Beruflich Dokumente
Kultur Dokumente
24.4
ABSTRACT art. In this study the test results and experience of the
hydraulic system implemented in a medium-sized wheel
In this article the authors have studied a hydraulic loader are presented. The emphasis in this study is to
system configuration where each actuator/supply system compare the performance in open circuit pump control to
comprises an electrically controlled variable other pump controlled solutions as well as to
displacement pump/motor working in an open circuit conventional load sensing technologies. The comparison
together with four separate electrically controlled valves. primarily covers energy efficiency and system
complexity level.
Performance, operability and energy consumption are
evaluated in a wheel loader, first with its original load THE OPEN CIRCUIT SOLUTION CONCEPT
sensing hydraulic system and then modified with a
completely new pump controlled hydraulic system. If the pump does not have a pre-defined high and low
Measurements published in this article demonstrate the pressure compartment, it is said to work in a closed
advantages and drawbacks of pump control in an open circuit. In the other case, when the pump only operates
circuit compared both to a pump controlled, closed against high pressure on one side, it is working in an
circuit solution and to a valve controlled, load sensing open circuit. The open circuit solution, in this article
system. Performance is evaluated by looking at the fuel referred to as OCS, comprises four separate valves
consumption, productivity, and operability of a wheel combined with a number of sensors on top of an
loader. Theoretical calculations of energy efficiency electronically controlled pump, used for either pressure
including the dominant losses in system components are or flow control. Figure 1 illustrates the simplified
evaluated and validated. Fuel consumption is measured schematics of an implementation of the OCS on two
and put side by side with measurements of the same drives. The two functions are mechanically connected in
machine equipped with a load sensing hydraulic system. parallel via the pump shaft. There are three pressure
sensors for each drive, which is a prerequisite to achieve
INTRODUCTION all the modes of operation studied in this article. The
required controllers for the pumps and valves and a
There are three energy related key benefits using an supervisory control are also shown in the figure. The
open circuit pump controlled system instead of a OCS was first presented by K. Heybroek, J-O. Palmberg
traditional valve controlled system in a wheel loader. in 2006(1).
TARGET APPLICATION
signals.
Figure 9 - Schematics of a proposed controller for
2) The present load pressure and the desired
actuator velocity are used in an algorithm to the OCS when used in a wheel loader.
select the best mode with regards to energy
THE IMPACT OF MODE SELECTION
efficiency. The main components in such
evaluations for recuperative motions are:
The four valves render a solution versatile in control, as
the cylinder chambers can be connected to pump and/or
a. Minimize losses in valves comparing
tank as well as be closed at any time. In previous
different control modes.
studies the authors has investigated what influence
alternative control modes have on energy efficiency(8).
b. Minimize losses in components such as
What is here referred to as “control mode” is the way of
pumps, cylinders and hydraulic lines, have
controlling the load at a requested velocity, i.e.
comparing different control modes.
lifting/lowering a hanging load is achieved either in non-
differential or differential mode, either with or without
3) A preliminary mode is selected for further
meter-out flow control. The objective is to recuperate the
evaluation.
most energy possible for a commanded specified motion
and still fulfill the lowering speed requirements. Ideally,
4) Investigate if there is any immediate need for
the recuperated energy equals the energy required to lift
energy to be recuperated and if the workload on
the load; in reality, this ratio is much lower due to losses.
the engine can be reduced.
The losses are mainly related to the efficiency of
cylinders, valves and pumps(7).
5) Find an alternative control mode that matches
the power need, go back to 4 and iterate over
Measurement results from the OCS prototype show the
the mode selection until a match is found.
differences in potentially recuperable energy in different
modes of operation. In the non-differential and
6) Given the selected mode, define rules for how to differential control mode the maximum lowering speed is
match pump and load pressure prior to opening restricted by the maximum pump flow. If meter-out
valves. control is used the lowering speed is restricted by the
flow taken through the meter-out valve. In tests where
7) Command a pump pressure defined by 6. meter-out is used the mean lowering time is specified as
3 seconds. All tests are performed with the diesel
8) Execute valve settings defined by the selected operating at idle speed, 700 rpm. The efficiency in
control mode. recuperation is here referred to as the recuperation ratio,
defined in Equation 1:
Depending on the chosen mode of operation the pump
must be controlled differently. This is handled by the
pump controller which has the mode and operator
E recup
η recup = (1)
joystick signal as input. The control signals are sent to Ein
the pump, which has its own distributed electrical control
system, regulating the swashplate angle. The control
where Erecup is the recuperated energy output on the
signal for the pump is either relative displacement or
pump shaft and Ein is the energy input on the pump shaft
pressure. A safety control loop handles for example
powering the hydraulics.
Non-differential lowering Differential lowering
Figure 10 illustrates the valve setting and operating Figure 13 illustrates the valve setting and operating
region of the control mode “non-differential lowering”. region for the “differential lowering”.
v v
F F F F
Differential
Normal working region
working region
qp pp vn* v qp pp vd* v
Figure 10 - Left: valve configuration for non- Figure 13 - Left: valve configuration for differential
differential control. Right: working region for mode. control. Right: working region for mode.
As the entire load flow is controlled by the pump in non- Due to the differential coupling the limited maximum
differential lowering, no throttling losses related to meter- allowable load force in this mode is decreased.
out control are present (the left efficiency plot in Figure Exceeding this limit requires pressure control in order to
11). The pump/motor efficiency combined with the valve stay below maximum system pressure(10). The entire
losses in non-differential mode is illustrated to the right load flow is still controlled by the pump; the left plot in
in Figure 11. Figure 14 shows that no throttling losses related to
5 System efficiency 5 System efficiency
meter-out control are present, although higher lowering
speed is achieved.
x 10 x 10
0.8
0.6
0.3
0.9
0.8
0.7
0.6 0.5
0.2 0.1
η η
0.7
0.6
0.10.2
0.5
0.4
6 6
0.3
0.2
1
0.4 0.3
0.7
0.40.3
0.4
0.5
5 5 5
x 10 System efficiency x 10
5 System efficiency
0.2
0.4
0.4
0.8 0.7
0.8
η
0.1
4 4 0.
0.2
0.3
6
0.7
0.5
0.6
6 2
0.2
0.2
0.8
0.3
0.3
0.7
0.6
0.9
0.8
0.3
0.7
0.6 0.5
0.2 0.1
F [N]
F [N]
0.7
0.6
0.10.2
0.3
0.5
0.4
0.9
1
0.6
0.3
0.2
0.5
0.3
0.5
0.7
3 3
0.8
5 5
0.5
0.40.3
0.4
0.5
0.4
0.6
0.4
0.6
0.1
0.9
0. 0.2
2 2 4 0.3 4
4
0.2
0.
1
0.40.2
0.8
F [N]
0.80.7
F [N]
4
0.1
0. 0.8 0. 0 .
0.3
0.5
0.6
7 6
0.3 2
7 0.5 0.
0.8
1 1
0.9
0.8
0.6
0.3
0.7
0.6
0.
0.2
3 0.9 0.9 3 6
0.7
0.6
0.2 0.1
1
0.4
0.5
0.4
0.5 0.7
0.3
0.2
0.4
0.3 0.1
3
0.
0.5
0 0
0.
0.7 0.6
2 2
0.4
0 0.1 0.2 0.3 0.4 0.5 0 0.1 0.2 0.3 0.4 0.5
3
0.4
0.5
0.1
0.9
V [m/s] V [m/s]
0.8
0.8
1
0.6
1 1
0.7
00..320.4
0.5
0.8
0.1
0.7
0.7
0.6 5
0.06.5
0.
0.2
0.6
0.9
0.4 0.3
0.2 0.3 0.1
Figure 11 - Left: efficiency including valve losses.
0.50.1 0.4
0 0 0.1 0.4 0.2 0.3
0 0.1 0.2 0.3 0.4 0.5 0 0.1 0.2 0.3 0.4 0.5
V [m/s] V [m/s]
Right: efficiency including valve and pump losses.
Lowering loads in non-differential mode is associated Figure 14 - Left: efficiency including valve losses.
with unacceptable lowering times, almost 15 seconds. In Right: efficiency including valve and pump losses.
Figure 12 the power and energy are illustrated for the Lowering the load at the same engine speed as in the
mode. The bar to the right illustrates the recuperation non-differential control mode the operation now takes 6
ratio calculated from measured pump pressure, relative seconds instead of 15. However, the recuperation ratio
pump displacement and calculated pump/motor is lower than for the non-differential control mode,
efficiency. The average recuperation ratio is 36%. averaging 30%.
0.7
0.25 6s 0.25
0.6
0.25 15 s 0.25
0.6
0 0 0.5
0 0 0.5
0.4
-0.25 -0.25
0.4
-0.25 -0.25 0.3
-0.5 -0.5
0.3
Power 0.2
-0.5 -0.5
0.2 -0.75 -0.75
Power Energy 0.1
-0.75 -0.75
Energy 0.1
-1.0 -1.0 0
0 5 10 15 20 25 30
-1.0
0 5 10 15 20 25 30
-1.0 0 Time [s]
Time [s]
Figure 16 illustrates how increased lowering speed is Figure 19 illustrates how increased lowering speed is
achieved by meter-out flow control. achieved by meter-out flow control.
v v
F F F F
Fn*
q-contr. Normal + meter-out q-contr.
working region Differential + meter-out
working region
Figure 16 - Left: valve setting for non-differential + Figure 19 - Left: valve configuration for differential +
meter-out control. Right: working region for mode. meter-out control. Right: working region for mode.
In order to achieve the required lowering time of 3 The differential mode is not sufficient to fulfill the
seconds, flow must be throttled over the meter-out requirement of 3 seconds in lowering time. However, in
orifice, whereas the loss related to control mode this mode half of the flow is throttled to tank. Again, the
increases dramatically. Only a fifth of the lowering flow pump losses are considered in combination with the
goes through the motor, the rest is throttled to tank. The losses associated with the control mode. The resulting
efficiency for this strategy is illustrated in Figure 17. efficiency is presented in Figure 20. It should be noted
that the operating conditions for the motor have changed
5
x 10 System efficiency x 10
5 System efficiency due to the transformation in pressure and flow that come
with this mode.
0.3
0.7
0.8
0.4
η η
0.7
0.3
0.8
0.6
0.3
0.7
0.6
0.5
0.4
0.2
6 6
0.5
0.4
0.3
0.2
0.9
0.1 0.2
0.7
0.6
0.5
0.6
0.1
1
0.4 0.5
0.2
5 5
5
x 10 System efficiency x 10
5 System efficiency
4 4 0.
0.8
0. η 3
η
1 0.70.9
0.6
0.1
0.3
2
0.8
0.4
0.7
0.5
6
0.1
F [N]
F [N]
0.7
0.3
0.4
6
0.8
0.3
0.20.3
0.3
0.6
0.7
0.
0.7
0.6
0.5
0.4
0.2 0.1
0.5
2
0.4
0.3
0.2
0.9
0.8 0.6
3 3
0.6
0.5
1
0.2
0.3
5 5
0.5
0.2
0.9
0.8
0.5
2 2 0.6 0. 0.
0.3 0.2
0.4
4 3
0.4
4 4
0.7 0.5
0.9
0.8
F [N]
F [N]
0.7
0.6
1
1 1
0.1
0 . 0.
0.8
0.3
0.4
0.5
0.8
0.1
0.6
0.4
0.20.3
0.3
7 8
0.7
7 5 4
3
0.0.5 0.2 0 . 0.
8
0.6 0.5
0.6
0.9 3
0.2
0.
0.2 3
0.
0.1 0.9
0.2
0.4
0.3
0.4 0.3
0.9
0.6
0.5
0.7
0.7
0.6
0.1
0.5
1
0.6
0.1 0.1
0.3
0.2
0.4
0 0
0 0.1 0.2 0.3 0.4 0.5 0 0.1 0.2 0.3 0.4 0.5
2 2
V [m/s] V [m/s]
0.5
0.4
0.6
0.5
0.7
0.7
1 1 0.8
0.8
0.7
1
0.1
00.0.5.6
0.7
0.8
0.5
0.9
0.1
0.6
4
0.3
0.4
0.3 0.3
0.2 0.4 0.6 0.2
0.5 0.3 0.1 0.2
0 0 0.1
0 0.1 0.2 0.3 0.4 0.5 0 0.1 0.2 0.3 0.4 0.5
The limit where meter-out control becomes necessary Figure 20 - Left: efficiency including valve losses.
naturally depends on pump size, engine speed and Right: efficiency including valve and pump losses.
piston area. In Figure 18 the bar to the right shows the
recuperation ratio for the lowering motion. The average The calculated recuperation ratio is roughly double for
ratio over three cycles is 8%. The achievable lowering the differential + meter mode compared to the non-
speed in this mode is a trade-off in recuperated energy differential + meter-out mode. The average ratio
versus lowering time. calculated over three cycles is 16% with a lowering time
averaging the targeted 3 seconds.
Power and energy ηrecup
1.0 1.0 1
Power and energy ηrecup
0.9 1.0 1.0 1
0.75 0.75
0.9
0.8 0.75 0.75
0.5 0.5
Normalized Energy [-]
0.8
Normalized Power [-]
0.7
0.5 0.5
Normalized Energy [-]
Normalized Power [-]
0 0 0.5
0.4
-0.25 -0.25
0.4
0.3 -0.25 -0.25
-0.5 -0.5
0.3
0.2
Power -0.5 -0.5
-0.75 -0.75 0.2
0.1 Power
Energy
-0.75 -0.75
0.1
-1.0 -1.0 0 Energy
0 1 2 3 4 5 6 7 8 9 10
Time [s] -1.0
0 1 2 3 4 5 6 7 8 9
-1.0
10
0
Time [s]
LS-S ELS-S,fuel OCS »ELS-S,fuel (1-erecup) EFFICIENCY TEST – TRUCK LOADING CYCLE
cycle t .
LS-S
ELS-S,fuel
Ein,LS-S
Diesel hydraulic
Figure 27 - The short loading cycle is a typical field system
of application for the wheel loader(9).
Ethrottle+metering losses
Losses in the reference wheel loader: Ed,loss Epump losses
PTO ELS-Dp losses
(» 0.6 ELS-S,fuel)
What really differ between the two systems are the 0.5 0.5 Ework Eother losses
losses in the hydraulic system. The predominant losses prop. hyd.
The pump losses are calculated from measured Figure 28 - Energy distribution in the wheel loader
pressure, shaft speed, relative displacement and during the truck loading cycle, using the load
mapped pump efficiency. sensing system.
0.2
0.6
η
0.3
0.4
6 0.9
0.3 0.5
Ein,OCS » 0.8 Ein,LS-S
0.7
0.8
0.1
0.8
0.2
0.
5 3
0.4
0.9
0.7
0.1
0.5 0.4
Diesel hydraulic Erecup 4 0.6
system 0.5
0.2
F [N]
0.4
0.6 0.7
0.3
0.6
0.4
0.5
0.3
3
0.8
0.7
0.1
0.5
0.4
0.1 0.2
0.6
0.7
Emotor losses
0.5
2 0.9 0.3
0.4
0.6
Epump losses
Ed,loss 0.2
PTO Ethrottle losses
0.5
19%
0.6
(» 0.6 ELS-S,fuel) 1
0.2
0.3
Eother losses 0.7 0.1
00. 0. .6
Ework 0.8 0.7
0.7
34
0.5 0.6 0.5 0.5
0 0.1 0.2
0.1 0.4 0.2 0.3 0.4 0.2 0.3
0.1
0.1 0
prop. hyd. -0.1 0 0.1 0.2 0.3 0.4
Ep,loss V [m/s]
Eh,loss
Ewheel Ework
Figure 31 - The energy recuperation ratio in the truck
Figure 29 - Energy distribution in the wheel loader loading cycle.
during the truck loading cycle, using the open circuit
solution. Lowering an empty bucket in the differential mode is not
a problem, but regarding differential operation of the
Switching to the differential control mode in the tilting drive, a full bucket of gravel unfortunately often
recuperative phase yields a different point of operation in results in too high a pressure level. However, choosing
pressure as well as displacement. This means that the the cylinder area ratio differently a higher recuperation
pump efficiency at a given speed and force couple ratio could also be achieved in this drive. In Figure 32
depends on which control mode is applied. In Figure 30 the power, energy and recuperation ratio throughout the
the pump efficiency during the recuperative phase of the loading cycle are illustrated, including both drives.
loading cycle is presented, operating in the two modes ηrecup
Power and energy
respectively. The efficiency is found through 1
0.7
the calculation. As seen in the figure the pump efficiency 0.6
is 5-10% higher in the differential control mode. 0.5
Lift
Tilt 0.4
1
0.3
Normal state
Differential state 0.2
0.8 Power
0.1
Energy
0
0.6 0 2 4 6 8 10 12 14 16 18
ηm,tot
Time [s]
0.4
0,8