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A Novel Energy Recovery System Integrating Flywheel and Flow Regeneration for a Hydraulic Excavator Boom System

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  • Jiansong Li

    (School of Mechatronic Engineering, China University of Mining and Technology, Xuzhou 221116, China
    Research and Development Center for Intelligent Manufacturing Technology of Engineering Equipment, Xuzhou College of Industrial Technology, Xuzhou 221140, China
    George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332, USA)

  • Jiyun Zhao

    (School of Mechatronic Engineering, China University of Mining and Technology, Xuzhou 221116, China)

  • Xiaochun Zhang

    (School of Mechatronic Engineering, China University of Mining and Technology, Xuzhou 221116, China)

Abstract

Implementing an energy recovery system (ERS) is an effective solution to improve energy efficiency for hydraulic excavators (HEs). A flywheel energy recovery system (FERS) is proposed based on this concept. A hydraulic pump motor (PM) is employed as the energy conversion component and a flywheel is used as the energy storage component. Since the pressure is low because the bucket is usually empty as the boom lowers, a relatively large PM should be used in the FERS. To overcome this drawback, a novel compound energy recovery system integrating flywheel and flow regeneration (FFERS) is proposed in this paper. The working principle of the system is analyzed in detail. The introduction of flow regeneration has two benefits; one is downsizing the displacement of PM and the other one is an extra improvement of energy efficiency. The primary parameters of both are matched based on a 4 t excavator. Compared with the PM used in the FERS, the PM displacement in the FFERS is reduced by 71%. For comparison, a general model that can operate in either the FERS mode or the FFERS mode is developed in AMESim. The modeling results show that the FFERS with a downsized PM contributes a 13% increase in energy recovery and reutilization efficiency (62%) as compared with the FERS.

Suggested Citation

  • Jiansong Li & Jiyun Zhao & Xiaochun Zhang, 2020. "A Novel Energy Recovery System Integrating Flywheel and Flow Regeneration for a Hydraulic Excavator Boom System," Energies, MDPI, vol. 13(2), pages 1-25, January.
    • Handle: RePEc:gam:jeners:v:13:y:2020:i:2:p:315-:d:306647
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    References listed on IDEAS

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    Cited by:

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    2. Do, Tri Cuong & Dang, Tri Dung & Dinh, Truong Quang & Ahn, Kyoung Kwan, 2021. "Developments in energy regeneration technologies for hydraulic excavators: A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 145(C).
    3. Ryszard Dindorf & Jakub Takosoglu & Piotr Wos, 2023. "Review of Hydro-Pneumatic Accumulator Models for the Study of the Energy Efficiency of Hydraulic Systems," Energies, MDPI, vol. 16(18), pages 1-45, September.
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    5. Paolo Casoli & Fabio Scolari & Carlo Maria Vescovini & Massimo Rundo, 2022. "Energy Comparison between a Load Sensing System and Electro-Hydraulic Solutions Applied to a 9-Ton Excavator," Energies, MDPI, vol. 15(7), pages 1-15, April.
    6. Daling Yue & Hongfei Gao & Zengguang Liu & Liejiang Wei & Yinshui Liu & Xiukun Zuo, 2023. "Potential Energy Recovery and Direct Reuse System of Hydraulic Hybrid Excavators Based on the Digital Pump," Energies, MDPI, vol. 16(13), pages 1-17, July.
    7. Giuseppe Fabri & Antonio Ometto & Marco Villani & Gino D’Ovidio, 2022. "A Battery-Free Sustainable Powertrain Solution for Hydrogen Fuel Cell City Transit Bus Application," Sustainability, MDPI, vol. 14(9), pages 1-16, April.

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