An Overview of Energy Savings Approaches on Hydraulic Drive Systems
DOI:
https://doi.org/10.13052/ijfp1439-9776.2114Keywords:
Power hydraulic system, energy savings, hybridization, energy recovery, regenerative system, energy lossAbstract
Different procedures to improve the energy efficiency of a hydraulic drive system have been surveyed in this article. The energy-saving approaches are classified into four categories: hybridization, control algorithms, waste energy recovery and reduction of energy losses. Also, the sub-categories of each strategy are discussed individually in brief. The energy efficiency can go up to 69% using a hybridization strategy, whereas using a fuel-saving strategy is within the range of 20–40%. Another strategy, i.e., control algorithms, yields 40% of fuel savings on the displacement-controlled excavator system. Similarly, the maximum potential to recover the braking energy is about 78% in the case of the Constant Pressure System (CPS) system using flywheel under the category of waste energy recovery. Moreover, 56–66.1% throttling energy saving potential is observed on an On/Off high-speed valve-controlled hydraulic system under the reduction of energy loss strategy. Different energy saving potentials of the hydraulic system have been presented in tabular form for a clear understanding of the historical development in this field.
Downloads
References
Ho T. H., Ahn K. K. (2012) Design and control of a closed-loop hydraulic energy-regenerative system. Automation in Construction, 22, pp. 444–458.
Divya K. C., Ostergaard J. (2009) Battery energy storage technology for power systems-An overview. Electric Power Systems Research, 79(4), pp. 511–520.
Lukic S. M., Cao J., Bansal R. C., Rodriguez F., Emadi A. (2008) Energy storage systems for automotive applications. IEEE Transactions on industrial electronics, 55(6), pp. 2258–2267.
Chen H., Cong T. N., Yang W., Tan C., Li Y., Ding Y. (2009) Progress in electrical energy storage system: A critical review. Progress in Natural Science, 19(3), pp. 291–312.
Shao Q., Zhao Y., Du S., Du Y. (2015) A Novel Hybrid Energy Storage Strategy Based on Flywheel and Lead-acid Battery in Wind Power Generation System. International Journal of Control and Automation, 8(7), pp. 1–12.
Cimuca G. O., Saudemont C., Robyns B., Radulescu M. M. (2006) Control and performance evaluation of a flywheel energy-storage system associated to a variable-speed wind generator. IEEE Transactions on Industrial Electronics, 53(4), pp. 1074–1085.
Strasik M., Hull J. R., Mittleider J. A., Gonder J. F., Johnson P. E., McCrary K. E., McIver C. R. (2010) An overview of Boeing flywheel energy storage systems with high-temperature superconducting bearings. Superconductor Science and Technology, 23(3), p. 034021.
Aljohani T. M. (2014) The Flywheel Energy Storage System: A Conceptual Study, Design, and Applications in Modern Power Systems. International Journal of Electrical Energy, 2(2), pp. 146–153.
Xu B., Yang J., Yang H. (2005) Comparison of energy-saving on the speed control of the VVVF hydraulic elevator with and without the pressure accumulator. Mechatronics, 15(10), pp. 1159–1174.
Kim Y. J. (2008) Integrated Modeling and Hardware-in-the-Loop Study for Systematic Evaluation of Hydraulic Hybrid Propulsion Options, A dissertation thesis for Doctor of Philosophy, The University of Michigan.
Stienecker A. W., Stuart T., Ashtiani C. (2006) Anultracapacitor circuit for reducing sulfation in lead acid batteries for Mild Hybrid Electric Vehicles. Journal of Power Sources, 156(2), pp. 755–762.
Aly A. A., Salem F. A., Hanafy T. O. S. (2014) Energy saving strategies of an efficient electro-hydraulic circuit (a review). International Journal of Control, Automation and Systems, 3(3).
Rydberg K. E. (2015) Energy Efficient Hydraulics: System solutions for loss minimization. The National Conference on Fluid Power, Hydraulikdagar’15, Linkoping, Sweden, March 16–17, 2015.
Ramakrishnan R., Hiremath S. S., Singaperumal M. (2012) Theoretical investigations on the effect of system parameters in series hydraulic hybrid system with hydrostatic regenerative braking. Journal of mechanical science and technology, 26(5), pp. 1321–1331.
Rydberg K. E. (2009) Energy Efficient Hydraulic Hybrid Drives: Scandinavian International Conference on Fluid Power, SICFP-09, Linkoping, Sweden.
Valente S., Ferreira H. (2008) Braking energy regeneration using hydraulic systems. Polytechnic Institute of Porto (IPP), Portugal, p. 8.
Chen J. S. (2015) Energy efficiency comparison between hydraulic hybrid and hybrid electric vehicles. Energies, 8(6), pp. 4697–4723.
Rodatz P., Paganelli G., Sciarretta A., Guzzella L. (2005) Optimal power management of an experimental fuel cell/supercapacitor-powered hybrid vehicle. Control engineering practice, 13(1), pp. 41– 53.
Thounthong P., Rael S., Davat B. (2006) Control strategy of fuel cell/supercapacitors hybrid power sources for electric vehicle. Journal of Power Sources, 158(1), pp. 806–814.
Li C. Y., Liu G. P. (2009) Optimal fuzzy power control and management of fuel cell/battery hybrid vehicles. Journal of power sources, 192(2), pp. 525–533.
Huang Y. J., Yin C. L., Zhang J. W. (2009) Design of an energy management strategy for parallel hybrid electric vehicles using a logic threshold and instantaneous optimization method. International Journal of Automotive Technology, 10(4), pp. 513–521.
Kim M. J., Peng H. (2007) Power management and design optimization of fuel cell/battery hybrid vehicles. Journal of power sources, 165(2), pp. 819–832.
Bozic A. (2007) Introducing hydraulic-electric synergy into hybrid transmission using the free-piston engine technology. SAE paper 2007-01-4112.
Ramakrishnan R., Hiremath S. S., Singaperumal M. (2014) Dynamic analysis and design optimization of series hydraulic hybrid system through power bond graph approach. International Journal of Vehicular Technology, Hindawi Publishing Corporation, 2014.
Hui S., Junqing J. (2010) Research on the system configuration and energy control strategy for parallel hydraulic hybrid loader. Automation in Construction, 19(2), pp. 213–220.
Tian D. W., Xie D. G., Cui S. M. (2009) Hybrid energy control strategy for hybrid electric drive system in military vehicle. Journal of Mechanical Engineering, 45(2), pp. 41–47.
Farzanehfard H., Beyragh D. S., Adib E. (2008) A bidirectional soft switched ultracapacitor interface circuit for hybrid electric vehicles. Energy Conversion and Management, 49(12), pp. 3578–3584.
Uzunoglu M., Onar O. C., Alam M. S. (2009) Modeling, control and simulation of a PV/FC/UC based hybrid power generation system for stand-alone applications. Renewable energy, 34(3), pp. 509–520.
Hui S., Lifu Y., Junqing J., Yanling L. (2011) Control strategy of hydraulic/electric synergy system in heavy hybrid vehicles. Energy Conversion and Management, 52(1), pp. 668–674.
Do H. T., Ahn K. K. (2012) A study of energy saving hydraulic system by a pressure coupling hydrostatic transmission. Journal of Drive and Control, 9(1), pp. 10–17.
Grabbel J., Ivantysynova M. (2005) An investigation of swash plate control concepts for displacement controlled actuators. International Journal of Fluid Power, 6(2),pp. 19–36.
Park S. H., Lee J. M., Kim J. S. (2009) Robust control of the pressure in a control-cylinder with direct drive valve for the variable displacement axial piston pump. Proceedings of the Institution of Mechanical Engineers, Part I: Journal of Systems and Control Engineering, 223(4), pp. 455–465.
Singh R., Kunt C. (1990) A linear time varying model for on-off valve controlled pneumatic actuators. Transactions of the ASME, 30, pp. 22– 48.
Shang T. (2004) Improving performance of an energy efficient hydraulic circuit, Doctoral dissertation, College of Graduate Studies and Research,University of Saskatchewan, Saskatoon, Saskatchewan.
Kaya D., Yagmur E. A., Yigit K. S., Kilic F. C., Eren A. S., Celik C. (2008) Energy efficiency in pumps. Energy Conversion and Management, 49(6), pp. 1662-1673.
Ho T. H., Ahn K. K. (2010) Modeling and simulation of hydrostatic transmission system with energy regeneration using hydraulic accumulator. Journal of Mechanical Science and Technology, 24(5), pp. 1163–1175.
Yang H., Sun W., Xu B. (2007) New investigation in energy regeneration of hydraulic elevators. IEEE/ASME transactions on mechatronics, 12(5), pp. 519–526.
Mingdong C., Dingxuan Z. (2011) Research on boom energy recovery system with closed circuit in Hydraulic Excavators. International Conference Transportation, Mechanical, and Electrical Engineering, TMEE-2011, pp. 954–957.
Ahn K. K., Ho T. H., Dinh Q. T. (2008) A study on energy saving potential of hydraulic control system using switching type closed loop constant pressure system. Proceedings of the Japan Fluid Power System Society (JFPS) International Symposium on Fluid Power, pp. 317–322.
Triet H. H., Ahn K. K. (2011) Comparison and assessment of a hydraulic energy-saving system for hydrostatic drives. Proceedings of the Institution of Mechanical Engineers, Part I: Journal of Systems and Control Engineering, 225(1), pp. 21–34.
Do H. T., Ahn K. K. (2011) A study on a closed-loop hydraulic braking energy regeneration system driven by a sliding mode controller. International Conference on Control, Automation and Systems (ICCAS-2011), IEEE, pp. 1594–1599.
Rannow M. B. (2016) Achieving Efficient Control of Hydraulic Systems Using On/Off Valves, Doctoral dissertation, University of Minnesota.
Tu H. C., Rannow M., Van de Ven J., Wang M., Li P. Y., Chase, T. (2007) High speed rotary pulse width modulated on/off valve. International Mechanical Engineering Congress, Proceedings of the ASME, Seattle, WA, pp. 42559.
Rannow M. B., Li P. Y. (2012) Soft switching approach to reducing transition losses in an on/off hydraulic valve. Journal of dynamic systems, measurement, and control, 134(6), p. 064501.
Van de Ven J. D. (2014) Soft switch lock-release mechanism for a switch-mode hydraulic pump circuit. Journal of Dynamic Systems, Measurement, and Control, 136(3), p. 031003.
Beckstrand B. K., Van De Ven J. D. (2014) Experimental validation of a soft switch for a virtually variable displacement pump. American Society of Mechanical Engineers/BATH 2014, Symposium on Fluid Power and Motion Control, pp. V001T01A038–V001T01A038.
Mahato A. C., Ghoshal S. K., Samantaray A. K. (2017) Influence of locking and passive soft switching on hydraulic circuit efficiency. Simulation, 93(3), pp. 237–249.
Mahato A. C., Ghoshal S. K., Samantaray A. K. (2017) Energy saving of a hydrostatic drive system by incorporating soft switch. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 39(6), pp. 1929–1945.
Hamzehlouia S., Izadian A., Anwar, S. (2013) Modeling and control of a hybrid hydraulic-electric propulsion system. Advances in Automobile Engineering, 2(1). http://dx.doi.org/10.4172/2167-7670.100 0102
Shen C., Shan P., Gao T. (2011) A comprehensive overview of hybrid electric vehicles. International Journal of Vehicular Technology, 2011, Article ID: 571683. https://doi.org/10.1155/2011/571683
Shakouri P., Ordys A., Darnell P., Kavanagh P. (2013) Fuel efficiency by coasting in the vehicle. International Journal of Vehicular Technology, 2013, Article ID: 391650. https://doi.org/10.1155/2013/391650
Chan C. C. (2007) The state of the art of electric, hybrid, and fuel cell vehicles. Proceedings of the IEEE, 95(4), pp. 704–718.
Burke A. F. (2007) Batteries and ultracapacitors for electric, hybrid, and fuel cell vehicles. Proceedings of the IEEE, 95(4), pp. 806–820.
Chan C. C., Bouscayrol A., Chen K. (2010) Electric, hybrid, and fuel-cell vehicles: Architectures and modeling. IEEE Transactions on Vehicular Technology, 59(2), pp. 589–598.
Dinçmen E., Güvenç B. A. (2012) A control strategy for parallel hybrid electric vehicles based on extremum seeking. Vehicle system dynamics, 50(2), pp. 199–227.
Wu B., Lin C. C., Filipi Z., Peng H., Assanis D. (2004) Optimal power management for a hydraulic hybrid delivery truck. Vehicle System Dynamics, 42(1–2), pp. 23–40.
Kim Y. J., Filipi Z. (2007) Simulation study of a series hydraulic hybrid propulsion system for a light truck. SAE Technical Paper. No. 2007-01-4151.
Cheong K.L., Li P.Y., Chase T.R. (2011) Optimal design of power-split transmissions for hydraulic hybrid passenger vehicles. Proceedings of the American Control Conference, pp. 3295–3300.
Rossetti A., Macor A.,Scamperle M. (2017) Optimization of components and layouts of hydromechanical transmissions. International Journal of Fluid Power, 18(2), pp. 123–134.
Kress J.H. (1968) Hydrostatic power-splitting transmissions for wheeled vehicles – classification and theory of operation. SAE Technical Paper 680549, 1968. https://doi.org/10.4271/680549
Sim T.P., Li P.Y. (2009) Analysis and control design of a hydro-mechanical hydraulic hybrid passenger vehicle. ASME 2009 Dynamic Systems and Control Conference, Paper No: DSCC2009-2616, pp. 667–674.
Sedler S.J. (2012) Design of a hydromechanical transmission with regeneration for a passenger vehicle. A thesis submitted to the University of Minnesota. http://hdl.handle.net/11299/140148
Du Z., Cheong K.L., Li P.Y., Chase T.R. (2013) Fuel economy comparisons of series, parallel and HMT hydraulic hybrid architectures. Proceedings of the American Control Conference, pp. 5954–5959.
Kepner R. P. (2002) Hydraulic power assist - a demonstration of hydraulic hybrid vehicle regenerative braking in a road vehicle application. SAE technical paper, No. 2002-01-3128.
Paul M., Jacek S. (2003) Development and simulation of a hydraulic hybrid powertrain for use in commercial heavy vehicles. SAE technical paper. No. 2003-01-3370DHSHD.
Heybroek K. (2008) Saving energy in construction machinery using displacement control hydraulics: Concept realization and validation. Doctoral dissertation, Linköping University Electronic Press.
Padovani D., Rundo M., Altare G. (2020) The Working Hydraulics of Valve-Controlled Mobile Machines: Classification and Review. Journal of Dynamic Systems, Measurement, and Control, 142(7). https: //doi.org/10.1115/1.4046334
Busquets, E. and Ivantysynova, M. (2013). Temperature Prediction of Displacement controlled multi-actuator machines. International Journal of Fluid Power, 14(1), pp. 25–36.
Sarkar B. K., Das J., Saha R., Mookherjee S., Sanyal D. (2013) Approaching servoclass tracking performance by a proportional valve-controlled system. IEEE/ASME Transactions on Mechatronics, 18(4), pp. 1425–1430.
Ahn K. K., Nam D. N. C., Jin M. (2014) Adaptive back stepping control of an electro hydraulic actuator. IEEE/ASME transactions on mechatronics, 19(3), pp. 987–995.
Backe W. (1991) Electro hydraulic load sensing. Proceedings of the International Off-Highway and Power plant Congress and Expostion, Sep 9–12, Milwaukee, USA.
Liang X., Virvalo T. (2001) What’s wrong with energy utilization in hydraulic cranes. Proceedings of the 5th International Conference on Fluid Power Transmission and Control, April 3-5, Hangzhou, China, pp. 419–424.
Backe W. (1993) Recent Research Projects in Hydraulics. Proceedings of the Second JHPS International Symposium on Fluid Power, September 6–9, Tokyo, Japan, pp. 3–27.
Luomaranta M. (1999) A Stable electro-hydraulic load sensing system based on a microcontroller. Proceedings of the Sixth Scandinavian International Conference on Fluid Power, May 26–28, Tampere, Finland, pp. 419–432.
Mansouri G., Misovec K., Johnson B., Babbitt G., Sturman O. (2001) Variable flow supply using switched-mode control of a fixed-displacement pump. Proceedings of the Seventh Scandinavian International Conference on Fluid Power, 110, pp. 361–376.
Liang X., Virvalo T., Linjama M. (1999) The Influence of Control valves on the efficiency of a Hydraulic Crane. Proceedings of the 6th Scandinavian International Conference on Fluid Power, May 26–28, Tampere, Finland, pp. 381–394.
Bedotti A., Campanini F., Pastori M., Riccò L.,Casoli P., (2017) Energy saving solutions for a hydraulic excavator. Energy Procedia, 126, pp. 1099–1106.
Borghi M., Zardin B., Pintore F.,Belluzzi F., (2014) Energy savings in the hydraulic circuit of agricultural tractors. Energy Procedia, 45, pp. 352–361.
Rahmfeld R., Ivantysynova M., Weber J. (2004) Displacement controlled wheel loader—a simple and clever solution. International Fluid Power Conference Proceedings, Dresden, Germany, 2, pp. 183–196.
Williamson C., Ivantysynova M. (2007) The effect of pump efficiency on displacement-controlled actuator systems. International Conference on Fluid Power, Tampere, Finland, 2, pp. 301–326.
Zimmerman J. (2008) Design and simulation of an energy saving displacement-controlled actuation system for a hydraulic excavator. Master’s thesis, Purdue University, West Lafayette, IN.
Quan Z., Quan L., Zhang J. (2014) Review of energy efficient direct pump controlled cylinder electro-hydraulic technology. Renewable and Sustainable Energy Reviews, 35, pp. 336–346.
Vanderlaan D., Ralf G. O. M. M., Shenouda A. (2014) Method of controlling an electro-hydraulic actuator system having multiple actuators. Parker Hannifin Corporation, U.S. Patent 8, 793, 023.
Chiang M.H., Chen C.C., Kuo C.F.J. (2009) The high response and high efficiency velocity control of a hydraulic injection molding machine using a variable rotational speed electro-hydraulic pump-controlled system. International Journal of Advance Manufacturing Technology, 43:841–851. http://dx.doi.org/10.1007/s00170-008-1759 -z
Chiang M.H. (2011) A novel pitch control system for a wind turbine driven by a variable-speed pump-controlled hydraulic servo system. Mechatronics, 21: 753-761. http://dx.doi.org/10.1016/j.mechatronics. 2011.01.003
Yoon J. I., Kwan A. K., Truong D. Q. (2009) A study on an energy saving electro-hydraulic excavator. ICCAS-SICE-2009, IEEE, pp. 3825–3830.
Lv C., Zhang J., Li Y., Yuan Y. (2015) Mechanism analysis and evaluation methodology of regenerative braking contribution to energy efficiency improvement of electrified vehicles. Energy Conversion and Management, 92, pp. 469–482.
Habibi S.R. (2000) Comparison of hydrostatic and servovalve controlled hydraulic actutation systems in robotics. SAE Technical Paper, 2000-01-2593. Milwaukee, Wisconsin: SAE.
Alle N., Hiremath S.S., Makaram S., Subramaniam K., Talukdar A. (2016) Review on electro hydrostatic actuator for flight control. International Journal of Fluid Power, 17(2), pp. 125–145.
Rongjie K., Zongxia J., Shaoping W., Lisha C. (2009) Design and simulation of electro-hydrostatic actuator with a built-in power regulator. Chinese Journal of Aeronautics, 22(6), pp. 700–706.
Dasgupta K. (2000) Analysis of a hydrostatic transmission system using low speed high torque motor. Mechanism and machine theory, 35(10), pp. 1481–1499.
Jen Y. M., Lee C. B. (1993) Influence of an accumulator on the performance of a hydrostatic drive with control of the secondary unit. Proceedings of the Institution of Mechanical Engineers, Part I: Journal of Systems and Control Engineering, 207(3), pp. 173–184.
Pourmovahed A., Beachley N. H., Fronczak F. J. (1992) Modeling of a hydraulic energy regeneration system: Part I - Analytical treatment. Journal of dynamic systems, measurement, and control, 114(1), pp. 155–159.
Pourmovahed A., Beachley N. H., Fronczak F. J. (1992) Modeling of a Hydraulic Energy Regeneration System: Part II - Experimental Program. Journal of dynamic systems, measurement, and control, 114(1), pp. 160–165.
Shimoyama H., Ikeo S., Koyabu E., Ichiryu K., Lee S. K. (2004) Study on hybrid vehicle using constant pressure hydraulic system with flywheel for energy storage, SAE Technical Paper, No. 2004-01-3064.
Cao J., Gu L., Wang F., Qiu M. (2005) Switch mode hydraulic power supply theory. International Mechanical Engineering Congress and Exposition, ASME, pp. 85–91.
Tu H.C., Rannow M. B., Wang M., Li P. Y., Chase T. R., Van de Ven J. D. (2012) Design, modeling, and validation of a high-speed rotary pulse-width-modulation on/off hydraulic valve. Journal of dynamic systems, measurement, and control, 134(6), p. 061002.
Borutzky W. (2011) Bond graph modelling of engineering systems. New York: Springer.
Borutzky W. (2009) Bond graph methodology: development and analysis of multidisciplinary dynamic system models. Springer Science & Business Media.
Mukherjee A., Karmakar R., Samantaray A.K. (2006) Bond graph in modeling, simulation and fault identification. I.K. International Pvt Ltd, New Delhi.