Electro Hydrostatic ActuationHighly efficient implement solution with energy recovery

Dale Vanderlaan

Sr. Program Mgr

Advanced Systems Technology

Hydraulics Group

Outline

• Off Highway Technology Trends

• EHA Technology Journey

• Application Test Results

• Key Conclusions

Technology Trend Current State

Fuel

ICE

Power train HydraulicsPower Source Mech Trans

Speed

Coupled

Systems

Machine

Focused

Operator

Dynamic

Braking

Loss

Inefficient operating points

Hydraulic distribution loss

Pump spinning loss

Confident load control

Valve throttle loss

Machine Efficiency Challenges Hydraulic Efficiency Challenges

Speed

Coupled

Systems

Machine

Focused

Operator

Dynamic

Braking

Loss

Machine

Technology Trend Future State

Power

Coupled

Systems

ICE efficiency optimization

Improve multi-function operation

Reduce idle lossReduced

distribution losses

Optimal component

efficiency

Dynamic

Braking

Recovery

Recover energy

Store energy / reduce ICE sizeEnergy recovery

Work

Focused

Operator

Power on demand

Adaptable controls

Power on demand

Improved

controllability

Hydraulics

Power

Coupled

Systems

Work

Focused

Operator

Dynamic

Braking

Recovery

Machine

Seamless power management

Energy storage

Power on demand

Adaptable controls

Motor / generator

Power Electronic Converter

Constant DC voltage bus ?

Technology Trend Hybrid Electric

Technology Trend Hybrid Electric

M/G

M/GAccessories

Steering, fans, cooling,

compressors…

Hydraulic Implement

Functions

Power Train

M/G

ICE Power =

Torque x Speed

M/G

3ΦAC Power =

Arms x VrmsCommon DC Bus Power = Vdc x Adc

Infinitely Variable Transmission

Bus Voltage

Set-point

Net System

Current

Technology Trend Hybrid Electric

M/G

M/GAccessories

Steering, fans, cooling,

compressors…

Hydraulic Implement

Functions

Power Train

M/G

ICE Power =

Torque x Speed

M/G

3ΦAC Power =

Arms x VrmsCommon DC Bus Power = Vdc x Adc

Infinitely Variable Transmission

Bus Voltage

Set-point

Net System

Current

Sys

tem

Valu

e

Fu

el S

avin

gs, P

rod

ucti

vit

y,

Co

ntr

oll

ab

ilit

y

System ConfigurationComplexity, Cost

7

?

Selection Criteria

• Strategy

• Minimum Change

• Fuel savings

• Productivity

• Safety

• Total Cost of Ownership …

EHA Technology Journey

System Configuration8

EHA Technology Journey

Distributed, LS

HydraulicsFull Power

On Demand

Power On Demand

Distribution Losses

Component Efficiency

Energy Recovery

?

Advanced Controls

Continuum

EHA Technology Journey EHA Technology

MG

Controller

Motor

Speed

Torque

Direction

Cylinder

Speed

Force

Direction

=

Electrical Mechanical

Energy Recovery

Pump

Flow

Pressure

Direction

= Fixed displacement, variable speed

Closed loop, hydrostatic

Servo inverter & electric motor

Mode select manifold

Controller, machine interface

4 Q Control

EHA Technology Journey EHA Technology

4 Q Control

Aiding Load

Resisting Load

Cylin

der E

xte

ndC

ylin

der

Retr

act

Energy To Source

Energy From Source

MG

Controller

-F

+V

Aiding Load

Resisting Load

Cylin

der E

xte

ndC

ylin

der

Retr

act

Energy To Source

Energy From Source

MG

Controller

-F

-V

Aiding Load

Resisting Load

Cylin

der E

xte

ndC

ylin

der

Retr

act

Energy To Source

Energy From Source

MG

Controller

+F

-V

Aiding Load

Resisting Load

Cylin

der E

xte

ndC

ylin

der

Retr

act

Energy To Source

Energy From Source

MG

Controller

+F

+V

Aiding Load

Resisting Load

Cylin

der E

xte

ndC

ylin

der

Retr

act

Energy To Source

Energy From Source

-F, -V-F, +V

DC bus

To other

functions

+ / - Net Power

Source & Storage

MG

Controller

MG

Controller

EHA Technology Journey Electro Hydraulic Pump

MG

Controller

Controllers Pumps

Hydraulics

Inverters

Electro Mechanical

Motors

EHA Technology Journey EHA Technology

Return SourceMachine CommDC Bus

3 Function EHA

EHA Verification

Lab Testing Application Testing

Wheel LoaderReach Stacker

14

3 Function Output

350 bar, 350 lpm

100 kw

Force x Speed

Energy

EHA Verification Application Test Results

Baseline System

EHA System

Load Sense

Hydraulics

Torque x Speed

Energy

EHA with Energy

Recovery

Volts x Amps

Energy

MG

MG

MG

DC

AC

DC

AC

Cylinder Energy Out

Energy In – Energy Recovered

Efficiency Metric

Po

wer

Kw

0

-75

175

30s Work Cycle

Total Recoverable

Input

Total 3 Function

Output

EHA Verification Application Test Results

Multi function

Multi function

System

Baseline EHA%

Improvement

Kwhr%Eff

MetricKwhr

%Eff

Metric

%Eff Metric

or

% Kw

Work

Cycle2.2 45% 1.3 80%

Transport 9 Kw 5 Kw

Idle 1.5 Kw .2 Kw

EHA Verification Application Test Results

• Significant fluid heat reduction

• Reduce thermal management energy

77%

44%

87%

1.0

30s Work Cycle

En

erg

y K

wh

r

EHA & Off Highway Hybrid Electric

• Significant benefits with power coupled systems

• Hybrid Electric is an effective approach

• Match hydraulic system solution to value objectives

• Proven, highly efficient EHA technology delivers

– Power on Demand

– Efficient multi-function operation

– Energy recovery

– Improved controllability