122 resultados para Hybrid working machines


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The aim of this work is to design a flywheel generator for a diesel hybrid working machine. In this work we perform detailed design of a generator. Mobile machines are commonly used in industry: road building machines, three harvesting machines, boring machines, trucks and other equipment. These machines work with a hydraulic drive system. This system provides good service property and high technical level. Manufacturers of mobile machines tend to satisfy all requirements of customers and modernized drive system. In this work also a description of the frequency inverter is present. Power electronics system is one of the basic parts for structures perform in the project.

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Commercially available haptic interfaces are usable for many purposes. However, as generic devices they are not the most suitable for the control of heavy duty mobile working machines like mining machines, container handling equipment and excavators. Alternative mechanical constructions for a haptic controller are presented and analysed. A virtual reality environment (VRE) was built to test the proposed haptic controller mechanisms. Verification of an electric motor emulating a hydraulic pump in the electro-hydraulic system of a mobile working machine is carried out. A real-time simulator using multi-body-dynamics based software with hardware-in-loop (HIL) setup was used for the tests. Recommendations for further development of a haptic controller and emulator electric motor are given.

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This master’s thesis has been done for Drive! –project in which a new electric motor solution for mobile working machines is developed. Generic simulation model will be used as marketing and development tool. It can be used to model a wide variety of different vehicles with and without electric motor and to show customer the difference between traditionally build vehicles and those with new electric motor solution. Customers can also use simulation model to research different solutions for their own vehicles. At the start of the project it was decided that MeVEA software would be used as main simulation program and Simulink will only be used to simulate the operation of electrical components. Development of the generic model started with the research of these two software applications, simulation models which are made with them and how these simulation models can be build faster. Best results were used for building of generic simulation model. Finished generic model can be used to produce new tractor models for real-time simulations in short notice. All information about model is collected to one datasheet which can be easily filled by the user. After datasheet is filled a script will automatically build new simulation model in seconds. At the moment generic model is capable of building simulation models for wide variety of different tractors but it can be easily altered for other vehicle types too which would also benefit greatly from electric drive solution. Those could be for example wheel loaders and harvesters.

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Työssä tutkitaan raskaiden työkoneiden hybridisointimitoitusta simuloimalla. Työssä esitetään simulation-in-the-loop-simulointiin perustuva järjestelmä, jolla esimerkkitapauksena oleva kaivoslastauskone työympäristöineen voidaan mallintaa mekaaniselta osaltaan monikappaledynamiikkaan perustuvalla ohjelmistolla ja hybridijärjestelmän osalta Simulinkissa. Yhdistetty simulointi mahdollistaa hybridityökoneen virtuaalimallin ohjaamisen käyttäjän toimesta reaaliajassa. Simuloinnista saadaan tuloksena mm. työsykli, jota voidaan käyttää hybridisointimitoitukseen. Hybridisointi toteutetaan kahdella erilaisella kokoonpanolla, joista analysoidaan suorituskykyä sekä polttoaineen kulutusta. Tuloksia verrataan pelkästään dieselmoottoria voimanlähteenä käyttävään lastauskoneeseen. Työssä tehty tutkimus osoittaa, että (sarja-) hybridisoinnilla voidaan saavuttaa merkittäviä etuja raskaiden työkoneiden polttoainetehokkuudessa. Dieselmoottoria voidaan ajaa sellaisessa staattisessa toimintapisteessä, jonka hyötysuhde on korkea riippumatta työkoneen kuormituksesta. Saavutettu hyöty on toteutetussa tutkimuksessa parhaimmillaan jopa 56 % vähennys polttoaineenkulutuksessa. Lisäksi tarvittava dieselin nimellisteho pienenee huomattavasti. Tutkimuksen osana esitellään myös Hardware-in-the-Loop -laitteisto, jonka avulla voidaan liittää oikea sähkömoottori ja taajuudenmuuttaja osaksi virtuaalisesti simuloitua työkonetta.

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The power demand of many mobile working machines such as mine loaders, straddle carriers and harvesters varies significantly during operation, and typically, the average power demand of a working machine is considerably lower than the demand for maximum power. Consequently, for most of the time, the diesel engine of a working machine operates at a poor efficiency far from its optimum efficiency range. However, the energy efficiency of dieseldriven working machines can be improved by electric hybridization. This way, the diesel engine can be dimensioned to operate within its optimum efficiency range, and the electric drive with its energy storages responds to changes in machine loading. A hybrid working machine can be implemented in many ways either as a parallel hybrid, a series hybrid or a combination of these two. The energy efficiency of hybrid working machines can be further enhanced by energy recovery and reuse. This doctoral thesis introduces the component models required in the simulation model of a working machine. Component efficiency maps are applied to the modelling; the efficiency maps for electrical machines are determined analytically in the whole torque–rotational speed plane based on the electricalmachine parameters. Furthermore, the thesis provides simulation models for parallel, series and parallel-series hybrid working machines. With these simulation models, the energy consumption of the working machine can be analysed. In addition, the hybridization process is introduced and described. The thesis provides a case example of the hybridization and dimensioning process of a working machine, starting from the work cycle of the machine. The selection and dimensioning of the hybrid system have a significant impact on the energy consumption of a hybrid working machine. The thesis compares the energy consumption of a working machine implemented by three different hybrid systems (parallel, series and parallel-series) and with different component dimensions. The payback time of a hybrid working machine and the energy storage lifetime are also estimated in the study.

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Tämä työ on osa Integrated Serial and Parallel Hybrid Drives in Working Machines projektia. Työssä simuloidaan ja lasketaan energian palautuspotentiaalia raskaassa liikkuvassa työkoneessa. Työn alussa aihetta käsitellään yleisesti kirjallisuuskatsauksen muodossa. Tukkikurottaja valittiin simulointien ja laskennan kohteeksi. Työssä suoritettiin alustavat simuloinnit, joiden tarkoituksena oli varmistua, että palautettavaa energiaa on olemassa. Tulokset osoittavat, että energian palauttaminen on mahdollista. Mittaukset ovat osa työtä. Mitatut muuttujat ovat paineet ja pituudet hydraulisylintereistä, rungon kiihtyvyys, sekä kaikki CAN-väylään kytkettyjen antureiden mittaustiedot. Lopulliset simuloinnit perustuvat mitattuihin työkiertoihin. Työsylintereiden ja ajovoimansiirron tehotarpeet valittiin simulointien tarkasteltaviksi mittaussuureiksi. Mahdollinen palautettavan energian määrä eri työkierroissa on työn lopputulos. Tulokset osoittavat, että palautettavan energian määrä on talteenoton kannalta riittävä.

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Työn tavoitteena oli mallintaa maastotyökoneen ajomoottorin hybridisointiin soveltuvan napavaihteiston dynamiikka. Työ tehtiin osana Saimaan ammattikorkeakoulun tutkimusprojektia, jonka tarkoituksena oli ajomoottorin ja integroidun napavaihteiston kaupallistaminen maastotyökoneisiin. Maastotyökoneena simulointimallissa käytettiin tyypillistä maataloustraktoria, johon kytkettiin vielä peräkärry. Traktorin renkaiden napaan oli kytketty ajomoottorina toimiva sähkömoottori, jonka sisään simuloitu napavaihteisto oli integroitu. Napavaihteiston dynamiikan mallintamiseen käytettiin monikappaledynamiikan simulointiohjelmistoa (Adams). Ohjelmalle määritettiin napavaihteiston komponenttien parametrit, joista voitiin simuloida vaihteiston dynaaminen käyttäytyminen. Simuloidusta mallista saatiin kytkimiin kohdistuvat voimat kytkentätilanteessa sekä sähkömoottorin väännön suunnanvaihtotilanteessa eri akselin pituuksilla, eri kytkinten nopeuseroilla, eri traktorin painoilla ja eri kuormilla ajettaessa. Mallissa simuloitiin myös sähkömoottorin käyttäytyminen vaihteenvaihtotilanteessa eri pyörimisnopeuden säätimen kertoimilla. Työssä huomattiin, että akselin mitoituksella voitiin vaikuttaa vaihteistossa ilmeneviin voimiin kytkimen kytkentähetkellä. Myös kytkimen hammastuksessa olevalla hammasvälyksellä voitiin vaikuttaa kytkimiin kohdistuviin voimiin suunnanvaihtotilanteissa. Vaihteistoon kohdistuvista voimista voidaan jatkossa suunnitella kytkimen ja akselin profiili, jotta vaihteisto kestää siihen kohdistuvat voimat.

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This doctoral thesis presents a study on the design of tooth-coil permanent magnet synchronous machines. The electromagnetic properties of concentrated non-overlapping winding permanent magnet synchronous machines, or simply tooth-coil permanent magnet synchronous machines (TC-PMSMs), are studied in details. It is shown that current linkage harmonics play the deterministic role in the behavior of this type of machines. Important contributions are presented as regards of calculation of parameters of TC-PMSMs,particularly the estimation of inductances. The current linkage harmonics essentially define the air-gap harmonic leakage inductance, rotor losses and localized temporal inductance variation. It is proven by FEM analysis that inductance variation caused by the local temporal harmonic saturation results in considerable torque ripple, and can influence on sensorless control capabilities. Example case studies an integrated application of TC-IPMSMs in hybrid off-highway working vehicles. A methodology for increasing the efficiency of working vehicles is introduced. It comprises several approaches – hybridization, working operations optimization, component optimization and integration. As a result of component optimization and integration, a novel integrated electro-hydraulic energy converter (IEHEC) for off-highway working vehicles is designed. The IEHEC can considerably increase the operational efficiency of a hybrid working vehicle. The energy converter consists of an axial-piston hydraulic machine and an integrated TCIPMSM being built on the same shaft. The compact assembly of the electrical and hydraulic machines enhances the ability to find applications for such a device in the mobile environment of working vehicles.Usage of hydraulic fluid, typically used in working actuators, enables direct-immersion oil cooling of designed electrical machine, and further increases the torque- and power- densities of the whole device.

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Nykyään monet käyttökohteet vaativat akuilta aiempaa parempaa suorituskykyä, joten on syntynyt kasvavaa tarvetta uusien akkujen kehittämiselle erilaisista uusista materiaaleista ja uusiin valmistusmenetelmiin pohjautuen. Työn tavoitteena on selvittää kirjallisuustutkimuksena litium-vanadiini-fosfaattiakun ja vanadiini-redoksi-virtausakun ominaisuuksia, saatavuutta, sovelluskohteita ja vertailla niitä muutamaan eri litiumakkutekniikkaan. Tutkimuksen perusteella litium-vanadiini-fosfaattiakkuja ei ole vielä saatavilla kaupallisesti, joten työssä tutkittiin niitä teknisten raporttien pohjalta. Raporttien pohjalta arvioituna, parhaita ominaisuuksia litium-vanadiini-fosfaattiakuilla on erinomainen kuormituksen kesto ja korkea nimellisjännite. Sähköisissä ajoneuvoissa litium-vanadiini-fosfaattiakuilla on suurimmat mahdollisuudet erilaisissa hybridiajoneuvoissa, mutta todennäköisesti ne soveltuvat täyssähköisiin ajoneuvoihin vähintään yhtä hyvin kuin esimerkiksi litium-rauta-fosfaattiakut, jos valmistuskustannukset olisivat samalla tasolla. Vanadiini-redoksi-virtausakkua on jo markkinoilla usean valmistajan toimesta. Niiden ominaisuudet poikkeavat paljon muista akkutyypeistä ja erikoisuutena on mahdollisuus akun pikalataukseen elektrolyyttinesteet vaihtamalla. Syklien kestossa päästään myös erinomaisiin arvoihin, mutta suurimmat ongelmat ovat lyijyakkuakin matalampi energiatiheys ja tehotiheys. Vanadiini-redoksi-virtausakut soveltuvat parhaiten suuren kokoluokan sähköverkkoratkaisuihin ja sähköisissä ajoneuvoissa niiden mahdollisuudet rajoittunevat täyssähköisiin linja-autoihin ja isoihin työkoneisiin.

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The accelerating adoption of electrical technologies in vehicles over the recent years has led to an increase in the research on electrochemical energy storage systems, which are among the key elements in these technologies. The application of electrochemical energy storage systems for instance in hybrid electrical vehicles (HEVs) or hybrid mobile working machines allows tolerating high power peaks, leading to an opportunity to downsize the internal combustion engine and reduce fuel consumption, and therefore, CO2 and other emissions. Further, the application of electrochemical energy storage systems provides an option of kinetic and potential energy recuperation. Presently, the lithium-ion (Li-ion) battery is considered the most suitable electrochemical energy storage type in HEVs and hybrid mobile working machines. However, the intensive operating cycle produces high heat losses in the Li-ion battery, which increase its operating temperature. The Li-ion battery operation at high temperatures accelerates the ageing of the battery, and in the worst case, may lead to a thermal runaway and fire. Therefore, an appropriate Li-ion battery cooling system should be provided for the temperature control in applications such as HEVs and mobile working machines. In this doctoral dissertation, methods are presented to set up a thermal model of a single Li-ion cell and a more complex battery module, which can be used if full information about the battery chemistry is not available. In addition, a non-destructive method is developed for the cell thermal characterization, which allows to measure the thermal parameters at different states of charge and in different points of cell surface. The proposed models and the cell thermal characterization method have been verified by experimental measurements. The minimization of high thermal non-uniformity, which was detected in the pouch cell during its operation with a high C-rate current, was analysed by applying a simplified pouch cell 3D thermal model. In the analysis, heat pipes were incorporated into the pouch cell cooling system, and an optimization algorithm was generated for the estimation of the optimalplacement of heat pipes in the pouch cell cooling system. An analysis of the application of heat pipes to the pouch cell cooling system shows that heat pipes significantly decrease the temperature non-uniformity on the cell surface, and therefore, heat pipes were recommended for the enhancement of the pouch cell cooling system.

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The objective of this dissertation is to improve the dynamic simulation of fluid power circuits. A fluid power circuit is a typical way to implement power transmission in mobile working machines, e.g. cranes, excavators etc. Dynamic simulation is an essential tool in developing controllability and energy-efficient solutions for mobile machines. Efficient dynamic simulation is the basic requirement for the real-time simulation. In the real-time simulation of fluid power circuits there exist numerical problems due to the software and methods used for modelling and integration. A simulation model of a fluid power circuit is typically created using differential and algebraic equations. Efficient numerical methods are required since differential equations must be solved in real time. Unfortunately, simulation software packages offer only a limited selection of numerical solvers. Numerical problems cause noise to the results, which in many cases leads the simulation run to fail. Mathematically the fluid power circuit models are stiff systems of ordinary differential equations. Numerical solution of the stiff systems can be improved by two alternative approaches. The first is to develop numerical solvers suitable for solving stiff systems. The second is to decrease the model stiffness itself by introducing models and algorithms that either decrease the highest eigenvalues or neglect them by introducing steady-state solutions of the stiff parts of the models. The thesis proposes novel methods using the latter approach. The study aims to develop practical methods usable in dynamic simulation of fluid power circuits using explicit fixed-step integration algorithms. In this thesis, twomechanisms whichmake the systemstiff are studied. These are the pressure drop approaching zero in the turbulent orifice model and the volume approaching zero in the equation of pressure build-up. These are the critical areas to which alternative methods for modelling and numerical simulation are proposed. Generally, in hydraulic power transmission systems the orifice flow is clearly in the turbulent area. The flow becomes laminar as the pressure drop over the orifice approaches zero only in rare situations. These are e.g. when a valve is closed, or an actuator is driven against an end stopper, or external force makes actuator to switch its direction during operation. This means that in terms of accuracy, the description of laminar flow is not necessary. But, unfortunately, when a purely turbulent description of the orifice is used, numerical problems occur when the pressure drop comes close to zero since the first derivative of flow with respect to the pressure drop approaches infinity when the pressure drop approaches zero. Furthermore, the second derivative becomes discontinuous, which causes numerical noise and an infinitely small integration step when a variable step integrator is used. A numerically efficient model for the orifice flow is proposed using a cubic spline function to describe the flow in the laminar and transition areas. Parameters for the cubic spline function are selected such that its first derivative is equal to the first derivative of the pure turbulent orifice flow model in the boundary condition. In the dynamic simulation of fluid power circuits, a tradeoff exists between accuracy and calculation speed. This investigation is made for the two-regime flow orifice model. Especially inside of many types of valves, as well as between them, there exist very small volumes. The integration of pressures in small fluid volumes causes numerical problems in fluid power circuit simulation. Particularly in realtime simulation, these numerical problems are a great weakness. The system stiffness approaches infinity as the fluid volume approaches zero. If fixed step explicit algorithms for solving ordinary differential equations (ODE) are used, the system stability would easily be lost when integrating pressures in small volumes. To solve the problem caused by small fluid volumes, a pseudo-dynamic solver is proposed. Instead of integration of the pressure in a small volume, the pressure is solved as a steady-state pressure created in a separate cascade loop by numerical integration. The hydraulic capacitance V/Be of the parts of the circuit whose pressures are solved by the pseudo-dynamic method should be orders of magnitude smaller than that of those partswhose pressures are integrated. The key advantage of this novel method is that the numerical problems caused by the small volumes are completely avoided. Also, the method is freely applicable regardless of the integration routine applied. The superiority of both above-mentioned methods is that they are suited for use together with the semi-empirical modelling method which necessarily does not require any geometrical data of the valves and actuators to be modelled. In this modelling method, most of the needed component information can be taken from the manufacturer’s nominal graphs. This thesis introduces the methods and shows several numerical examples to demonstrate how the proposed methods improve the dynamic simulation of various hydraulic circuits.

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Työn tavoitteena on selvittää menetelmiä hybridityökoneiden markkinapotentiaalin määrittämiseen, työkonemarkkinoiden kokoa ja kasvupotentiaalia, hybridityökoneiden markkinapotentiaalia sekä uuden teknologian kaupallistamisen teorioita. Vuonna 2010 liikkuvien työkoneiden markkinat arvioitiin olevan noin 94–98 miljardia dollaria. Markkinat kasvavat keskimäärin noin 5 prosenttia vuodessa. Alan suurimmat markkinat löytyvät Kiinasta, Euroopasta ja Yhdysvalloista.Hybridityökoneiden markkinapotentiaalia Kiinassa nostaa markkinoiden suuri koko ja nopea kasvuvauhti. Yhdysvaltojen valtti on tukijärjestelmät jotka parantavat hybridiratkaisujen kilpailukykyä. Euroopan potentiaalia nostavat tiukat päästönormit sekä korkea polttoaineen hinta. Markkinapotentiaalin määrittämisen on olemassa useita matemaattisia menetelmiä. Niiden soveltamista hybridityökoneisiin rajoittaa eniten riittävän datan hankinnan haasteellisuus. Vertailemalla yrityksiä teknologian kaupallistamisen teorioissa esiteltyjen menestystä edistävien piirteiden suhteen on teknisen ratkaisun kehittäjän mahdollista valita paras mahdollinen yhteistyökumppani. Soveltamalla kaupallistamisprosessissa kurinalaista mallia, johon kuuluvat sekä teknologiaettä tuotekehitys ja niiden välillä teknologiansiirtovaihe, on teknisen ratkaisun soveltaminen hybriditeknologiaan ja työkoneisiin mahdollista toteuttaa onnistuneesti ja tuoda siten markkinoille kaupallisesti kilpailukykyinen tuote.

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Over the recent years, development in mobile working machines has concentrated on reducing emissions owing to the tightening rules and needs to improve energy utilization and reduce power losses. This study focuses on energy utilization and regeneration in an electro-hydraulic forklift, which is a lifting equipment application. The study starts from the modelling and simulation of a hydraulic forklift. The energy regeneration from the potential energy of the load was studied. Also a flow-based electric motor speed control was suggested in this thesis instead of the throttle control method or the variable displacement pump control. Topics related to further development in the future are discussed. Finally, a summary and conclusions are presented.

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Virtual environments and real-time simulators (VERS) are becoming more and more important tools in research and development (R&D) process of non-road mobile machinery (NRMM). The virtual prototyping techniques enable faster and more cost-efficient development of machines compared to use of real life prototypes. High energy efficiency has become an important topic in the world of NRMM because of environmental and economic demands. The objective of this thesis is to develop VERS based methods for research and development of NRMM. A process using VERS for assessing effects of human operators on the life-cycle efficiency of NRMM was developed. Human in the loop simulations are ran using an underground mining loader to study the developed process. The simulations were ran in the virtual environment of the Laboratory of Intelligent Machines of Lappeenranta University of Technology. A physically adequate real-time simulation model of NRMM was shown to be reliable and cost effective in testing of hardware components by the means of hardware-in-the-loop (HIL) simulations. A control interface connecting integrated electro-hydraulic energy converter (IEHEC) with virtual simulation model of log crane was developed. IEHEC consists of a hydraulic pump-motor and an integrated electrical permanent magnet synchronous motorgenerator. The results show that state of the art real-time NRMM simulators are capable to solve factors related to energy consumption and productivity of the NRMM. A significant variation between the test drivers is found. The results show that VERS can be used for assessing human effects on the life-cycle efficiency of NRMM. HIL simulation responses compared to that achieved with conventional simulation method demonstrate the advances and drawbacks of various possible interfaces between the simulator and hardware part of the system under study. Novel ideas for arranging the interface are successfully tested and compared with the more traditional one. The proposed process for assessing the effects of operators on the life-cycle efficiency will be applied for wider group of operators in the future. Driving styles of the operators can be analysed statistically from sufficient large result data. The statistical analysis can find the most life-cycle efficient driving style for the specific environment and machinery. The proposed control interface for HIL simulation need to be further studied. The robustness and the adaptation of the interface in different situations must be verified. The future work will also include studying the suitability of the IEHEC for different working machines using the proposed HIL simulation method.

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Power electronic converter drives use, for the sake of high efficiency, pulse-width modulation that results in sequences of high-voltage high-frequency steep-edged pulses. Such a signal contains a set of high harmonics not required for control purposes. Harmonics cause reflections in the cable between the motor and the inverter leading to faster winding insulation ageing. Bearing failures and problems with electromagnetic compatibility may also result. Electrical du/dt filters provide an effective solution to problems caused by pulse-width modulation, thereby increasing the performance and service life of the electrical machines. It is shown that RLC filters effectively decrease the reflection phenomena in the cable. Improved (simple, but effective) solutions are found for both differential- and common-mode signals; these solutions use a galvanic connection between the RLC filter star point and the converter DC link. Foil chokes and film capacitors are among the most widely used components in high-power applications. In actual applications they can be placed in different parts of the cabinet. This fact complicates the arrangement of the cabinet and decreases the reliability of the system. In addition, the inductances of connection wires may prevent filtration at high frequencies. This thesis introduces a new hybrid LC filter that uses a natural capacitance between the turns of the foil choke based on integration of an auxiliary layer into it. The main idea of the hybrid LC filter results from the fact that both the foil choke and the film capacitors have the same roll structure. Moreover, the capacitance between the turns (“intra capacitance”) of the foil inductors is the reason for the deterioration of their properties at high frequencies. It is shown that the proposed filter has a natural cancellation of the intra capacitance. A hybrid LC filter may contain two or more foil layers isolated from each other and coiled on a core. The core material can be iron or even air as in the filter considered in this work. One of the foils, called the main foil, can be placed between the inverter and the motor cable. Other ones, called auxiliary foils, may be connected in star to create differential-mode noise paths, and then coupled to the DC link midpoint to guarantee a traveling path, especially for the common-mode currents. This way, there is a remarkable capacitance between the main foil and the auxiliary foil. Investigations showed that such a system can be described by a simple equivalent LC filter in a wide range of frequencies. Because of its simple hybrid construction, the proposed LC filter can be a cost-effective and competitive solution for modern power drives. In the thesis, the application field of the proposed filter is considered and determined. The basics of hybrid LC filter design are developed further. High-frequency behaviour of the proposed filter is analysed by simulations. Finally, the thesis presents experimental data proving that the hybrid LC filter can be used for du/dt of PWM pulses and reduction of common-mode currents.