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A novel hydromechanical hybrid motion system for construction machines
Linköping University, Department of Management and Engineering, Fluid and Mechatronic Systems. Linköping University, Faculty of Science & Engineering. Driveline Systems, Volvo Construction Equipment, Eskilstuna, Sweden.
Linköping University, Department of Management and Engineering, Fluid and Mechatronic Systems. Linköping University, Faculty of Science & Engineering. Emerging Technologies, Volvo Construction Equipment, Eskilstuna, Sweden.
Driveline Systems, Volvo Construction Equipment, Eskilstuna, Sweden.
Linköping University, Department of Management and Engineering, Fluid and Mechatronic Systems. Linköping University, Faculty of Science & Engineering.ORCID iD: 0000-0002-2315-0680
2017 (English)In: International Journal of Fluid Power, ISSN 1439-9776, Vol. 18, no 1, 17-28 p.Article in journal (Refereed) Published
Abstract [en]

This paper deals with a novel type of hybrid motion system for construction machines based on a common pressure rail shared between a hydromechanical power-split transmission and secondary controlled work hydraulics. A construction machine with driveline and work functions is a complex coupled motion system and the design of an effective hybrid system needs to take both subsystems into account. Studies on energy efficient hybrid systems for construction machines have hitherto principally focused on one subsystem at a time - work hydraulics or driveline. The paper demonstrates a use case with a specific transmission concept proposal for a medium-sized wheel loader. The system is modelled and simulated using an optimal energy management strategy based on dynamic programming. The results show the benefits of a throttle-free bidirectional link between the machine's subsystems and the energy storage, while taking advantage of the complex power flows of the power-split transmission.

Place, publisher, year, edition, pages
Abingdon, UK: Taylor & Francis, 2017. Vol. 18, no 1, 17-28 p.
National Category
Mechanical Engineering
Identifiers
URN: urn:nbn:se:liu:diva-142329DOI: 10.1080/14399776.2016.1210423OAI: oai:DiVA.org:liu-142329DiVA: diva2:1152731
Available from: 2017-10-26 Created: 2017-10-26 Last updated: 2017-11-09Bibliographically approved
In thesis
1. On Energy Efficient Mobile Hydraulic Systems: with Focus on Linear Actuation
Open this publication in new window or tab >>On Energy Efficient Mobile Hydraulic Systems: with Focus on Linear Actuation
2017 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

In this dissertation, energy efficient hydraulic systems are studied. The research focuses on solutions for linear actuators in mobile applications, with emphasis on construction machines. Alongside the aspect of energy efficiency, the thesis deals with competing aspects in hydraulic system design found in the development of construction machines. Simulation models and controls for different concepts are developed, taking the whole machine into account. In line with this work, several proof of concept demonstrators are developed.

First, pump controlled systems are studied and a novel concept based on an open-circuit pump configuration is conceived. Special consideration is paid to multi-mode capabilities that allow for a broadened operating range and potential downsizing of components. Simulation models and controls are developed and the system is experimentally validated in a wheel loader application.

Second, the possibility for energy recuperation in valve controlled systems is investigated. In such solutions, a hydraulic motor, added to the meter-out port, is used for energy recovery during load lowering and in multi-function operation. Recuperated energy is either be used momentarily or is stored in a hydraulic accumulator. The proposed solution means an incremental improvement to conventional systems, which is sometimes attractive to machine manufacturers due to fewer uncertainties in reliability, safety and development cost. The energy recovery system is studied on a conceptual level where several alternative systems are proposed and a concept based on a two-machine hydraulic pressure transformer is selected for a deeper control study followed by experimental validation.

Third, so-called `common pressure rail' systems are suggested. This technique is well established for rotary drives, at least for the industrial sector. However, in applying this technique to mobile hydraulics, feasible solutions for linear actuators are needed. In this dissertation, two approaches to this problem are presented. The first one is the hydraulic pressure transformer, studied in simulation as the key-component of a `series hybrid' topology for wheel loaders. In the second approach variable displacement linear actuators (VDLA) based on a 4-chamber cylinder and multi-mode control is applied. In a theoretical study a model predictive control approach is suggested and new insights to the trade-off between controllability and energy efficiency of a multi-chamber cylinder are presented. Finally, a fullscale hydraulic hybrid system based on secondary controlled hydraulic motors and VDLAs is designed and experimentally validated on a large excavator.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2017. 82 p.
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 1857
National Category
Vehicle Engineering
Identifiers
urn:nbn:se:liu:diva-142326 (URN)10.3384/diss.diva-142326 (DOI)9789176855119 (ISBN)
Public defence
2017-11-17, C3, C-huset, Campus Valla, Linköping, 10:15 (English)
Opponent
Supervisors
Funder
Swedish Energy AgencyVINNOVA
Available from: 2017-10-26 Created: 2017-10-26 Last updated: 2017-11-09Bibliographically approved
2. Conceptual Design of Complex Hydromechanical Transmissions
Open this publication in new window or tab >>Conceptual Design of Complex Hydromechanical Transmissions
2017 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

This thesis explores the conceptual design process of complex hydromechanical transmissions for mobile working machines. Efficient methods for design optimisation and controller development are presented to support the final concept selection.

In the endeavour to develop new fuel-efficient driveline solutions for construction machines and off-road equipment new complex hydromechanical transmission concepts are being investigated. This pursuit is driven by stricter emission legislation, high fuel prices and a desire for a greener image both for customers and manufacturers. The trend towards more complex transmission architectures increases the need for more sophisticated product development methods. Complex multiple-mode transmissions are difficult to design and prototype and can be realised in a great number of architectures. By introducing a secondary energy storage in the machine the design space expands further for both hardware and software. There is accordingly a need for more reliable concept assessment in early design stages and the possibility to support concurrent engineering throughout the development process.

Previous research on the design and development of hydromechanical transmissions has been limited to analysis of fixed concept designs or design optimization using very simple performance indicators. Existing methodologies for electrified on-road vehicles are not suitable for off-road working machines with hydromechanical transmissions and hydraulic energy storage.

The proposed conceptual design process uses detailed quasi-static simulation models and targets to optimise the fuel efficiency of the specific machine specifications and operations. It is also shown how high-speed dynamic simulations can be used for controller development and hardware-in-the-loop simulations to support an efficient product design process. The methods are demonstrated for typical use cases targeting new transmission development for construction machines. Software control development is also treated using control optimisation and real-time simulation. Finally a novel hybrid hydromechanical motion system is presented for which an efficient design process is crucial to its end performance.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2017. 70 p.
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 1883
National Category
Embedded Systems
Identifiers
urn:nbn:se:liu:diva-142895 (URN)10.3384/diss.diva-142895 (DOI)9789176854471 (ISBN)
Public defence
2017-12-08, ACAS, Hus A, Campus Valla, Linköping, 10:15 (English)
Opponent
Supervisors
Note

In the printed verison the series name Linköping studies in Arts and Science is incorrect. The correct series name is Linköping studies in science and technology. Dissertations.

Available from: 2017-11-09 Created: 2017-11-09 Last updated: 2017-11-30Bibliographically approved

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Pettersson, KarlHeybroek, KimKrus, Petter

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