Hydraulic Hybrid Team

Team:Kevin Alexander- Market and Test skidPhillip Bacon- AccumulatorsTyler Degen- AccumulatorsBrandon Diegel- Pump/MotorNick Hemenway- Markets and BusinessLuke Jackson- Valves and Control SystemsChristian L’Orange- Computer Modeling and AnalysisGrant Mattive- Pump/MotorDean Simpson- Computer Modeling and Analysis

Advisors:Dr. Allan Kirkpatrick, CSUDr. Guy Babbitt, Czero Solutions, Inc.Chris Turner, Czero Solutions, Inc.

Presentation Outline

• Hydraulic Hybrid Overview

• Project Problem Statement

• Objectives and Constraints

• Market Opportunities

• Components and Research

Courtesy of Linde Pumps

Courtesy of viaggiaresempre.it

Hydraulic Hybrid Overview

• Utilizes regenerative braking

• Reduces fuel consumption and emissions

• High energy and power density

• Optimal for frequent stop and go driving of large vehicles

• Configurations Investigated: Series and Parallel

• Current development based in US and Europe

Energy Comparisons

Courtesy of Parker.com

Courtesy of HHV system panel

Series Hybrid

Pump

Low Pressure

High Pressure5000 psi Pump/Motor

Parallel Hybrid

Pump/MotorLow Pressure

High Pressure5000 psi Driveshaft

Problem Statement

• Increase vehicle fuel economy through regenerative braking

• Be adaptable to multiple vehicles with only component resizing

• Reduce vehicle emissions

• Reduce vehicle maintenance costs Courtesy of ourworldtravels.com

Design a hydraulic hybrid vehicle that will:

Objectives and Constraints

Courtesy of ITDP

Objectives and Constraints

Constraints• New components cannot add more than 10% of original vehicle mass to the vehicle

• Payback period: less than 2 years through fuel savings and reduced maintenance cost

• Major components sourced from commercial manufacturers

• Must have an expected life span of at least 10 years

Market Decisions• Population Density

• Refinement expectations of the vehicle

• Heavy reliance on bus system

• Find size ranges most widely used in many countries

• Most common chassis layout

• Short bus routes or stop and go drive cycles

Target Vehicle and Countries

• Focus on India, China, and Singapore

• Design will be based around 7000kg GVW

Typical of Class 4 vehicle

• Initial design will focus on front engine layout

• Simplistic control system to minimize cost

Major Components

• Functions as both a pump and a motor (P/M)

• Regenerative mode: P/M pumps fluid

• Acceleration: P/M is driven by fluid

• Many types of pumps and motors, but only a few that fit our application

• Needs to be low speed, high torque, and variable displacement

Pump/Motor Gear Screw Axial

PistonRadial Piston

Vane

Variable Displacemen

t

- - + + +

High Pressure (5000 psi)

- - + + -

Displacement size

- - + - +

Pump and motor

operation

- - + - -

Applicable to HHV

No No Yes No No

Major Components• Axial Piston Pump – Odd number of pistons situated parallel to each other rotating around a common shaft

• Variable Displacement – Displacement can be adjusted to increase or decrease the amount of fluid pumped per revolution

• Torque=Pressure*Displacement

Bent Axis Piston Pump

Swash Plate Pump

Major Components

Bent Axis Variable Displacement Pump Example

0 deg 22 deg 45 deg

www.epa.gov/otaq/technology

Major Components Accumulators

• An energy storage device

• Two main types: Gas charged and spring loaded

• During braking, hydraulic fluid compresses an inert gas or spring to store energy

• Stored energy is then released back to the system when needed

• Main types of gas accumulators are bladder, diaphragm, and piston

Bladder Type Accumulatorwww.Liquid-dynamics.com/animations

Major ComponentsAccumulators

Piston Type www.Liquid-dynamics.com/animations

Diaphragm Typewww.Liquid-dynamics.com/animations

Diaphragm Type

Piston Type

Bladder Type

Pressure to ~5000 psi

+ 0 +

Storage Capacity Range

- 0 +

Weight + 0 +

Safety + 0 +

Applicable to HHV No Yes Yes

System ModelingModeling Simulates System Performance

• Pump efficiencies• Operating pressures• Flow rates• Control system analysis• Valve control

Advantages• Changes in component size/operating conditions can quickly be analyzed• Vehicle drive cycle simulation• System control integration

Mototron

System ModelingModeling Software

• Matlab/Simulink R2007a• Matlab/Simhydraulic• Hysan

Summary• Recapture energy lost through braking

• Take advantage of wide and varied potential markets

• Seeking to fill retrofit applications

• Creating a dynamic computer simulation of system

• Designing a test bed model for system performance analysis

• Install and test system in vehicle

Special Thanks To:Dr. Kirkpatrick (Advisor-Colorado State University)

Dr Guy Babbitt (Advisor-Czero Solutions)Chris Turner (Advisor-Czero Solutions)

Staff and Employees of The Engines and Energy Conversion LaboratoryHysan Modeling