Real-world operating characteristics of hydraulic excavators: A large-sample empirical study and implications for energy efficiency optimization

With the global push for energy conservation and green development, carbon reduction and pollution control in the construction machinery industry have become critical issues that need urgent attention. Existing research is often limited by sample size and analytical methods, resulting in insufficient generalizability and reliability of the findings. This study developed an innovative online identification platform to collect multi-sample dynamic operational data from 260 excavators over nearly 1 million cumulative operating hours. The data includes key parameters such as pilot secondary pressure, hydraulic pump outlet pressure, and engine status. A multidimensional dynamic operational characteristic quantification model for excavator operations was established. The results of the analysis show the following key findings: (1) Working condition time accounted for the highest proportion (65%-70%), idle time (20%-25%) was positively correlated with tonnage, and moving condition time accounted for the lowest proportion (8%-15%), negatively correlated with tonnage; (2) General mode demand was dominant (42%-56%) and negatively correlated with tonnage, while heavy-load mode demand ranged from 13% to 30% and was positively correlated with tonnage; (3) The demand intensity for operational actions decreased in the following order: slewing > bucket curl/extend > boom raise, with slewing and moving actions accounting for 35%-52% of total demand, negatively correlated with tonnage; (4) In the power system, average engine load was 55%/65% in general/heavy-load modes, low-load conditions accounted for 45%-57%, and hydraulic pump low-pressure intervals occupied 30%-40%, both negatively correlated with tonnage. These findings provide a theoretical basis for low-carbon optimization design for excavators, offer data support for green policy formulation and environmental impact assessment, and contribute to the green transformation of the construction machinery industry.