This paper focuses on the low-level control of heavy complex hydraulic hybrids, taking stability and the dynamic properties of the included components into account. A linear model which can describe a high number of hybrid configurations in a straightforward manner is derived and used for the development of a general multiple input multiple output (MIMO) decoupling control strategy. This strategy is tested in non-linear simulations of an example vehicle and stability requirements for the low-level actuators are derived. The results show that static decoupling may be used to simplify the control problem to three individual loops controlling pressure, output speed and engine speed. In particular, the pressure and output speed loops rely on fast displacement controllers for stability. In addition, it was found that the decoupling is facilitated if the hydrostatic units have equal response. The low-level control of heavy complex hydraulic hybrids may thus imply other demands on actuators than what is traditionally assumed.
The need for efficient propulsion in heavy vehicles has led to an increased interest in hybrid solutions. Hydraulic hybrids rely on variable hydraulic pumps/motors to continuously convert between hydraulic and mechanical power. This process is carried out via the implementation of secondary control which, in turn, is dependent on a fast displacement controller response. This paper reports on a study of a prototype axial piston pump of the in-line type, in which the displacement is measured with a sensor and controlled using a software-based controller. A pole placement control approach is used, in which a simple model of the pump is used to parametrise the controller using desired resonance and damping of the closed loop controller as input. The controller's performance is tested in simulations and hardware tests on the prototype unit. The results show that the pole placement approach combined with a lead-compensator controller architecture is flexible, easy to implement and is able to deliver a fast response with high damping. The results will in the future be used in further research on full-vehicle control of heavy hydraulic hybrids.
When dealing with electrification of working machines, energy-efficient operation is key to maximise the usage of the limited capacity of on-board batteries. Previous research indicate that plenty is gained by reducing component and system losses by means of design. In contrast, this paper focuses on how to maximise energy efficiency by means of control optimisation. Dynamic programming with backward-facing simulation is used to find the optimal electric motor speed trajectory for a scooptram machine equipped with pump control, using digital displacement pumps with dynamic flow sharing as enabling technology. The results show that low shaft speed is preferred to minimise drag losses from parasitic components, partly facilitated by the relatively high and operation point-independent efficiencies of the pumps and electric motor. The results indicate energy reduction of 5 - 9 %, where higher figures could be expected for other, more hydraulic-intense applications, such as excavators.
Hydraulic hybrid system solutions are promising in the quest for energy efficiency in heavy construction machines. Hardware-in-the-loop simulations, where hardware is included in software simulations in real time, may be used to facilitate the development process of these systems without the need to build expensive prototypes. In this paper, the displacement actuator of a prototype pump used in a hardware-in-the-loop simulation test rig is modelled and validated against hardware, in order to draw conclusions regarding its dynamic behaviour in a future control design. The results show that the dynamic response of the modelled displacement actuator is mainly determined by the system pressure as well as the response and geometry of the control valve.
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