A Hydraulic Hybrid Architecture combining an

Open Center with a Constant Pressure

System for Excavators

Hijikata Seiji

3/21/2018
Hijikata, Seiji 1
 Contents

1 Introduction

2 Design of New System

3 Simulation

4 Conclusion and Outlook

3/21/2018
Hijikata, Seiji 2
 Introduction of Hydraulic Systems

Reference
Three Pump Open Center System Constant Pressure System

Controller
STEAM

HP
MP
TP

ICE
Eng
HP MP

• High efficiency of hydraulic system • High efficiency of engine operation

• Energy can not be recuperated. • Energy can be recuperated.
• Large idle losses • Large number of the valves
To design a new hybrid sytem which combines open center with
constant pressure system

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Hijikata, Seiji 3
 Contents

1 Introduction

2 Design of New System

3 Simulation

4 Conclusion and Outlook

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Hijikata, Seiji 4
 Basic Principles of New System
New System η

Torque
η𝒓𝒆𝒍 =
η𝒎𝒂𝒙

Eng

Rotation speed
Charged Maximum Flow
Accumulator Flow of Actuator
Flow rate

High efficiency engine operation

Pump Flow Recuperating energy

Actuator Flow

time

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 Basic Principles of New System

New System 𝑝𝐻𝑃 − 𝛼𝑝𝑇𝑃

Load pressure
𝑝𝐻𝑃 − 𝛼𝑝𝑀𝑃
𝑝𝑀𝑃 − 𝛼𝑝𝑇𝑃
𝑝𝐻𝑃 − 𝛼𝑝𝐻𝑃
𝑝𝑀𝑃 − 𝛼𝑝𝑀𝑃
𝑝𝑀𝑃 − 𝛼𝑝𝐻𝑃
𝑝𝑇𝑃 − 𝛼𝑝𝑇𝑃

Eng Load flow

𝑝𝐻𝑃 − 𝛼𝑝𝑇𝑃

Load pressure
𝑝𝐻𝑃 − 𝛼𝑝𝑀𝑃
𝑝𝑀𝑃 − 𝛼𝑝𝑇𝑃
Flow rate is provided by pump directly.
𝑝𝐻𝑃 − 𝛼𝑝𝐻𝑃
𝑝𝑀𝑃 − 𝛼𝑝𝑀𝑃
2 pump open center valves are used. Pump

Load flow

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 Levelling Cycle

Boom
Roll-in
Arm

Roll-out

100
Boom
% Stroke [%]

50

0
5 6 7 8 9 10 11 12 Time [s]

Arm 100
% Stroke [%]

50

0
5 6 7 8 9 10 11 12 Time [s]

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 Data Analysis of Levelling Cycle

Boom down Boom up Arm roll-out Arm roll-in

Frequency [%]
Load Pressure [%]

Frequency [%]
14
14
30 12 30 Low Pressure
12
10
10
15 15
8
𝑝𝐿 𝑝𝐿 8
6
0 0 6
Middle Pressure 4
−𝑝𝐿 −𝑝𝐿 4
-15 2 -15 2

100 65 30 0 30 65 100 65 30 0 30 65
Load flow [%] Load flow [%]

Motions Pump1 Pump2 Accumulator

Levelling - Arm - Arm - Boom
Roll-in
Levelling - Accumulator - Accumulator - Arm
Roll-out charge charge - Boom recuperation

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 Hydraulic Circuit of New System

Open center valves

Pump1 Pump2
Eng

Boom Arm
Additional valves

The number of valves can be reduced by using the open center valves.

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Hijikata, Seiji 9
 Contents

1 Introduction

2 Design of New System

3 Simulation

4 Conclusion and Outlook

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Hijikata, Seiji 10
 Simulation – Cycle Power Analysis
Roll-in Roll-out
100
100
Pump to accumulator
8080
Power [%]

Pump to arm
6060

4040

2020

00
-20
-20
-40
-40
13 14 15 16 17 18 19
1 2 3 4 5 6 7
Time [s]

100
100
Accumulator to arm
8080
Power [%]

60
Accumulator to boom
60
4040

2020

00
-20
-20
Boom recuperation
-40
-40
1
13 2
14 3
15 4
16 5
17 6
18 7
19
Time [s]

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 Sankey Diagram for System Efficiency

• Three Pump Open Center System

35.8% 29.6% 11.0% 5.5%
100% Eact
EDiesel

64.2% 6.2% 5.5% Erecoverable

18.6%
Eloss.Eng Eaux+ Eloss.pump Eloss.valve

• New System 4.1% Eloss.recovery

Erecovered
3.7% Erecoverable
7.8%
100% 37.5% 34.8% 7.8%
Eact
EDiesel

62.5% 19.1%
Eloss.Eng 6.4%
Eaux+ Eloss.pump Eloss.valve

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 Engine Operation with Efficiency Map

Three Pump Open Center System New System

Torque [%]
100 30 100 30
Torque [%]

85 25 85 25

70 20 70 20

Frequency [%]

Frequency [%]
55 15 55 15

40 10 40 10

25 5 25 5

10 0 10 0
40 50 60 70 80 90 100 40 50 60 70 80 90 100
Rotation speed [%] Rotation speed [%]

The new system shows potential 30 % less fuel compared to

three pump open center system.

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 Contents

1 Introduction

2 Design of New System

3 Simulation

4 Conclusion and Outlook

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Hijikata, Seiji 14
 Conclusion and Outlook

Conclusion
• Basic principles for the new system was
shown with analysis of measurement
data.
• The hydraulic circuit for the new system
was explained.
• The new system has consumed 30 %
less fuel than three pump open center
system.

Outlook
• Experiments will be conducted with a
test rig.

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Hijikata, Seiji 15
Thank you for your attention!
Contact:
・RWTH Aachen University
Institute for Fluid Power Drives and Systems (IFAS)
Campus-Boulevard 30, 52074 Aachen, Germany

・E-Mail: [email protected]

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Hijikata, Seiji 16