Investigation and Optimization of Energy Consumption for Hybrid Hydraulic Excavator with an Innovative Powertrain

Abstract

This paper presents an innovative powertrain design and an energy regeneration system for hybrid hydraulic excavators to reduce energy consumption and emissions. The proposed system is designed to maximize engine efficiency and make full use of the energy gained from boom and arm retraction. The powertrain features an innovative design that incorporates a continuously variable transmission (CVT), which drives the main pump. It enables precise control of both the engine’s speed and torque, ensuring that the engine operates within the high-efficiency range. The energy regeneration system is applied to regenerate the potential energy of the boom and arm, which can be used to either charge the battery or directly supply power to the main pump. Moreover, an energy management strategy based on an equivalent consumption minimization strategy is used to distribute the power while offering maximum engine efficiency. When compared with the existing hybrid system and conventional system, the simulation results indicated that the proposed approach achieves energy-saving efficiencies of 16.9% and 77.1%, respectively, at high velocities and 22.25% and 53.5%, respectively, at medium velocities. This research signifies a promising advancement for sustainable and efficient hydraulic excavator operations.