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Hydraulic Hybrid Excavator—Mathematical Model Validation and Energy Analysis

Author

Listed:
  • Paolo Casoli

    (Industrial Engineering Department, University of Parma, Parco Area delle Scienze 181/A, 43124 Parma, Italy)

  • Luca Riccò

    (Casappa S.p.A., Via Balestrieri 1, Lemignano di Collecchio, 43044 Parma, Italy)

  • Federico Campanini

    (Industrial Engineering Department, University of Parma, Parco Area delle Scienze 181/A, 43124 Parma, Italy)

  • Andrea Bedotti

    (Industrial Engineering Department, University of Parma, Parco Area delle Scienze 181/A, 43124 Parma, Italy)

Abstract

Recent demands to reduce pollutant emissions and improve energy efficiency have driven the implementation of hybrid solutions in mobile machinery. This paper presents the results of a numerical and experimental analysis conducted on a hydraulic hybrid excavator (HHE). The machinery under study is a middle size excavator, whose standard version was modified with the introduction of an energy recovery system (ERS). The proposed ERS layout was designed to recover the potential energy of the boom, using a hydraulic accumulator as a storage device. The recovered energy is utilized through the pilot pump of the machinery which operates as a motor, thus reducing the torque required from the internal combustion engine (ICE). The analysis reported in this paper validates the HHE model by comparing numerical and experimental data in terms of hydraulic and mechanical variables and fuel consumption. The mathematical model shows its capability to reproduce the realistic operating conditions of the realized prototype, tested on the field. A detailed energy analysis comparison between the standard and the hybrid excavator models was carried out to evaluate the energy flows along the system, showing advantages, weaknesses and possibilities to further improve the machinery efficiency. Finally, the fuel consumption estimated by the model and that measured during the experiments are presented to highlight the fuel saving percentages. The HHE model is an important starting point for the development of other energy saving solutions.

Suggested Citation

  • Paolo Casoli & Luca Riccò & Federico Campanini & Andrea Bedotti, 2016. "Hydraulic Hybrid Excavator—Mathematical Model Validation and Energy Analysis," Energies, MDPI, vol. 9(12), pages 1-19, November.
    • Handle: RePEc:gam:jeners:v:9:y:2016:i:12:p:1002-:d:83978
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    Citations

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    Cited by:

    1. Andrea Vacca, 2018. "Energy Efficiency and Controllability of Fluid Power Systems," Energies, MDPI, vol. 11(5), pages 1-6, May.
    2. Tri Cuong Do & Hoai Vu Anh Truong & Hoang Vu Dao & Cong Minh Ho & Xuan Dinh To & Tri Dung Dang & Kyoung Kwan Ahn, 2019. "Energy Management Strategy of a PEM Fuel Cell Excavator with a Supercapacitor/Battery Hybrid Power Source," Energies, MDPI, vol. 12(22), pages 1-24, November.
    3. Kwangman An & Hyehyun Kang & Youngkuk An & Jinil Park & Jonghwa Lee, 2020. "Methodology of Excavator System Energy Flow-Down," Energies, MDPI, vol. 13(4), pages 1-19, February.
    4. Tatiana Minav & Jani Heikkinen & Thomas Schimmel & Matti Pietola, 2019. "Direct Driven Hydraulic Drive: Effect of Oil on Efficiency in Sub-Zero Conditions," Energies, MDPI, vol. 12(2), pages 1-10, January.
    5. Antti Lajunen & Panu Sainio & Lasse Laurila & Jenni Pippuri-Mäkeläinen & Kari Tammi, 2018. "Overview of Powertrain Electrification and Future Scenarios for Non-Road Mobile Machinery," Energies, MDPI, vol. 11(5), pages 1-22, May.
    6. Ryszard Dindorf & Jakub Takosoglu & Piotr Wos, 2023. "Review of Hydro-Pneumatic Accumulator Models for the Study of the Energy Efficiency of Hydraulic Systems," Energies, MDPI, vol. 16(18), pages 1-45, September.
    7. Paolo Casoli & Mirko Pastori & Fabio Scolari & Massimo Rundo, 2019. "Active Pressure Ripple Control in Axial Piston Pumps through High-Frequency Swash Plate Oscillations—A Theoretical Analysis," Energies, MDPI, vol. 12(7), pages 1-18, April.
    8. Lin Li & Tiezhu Zhang & Kaiwei Wu & Liqun Lu & Lianhua Lin & Haigang Xu, 2022. "Design and Research on Electro-Hydraulic Drive and Energy Recovery System of the Electric Excavator Boom," Energies, MDPI, vol. 15(13), pages 1-17, June.
    9. Paolo Casoli & Fabio Scolari & Carlo Maria Vescovini & Massimo Rundo, 2022. "Energy Comparison between a Load Sensing System and Electro-Hydraulic Solutions Applied to a 9-Ton Excavator," Energies, MDPI, vol. 15(7), pages 1-15, April.
    10. Gong, Jun & Zhang, Daqing & Guo, yong & Liu, Changsheng & Zhao, Yuming & Hu, Peng & Quan, weicai, 2019. "Power control strategy and performance evaluation of a novel electro-hydraulic energy-saving system," Applied Energy, Elsevier, vol. 233, pages 724-734.
    11. Daniele Beltrami & Paolo Iora & Laura Tribioli & Stefano Uberti, 2021. "Electrification of Compact Off-Highway Vehicles—Overview of the Current State of the Art and Trends," Energies, MDPI, vol. 14(17), pages 1-30, September.
    12. Abinab Niraula & Shuzhong Zhang & Tatiana Minav & Matti Pietola, 2018. "Effect of Zonal Hydraulics on Energy Consumption and Boom Structure of a Micro-Excavator," Energies, MDPI, vol. 11(8), pages 1-22, August.

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