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net/publication/318858881
Direct Driven Hydraulic Drive for New Powertrain Topologies for Non-Road
Mobile Machinery
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Matti Pietola
Aalto University
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Article history: Tightening of emission rules and a desire to improve energy efficiency pushes even further the need for
Received 22 July 2015 hybridization of non-road mobile machinery (NRMM). Consequently, this paper illustrates potential of
Received in revised form 24 August 2016 the application of directly driven hydraulic drive (DDH) for NRMM from an energy efficiency point of view.
Accepted 2 August 2017
The control of the DDH system was implemented directly with a servomotor driving a pump without
conventional hydraulic control valves. Angular speed of the servomotor, in-coming oil flow from the
Keywords:
pump, and out-going flow to the hydraulic motor determined the velocity of the double-acting cylinder
Drive
piston. An earlier study by the authors presented that the hydro-mechanical losses were dominant in
Direct driven hydraulics
Energy efficiency
the original DDH setup. Resulting theoretical investigation indicated that the best scenario efficiency
Topology for DDH was estimated to be 76.7%. Therefore, this paper provides a detailed analysis based on Sankey
Non-road mobile machinery diagrams of various powertrain topologies with DDH. This study of powertrains illustrated that DDH
Servomotor has the highest impact with 174% efficiency improvement with an electric NRMM powered by batteries
Variable speed drive control instead of a conventional topology.
Hydraulics © 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND
license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
http://dx.doi.org/10.1016/j.epsr.2017.08.003
0378-7796/© 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.
0/).
T.A. Minav et al. / Electric Power Systems Research 152 (2017) 390–400 391
Fig. 1. DDH (a) Simplified schematics of the test setup: a—double-acting cylinder, b—wire-actuated encoder, c—pressure sensor, d—reversible gear pump/motor P1 ,
e—pressure sensor in tank line, f—torque sensor, g- T-gear, h—torque sensor, (i) PMSM motor/generator, j—current and voltage probes, k—frequency converter, l—oil tank,
m—hydraulic accumulator, n—pressure sensor, o—reversible gear pump/motor P2 and p—pressure sensor in the tank line. *Sensors are utilized for system diagnostic purpose
only. (b) PMSM motor/generator connected through T-gear into two internal gear motor/pumps [20], (c) experimental setup.
iPM
Rs q Ls
id
id+iD+iPM iD
ud d md Lmd LD iPM
RD
iq Rs d Ls
iq+iQ iQ
uq q mq Lmq LQ
RQ
ized power network opens up new approaches for hydraulic- and high efficiency with a speed regulation loop without conventional
hybrid circuits for NRMM [10–12]. As a result, electro-hydraulic valves [19,20]. All these features can be beneficial in creating new
systems with motor- or pump-controlled systems are observed on powertrain topologies in NRMM.
the market and research areas [13–18]. These electro-hydraulic sys- Consequently, the development of electro-hydraulic compact
tems are attracting an attention of industry due to advantages of systems motivates current research activities, however no effi-
their size-to-power ratios and the ability to produce large force ciency analysis was found concerning their application in the
and torque only on demand. These technologies provide opportu- NRMM systems. Therefore, the effect of a direct driven hydraulic
nities, compared with traditional systems, a compact structure and setup (DDH) on the efficiency of a variety of powertrain topologies
392 T.A. Minav et al. / Electric Power Systems Research 152 (2017) 390–400
Input : energy
100.0 [%]
Output: mechanical energy
76.7 [%]
Fig. 5. Best scenario Sankey diagram of the DDH setup (efficiency of the frequency converter is not included).
made based on the motor parameters and vector equivalent circuits Next DDH setup components under investigation are the
for a PMSM illustrated in Fig. 2. For detail explanation see Ref. [24]. hydraulic ones. Main hydraulic component is the pump. In the
Fig. 3 illustrates the efficiency chart for the servomotor made content of this research, a hydraulic motor is utilised as a pump,
based on the estimation. The efficiency contours are closed and therefore, it will be named pump/motor. In the experiments, two
have large areas with efficiencies above 90%. Moreover, the effi- hydraulic motors of type XV–2 M by Vivoil [27] were utilised with
ciency islands are typically located in areas of nominal speed and a fixed displacement of 14.4 and 22.8 cm3 /rev for P2 and P1 respec-
rated power. In electric motor’s case it may also be similar situa- tively. These hydraulic motors are also capable of working as a
tion to diesel engine that the motor–controller combination is not pumps. According to Fig. 4, depending on the operating point of
operating in its optimum area. the hydraulic pump/motor unit on its performance curve, the rela-
In the experimental study of the DDH, a 400 V servomotor with tionship between flow and hydraulic losses varies significantly. The
a frequency converter Unidrive SP1406 by Emerson Control Tech- pump/motor internal leakage increases with the higher operating
niques [26] was utilised. The Unidrive provides speed, torque, and pressure and lower fluid viscosity. These variables are difficult to
motion control for the servomotor with efficiency in the range of take into account in the calculation of unit efficiency as they vary
97–98%. with time and temperature. Therefore, in our test setup, the power
394 T.A. Minav et al. / Electric Power Systems Research 152 (2017) 390–400
Fig. 7. Measured Sankey diagram of the DDH with motor speed 300 rpm and payload of 175 kg (efficiency of the frequency converter is not included) [19].
3. Powertrain study
60
50
0.36
0. 3
6
40
0.
43
0.34
T, [Nm]
0.
30 32
0.32
0.3
0.3
0.28
20
0. 2 0.28
6
0.26
0. 2
0.24
0.22
10 0.1 0.2
6
0.18
0
80 100 120 140 160 180 200 220 240
, [rad/s]
350 5 leakage. In this study, valve losses follow the best-case scenario and
54
0 0. 7 1 76
68
0. .722 02 38
0. 7 46
26 0 0.8
43 99
0. 68
300
0.8
9 38 5
48 2
6 68
2
7
0.84
5 1
0.
73 91
78
250 0. 86 87 isation of new topologies for non-road mobile machinery are also
0. 8
45
7
6 6 26 0
0
Current, A
0.88
8
86
84
91
0 0 0.
53
87 0.908 high state of charge regions. According to Ref. [31], efficiency of 95%
150 0. 8 14
0.929
8
covers working region of NRMM and this value will be utilized for
7
08
0. 9 0.949 7
6
86
0. 0
100 In following Section 3.2 are the component efficiency datas from
1 4
79 291 0.94976
88 0.9 the current section and Section 2.1. These were utilized to calculate
0. 6
0.949
7 0.97037 the overall efficiencies for the conventional and alternative NRMM
50 0.97037
0 .9 7 0 37 topologies.
0 10 20 30 40 50 60 70 80 90 100
Fig. 11. (a) Schematics of cconventional powertrain, (b) Sankey diagram of the conventional NRMM powertrain.
Table 1 topology with the best case scenario of the DDH. The best case
Maximum theoretical efficiencies and losses of powertrain components in %.
scenario total efficiency of the powertrain of this system is 27.5%,
Component Maximum theoretical which is slightly higher compared to the conventional powertrain’s
efficiency, [%] 25.8%.
Diesel engine efficiency 40 Fig. 13a presents the electric version where the original engine
Electrical machine (generator and 95 and generator of the NRMM was replaced with a battery. A fre-
motor) efficiency quency converter is used to supply and control the electrical
Hydraulic pump efficiency 85
machine. Pump delivers the flow to all the actuators in the system
Valve losses 20
Hydraulic cylinder efficiency 95 thru conventional valves that control the actuator motions.
Frequency converter/rectifier 97 Fig. 13b illustrates the Sankey diagram for the electric NRMM
efficiency topology with a conventional hydraulic line. Most significant losses
Measured DDH efficiency 50
are due to the valves in hydraulic section of the system. Despite this
Best scenario DDH efficiency 76.7
Lithium titanate battery efficiency 95 fact, overall efficiency is higher compared to conventional engine
driven powertrain (Fig. 11a).
In Fig. 14a is illustrated the second electric approach where the
engine is replaced with a battery, frequency converter is utilised
Fig. 11 illustrates a conventional powertrain, where 100% is to supply the ac network of the machine, control the charging of
input energy from fuel. the batteries and maintain voltage levels in the system. Conven-
According to Fig. 11, significant concentration of losses of the tional hydraulics including the valves are replaced with the DDH
powertrain is located in diesel engine, where 60% is generally dis- per actuator.
carded as heat loss. Total system efficiency in conventional NRMM Fig. 14b illustrates a Sankey diagram where the total efficiency
is 25.8% in optimal operational region. of this powertrain topology is 46.1% which is significantly higher
In order to compare the disadvantages of the conventional compared to the conventional system. By applying the best scenario
NRMM system, the proposed hybrid and electric topologies are of DDH in Fig. 14c, efficiency of the electric powertrain is increased
analysed in identical way. from 46.1% to 70.7%.
Fig. 12a displays a hybrid topology for NRMM with DDH. Gen- Following section contains overall discussion about possible
erator (G) collects energy generated by the engine; as a result the improvements in the powertrain, which can be achieved by
engine can be forced to constantly work in the high-efficiency zone. changes in the utilized topology.
In this topology energy is transferred using direct current directly
to DDH, where the actuator is driven directly by an electrical motor. 4. Discussion
Fig. 12b illustrates hybrid powertrain with measured DDH effi-
ciency. In this topology, DDH losses are second biggest after the The experimental investigation of the DDH demonstrated that
engine. Fig. 12c presents the theoretical efficiencies of the hybrid achieved measured performance was up to 50%. However, the lim-
T.A. Minav et al. / Electric Power Systems Research 152 (2017) 390–400 397
Fig. 12. (a) Schematics of hybrid powertrain with a DDH, (b) Sankey diagram of the series hybrid powertrain with measured DDH efficiency, (c) Sankey diagram of the hybrid
powertrain with best case scenario DDH efficiency.
iting factor of the DDH is hydraulic losses. The best scenario values scenario DDH) gives an improvement of 7% (Figs. 11b and 12c) of
of 76.7% can be achieved with optimal selection of components for overall efficiency of NRMM’s powertrain.
the DDH. Based on the Sankey diagrams, it can be seen that the From electrification of a conventional NRMM with valve-
optimisation of the DDH’s total efficiency is important. For exam- controlled hydraulics it is possible to get a 118% improvement
ple, with DDH optimized, the powertrain efficiency increased from based on comparison of Figs. 11b and 14b. It is worth mention-
17.9 to 27.5% in hybrid (Figs. 12b and c) and in electric proposal ing that electric proposal is limited mainly by battery capacity and
from 46.1 to 70.7% (Figs. 14b and c). techno-economical boundaries of today’s technical solutions.
Combustion engine is clearly the most non-efficient part in any The comparison of Figs. 11b and 14c indicated that, 174%
powertrain and it was shown that optimizing of hydraulic compo- increase in overall powertrain efficiency can be achieved by con-
nents and locating them closer to the actuators (creating the best verting conventional NRMM to electric topology with the best
398 T.A. Minav et al. / Electric Power Systems Research 152 (2017) 390–400
Fig. 13. (a) Schematic of an electric powertrain with conventional hydraulics, (b) Sankey diagram of the electric NRMM powertrain with conventional lifting cylinder.
case scenario of efficiencies of a DDH. Improving efficiency would (NRMM). This paper investigates a directly driven hydraulic drive’s
besides the energy savings, reduce the demand of cooling which is (DDH) effect on the efficiency of various NRMM powertrain topolo-
one of the system issues of today’s machines in terms of volume, gies and analyses them with help of Sankey diagrams. DDH’s
costs, weight and maintenance. measured energy efficiency varies up to 50% depending on the
Assumptions that efficiency of a combustion engine is constant, direction of the cylinder’s motion and the motor speed. The best
engine is working in its maximum efficiency and excluding working scenario efficiency for the DDH was estimated to be 76.7%. Accord-
cycle is very optimistic and simplifies things significantly, which ing to the Sankey diagrams, the hydro-mechanical losses dominate
causes non-significant difference between the conventional and in the DDH and should be improved. Despite this, the DDH pow-
hybrid topology with regards to efficiency (Figs. 11b and 12c). ertrain without conventional control valves illustrated a 174%
Despite that, effect of the DDH is clearly visible in the electric pow- best scenario increase in overall powertrain efficiency that can be
ertrain proposals. achieved by converting a conventional NRMM to electric topology.
Therefore, the study indicates that DDH can increase the effi- Therefore, further study on optimising the DDH hydro-mechanical
ciency of NRMM. Its full potential can be only realized if NRMM components and investigation on the regenerative energy modes
is converted to be fully electric. It is important to also mention is vital in order to explore all benefits of proposed powertrains.
that current study analysed only linear movements of NRMM and
without energy regenerative features of the DDH. For future devel-
opment, these features should be taken into account. Acknowledgements
Fig. 14. (a) Schematic of an electric powertrain with DDH hydraulics, (b) Sankey diagram of the electric powertrain with measured DDH efficiency during lifting, (c) Sankey
diagram of the electric powertrain with best scenario DDH efficiency.
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