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Construction Equipment
http://www.constructionequipment.com/print/114528
01-Mar-13
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manner that, when serving as a motor, it can add rotational force to that of the engine or can assist in driving hydraulic pumps, thus easing the burden on the engine and saving fuel. As a generator, the motor/generator supplies current to other electric motors in the system or charges electrical storage devices, such as a battery or capacitor, a device that rapidly stores and releases large amounts of electrical energy.
http://www.constructionequipment.com/print/114528
01-Mar-13
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motor/generator, says Hitachi, is connected to the hydraulic pumps [and] adjusts the amount of electrical energy stored in the capacitor, indicating, it seems, that it can both assist the engine and charge the capacitor. The hybrid system in Kobelcos SK-80H-2 excavator [8] (developed for the Japanese market in 2010) is distinctive in that it combines both electric and hydraulic aspects. The system uses an engine-driven generator to charge both a capacitor and a nickelmetal hydride battery via a converter. Stored power is directed through inverters to four electric motors. Three of the motors drive a connected hydraulic pump, thus creating oil flow to the boom, arm/bucket, and travel circuits. The fourth electric motor powers the swing function directly, and, when acting as a generator during swing deceleration, it charges the capacitor and battery. In addition, the Kobelco system places the electric-motor/hydraulic-pump combination that powers the boom on a separate circuit, so when the boom is lowered, kinetic energy in the descending boom forces oil exiting the boom circuit to drive the circuits pump as a motor. The pump-turned-motor subsequently drives its connected electric motor as a generator, sending current, along with that from the swing motor, to the battery and capacitor for storage. In some instances, says Kobelco, the entire machine can be powered electricallywith the engine offresulting in significant fuel savings and whisper-quite operation in sensitive environments.
Electrical/mechanical designs
LeTourneau wheel loaders have used a basic diesel/electric drive train for decades, with an engine-driven generator powering four electric motors at the wheels. When stopping these machines, some with operating weights approaching 600,000 pounds, conventional friction brakes converted the loaders kinetic energy to heat. Generation 2 models, however, with their Switched Reluctance Hybrid Technology Propulsion System, come to a stop via regenerative braking, converting huge amounts of kinetic energy into electrical energy. The regenerative-braking system, says the manufacturer, brings the loader to a stop without using its conventional friction brakes, saving mechanical wear. In addition, although details are unavailable for explaining precisely how captured energy is employed to assist machine operation, the hybrid drive system is credited with promoting reductions in fuel consumption of up to 45 percent, compared with predecessor models. Although LeTourneau wheel loaders have attained hybrid status with their Generation 2 design, their basic diesel/electric drive system is not new. But diesel/electric drive in a smaller wheeler loader (Deeres 944K) and the integration of electrical- and mechanical-drive systems in the Cat D7E dozer and Deere 644K Hybrid wheel loader (Deere is curently taking orders) are designs far from conventional. Tilt the cab of the Cat D7E and youll notice that un-crawler-like componentssuch as an engine-driven generator, power inverter, and propulsion module have replaced the conventional torque converter and power-shift transmission. The generator produces 480 volts of AC power that the system converts to both DC current and frequency-controlled AC current, the latter powering two large electric motors geared together in the propulsion module, which drives a conventional Cat differential steering system and planetary finals. DC current at 340 volts powers the machines water pump and air-conditioning system.
http://www.constructionequipment.com/print/114528
01-Mar-13
Page 4 of 6
Deeres 944K is similar in design to that of LeTourneau loaders, but uses two enginedriven motor/generators to power its four electric drive motors. The 944K recovers the kinetic energy of machine deceleration via the drive motors working as generators, then applies the captured energy, says Deere, back to the engine crankshaft to reduce engine load and fuel consumption, as well as to deliver power to other vehicle systems. The 644K Hybrid reflects a different approach, using an engine-driven motor/generator to power a single electric motor via a water-cooled inverter. The motor drives a simplified power-shift transmission (no torque converter and no reverse gearing, because the motor reverses) and conventional axles. The machine employs regenerative braking when, during deceleration, the mechanical drive train turns the electric motor as a generator, capturing energy that the motor/generator can use to drive hydraulics and save fuel, says Deere. The system also incorporates a watercooled brake resistor to consume excess recycled energy. Eatons electric hybrid system [9]available for commercial trucksinserts a motor/generator between the clutch and the transmission. Regenerative braking occurs during deceleration, when the trucks inertia works through a conventional drive train to force the motor/generator to work as generator, storing power in lithium-ion batteries. Stored power, regulated by an electronic control system, is then used to drive the motor/generator as a motor to either blend its force with engine torque, or to move the truck (launching it from a stop) independent of the engine.
Hydraulic hybrids
Eatons Hydraulic Launch Assist hydraulic hybrid system combines the trucks conventional power train with a hydraulic pump/motor that is connected to the driveline via a transfer case. During deceleration, the drive train converts the vehicles kinetic energy to hydraulic energy as it turns the pump/motor as a pump, which transfers hydraulic fluid to a high-pressure accumulator, capturing some 70 percent of the available energy, says Eaton. The hydraulically stored energy alone can be used to accelerate the truck until the accumulator empties (improving fuel economy), or can be blended with the engines torque (for faster acceleration). The Parker RunWise 3-Gear System is hydraulically based and uses the trucks engine to drive a pump/motor to initially charge a high-pressure accumulator. The truck then is hydrostatically powered as the accumulator supplies flow to hydraulic motors that drive the wheels. Low-hydrostatic mode accelerates the truck to 25 mph, then highhydrostatic mode powers it to 45 mph. In hydrostatic drive, the engine runs just above idle. Above 45 mph, the engine alone powers the truck via direct mechanical drive. As the truck makes frequent stops, the systems pump/motors function as pumps to regenerate the accumulators charge. The hybrid design of the Cat 966K XE wheel loader combines the outputs of a mechanical drive system (less torque converter) and a hydrostatic system, converging the dual power outputs in a series of planetary gear sets to maximize transmission efficiency, says Caterpillar. As we understand the system, it is capable of capturing braking energy via the hydrostatic portion of the drive train, subsequently creating hydraulic flow that is used, says the company, to power implements or the cooling fan, allowing the engine to work at lower speeds.
http://www.constructionequipment.com/print/114528
01-Mar-13
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On the mining side, Caterpillar is developing hybrid systems for its 6120 H FS hydraulic mining shovel and 7495 electric rope shovel that capture energy from swing deceleration and boom-down functions. Likewise, Joy Global, manufacturer of LeTourneau wheel loaders, has introduced its P&H 2650 diesel/electric rope shovel, which, says the company, borrows hybrid technology from its wheel loader counterparts. Hybrid systems that apply unconventional energy-use technology promise lower fuel consumption and the potential for increased productivity. Hybrid systems that apply unconventional energy-use technology promise lower fuel consumption and the potential for increased productivity. By Walt Moore, Editor Wed, 2013-02-27 09:19
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http://www.constructionequipment.com/print/114528
01-Mar-13
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http://www.constructionequipment.com/print/114528
01-Mar-13