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Counterbalance valves (CBVs) are widely used in hydraulic machines handling gravitational loads. They are usually adopted in hydraulic circuits that set the flow to the actuator with either metering control strategies or primary control strategies. In these circuits, the CBV does not determine the actuator velocity, but it establishes a proper counterpressure that balances the actuator during overrunning loads. A well-known problem of CBVs is the excessive power consumption introduced into the circuit, which is due to an excessive pressurization of the flow supply. This paper presents a solution for using CBVs to control the actuator velocity while also reducing energy consumption. The method consists in controlling the pilot port of the CBV through an external pressure source (adjustable pilot). The solution is first studied analytically, considering all the possible loading conditions at the actuator. Two different control strategies are presented: the "Smart CBV," where the CBV does not control the actuator velocity but it minimizes the system pressure; and the "Smart System" that uses the CBV to efficiently control the actuator velocity during overrunning load conditions. An experimental validation of the proposed solutions is also provided, taking as reference a truck-mounted hydraulic crane. The results of the proposed solutions are compared to those achieved by the traditional circuit of the reference hydraulic crane which uses standard CBVs. For both cases of smart CBV and smart system, a remarkable power saving, respectively, up to 75% and up to 90% is observed. [ABSTRACT FROM AUTHOR]

This paper proposes a novel hybrid power-split transmission to drive hydraulic implements in construction machinery. The highly efficient power-split hybrid transmission is combined with displacement-controlled (DC) actuators to eliminate throttling losses within the hydraulic system and achieve higher fuel savings. The architecture design, sizing, and power-management are addressed. Simulation results considering a realistic truck-loading cycle on a mini-excavator demonstrate the feasibility of the idea. A systematic comparison between the proposed system and the previously developed series-parallel hybrid is also carried out. The paper compares engine operation and fuel consumption of the previously mentioned hybrid system with the original nonhybrid load-sensing (LS) machine. It is shown that by implementing an efficient engine operation control, the proposed system can achieve up to 60.2% improvement in fuel consumption when compared to the original machine and consume 11.8% less than the previously developed series-parallel hybrid with DC actuation. Other advantages of the proposed solution include a much steadier engine operation, which open to the possibility of designing an engine for optimal consumption and emissions at a single operating point as well as greatly reduce pollutant emissions. A steadier prime mover operation should also benefit fully electric machines, as the battery would not be stressed with heavy transients. [ABSTRACT FROM AUTHOR]

• Integrating hydraulic and electric machines leads to greater power density. • Electrification allows novel throttle less actuator control strategies. • Electro-hydraulic drives allow energy recovery. • The hydraulic gear machine optimal rotation speed needs to be increased. This paper presents an innovative design of an integrated electro-hydraulic (EH) flow generation unit able to operate in multiple quadrants. The proposed unit is composed of a hydraulic machine which can operate in either pumping or motoring mode, and an electric machine, which can operate as electric motor or generator. The adopted morphological integration of the two unit fulfills the goals of maximizing compactness, power to weight ratio, energy efficiency and quietness. The design results from a numerical optimization procedure that includes detailed simulation of both the electric machine and the hydraulic machine, using simulation tools previously developed by the authors, but combined for the first time in this work. After describing the optimization procedure, the paper focuses on the design integration aspects of the novel unit. A 9 kW prototype of the integrated unit was also fabricated and tested to verify its performance. Tests results show a measured overall energy efficiency up to 69%, demonstrating the potentials of the proposed concept, despite some limitations present in the first prototypes which could be addressed in future design refinements. [ABSTRACT FROM AUTHOR]

Highlights: [•] A graphical method to study the operation of counterbalance valves is presented. [•] The method is suitable to study the impact of valve settings on energy consumption. [•] Energetic considerations on a hydraulic crane were performed through numerical simulations. [•] Test were performed to validate the model on steady-state and transient conditions. [•] Energy consumption reduction potentials in current applications were discussed. [ABSTRACT FROM AUTHOR]

Load sensing (LS) is a dominant fluid power actuation technology in mobile machines, particularly in construction and agriculture. It has the advantage of guaranteeing good controllability in systems with multiple actuators while promoting higher energy efficiency. Several variants of LS systems have been proposed over the years, and research on cost-effective methods to further increase their efficiency is still of interest for original equipment manufacturers (OEMs) and the fluid power community. This article presents two solution, referred to as variable pump margin (VPM) and hybrid variable margin (HVM), suitable to improve the energy efficiency in pre-compensated LS systems such as those used in agricultural tractors. Both methods allow either downsizing the control valves or reducing the power consumption over the working range. Compared to a standard LS system, the VPM solution lowers the pump pressure using an electronic proportional pressure-reducing valve (ep-PRV), while the HVM solution uses a second ep-PRV in the compensator’s pilot line to further minimize the pressure differential across the LS valve. Simulation and experimental results show that, among the main working conditions, the VPM solution on average achieved 6.7% power saving over the standard LS system, while the model predicted an average improvement of 15.6% for the HVM solution. [ABSTRACT FROM AUTHOR]

The author reflects on research efforts made by both the energy industry and academia to improve fluid power technology. It cites that topics of interest include reduction of oscillations and vibrations of fluid power machines, digital and switched fluid power systems, and new system configurations to reduce fuel consumption and increase productivity of fluid power machines.

This paper proposes a cost-effective, robustly practical solution for a high-efficient electro-hydraulic actuator (EHA) for linear drives. The solution addresses the challenges of high costs and limited efficiency that limit the application of EHA for the electrification of many off-road vehicles. Based on a variable-speed electric motor and a low-cost technology for a fixed-displacement pump, the proposed solution is suitable for a compact implementation and it is capable of energy regeneration under overrunning load conditions. Two different architectures—an open circuit and a closed circuit one—are considered to determine the most practical and efficient configuration as well as the control features. Both architectures minimize throttling losses associated with the conventional regulation of hydraulic actuators. Actuator velocities below the minimum and beyond the maximum allowable pump flow rate are achieved in both architectures using a proportional valve that bypasses the pump flow. The paper describes the design methodology as well as the simulation and experimental activities performed to verify the control strategies as well as energy efficiency. Considering an EHA system of about 20 kW, a complete efficiency map of the system is determined for all the possible four quadrants of operation thus including both resistive and overrunning loads, where energy recuperation is implemented. Simulation and experimental results show that the energy efficiency of the hydraulic systems can reach 84.7% in resistive phases. In assistive phases, the hydraulic system can recover up to 81.8% of the actuator energy. The comparison between open-circuit and closed-circuit structures shows the advantages of the former in terms of energy efficiency. The proposed solution is suitable for electrified hydraulic actuation systems, in both industrial and mobile applications. With the advantages of the low cost of the hydraulic unit and high energy efficiency, it is particularly suitable for mobile applications such as construction machines, that are recently experiencing a significant electrification trend. • A cost-effective electro-hydraulic actuator is proposed with high efficiency. • The solution uses fixed-displacement pump and variable-speed electric motor. • Low-speed actuation is allowed by the usage of bypass valve in the architecture. • The efficiency of the system is verified by both simulation and experiments. • Four-quadrant efficiency maps demonstrate energy performance. [ABSTRACT FROM AUTHOR]

In the context of improving energy efficiency and fuel consumption of mobile hydraulic equipment, it is important to analyze all the sources of power loss occurring within the hydraulic systems. While plenty of analyses have been performed on the working implements and the main transmission systems, very little attention has been paid to low-pressure (LP) systems until recently. LP systems are required on closed-circuit hydraulic systems to replenish losses, provide cooling flow, and maintain a pilot pressure necessary to operate hydraulic control valves and variable displacement units. It is shown that these circuits, which are often thought to have minimal impact on power consumption, actually cause significant, continuous power loss. A new method of power savings in these circuits is investigated through management of charge pump flow by application of an accumulator-sense pump-unloading (ASPU) valve. This work further proposes the combination of a split LP architecture with an ASPU valve. Three systems are simulated using Simcenter Amesim® and MATLAB/Simulink®. Using realistic duty cycles and unit loss models on a circuit for mobile off-road hydraulic equipment, it is shown that a standard LP system can consume about 5 kW of power. Power savings of up to 65% over a standard LP system are demonstrated by the proposed architecture. [ABSTRACT FROM AUTHOR]

Hydrostatic transmissions (HT) are widely applied to heavy-duty mobile applications because of the advantages of layout flexibility, power to weight ratio, and ease of control. Though applications of fluid power in light-duty vehicles face challenges, including the unavailability of off-the-shelf components suitable to the power scale, there are potential advantages for HTs in human-powered vehicles, such as bicycles, the most important one being the energy-saving advantage achievable through regenerative braking in a hybrid HT. This paper describes an innovative design for a hydraulic hybrid bicycle, i.e., the PurdueTracer. The PurdueTracer is an energy-efficient human-powered hydraulic bicycle with flexible operation and software aids. An open-circuit hydraulic hybrid transmission allows PurdueTracer to operate in four modes: Pedaling, Charging, Boost, and Regeneration, to satisfy users' need for different riding occasions. An aluminum chassis that also functions as a system reservoir was customized for the PurdueTracer to optimize the durability, riding comfort, and space for components. The selection of the hydraulic components was performed by creating a model of the bicycle in AMESim simulation software and conducting a numerical optimization based on the model. The electronic system equipped users with informative feedback showing the bicycle performance, intuitive execution of functions, and comprehensive guidance for operation. This paper describes the design approach and the main results of the PurdueTracer, which also won the 2017 National Fluid Power Association Fluid Power Vehicle Challenge. This championship serves to prove the excellence of this vehicle in terms of effectiveness, efficiency, durability, and novelty. [ABSTRACT FROM AUTHOR]