A numerical and experimental study on energy saving solutions for mobile hydraulic machinery

Energy saving in mobile hydraulic machinery, aimed to fuel consumption reduction, has been one of the principal interests of many researchers and OEMs in the last years. Many different solutions have been proposed and investigated in the literature in order to improve the fuel efficiency, from novel system architectures and strategies to control the system to hybrid solutions. This thesis deals with the energy analysis of a hydraulic system of a middle size excavator through mathematical tools. In order to conduct the analyses the multibody mathematical model of the hydraulic excavator under investigation will be developed and validated on the basis of experimental activities, both on test bench and on the field. The analyses will be carried out considering the typical working cycles of the excavators defined by the JCMAS standard. The simulations results will be analysed and discussed in detail in order to define different solutions for the energy saving in LS hydraulic systems. Among the proposed energy saving solutions, energy recovery systems seem to be very promising for fuel consumption reduction in mobile machinery. In this thesis a novel energy recovery system architecture will be proposed and described in detail. Its dimensioning procedure takes advantage of the dynamic programming algorithm and a prototype will be realized and tested on the excavator under investigation. Finally the energy saving proposed solutions will be compared referring to the standard machinery architecture and a novel hybrid excavator with an energy saving up to 11% will be presented.

Numerical modelling of unsteady mixed flows

This thesis concerns mixed flows (which are characterized by the simultaneous occurrence of free-surface and pressurized flow in sewers, tunnels, culverts or under bridges), and contributes to the improvement of the existing numerical tools for modelling these phenomena. The classic Preissmann slot approach is selected due to its simplicity and capability of predicting results comparable to those of a more recent and complex two-equation model, as shown here with reference to a laboratory test case. In order to enhance the computational efficiency, a local time stepping strategy is implemented in a shock-capturing Godunov-type finite volume numerical scheme for the integration of the de Saint-Venant equations. The results of different numerical tests show that local time stepping reduces run time significantly (between −29% and −85% CPU time for the test cases considered) compared to the conventional global time stepping, especially when only a small region of the flow field is surcharged, while solution accuracy and mass conservation are not impaired. The second part of this thesis is devoted to the modelling of the hydraulic effects of potentially pressurized structures, such as bridges and culverts, inserted in open channel domains. To this aim, a two-dimensional mixed flow model is developed first. The classic conservative formulation of the 2D shallow water equations for free-surface flow is adapted by assuming that two fictitious vertical slots, normally intersecting, are added on the ceiling of each integration element. Numerical results show that this schematization is suitable for the prediction of 2D flooding phenomena in which the pressurization of crossing structures can be expected. Given that the Preissmann model does not allow for the possibility of bridge overtopping, a one-dimensional model is also presented in this thesis to handle this particular condition. The flows below and above the deck are considered as parallel, and linked to the upstream and downstream reaches of the channel by introducing suitable internal boundary conditions. The comparison with experimental data and with the results of HEC-RAS simulations shows that the proposed model can be a useful and effective tool for predicting overtopping and backwater effects induced by the presence of bridges and culverts.