include all core components needed for mobile electrification, including 700 V motors, generators, inverters, and gear units. Other electrical components, such as DC/DC converters, power distribution modules (PDMs), on-board chargers, and high-voltage cables, are available.
High Efficiency
OEMs can enhance efficiency and increase machine performance by optimally controlling electric motors combined with gear units or hydraulic pumps for traction or implement functions.
Specific Design
The eLION high voltage portfolio is specifically designed for the mobile/off-highway market, including all the right products and solutions for functional safety.
Reduced Emissions
With eLION electrification solutions, we are committed to contributing sustainable solutions for noise reduction and local zero-emission operations.
Scalability
The 700 V motor-generators are available in four sizes with different lengths and winding configurations and, depending on design, in a fast or standard-speed version. Over 80 configurations are possible, creating maximum design freedom for OEMs when electrifying existing and new vehicle architectures.
BODAS Software
BODAS software modules are available for the entire eLION portfolio, along with matching hydraulic components, such as axial piston pumps.