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.