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Simulation analysis of potential energy recovery system of hydraulic hybrid excavator

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Abstract

A new hydraulic hybrid excavator potential energy recovery system is proposed in this paper. The energy recovery system uses threechamber cylinders (TCCs) and accumulators to recover potential energy during work cycle. Within this structure, there is no throttle valve in the primary loop, and the recovered energy is stored in the form of hydraulic energy. Hence, energy loss of throttle valve and energy conversion process are avoided, and energy efficiency is improved. The mathematical model is established to analyze dynamic and energy recovery characteristics. From simulation analysis, the usage of accumulators and TCC influences the dynamic response and stability. The increase of accumulator volume weakens the control performance but heightens the stability. When the cross sectional area of the TCC increases, the control performance of the system are improved. In addition, the maximum power and energy consumption of pumps and engine with different accumulator volumes and different TCC diameters are obtained. Also, the maximum power and energy consumption of each pump and engine in different working conditions are obtained and compared with those without potential energy recovery system. According to the comparison, the potential energy recovery system can reduce the maximum power and energy of engine by 50%.

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Abbreviations

A 11 :

cross sectional area of boom cylinder counterweight chamber

A 12 :

cross sectional area of boom cylinder chamber without piston rod

A 13 :

cross sectional area of boom cylinder chamber with piston rod

B 1 :

viscous damping coefficient of boom cylinder

C 11 :

external leakage coefficient of counterweight chamber

C 12 :

internal leakage coefficient between counterweight chamber and the chamber with piston rod

C 13 :

internal leakage coefficient between the chambers with and without piston rod

C 14 :

external leakage coefficient of the chamber without piston rod

C 15 :

external leakage coefficient of the chamber with piston rod

C e :

equivalent viscous damping of engine

C 1P :

sum of internal and external leakage coefficient of pump

C ve :

compression loss coefficient of pump

C vs :

structure leakage coefficient of pump

D 1 :

viscous damping coefficient of boom

D P :

displacement of pump

d P :

diameter of pipe

F 1 :

output force of boom cylinder

F 2 :

output force of arm cylinder

F 3 :

output force of bucket cylinder

f 1 :

friction force of boom cylinder

F load :

weight of load

F G1 :

weight of boom

F G2 :

weight of arm

F G3 :

weight of bucket and load

G 1 :

barycenter of boom

G 2 :

barycenter of arm

G 3 :

barycenter of bucket

J 11 :

rotational inertia of boom rotating around point B

J 12 :

rotational inertia of arm rotating around point B

J 13 :

rotational inertia of bucket and load rotating around point B

J e :

equivalent rotational inertia of engine

J p :

equivalent rotational inertia of pump

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Authors and Affiliations

  1. State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou, 310027, China

    Peng-Yu Zhao, Ying-Long Chen & Hua Zhou

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  1. Peng-Yu Zhao
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  2. Ying-Long Chen
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  3. Hua Zhou
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Correspondence to Hua Zhou.

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Zhao, PY., Chen, YL. & Zhou, H. Simulation analysis of potential energy recovery system of hydraulic hybrid excavator. Int. J. Precis. Eng. Manuf. 18, 1575–1589 (2017). https://doi.org/10.1007/s12541-017-0187-0

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  • DOI: https://doi.org/10.1007/s12541-017-0187-0

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