Design, modeling, and pressure control of a 300-kW-class hydraulic pump/motor loading system with energy regeneration

Abstract

Energy consumption and temperature rise are challenging in traditional high-power hydraulic pump/motor loading systems. This study develops a novel loading system configuration where energy can be regenerated by mechanical compensation. A compound loading method is proposed to implement static loading with displacement control and dynamic loading with valve control, respectively. This method combines the high energy-regeneration capability of the displacement control and the fast dynamic response of the valve control. Pressure controllers are designed based on system modeling and characteristics analysis. For static loading, a proportional–integral–derivative controller is employed, and the variation of rotational speed is taken into consideration to reduce overshoot and oscillation. For dynamic loading, an off-line learning method is developed by using least square calibration to keep the relief flow rate at a low level without flow meters. An experimental setup of a 300-kW-class loading system is manufactured, and experiments in various loading modes are performed. The results show that the designed system and controllers have accurate pressure tracking performance and low energy consumption.

A learning-based optimal tracking controller for continuous linear systems with unknown dynamics: Theory and case study

“…In this section, the tracking control of a hydraulic loading system for hydraulic motors is taken as a case study. 25 The hydraulic loading system utilizes energy regeneration technique to improve efficiency. [26][27][28] The photograph of the experimental setup is shown in Figure 2.…”

Development of a hydraulic pump motor test stand based on mechanical power recovery

“…The literature [12] uses a loading pump to provide a load to the system, and the load torque is changed by adjusting the hydraulic pump outlet pressure and flow rate to achieve simulated load operation, and the hydraulic components under test can be simulated and monitored within the design value, and the load flow rate is manually adjusted. The literature [13] introduced loading methods for load systems, including eddy current dynamometer loading and hydrodynamic dynamometer loading methods, which cause energy waste and have a large equipment structure. The literature [14] realizes different loading pressure by adjusting the flow rate of the load pump and adjusting the solenoid proportional relief valve can adjust the flow rate to realize the regulation of the system loading pressure.…”