Hydraulic Energy Efficiency of Concepts on an Articulated Hauler

98 Pages·2015·15.71 MB·English

Hydraulic Energy Efficiency
of
Concepts on an Articulated Hauler
Design and evaluation of different hydraulic concepts
with focus on energy efficiency
Written by
Andre´ Arana Escobedo
Oskar Gunnarsson
Link¨oping University
Link¨oping
Master Thesis LIU-IEI-TEK-A--15/02236–SE
Department of Management and Engineering
Fluid and Mechatronic systems

Hydraulic Energy Efficiency
of
Concepts on an Articulated Hauler
Design and evaluation of different hydraulic concepts
with focus on energy efficiency
Written by
Andre´ Arana Escobedo
Oskar Gunnarsson
Link¨oping University
Link¨oping
Examiner at LiU: Liselott Ericson
Supervisor at LiU: L. Viktor Larsson
Supervisor at Volvo CE: Robert Morelius
Supervisor at Volvo CE: Vilhelm Fredriksson
Master Thesis LIU-IEI-TEK-A--15/02236–SE
Department of Management and Engineering
Fluid and Mechatronic systems

Abstract
This master’s thesis has evaluated different system designs for the hydraulic system on
anarticulatedhauleratVolvoConstructionEquipment(CE).Thecurrentsystemsuffers
from great losses when running on low pump displacement settings. This is due to large
installed displacements as a result of regulations and market demands. New system
concepts have been generated and simulations in Matlab and Amesim show that some
of the concepts can be implemented in order to increase energy efficiency up to 65%.
However, increasing efficiency does in most cases also increase cost, making some of the
concepts unrealistic to implement. The suggested solution for Volvo CE is to remove
one pump and allow for the fan pumps to supply oil to the steering and dumping,
as described in the Displacement reduction concept. They should also examine the
possibility to implement clutches further.
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VI
Acknowledgements
When our time as master students at Volvo CE in Eskilstuna is coming to an end we
feel grateful that we have had this opportunity to do our thesis at a company with
such a great atmosphere between co-workers. In this thesis we have put a lot of the
knowledge achieved during our studies at Link¨oping University to use and we are proud
of the result. We hope that Volvo CE feels the same and that our collaboration has been
worthwhile.
We would like to thank the hydraulics department at Volvo CE for making us feel
welcome and for taking the time to answer our questions. Specifically we would like to
expressourgratitudetowardsoursupervisors,RobertMoreliusandVilhelmFredriksson,
who supported us throughout our work. Another person who has our gratitude is Erik
Norlin who has been a great support when programming in Matlab. We would also like
to thank our supervisor at Link¨oping University, L. Viktor Larsson. We would like to
thank our friends and family and Oskar would like to thank his girlfriend for her support
and for putting up with him being away all the time.
May 2015
Andr´e Arana Escobedo & Oskar Gunnarsson
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Contents
1 Introduction 1
1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Aims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Problem Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Delimitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Contribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Method 7
3 Hydraulic systems 9
3.1 Conventional Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.1 Constant Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.2 Constant Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Load Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Digital Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5.1 Linear actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.2 Angular actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.6 Individual Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 Hydraulic Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.8 Valveless Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.8.1 Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.8.2 Pump Controlled Actuators . . . . . . . . . . . . . . . . . . . . . . 21
3.8.3 Electro Hydraulic Actuators . . . . . . . . . . . . . . . . . . . . . . 21
4 Mathematical model 23
4.1 Simulation Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.1 Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.2 Current System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.3 Conventional Systems . . . . . . . . . . . . . . . . . . . . . . . . . 28
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4.2.4 Displacement Reduction . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.5 Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.6 Flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.7 Digital pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.8 Individual Metering – Regenerative mode . . . . . . . . . . . . . . 29
4.2.9 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.10 Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5 Concepts 33
5.1 Conventional Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Displacement Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.3.1 Current system with Clutch . . . . . . . . . . . . . . . . . . . . . . 34
5.3.2 Displacement Reduction with Clutch . . . . . . . . . . . . . . . . . 34
5.4 Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.4.1 Current system with Flow Control . . . . . . . . . . . . . . . . . . 35
5.4.2 Displacement Reduction with Flow Control . . . . . . . . . . . . . 35
5.4.3 Clutch and Flow Control . . . . . . . . . . . . . . . . . . . . . . . 35
5.5 Digital hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5.1 Linear actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5.2 Angular actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.6 Individual Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.7 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.7.1 Accumulator in constant pressure system . . . . . . . . . . . . . . 36
5.7.2 Accumulator to reduce auxiliary steering pump . . . . . . . . . . . 37
5.7.3 Dump using accumulators . . . . . . . . . . . . . . . . . . . . . . . 37
5.8 Valveless Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.9 Fan Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6 Results 41
6.1 Current System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.2 Simulation Result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.2.1 Constant Flow and Constant Pressure . . . . . . . . . . . . . . . . 44
6.2.2 Displacement reduction . . . . . . . . . . . . . . . . . . . . . . . . 48
6.2.3 Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.2.4 Flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.2.5 Digital Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.2.6 Individual Metering . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.2.7 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.2.8 Fan Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3 Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7 Conclusions and Discussion 59
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